Method of manufacturing a metal article by powder metallurgy

Patent 7407622 Issued on August 5, 2008. Estimated Expiration Date:

November 15, 2025. Estimated Expiration Date is calculated based on simple USPTO term provisions. It does not account for terminal disclaimers, term adjustments, failure to pay maintenance fees, or other factors which might affect the term of a patent.

Abstract Claims Description Full Text

Patent References

Container for hot consolidating powder
Patent #: 4142888
Issued on: 03/06/1979
Inventor: Rozmus

Method for molding of powders
Patent #: 4927600
Issued on: 05/22/1990
Inventor: Miyashita, et al.

Powder forging of hollow articles
Patent #: 5130084
Issued on: 07/14/1992
Inventor: Matheny, et al.

Method of forming high-temperature components and components formed thereby Patent #: 6168871
Issued on: 01/02/2001
Inventor: Ritter, et al.

Inventors

Assignee

Rolls Royce PLC

Application

No. 11273027 filed on 11/15/2005

US Classes:

419/5, Making composite or hollow article419/48, Heat and pressure simultaneously to effect sintering419/49Hot isostatic pressing (HIP)

Examiners

Primary: King, Hoy
Assistant: Mai, Ngoclan

Attorney, Agent or Firm

Foreign Patent References

1 075 885 EP 12/01/2001
1 260 300 EP 11/01/2002
1 399 669 SP GB 07/01/1975
1 400 118 SP GB 07/01/1975
2 306 353 GB 05/01/1997
58141896 AB JP 08/01/1983

International Classes

B22F 3/14
B22F 5/10

Abstract

A method of manufacturing a fan blade (26) for a gas turbine engine by powder metallurgy comprises the steps of forming a container (52) and placing at least one metal insert (52) at a predetermined position within the container (52) and filling the container (52) with metal powder (60). The at least one metal insert (62) has a predetermined pattern of stop off material (68,70) on at least one surface of the metal insert (64,66). The container (52) is evacuated and then sealed. The container (52) is hot pressed to consolidate the metal powder (60) into a consolidated metal powder preform (72). The container (52) is removed from the consolidated metal powder preform (72). The consolidated metal powder preform (72) is heated and a fluid is supplied to the predetermined pattern of stop off material (68,70) to hot form at least a portion of the consolidated metal powder preform (72) to form the hollow metal fan blade (26).