Method of shaping green part and manufacturing method using same

Patent metadata

Field	Value
Publication number	US-9517507-B2
Application number	US-201414333954-A
Country	US
Kind code	B2
Filing date	Jul 17, 2014
Priority date	Jul 17, 2014
Publication date	Dec 13, 2016
Grant date	Dec 13, 2016

Abstract

A method of shaping a part in a green state obtained through powder injection molding, including placing a surface of the part in contact with a shaping surface of a setter with at least one section of the surface of the part not conforming to the shaping surface, and locally heating at least one area of each of the at least one section to deform the part until the at least one section conforms to the shaping surface. The part remains in the green state during the local heating. The part may be a heat shield panel for a gas turbine engine.

First claim

The invention claimed is:

1. A method of manufacturing a heat shield panel for a gas turbine engine, the method comprising:
molding the heat shield panel in a green state by powder injection molding, the heat shield panel having a platform section defining a reference surface;
with the heat shield panel in the green state, placing the platform section on a setter with the reference surface against a shaping surface of the setter, the reference surface having an initial shape not conforming to the shaping surface;
locally heating at least one area of the platform section to deform the platform section until the reference surface conforms to the shaping surface and has a final shape different from the initial shape, the at least one area of the heat shield panel remaining in the green state during the local heating; and
debinding and sintering the heat shield panel after the reference surface has reached the final shape.

2. The method as defined in claim 1 , wherein the at least one area is heated to melt only some components of a binder of the heat shield panel in the at least one area, the other components of the binder in the at least one area remaining solid.

3. The method as defined in claim 1 , wherein the at least one area includes a plurality of areas which are heated sequentially as the platform section deforms.

4. The method as defined in claim 1 , wherein the at least one area is heated using an unfocussed and/or moving laser beam.

5. The method as defined in claim 1 , further including applying a force against the platform section towards the shaping surface to deform the platform section until the reference surface conforms to the shaping surface.

6. The method as defined in claim 1 , wherein molding the heat shield panel includes molding attachment members extending from a surface of the platform section opposed from the reference surface, and deforming the platform section changes a relative orientation of at least some of the attachment members.

7. The method as defined in claim 1 , wherein the initial shape of the reference surface is planar.

8. The method as defined in claim 7 wherein the final shape of the reference surface defines part of a cylinder.

9. A method of manufacturing a panel element for a gas turbine engine, the method comprising:
molding the panel element in a green state by powder injection molding, the panel element defining a reference surface and two elongated features each extending along a respective axis;
with the panel element in the green state, placing the panel element on a setter with the reference surface against a shaping surface of the setter, the reference surface having an initial shape not conforming to the shaping surface;
locally heating at least one area of the panel element spaced apart from the elongated features to deform the panel element until the reference surface conforms to the shaping surface and has a final shape different from the initial shape, an angle between the respective axes of the elongated features changing as the panel element deforms to reach a final desired angle once the reference surface conforms to the shaping surface, the at least one area of the panel element remaining in the green state during the local heating; and
debinding and sintering the panel element after the reference surface has reached the final shape.

10. The method as defined in claim 9 , wherein the at least one area is heated to melt only some components of a binder of the panel element in the at least one area, the other components of the binder in the at least one area remaining solid.

11. The method as defined in claim 9 , wherein the at least one area includes a plurality of areas which are heated sequentially as the panel element deforms.

12. The method as defined in claim 9 , wherein the at least one area is heated using an unfocussed and/or moving laser beam.

13. The method as defined in claim 9 , further including applying a force against the panel element towards the shaping surface to deform the panel element until the reference surface conforms to the shaping surface.

14. The method as defined in claim 9 , wherein the elongated features include threaded members extending from a surface of the panel element opposed from the reference surface.

15. The method as defined in claim 9 , wherein the initial shape of the reference surface is planar.

16. The method as defined in claim 15 , wherein the final shape of the reference surface defines part of a cylinder.

17. A method of shaping a part in a green state obtained through powder injection molding, the method comprising:
with the part in the green state, placing a surface of the part in contact with a shaping surface of a setter, at least one section of the surface of the part not conforming to the shaping surface; and
locally heating at least one area of each of the at least one section to deform the part until the at least one section conforms to the shaping surface, the part remaining in the green state during the local heating.

18. The method as defined in claim 17 , wherein the at least one area is heated to melt only some components of a binder of the part in the at least one area, the other components of the binder in the at least one area remaining solid.

19. The method as defined in claim 17 , wherein the at least one area includes a plurality of areas which are heated sequentially as the part deforms.

20. The method as defined in claim 17 , further including applying a force against the part towards the shaping surface to deform the part until the at least one section of the surface conforms to the shaping surface.

Assignees

• Pratt & Whitney Canada

Inventors

• Campomanes Marc
• Scalzo Orlando
• Poitras Guillaume

Classifications

• B21D11/00

  Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00 (corrugating or bending into wave form B21D13/00, B21D15/00; flanging B21D19/00); Twisting · CPC title

• C04B2235/6022

  Injection moulding · CPC title

• B22F3/225

  by injection molding · CPC title

• F23R3/002

  Wall structures (F23R3/02 and F23R3/007 take precedence) · CPC title

• F23R2900/00018

  Manufacturing combustion chamber liners or subparts · CPC title