U.S. patent application number 16/023879 was filed with the patent office on 2020-01-02 for fabricating composite metallic components.
The applicant listed for this patent is United Technologies Corporation. Invention is credited to Benjamin Heneveld, John Paulus, Joel H. Wagner.
Application Number | 20200001368 16/023879 |
Document ID | / |
Family ID | 67137860 |
Filed Date | 2020-01-02 |
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United States Patent
Application |
20200001368 |
Kind Code |
A1 |
Heneveld; Benjamin ; et
al. |
January 2, 2020 |
FABRICATING COMPOSITE METALLIC COMPONENTS
Abstract
A method of fabricating a composite component is provided. The
method includes manufacturing a cast metallic component including a
surface and defining an attachment point along the surface, placing
a fugitive mold defining an element feature against the surface
such that the element feature aligns with the attachment point,
filling the element feature with powdered metallic material and
heating the cast metallic component and the powdered metallic
material to a temperature above a sintering temperature of the
powdered metallic material and below a melting temperature of the
cast metallic component.
Inventors: |
Heneveld; Benjamin;
(Arlington, VA) ; Wagner; Joel H.; (Wethersfield,
CT) ; Paulus; John; (Afton, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
United Technologies Corporation |
Farmington |
CT |
US |
|
|
Family ID: |
67137860 |
Appl. No.: |
16/023879 |
Filed: |
June 29, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F05D 2230/14 20130101;
B22F 2005/005 20130101; B22F 5/009 20130101; B22F 5/04 20130101;
B22F 7/08 20130101; B22C 9/04 20130101; F05D 2300/607 20130101;
F01D 5/282 20130101; F05D 2230/211 20130101; B22F 3/004 20130101;
B23P 15/006 20130101; B22F 7/062 20130101; F05D 2230/22 20130101;
B22F 2998/10 20130101 |
International
Class: |
B22F 7/06 20060101
B22F007/06; B22C 9/04 20060101 B22C009/04; B22F 7/08 20060101
B22F007/08 |
Claims
1. A method of fabricating a composite component, the method
comprising: manufacturing a cast metallic component comprising a
surface and defining an attachment point along the surface; placing
a fugitive mold defining an element feature against the surface
such that the element feature aligns with the attachment point;
filling the element feature with powdered metallic material; and
heating the cast metallic component and the powdered metallic
material to a temperature above a sintering temperature of the
powdered metallic material and below a melting temperature of the
cast metallic component.
2. The method according to claim 1, wherein: the attachment point
has undercut features, and the undercut features comprise one or
more of dovetails, zig-zags, spirals, curves and multi-directional
extrusions.
3. The method according to claim 1, wherein the cast metallic
component comprises a fastening element for fastening a sintered
element to the cast metallic component at the attachment point.
4. The method according to claim 1, wherein the element feature
comprises an opening with protruding undercuts.
5. The method according to claim 1, further comprising: continuing
the heating until the powdered metallic material is cured into an
element attached to the surface at the attachment point; and
removing a remainder of the fugitive mold following the
heating.
6. The method according to claim 5, wherein the heating results in
up to 15% shrinkage of the element from a volume of the powdered
metallic material at the attachment point.
7. The method according to claim 5, further comprising designing
the attachment point such that the element tightens onto the cast
metallic component during the heating.
8. The method according to claim 5, wherein the attachment point is
designed such that the element has a tooth-root shape.
9. A method of fabricating a composite component, the method
comprising: manufacturing a cast metallic component comprising a
surface and defining dovetail-shaped attachment points along the
surface; placing a fugitive mold defining openings with protruding
undercuts against the surface such that each opening aligns with a
corresponding one of the dovetail-shaped attachment points; filling
the openings with powdered metallic material; and heating the cast
metallic component and the powdered metallic material to a
temperature above a sintering temperature of the powdered metallic
material and below a melting temperature of the cast metallic
component.
10. The method according to claim 9, wherein: each dovetail-shaped
attachment point comprises a neck section proximate to an uppermost
portion of the surface and a tapered section having an increasing
width with increasing depth from the neck section, and each opening
has a diameter which corresponds to a diameter of the neck section
of the corresponding one of the dovetail-shaped attachment
points.
11. The method according to claim 10, wherein each opening is
corrugated.
12. The method according to claim 9, wherein the cast metallic
component comprises one or more fastening elements for fastening
one or more sintered elements to the cast metallic component at one
or more of the attachment points.
13. The method according to claim 9, further comprising: continuing
the heating until the powdered metallic material is cured into
elements attached to the surface at each of the attachment points;
and removing a remainder of the fugitive mold following the
heating.
14. The method according to claim 13, wherein the heating results
in up to 15% shrinkage of the elements from a volume of the
powdered metallic material at each of the attachment points.
15. The method according to claim 13, further comprising designing
the attachment points such that each of the elements tighten onto
the cast metallic component during the heating.
16. The method according to claim 13, wherein the attachment points
are designed such that the elements have tooth-root shape.
17. A composite component, comprising: a cast metallic component
comprising a surface and defining attachment points along the
surface; elements of sintered powdered metallic material
respectively comprising first and second parts, the first parts
being respectively secured in a corresponding one of the attachment
points, the second parts extending outwardly from corresponding
ones of the first parts to protrude from the surface, and the first
and second parts cooperatively forming a tooth-root shape.
18. The composite component according to claim 17, wherein: the
attachment points each comprise attachment features that extend
into the cast metallic component curvi-linearly outwardly, and the
first parts of each of the elements comprise sintered attachment
protrusions that extend into the cast metallic component
curvi-linearly outwardly.
19. The composite component according to claim 17, wherein the
second parts of each of the elements are corrugated.
20. The composite component according to claim 17, wherein each of
the first parts has a lesser volume than the corresponding one of
the attachment points.
Description
BACKGROUND
[0001] Exemplary embodiments of the present disclosure relate
generally to fabrication of composite metallic components and, in
one embodiment, to methods of fabricating composite cast and
sintered metallic components.
[0002] Various manufacturing methods and material systems have
different advantages and drawbacks. Therefore, it may be
advantageous to combine different manufacturing methods and
material systems together in order to create composite components
that enable synergistic benefits or to overcome the specific
limitations of a single technology.
[0003] For example, a single crystal nickel-based super alloy
casting exhibits superior material properties for high temperature
creep resistance, but it may be difficult to cast certain
geometries in a single crystal alloy without increasing
manufacturing expenditures due to increased tooling costs or issues
such as recrystallization certain geometry. Similarly, geometry
changes to a component with an already manufactured tool set can be
expensive as they will often require complete new tooling.
Likewise, components made from sintered powdered metals can be much
less expensive to produce, allow for a wider range of geometric
designs, but generally have less robust material properties.
BRIEF DESCRIPTION
[0004] According to an aspect of the disclosure, a method of
fabricating a composite component is provided. The method includes
manufacturing a cast metallic component including a surface and
defining an attachment point along the surface, placing a fugitive
mold defining an element feature against the surface such that the
element feature aligns with the attachment point, filling the
element feature with powdered metallic material and heating the
cast metallic component and the powdered metallic material to a
temperature above a sintering temperature of the powdered metallic
material and below a melting temperature of the cast metallic
component.
[0005] In accordance with additional or alternative embodiments,
the attachment point has undercut features and the undercut
features include one or more of dovetails, zig-zags, spirals,
curves and multi-directional extrusions.
[0006] In accordance with additional or alternative embodiments,
the cast metallic component includes a fastening element for
fastening a sintered element to the cast metallic component at the
attachment point.
[0007] In accordance with additional or alternative embodiments,
the element feature includes an opening with protruding
undercuts.
[0008] In accordance with additional or alternative embodiments,
the method further includes continuing the heating until the
powdered metallic material is cured into an element attached to the
surface at the attachment point and removing a remainder of the
fugitive mold following the heating.
[0009] In accordance with additional or alternative embodiments,
the heating results in up to 15% shrinkage of the element from a
volume of the powdered metallic material at the attachment
point.
[0010] In accordance with additional or alternative embodiments,
the method further includes designing the attachment point such
that the element tightens onto the cast metallic component during
the heating.
[0011] In accordance with additional or alternative embodiments,
the attachment point is designed such that the element has a
tooth-root shape.
[0012] According to another aspect of the disclosure, a method of
fabricating a composite component is provided and includes
manufacturing a cast metallic component including a surface and
defining dovetail-shaped attachment points along the surface,
placing a fugitive mold defining openings with protruding undercuts
against the surface such that each opening aligns with a
corresponding one of the dovetail-shaped attachment points, filling
the openings with powdered metallic material and heating the cast
metallic component and the powdered metallic material to a
temperature above a sintering temperature of the powdered metallic
material and below a melting temperature of the cast metallic
component.
[0013] In accordance with additional or alternative embodiments,
each dovetail-shaped attachment point includes a neck section
proximate to an uppermost portion of the surface and a tapered
section having an increasing width with increasing depth from the
neck section and each opening has a diameter which corresponds to a
diameter of the neck section of the corresponding one of the
dovetail-shaped attachment points.
[0014] In accordance with additional or alternative embodiments,
each opening is corrugated.
[0015] In accordance with additional or alternative embodiments,
the cast metallic component includes one or more fastening elements
for fastening one or more sintered elements to the cast metallic
component at one or more of the attachment points.
[0016] In accordance with additional or alternative embodiments,
the method further includes continuing the heating until the
powdered metallic material is cured into elements attached to the
surface at each of the attachment points and removing a remainder
of the fugitive mold following the heating.
[0017] In accordance with additional or alternative embodiments,
the heating results in up to 15% shrinkage of the elements from a
volume of the powdered metallic material at each of the attachment
points.
[0018] In accordance with additional or alternative embodiments,
the method further includes designing the attachment points such
that each of the elements tighten onto the cast metallic component
during the heating.
[0019] In accordance with additional or alternative embodiments,
the attachment points are designed such that the elements have
tooth-root shape.
[0020] According to yet another aspect of the disclosure, a
composite component is provided and includes a cast metallic
component including a surface and defining attachment points along
the surface, elements of sintered powdered metallic material
respectively comprising first and second parts, the first parts
being respectively secured in a corresponding one of the attachment
points, the second parts extending outwardly from corresponding
ones of the first parts to protrude from the surface and the first
and second parts cooperatively forming a tooth-root shape.
[0021] In accordance with additional or alternative embodiments,
the attachment points each include attachment features that extend
into the cast metallic component curvi-linearly outwardly and the
first parts of each of the elements include sintered attachment
protrusions that extend into the cast metallic component
curvi-linearly outwardly.
[0022] In accordance with additional or alternative embodiments,
the second parts of each of the elements are corrugated.
[0023] In accordance with additional or alternative embodiments,
each of the first parts has a lesser volume than the corresponding
one of the attachment points.
[0024] These and other advantages and features will become more
apparent from the following description taken in conjunction with
the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0026] FIG. 1 is a side view of a cast metallic component with a
surface and dovetail-shaped attachment points in accordance with
embodiments;
[0027] FIG. 2 is a side view of a cast metallic component with a
surface and zig-zag, spiral, curved and multi-directional extrusion
attachment points in accordance with embodiments;
[0028] FIG. 3 is a side view of a fugitive mold with opening placed
against the cast metallic component of FIG. 1 such that the
openings align with the attachment points;
[0029] FIG. 4 is a side view of powdered metallic material filled
into the openings of the fugitive mold of FIG. 3;
[0030] FIG. 5 is a side view of sintered elements securably
attached to the cast metallic component at the attachment points
once the powdered metallic material of FIG. 4 has been cured and a
remainder of the fugitive mold of FIG. 4 has been removed;
[0031] FIG. 6 is an enlarged view of the encircled portion of FIG.
5; in accordance with embodiments;
[0032] FIG. 7 is a side view of an attachment point design that
causes a tightening of the sintered elements of FIG. 5 due to
curing in accordance with embodiments; and
[0033] FIG. 8 is a flow diagram illustrating a method of
fabricating a composite component in accordance with
embodiments.
[0034] These and other advantages and features will become more
apparent from the following description taken in conjunction with
the drawings.
DETAILED DESCRIPTION
[0035] A detailed description of one or more embodiments of the
disclosed apparatus and method are presented herein by way of
exemplification and not limitation with reference to the
Figures.
[0036] As will be described below, a fabrication method is provided
in which composite components that have a robust structure are
formed by cast metal and detailed complex features are formed by
powdered metal.
[0037] With reference to FIGS. 1-6, a method of fabricating a
composite component is provided.
[0038] As shown in FIG. 1, a cast metallic component 10 is cast in
an initial operation with one or more appropriate fabrication
techniques. The cast metallic component 10 has a surface 11 and is
formed to define attachment points 12. Each attachment point 12
extends inwardly relative to a body of the cast metallic component
10 from an uppermost portion 110 of the surface 11 and, in
accordance with embodiments, may have a dovetail-shaped
cross-section. That is, each attachment point 12 may have a
relatively narrow neck section 120 at or proximate to the uppermost
portion 110 of the surface 11 and a tapered section 121. The
tapered section 121 extends inwardly from the neck section 120 and
has an increasing width with increasing depth from the neck section
120 and thus forms protruding undercut portions 121.
[0039] With reference to FIG. 2 and in accordance with alternative
embodiments, it is to be understood that the attachment points can
have various cross-sectional shapes and sizes and that, while the
following description generally relates to the dovetail-shape case,
this is not required. For example, as shown in FIG. 2, the
attachment points 12 can be provided as zig-zag attachment points
13, spiral attachment points 14, curved attachment points 15 and
multi-directional extrusion attachment points 16. In any case, the
attachment points 12 should have a shape that can securely maintain
a cured sintered element (see FIGS. 5 and 6) therein.
[0040] Next, as shown in FIG. 3, one or more fugitive molds 20 is
placed against the surface 11 of the cast metallic component 10.
The fugitive mold 20 may be configured to form or define engineered
surface features or openings 21 that align with the attachment
points 12. As a general matter, each of the openings 21 may have a
more complex geometry than the attachment points 12 and, for
example, they may have diameters that correspond to the diameters
of the neck sections 120 (see FIG. 1) of the attachment points 12
and that may have protruding undercuts 210 or corrugations along
longitudinal axes thereof.
[0041] Once the one or more fugitive molds 20 are placed against
the surface 11, the openings 21 are filled with powdered metallic
materials as shown in FIG. 4.
[0042] As shown in FIGS. 5 and 6, the powdered metallic materials
cured into sintered elements 30 and remainders of the one or more
fugitive molds 20 are removed. The curing involves heating the cast
metallic component 10 and the powdered metallic materials to a
temperature which is above the sintering temperature of the
powdered metallic materials and below the melting point of the cast
metallic component 10. The heating continues until the powdered
metallic materials are sufficiently densified and form the sintered
elements 30.
[0043] Each sintered element 30 has a cross-sectional shape which
mimics the cross-sectional shapes of the attachment point 12 and
the opening 21 it is formed in. Thus, each sintered element 30 has
a first part 31 and a second part 32. The first part 31 is formed
within the neck portion 120 and the tapered portion 121 of the
corresponding attachment point 12. The second part 32 is integrally
coupled to the first part 31 and extends from the first part 31 to
protrude outwardly from the surface 11. In an event the
corresponding attachment point 12 has a dovetail-shape and the
corresponding opening 21 is corrugated, the first part 31 will have
a corresponding dovetail-shape 310 and the second part 32 will have
a corresponding corrugated shape 320.
[0044] In accordance with embodiments, a final volume of each of
the sintered elements 30 may be reduced from an initial volume of
the powdered metallic material of the corresponding attachment
point 12 and the corresponding opening 21. This volume reduction is
a consequence of the curing process and may result in up to 15%
reduction in volume. This can be seen in FIG. 6 in which the local
edge 33 of the sintered element 30 is shown as having receded from
the edge of the tapered section 121 of the corresponding attachment
point 12.
[0045] To the extent that the volume reduction or shrinkage
illustrated in FIG. 6 occurs, the cross-sectional shapes of the
attachment points 12 are designed to secure the sintered elements
30. For the dovetail-shaped attachment points 12, the diameter of
the neck portion 120 (see FIG. 1) should be sufficiently small as
compared to the proximal portion of the tapered section 121 (see
FIG. 1) so as to limit potential movement of the resulting sintered
element 30 with the volume reduction having occurred.
[0046] With reference to FIG. 7 and, in accordance with further
embodiments of the invention, the securing of the sintered elements
30 in the attachment points may be achieved by the use of fasteners
to fasten the sintered elements 30 in the attachment points 12 or
by the design or geometry of the attachment points 12 whereby the
sintered elements 30 tighten into position even with the volume
reduction occurring (see FIG. 7).
[0047] That is, as shown in FIG. 7, the geometry of the attachment
point 12 includes two or more attachment features 701 for a given
sintered element 30. These attachment features 701 may be defined
substantially opposite one another and may be designed such that
the shrinkage of the sintered element 30 during the sintering
thereof automatically results in a compression pressure being
exerted between the sintered attachment protrusions 702 and the
substrate material in and around the sintered attachment
protrusions 702. The compression pressure serves to prevent the
movement of the sintered element 30 with respect to the cast
metallic component 10 and may increase an effective heat transfer
between the cast metallic component 10 and the sintered element
30.
[0048] In particular, the attachment features 701 may extend into
the cast metallic component 10 curvi-linearly outwardly such that
the resulting sintered attachment protrusions 702 similarly extend
into the cast metallic component 10 curvi-linearly. The attachment
features 701 a taper away from each other with increasing depth
into the cast metallic component 10 and the sintered attachment
protrusions 702 similarly taper away from each other with
increasing depth into the cast metallic component 10. Each
attachment feature 701 and each corresponding sintered attachment
protrusion 702 can have a substantially similar radius of outward
curvature. Outer surfaces 7021 of the sintered attachment
protrusions 702 may be nearly aligned in a radial dimension with an
exterior surface 321 of the second part 32 and inner surfaces 7022
of the sintered attachment protrusions 702 may be separated from
one another by a radial distance DR. The first and second parts 31
and 32 of the given sintered element 30 thus cooperatively form a
tooth-root shaped element 710.
[0049] With reference to FIG. 8, a method of fabricating a
composite component is provided. As shown in FIG. 8, the method
includes manufacturing a cast metallic component comprising a
surface (801) and defining an attachment point along the surface
(802), placing a fugitive mold defining an element feature against
the surface such that the element feature aligns with the
attachment point (803), filling the element feature with powdered
metallic material (804) and heating the cast metallic component and
the powdered metallic material to a temperature above a sintering
temperature of the powdered metallic material and below a melting
temperature of the cast metallic component (805).
[0050] Benefits of the features described herein are the provision
for production of a composite component that takes advantage of the
beneficial properties of different manufacturing techniques and
material systems. The fabrication methods can rely on a cast
substrate for structural and creep resistance purposes and can use
powdered metal features to create additional surface area or
detailed geometry that could not be achievable with cast metal due
to recrystallization, tooling costs or other limitations.
Additionally, tooling costs for a fugitive mold is significantly
less than for a traditional wax pattern tool set. This allows for
multiple different fugitive molds to be used on a single substrate
thereby allowing numerous and varying designs to be produced and
tested while requiring less tooling cost and time as compared to
having to use different traditional tool sets. This can in turn
allow for multiple complex designs to be built and tested for less
cost than a single complex design, which is fabricated using
conventional techniques and can result in faster innovations and a
more valuable final product.
[0051] The term "about" is intended to include the degree of error
associated with measurement of the particular quantity based upon
the equipment available at the time of filing the application.
[0052] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the present disclosure. As used herein, the singular forms "a",
"an" and "the" are intended to include the plural forms as well,
unless the context clearly indicates otherwise. It will be further
understood that the terms "comprises" and/or "comprising," when
used in this specification, specify the presence of stated
features, integers, steps, operations, elements, and/or components,
but do not preclude the presence or addition of one or more other
features, integers, steps, operations, element components, and/or
groups thereof.
[0053] While the present disclosure has been described with
reference to an exemplary embodiment or embodiments, it will be
understood by those skilled in the art that various changes may be
made and equivalents may be substituted for elements thereof
without departing from the scope of the present disclosure. In
addition, many modifications may be made to adapt a particular
situation or material to the teachings of the present disclosure
without departing from the essential scope thereof. Therefore, it
is intended that the present disclosure not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this present disclosure, but that the present
disclosure will include all embodiments falling within the scope of
the claims.
* * * * *