Method of using powder metallurgy fabrication for manufacturing integral header and tube replacement sections

Abstract

A method of manufacturing integral head and tube replacement sections includes the steps of providing a reverse mold of a head and tube replacement section, providing an atomized steel powder, and filling the reverse mold with the atomized steel powder. The method further includes the step of inserting the mold into a hot isostatic processing (HIP) furnace to consolidate and sinter the powder into the shape of the head and tube replacement section.

1 . A method of manufacturing integral head and tube replacement sections, comprising the steps of:
 (a) providing a reverse mold of a head and tube replacement section;   (b) providing an atomized steel powder;   (c) filling the reverse mold with the atomized steel powder; and   (d) inserting the mold into a hot isostatic processing (HIP) furnace to consolidate and sinter the powder into the shape of the head and tube replacement section.   
     
     
         2 . The method according to  claim 1 , further including the step of subjecting the mold to a vacuum to eliminate air pockets. 
     
     
         3 . The method according to  claim 2 , further including the step of sealing the mold to maintain vacuum. 
     
     
         4 . The method according to  claim 1 , further including the step of bringing the HIP furnace up to a high pressure and a high temperature to consolidate and sinter the powder. 
     
     
         5 . The method according to  claim 4 , wherein the HIP furnace is brought up to a high temperature and high pressure in an inert gas atmosphere. 
     
     
         6 . The method according to  claim 4 , further including the step of maintaining the HIP furnace at a high temperature and high pressure for a pre-determined amount of time. 
     
     
         7 . The method according to  claim 1 , further including the step of cooling the mold and sintered powder to room temperature. 
     
     
         8 . The method according to  claim 1 , further including the step of heat treating the head and tube replacement section. 
     
     
         9 . The method according to  claim 1 , further including the step of finishing the head and tube replacement section into final form. 
     
     
         10 . The method according to  claim 9 , wherein the step of finishing includes the step of grinding the outer surface of the head and tube replacement section to remove any residuals and obtain a final surface. 
     
     
         11 . The method according to  claim 9 , wherein the step of finishing includes the step of boring a stub tube of the head and tube replacement section to produce an inner penetration. 
     
     
         12 . The method according to  claim 9 , wherein the step of finishing includes the step of chamfering an inside of bore regions of the head and tube replacement section.