Powder Metallurgy for Complex Metal Components

Isostatic pressing canister for manufacturing components using isostatic pressing that reduces filling time and prevents canister failure compared to using multiple filling points. The canister has a filling point with a hole in the wall. Inside the cavity, a structure is positioned between the hole and the opposite wall. This deflects powder falling from the hole away from the opposite wall during filling, preventing powder piling up and blocking the hole. This allows complete filling of complex canister shapes without multiple points. The canister can be retained as part of the component to consolidate the powder inside.

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Canisters for hot isostatic pressing (HIP) of powdered materials that dissolve in acid faster than the rest of the canister body. This allows easier removal of the canister after HIP processing compared to machining or acid etching. The canister has a body with a cavity for the powder, an insertion opening, and a sealable closure. A weakening area is created in the body that dissolves faster in acid. This area can be left uncoated or unsealed to enable acid etching to selectively remove it. After HIP processing, the canister can be dissolved in acid to separate the etched-away weakening area from the formed part. This avoids issues like ejected pieces or difficulty recycling material from conventional machining.

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Automated method for packing powdered metal for additive manufacturing. The method involves adding powder to a reservoir, inserting a vibrating tool to compact the powder, and repeating the process. The vibrating tool has a sleeve that envelops a vibration source. The sleeve is clamped onto the tool. The tool is inserted into the powder reservoir and vibrated to compact the powder.

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Understanding the packing behavior of binary mixtures of non-spherical particles like cylinders to improve compression strength and other properties compared to spherical particles. The study uses simulation and analysis techniques to investigate the local packing structure and porosity patterns of binary mixtures of cylindrical particles with varying aspect ratios. It compares the packing microstructure using methods like Voronoi tessellation and voxelization to analyze the compacts' regional porosity structure and plane packing fraction allocations across all axes. This provides insights into the effects of particle shape, size, density, and packing progression factors on the packing structure of binary mixtures of non-spherical particles.

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Method and apparatus for packing powder for additive manufacturing using a vibrating tool to compact the powder uniformly in the reservoir. The packing tool has a vibration source enclosed in a sleeve that can be removed. The tool is inserted into the reservoir and vibrated at variable frequency and intensity to compact the powder. This is repeated rotating the tool 90 degrees each time until it completes a full rotation. The tool is also equipped with a pressure sensor to prevent over-compaction. The powder can be fed into the reservoir through tubes before packing starts.

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Automated method for packing powdered metal for additive manufacturing. The method involves adding powder to a reservoir, inserting a packing tool with a vibrating source and mechanical member, vibrating the tool to compact the powder, adding more powder, and repeating. The packing tool has a sleeve that envelops the vibration source and a clamp that grips the sleeve. The vibrating source and mechanical member compact the powder into a layer.

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Isostatic pressing canister for manufacturing components using isostatic pressing that reduces filling time and risks of canister failure compared to using multiple filling points. The canister has a single filling point with a hole in the wall. Inside the cavity, a structure is located between the hole and the opposite wall surface. This deflects powder falling from the hole away from the opposite wall surface during filling, preventing powder piling up there. This allows complete filling of complex-shaped cavities without needing multiple filling points.

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Powder metallurgy method for making complex metal parts without the need for intermediate steps like billet production. The method involves compressing and consolidating metal powder inside a sealed container using a hot isostatic pressing process. The container deforms during pressing to fuse and consolidate the powder into a solid shape. The container is then removed to access the consolidated part. This enables making intricate metal components directly from powder without requiring separate billets.

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Powder metallurgy method to produce metal components with improved properties compared to traditional powder metallurgy methods. The method involves using a sealed canister with an annular chamber to consolidate metal powder using hot isostatic pressing (HIP) instead of sintering. The powder is inserted into the canister, the chamber evacuated, and then subjected to HIP processing where heat and pressure cause fusion and consolidation. The canister deforms during HIP but is removed after consolidation to reveal the dense metal component inside. This allows forming complex shapes with high density and properties without the need for further machining.

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Hot isostatic pressing (HIP) canister design for consolidating powdered materials using HIP processing to improve mechanical properties and workability. The canister has a unique endplate shape to reduce stress concentration during HIP consolidation. The endplate thickness increases from the center to a corner region where it transitions into a lip that mates with the canister body. This gradual taper and radiused corner smooth transition eliminates sharp corners and high stress points. It allows the canister to deform uniformly during HIP without failure or cracking. The canister also has a single fill stem instead of multiple stems. This simplifies filling and degassing without requiring canister inversion during HIP. The canister shape reduces powder settling and improves compaction efficiency compared to conventional HIP canisters. The endplate material can be selected based on the powder being HIPped.

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HIP canister endplate design that reduces stress concentrations in the corner regions during consolidation. The endplate has a central region with uniform thickness, then gradually increases thickness towards the corner. This creates an incline angle. The inner corner surface has a curved transition to smoothly connect the major region to the lip that engages the canister body. This gradual transition distributes stresses and prevents localized strain and weld breakage compared to abrupt corner edges. The design improves consolidation uniformity and reduces billet defects.

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Automated powder packing method for additive manufacturing using a vibrating tool to consistently and quickly pack powder into a reservoir. The method involves adding powder, inserting a vibrating tool with multiple vibration elements, and vibrating the elements to pack the powder. The tool has a top plate with vibration elements that extend down to the bottom plate. The bottom plate can be raised while vibrating to a pressure limit. The tool is rotated and lowered repeatedly to pack the powder uniformly. The vibration isolates the powder reservoir from external vibrations.

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Automated powder packing system for additive manufacturing that consistently and quickly packs powder into the build chamber for 3D printing. The packing tool has a vibrating sleeve enveloping an electrically powered vibration source. This tool is inserted into the powder reservoir and vibrated to compact the powder into layers. The tool has a pressure sensor to monitor density. The tool can be raised while vibrating to reach a pressure limit, then lowered into the chamber. This repeatable packing process ensures uniform density without operator variability.

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A low-cost titanium composite material for applications like land transportation where titanium's high cost is a barrier. The composite has an outer layer with titanium properties and an inner layer with lower titanium content. The outer layer prevents contamination of the inner layer during processing. The outer layer thickness is 0.1 mm or more to improve mechanical properties. The composite is manufactured by hot processing a packing body containing titanium powder and other materials. After processing, the outer layer is peeled off to reveal the inner layer with reduced titanium content. This reduces production cost compared to making a solid titanium part.

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