Method of Making Near-Net Shapes From Powdered Metals

Abstract

A method of manufacturing a product includes forming a metal powder into a desired shape, transferring the formed metal powder and pressure transmission media into a container, and applying heat and pressure to the container to form a consolidated product from the formed metal powder.

1 . A method of manufacturing a product, comprising:
 forming a metal powder into a desired shape;   transferring the formed metal powder and pressure transmission media into a container; and   applying heat and pressure to the container to form a consolidated product from the formed metal powder.   
     
     
         2 . The method of  claim 1 , wherein the metal powder includes an alloy or intermetallic compound. 
     
     
         3 . The method of  claim 1 , wherein forming the metal powder into the desired shape includes loading the metal powder into a mold having at least one cavity therein that is shaped to correspond to a near final shape of the product. 
     
     
         4 . The method of  claim 3 , wherein the formed metal powder is transferred into the container with the mold. 
     
     
         5 . The method of  claim 3 , wherein the formed metal powder is at least partially sintered and separated from the mold before being transferred into the container. 
     
     
         6 . The method of  claim 5 , further comprising repeating the method while reusing the mold. 
     
     
         7 . The method of  claim 1 , wherein a composition of the metal powder includes at least one of Ni and Ti. 
     
     
         8 . The method of  claim 7 , wherein a composition of the metal powder includes 58-62 wt % Ni and 38-42 wt % Ti. 
     
     
         9 . The method of  claim 8 , wherein the composition of the metal powder further includes up to 5% of other elements. 
     
     
         10 . The method of  claim 1 , wherein the pressure transmission media includes at least one of alumina and zircon sand. 
     
     
         11 . The method of  claim 1 , further comprising, between the steps of transferring the formed metal powder and pressure transmission media into the container and applying heat and pressure to the container:
 sealing a lid onto an opening of the container, the lid having a vacuum port therein;   applying a vacuum via the vacuum port to evacuate the interior of the container; and   sealing the vacuum port while under vacuum to provide an sealed evacuated container.   
     
     
         12 . The method of  claim 1 , wherein applying heat and pressure to the container includes hot isostatically pressing the container. 
     
     
         13 . The method of  claim 1 , further comprising finishing the consolidated product to form the final shape of the product. 
     
     
         14 . The method of  claim 1 , wherein forming the metal powder into the desired shape includes forming the powder via an additive manufacturing process. 
     
     
         15 . The method of  claim 14 , wherein the additive manufacturing process includes cold or thermal spray, or directed energy additive manufacturing. 
     
     
         16 . A method of preparing a metal powder for consolidation, comprising:
 forming a metal powder into a desired shape;   transferring the formed metal powder and pressure transmission media into a container; and   applying a vacuum to and sealing the container.