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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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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A hot isostatic pressing (HIP) canister design that improves powder filling and prevents failure during HIP processing compared to conventional multi-stem canisters. The single-stem canister has an end plate with a tapered thickness increasing from the center to corners. The inner corner has a radiused transition to smoothly join the main area. This geometry reduces stress concentrations and prevents collapse during HIP. The single filling stem allows filling the canister by turning it inside out, eliminating the need to flip multiple-stem canisters. The smooth corner transitions also prevent powder segregation and enable complete filling. The tapered end plate reduces stress and improves bonding compared to flat corners. The canister geometry prevents collapse and improves HIP performance.

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Hot isostatic pressing (HIP) canister design for consolidating powder materials using hot pressure to improve properties. The canister has a cylindrical body with endplates at each end. The endplate design reduces stress concentration and failures during HIP consolidation. The endplate has a central region with uniform thickness, transitioning radially to a corner with a lip that mates to the canister end. This tapered corner radius smoothly transitions the endplate to the canister. This eliminates sharp corners and welds that can fail under HIP pressure. A single fill stem through the endplate allows powder introduction and degassing without flipping the canister.

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Cemented carbide devices for press dies and punches used in manufacturing bottle caps with improved wear resistance and strength. The devices are made by a process involving ball milling, vacuum treatment, and high-speed sintering. The process steps are: 1) Ball milling tungsten carbide and cobalt powders. 2) Vacuum treating the mixed powder. 3) High-speed sintering the powder under pressure using direct current. The powder mixture contains 11-17% cobalt, ball milled with reinforced stainless steel containers to minimize impurities. The sintering is perpendicular to the pressing direction.

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Wear plates for balers that have a profiled surface to increase durability compared to flat plates. The profiled surface can have wave, trapezoidal, triangular, or mixed shapes. The profiled wear plates are manufactured using additive manufacturing techniques where a powder of a second metal is applied as an outer layer on a support made of a first metal. This allows complex shapes to be generated without the need for machining hard metals like hardox. The profiled shapes provide improved wear resistance compared to flat plates, particularly in high-stress baling applications.

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Hot isostatic pressing container design for consolidating powdered materials like metals into solid billets without internal mandrels to improve filling and reduce billet cracking. The container has an end plate with a conical inner surface and rounded corner to spread stress during consolidation instead of concentrated corners. This reduces the risk of weld failure and billet damage. The conical end plate shape enables complete powder filling without inverting the container.

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Hot isostatic pressing (HIP) canister design for consolidating metal powders using high pressure and temperature to improve material properties. The canister has an endplate with a tapered corner that reduces stress concentration during HIPping. The endplate thickness increases from the center to the corner and has a radiused transition to the lip that mates with the canister body. This avoids sharp corners and welds that can fail under the high pressures and strains of HIPping. The tapered corner design allows uniform compression of the powder and prevents cracking or deformation issues in the corners.

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Hot isostatic pressing (HIP) canister design that improves powder filling and reduces failure during consolidation compared to conventional canisters with multiple fill stems. The canister has a single fill stem through one endplate. The endplate has a tapered corner with a radiused transition to the body. This shape reduces stress concentration and enables complete powder filling without flipping the canister during HIPping. The tapered corner allows smooth mating with the cylindrical body. The single fill stem simplifies powder introduction and evacuation without inverting the canister. The tapered corner design also reduces cracking at the corner during HIPping.

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Hot isostatic pressing (HIP) container for compacting powder materials using isostatic compression. The container has an end plate with a tapered thickness from the center to the edge. This tapered shape reduces stress concentrations and prevents weld failure during HIP sealing. The end plate also has a single filler rod for loading powder instead of multiple rods that require container turning. The rounded inner corner smooths powder flow.

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Hot isostatic pressing (HIP) can for powder consolidation with improved powder filling, reduced weld failures, and flatter billet ends compared to conventional can designs. The can has end plates with tapered inner faces that transition to the cylindrical body. This allows complete powder filling without stems and reduces stress concentrations at the end plate corners during consolidation. The tapered end faces also flatten during HIPping, avoiding convex ends on the billets that require machining.

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A hot isostatic pressing (HIP) canister design with a shaped endplate to improve powder filling and reduce cracking during HIP consolidation. The endplate has a central region with uniform thickness, transitioning into a corner region with increasing thickness and a radiused transition. This gradual taper reduces stress concentration and prevents weld failure during HIP. The corner lip mates with the canister body and the fill stem enters through the central region. This allows complete powder filling without needing multiple stems or inverting the canister.

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HIPping canister design with improved powder filling and reduced stress concentration during hot isostatic pressing (HIP) that eliminates the need to flip the canister during filling or HIPping. The canister has an endplate with a tapered corner that smoothly transitions into the cylindrical body. This shape avoids sharp corners that can trap powder during filling or HIPping, preventing complete consolidation. The endplate thickness increases toward the corner to reduce stress concentration. The endplate can have a bore for powder introduction and air evacuation through a fill stem. This simplified design avoids multiple fill stems and allows complete filling without inversion.

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Hot isostatic pressing (HIP) canister design that reduces stress concentrations and improves filling efficiency compared to conventional canisters. The canister has endplates with tapered corners that smoothly transition into the body of the canister. The thickness of the endplate increases from the center to the corner to match the canister thickness. This gradual taper prevents sharp corners during HIP consolidation that can cause weld failure and incomplete densification. The endplates also have a bore for powder filling and an external fill stem. This eliminates the need for multiple fill stems that add cost and complexity.

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Hot isostatic pressing (HIP) canister design for uniformly compacting and consolidating powders during HIP processing to improve mechanical properties and workability of metal parts. The canister has an end plate with a tapered shape that reduces stress concentration at the corners during HIP consolidation. The end plate thickness increases from the center to the corners to define a taper angle. The inner surface of the corners contains a radiused transition to smoothly connect the main area to the outer lip. This gradual taper and radiused corners prevent localized high strain and cracking during HIP consolidation. The canister also has a single filling stem instead of multiple stems to simplify filling and avoid stem failures. The stem can be crimped to seal the canister after filling. The canister shape allows complete filling and uniform powder flow without turning the canister inside out. The end plate design reduces stress concentration and improves consolidation

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