Powder metallurgy processes – Powder metallurgy processes with heating or sintering – Powder pretreatment
Patent
1992-06-23
1993-12-28
Nelson, Peter A.
Powder metallurgy processes
Powder metallurgy processes with heating or sintering
Powder pretreatment
419 36, 419 37, 419 42, 419 49, 428544, B22F 102
Patent
active
052737080
ABSTRACT:
In making a dual alloy gas turbine rotor, a plurality of superalloy components are formed to include an airfoil having a directionally solidified columnar grain structure or a single crystal grain structure. A boron-bearing melting point depressant material is applied to the inner surface and a side surface of the components. The components are arranged side-by-side in an annular array with the first side surface of one component juxtaposed to the second side surface of an adjacent component and with the inner surfaces defining a spray-receiving surface. The airfoils extend in a radial axis or direction of the array while the spray-receiving surface extends in a circumferential direction of the article. A sealing member is positioned adjacent an axial end of the array of the components to close off that end and form a spray-receiving cavity. Boron-bearing melting point depressant material is provided between the sealing member and the end of the array. The array/sealing member is heated to form an exposed liquid layer on the spray-receiving surface at the onset of plasma spraying of a molten metal and also to form a fusion joint between the juxtaposed first and second surfaces of the components and between the sealing member and the end of the array. A superalloy hub material is plasma sprayed onto the exposed liquid layer to buildup up a deposit in the cavity that forms a hub precursor of the rotor. The array/deposit is hot isostatically pressed using pressurized gas and then heated treated to develop desired properties in the components and the hub precursor.
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Howmet Corporation
Nelson Peter A.
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