Powder Metallurgy Alloy Forging

Abstract

A method for forming an article by introducing one or more powders into a bag. Vacuum is applied to the bag. The bag is sealed. The one or more powders in the sealed bag are forged.

What is claimed is: 
     
         1 . A method for forming an article ( 60 ) comprising:
 introducing one or more powders ( 331 ) to a bag ( 310 );   applying vacuum and/or gas to the bag;   sealing the bag; and   forging the one or more powders in the sealed bag to form at least a precursor ( 604 ,  606 ,  608 ) of the article.   
     
     
         2 . The method of  claim 1  wherein the forging is a first forging in a first die ( 600 ) and the method further comprises:
 a second forging in a second die ( 610 ). 
 
     
     
         3 . The method of  claim 2  wherein:
 a third forging in a third die ( 620 ). 
 
     
     
         4 . The method of  claim 3  wherein:
 the first forging, the second forging, and the third forging are the only forgings. 
 
     
     
         5 . The method of  claim 3  further comprising:
 a heat soak between the first forging and the second forging; and 
 a heat soak between the second forging and the third forging. 
 
     
     
         6 . The method of  claim 2  wherein:
 there is no die extrusion step. 
 
     
     
         7 . The method of  claim 2  further comprising:
 a machining after the second forging. 
 
     
     
         8 . The method of  claim 1  wherein:
 the article is a blade comprising:
 an airfoil ( 62 ); and 
 an attachment root ( 64 ). 
 
 
     
     
         9 . The method of  claim 1  wherein:
 the article comprises an aluminum alloy. 
 
     
     
         10 . The method of  claim 9  wherein:
 the aluminum alloy is a SAM alloy comprising Al with Y, Ni, Co, Zr. 
 
     
     
         11 . The method of  claim 9  wherein:
 the aluminum alloy is an I-phase alloy comprising Al with Cr, Mn, Co, and Zr. 
 
     
     
         12 . The method of  claim 1  wherein:
 a peak temperature is less than 500° C. 
 
     
     
         13 . The method of  claim 1  wherein:
 the bag comprises an aluminum alloy having a wall thickness less than 6.5 mm. 
 
     
     
         14 . The method of  claim 1  wherein:
 the bag comprises an aluminum alloy having a wall thickness less than 1.5 mm. 
 
     
     
         15 . The method of  claim 1  wherein:
 the bag comprises an inner surface which is separated from the outer surface by a thin-walled metal that, unlike a can, is collapsible or partially collapsible due to atmospheric pressure on the outer surface when the inner surface is subjected to a vacuum. 
 
     
     
         16 . The method of  claim 1  wherein:
 the bag comprises a polymer having a wall thickness less than 2 mm. 
 
     
     
         17 . The method of  claim 1  wherein:
 the sealing comprises either liquid or solid-state welding. 
 
     
     
         18 . An article produced by the method of  claim 1 .