Three-Dimensional Printed Hot Isostatic Pressing Containers and Processes for Making Same

Abstract

Methods are disclosed for making a hot isostatic pressing container for hot isostatic pressing a powder material to form an article comprising three-dimensionally printing the container from a build powder, the container having a cavity for receiving the powder material and an outer section having an outer surface, the cavity having a surface and being shaped and sized so that hot isostatic pressing the container with the powder material within the cavity results in the production of the article. Methods are also disclosed for making the hot isostatically pressed article using the container.

What is claimed is: 
     
         1 . A method for making a container ( 20 ) for hot isostatic pressing a powder material to form an article ( 2 ) comprising three-dimensionally printing the container ( 2 ) from a build powder, the container having a cavity ( 26 ) for receiving the powder material and an outer section ( 22 ) having an outer surface, the cavity having a surface and being shaped and sized so that hot isostatic pressing the container ( 20 ) with the powder material within the cavity ( 26 ) results in the production of the article ( 2 ) surrounded by the container ( 20 ). 
     
     
         2 . The method of  claim 1 , wherein the article ( 2 ) has an internal passageway ( 8 ) and the step of three-dimensionally printing the container ( 20 ) includes forming a core ( 24 ) adjacent to the cavity ( 26 ). 
     
     
         3 . The method of  claim 1 , further comprising the step of sealingly coating at least a portion of the outer surface with at least one layer of a gas-impervious coating ( 42 ). 
     
     
         4 . The method of  claim 3 , wherein the step of sealingly coating includes applying the gas-impervious coating ( 42 ) by at least one selected from the group consisting of electrolplating and electroless plating. 
     
     
         5 . The method of  claim 3 , wherein the gas-impervious coating ( 42 ) comprises nickel. 
     
     
         6 . The method of  claim 3 , wherein the gas-impervious coating ( 42 ) has a thickness in the range of 60 microns to 100 microns. 
     
     
         7 . The method of  claim 3 , wherein the step of sealingly coating includes applying the gas-impervious coating ( 42 ) by dipping the container ( 20 ) into a bath comprising the coating material. 
     
     
         8 . The method of  claim 3 , wherein the step of sealingly coating includes applying the gas-impervious coating ( 42 ) by plasma-spray deposition. 
     
     
         9 . The method of  claim 1 , further comprising the step of increasing the inertness of a portion of the cavity surface which is to come in contact with the powder material. 
     
     
         10 . The method of  claim 9 , wherein the step of increasing the inertness includes contacting the cavity surface with at least one of chemical solution and a suspension. 
     
     
         11 . The method of  claim 9 , wherein the step of increasing the inertness includes exposing the cavity surface to a gas or combination of gasses at a preselected temperature. 
     
     
         12 . The method of  claim 9 , wherein the step of increasing the inertness includes coating the cavity surface with an inert material. 
     
     
         13 . The method of  claim 12 , wherein the inert material is at least one selected from the group consisting of boron nitride and alumina. 
     
     
         14 . The method of  claim 1 , wherein the build powder comprises a steel powder. 
     
     
         15 . A method for making an article ( 2 ) including the steps of:
 three-dimensionally printing a hot isostatic pressing container ( 20 ) from a build powder, the container ( 20 ) having a cavity ( 26 ) for receiving a powder material and an outer section ( 22 ) having an outer surface, the cavity ( 26 ) having a surface and being shaped and sized so that hot isostatic pressing the container with the powder material within the cavity ( 26 ) results in the production of the article ( 2 ) surrounded by the container ( 20 );   loading the powder material into the cavity ( 26 ); and   hot isostatically compressing the container ( 20 ) with the powder material within the cavity ( 26 ).   
     
     
         16 . The method of  claim 15 , wherein the article ( 2 ) has an internal passageway ( 8 ) and the step of three-dimensionally printing the container ( 20 ) includes forming a core ( 24 ) adjacent to the cavity ( 26 ). 
     
     
         17 . The method of  claim 15 , further comprising the step of sealingly coating at least a portion of the outer surface with at least one layer of a gas-impervious coating ( 42 ). 
     
     
         18 . The method of  claim 17 , wherein the gas-impervious coating ( 42 ) comprises nickel. 
     
     
         19 . The method of  claim 15 , further comprising the step of increasing the inertness of a portion of the cavity surface which is to come in contact with the powder material. 
     
     
         20 . The method of  claim 1 , wherein the build powder comprises a steel powder.