Method of manufacturing a component

Patent metadata

Field	Value
Publication number	US-2018200799-A1
Application number	US-201815864183-A
Country	US
Kind code	A1
Filing date	Jan 8, 2018
Priority date	Jan 13, 2017
Publication date	Jul 19, 2018
Grant date	—

Abstract

A method of manufacturing a component ( 100 ) having a main part ( 101 ) and a projecting feature ( 104,114 ), the method comprising providing a shaped void ( 210 ) corresponding to the component, locating a pre-formed element ( 214 ) in a feature region of the shaped void which corresponds to the projecting feature, locating powder ( 212 ) within the shaped void; and forming the element and the powder into the component such that the element creates at least a part of the projecting feature.

First claim

1 . A method of manufacturing a component having a main part and a projecting feature, the method comprising:
providing a shaped void corresponding to the component within a canister, the shaped void further comprising a recess to provide a feature region for receiving a pre-formed element to provide the projecting feature; locating the pre-formed element in the feature region of the shaped void which corresponds to the projecting feature such that the pre-formed element only partially fills the feature region such that it can be surrounded by powder within the feature region; locating powder within the shaped void and around the pre-formed element within the feature region; and forming the element and the powder into the component such that the element creates at least a part of the projecting feature.

2 . A method as claimed in claim 1 , wherein the shaped void comprises an annular gap between a first and second canisters or parts.

3 . A method as claimed in either of claim 1 , wherein the recess has a first thickness corresponding to the projecting feature, and a second region having a second thickness less than the first thickness corresponding to the main part.

4 . A method as claimed in claim 1 , wherein the pre-formed element and the powder are formed into the component using a hot isostatic pressing process.

5 . A method as claimed in claim 1 , wherein the pre-formed element is formed of substantially the same material as the powder.

6 . A method as claimed in claim 1 , wherein the pre-formed element is shaped such that a depth of the powder between the pre-formed element and a wall of the shaped void is substantially constant.

7 . A method as claimed in claim 1 , wherein the projecting feature is a boss or duct of the component.

8 . A method as claimed in claim 7 , wherein the boss or duct comprises a bore from an interior to an exterior of the component, and wherein the element comprises a bore cavity which forms at least a part of the bore.

9 . A method as claimed in claim 1 , wherein the component is an aerospace component.

10 . A method as claimed in claim 9 , wherein the component is an engine casing, and wherein the projecting feature is a boss or duct of the engine casing.

11 . A method as claimed in claim 1 , further comprising forming the pre-formed element using hot isostatic pressing.

12 . A method as claimed in claim 1 , wherein the pre-formed element is supported in the feature region by one or more support members of the element.

13 . A method as claimed in claim 12 , wherein the one or more support elements contact the canister.

14 . A method as claimed in claim 1 , wherein the component has a plurality of projecting features, and wherein the pre-formed element is located in each of a plurality of feature regions of the shaped void corresponding to the plurality of projecting features.

15 . A method as claimed in claim 1 , wherein the pre-formed element contacts the canister within the shaped void.

16 . A method as claimed in claim 1 , wherein the pre-formed element is encapsulated by the powder on all sides such that it does not contact the canister.

Assignees

• Rolls Royce Plc

Inventors

• Mulcaire Thomas G

Classifications

• B29L2031/748

  Machines or parts thereof not otherwise provided for (conveyor belts B29L2031/7092; driving belts B29L2031/7094; bearings B29L2031/04) · CPC title

• B29C2043/189

  the parts being joined · CPC title

• B28B3/003

  Pressing by means acting upon the material via flexible mould wall parts, e.g. by means of inflatable cores, isostatic presses (isostatic presses in general B30B5/02) · CPC title

• B22F5/008

  of engine cylinder parts or of piston parts other than piston rings (of piston rings B22F5/02) · CPC title

• B29C43/18

  incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} · CPC title