Process for producing an article

Patent metadata

Field	Value
Publication number	US-2016258298-A1
Application number	US-201514639464-A
Country	US
Kind code	A1
Filing date	Mar 5, 2015
Priority date	Mar 5, 2015
Publication date	Sep 8, 2016
Grant date	—

Abstract

A process of producing an article and an article made are provided. The process includes producing a near-net shape component. The process includes forming a consolidation shell by additive manufacturing. The consolidation shell defines an interior space having a geometry corresponding to a component. A metallic powder is provided to the interior space. Gas is removed from the interior space. The metallic powder is consolidated in the consolidation shell under sufficient heat and pressure to form the near-net shape component.

First claim

What is claimed is:

1 . A process of producing a near-net shape component, the process comprising:
forming a consolidation shell by additive manufacturing, the consolidation shell defining an interior space having a geometry corresponding to a component; providing a metallic powder to the interior space; removing gas from the interior space; and consolidating the metallic powder in the consolidation shell under sufficient heat and pressure to form the near-net shape component.

2 . The process of claim 1 , wherein the consolidating includes hot isostatic pressing.

3 . The process of claim 1 , wherein the metallic powder includes metals selected from the group consisting of nickel, cobalt, titanium, iron, alloys thereof and combinations thereof.

4 . The process of claim 1 , wherein the geometry corresponding to the component includes a geometry that forms the near-net shape component after consolidation.

5 . The process of claim 1 , further comprising removing the consolidation shell.

6 . The process of claim 5 , wherein removing the consolidation shell includes a removal process selected from the group consisting of machining, electrical removal or chemical removal.

7 . The process of claim 1 , wherein the consolidation shell includes a second, removable material to form channels in the component.

8 . The process of claim 1 , wherein the near-net shape component is a compressor blade.

9 . The process of claim 1 , wherein the providing a metallic powder to the interior space includes providing a first metallic powder and a second metallic powder.

10 . The process of claim 9 , wherein the first metallic powder and the second metallic powder have dissimilar compositions.

11 . The process of claim 9 , wherein the first metallic powder and the second metallic powder have dissimilar properties.

12 . The process of claim 1 , wherein the consolidation shell forms a coating material on the component.

13 . A consolidation shell comprising:
an interior space having a geometry corresponding to a component; and a conduit extending from the interior space; wherein metallic powder is present in the interior space.

14 . The consolidation shell of claim 13 , wherein the component is a compressor blade.

15 . The consolidation shell of claim 13 , wherein the metallic powder is a metal selected from the group consisting of nickel, cobalt, titanium, iron, alloys thereof and combinations thereof.

16 . The consolidation shell of claim 13 , wherein the metallic powder includes a first metallic powder and a second metallic powder.

17 . A component comprising:
a consolidation shell formed by additive manufacturing, the consolidation shell defining an interior space having a geometry corresponding to the component, the interior space being at least partially filled with a consolidated powder.

18 . The component of claim 17 , wherein the component is selected from the group consisting of a turbine bucket, a compressor blade, a compressor vane, an airfoil segment, a nozzle, a shroud, and a combustion component.

19 . The component of claim 17 , wherein the component is a compressor blade.

20 . The component of claim 17 , wherein the consolidation shell forms a coating on the component.

Assignees

• Gen Electric

Inventors

• Channel Timothy Eden
• Bouse Gregory Keith

Classifications

• B22F3/15 Primary

  Hot isostatic pressing · CPC title

• F05D2300/502

  Thermal properties · CPC title

• B22F3/1258

  Container manufacturing · CPC title

• F05D2240/35

  Combustors or associated equipment · CPC title

• B23P15/02

  turbine or like blades from one piece · CPC title