Method of forming high-temperature components and components for

Details Method of forming high-temperature components and components for Method of forming high-temperature components and components for

1998-03-06

1999-09-28

Mai, Ngoclan

Powder metallurgy processes

Powder metallurgy processes with heating or sintering

Making composite or hollow article

419 8, 419 57, 419 60, G22B 700

Patent

active

059602490

ABSTRACT:
A method for forming an exterior surface of a high-temperature component, such as a blade or vane of a gas turbine engine. The method entails forming a shell by a powder metallurgy technique that yields an airfoil whose composition can be readily tailored for the particular service conditions of the component. The method generally entails providing a pair of inner and outer mold members that form a cavity therebetween. One or more powders and any desired reinforcement material are then placed in the cavity and then consolidated at an elevated temperature and pressure in a non-oxidizing atmosphere. Thereafter, at least the outer mold member is removed to expose the consolidated powder structure. By appropriately shaping the mold members to tailor the shape of the cavity, the consolidated powder structure has the desired shape for the exterior shell of a component, such that subsequent processing of the component does not require substantially altering the configuration of the exterior shell. The airfoil can be produced as a free-standing article or produced directly on a mandrel that subsequently forms the interior structure of the component. In one embodiment, an airfoil is configured to have double walls through which cooling air flows.

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Pending U.S. Patent Application Serial No. 08/905,628, filed Aug. 4, 1997, by Jackson et al., entitled "Graded Bond Coat for a Thermal Barrier Coating System".

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