Method for making turbine engine components using metal injection molding

Abstract

A method for manufacturing a turbine shroud segment with at least one undercut region. The method includes forming a removable insert including an external surface corresponding to at least a portion of a wall of the undercut region in the turbine shroud segment; placing the removable insert in a mold including a mold cavity corresponding to a shape of the turbine shroud segment; injecting a metal injection molding (MIM) feedstock into the mold cavity and around the removable insert to form a shroud green body with the at least one undercut region; and, sintering the shroud green body to form the shroud body.

1 . A method for manufacturing a turbine shroud segment with at least one undercut region comprising an overhang and at least one arcuate wall portion, the method comprising:
 providing a mold comprising a mold cavity corresponding to a shape of the turbine shroud segment, wherein the mold cavity comprises a first adjustable tool with an external surface corresponding to a shape of the at least one an arcuate wall portion in a first undercut region of the at least one undercut region, wherein the mold cavity comprises a second adjustable tool with an external surface corresponding to a shape of an arcuate wall portion in a second undercut region of the at least one undercut region;   adjusting the first adjustable tool to provide a desired configuration of the arcuate wall portion in the first undercut region, wherein the first adjustable tool does not extend beyond the first undercut region;   adjusting the second adjustable tool to provide a desired configuration of the arcuate wall portion in the second undercut region, wherein the second adjustable tool does not extend beyond the second undercut region;   injecting with a metal injection molding (MIM) process a metal powder mixture into the mold cavity and around the first adjustable tool and the second adjustable tool to form a shroud green body having the first undercut region and the second undercut region; and   sintering the shroud green body to form the shroud body.   
     
     
         2 . The method of  claim 1 , wherein the first adjustable tool and the second adjustable are removed from the shroud green body following the sintering step. 
     
     
         3 . The method of  claim 1 , wherein the first adjustable tool and the second adjustable tool comprise at least one collapsible section. 
     
     
         4 . The method of  claim 1 , wherein each of the first adjustable tool and the second adjustable tool comprises a first arm for attachment to the mold and a second arm for supporting the overhang. 
     
     
         5 . The method of  claim 4 , wherein the first arm and the second arm are joined with at least one fastener. 
     
     
         6 . The method of  claim 4 , wherein the first arm and the second arm are joined with a threaded rod. 
     
     
         7 . The method of  claim 4 , wherein the second arm is formed from a plurality of telescoping segments. 
     
     
         8 . The method of  claim 1 , wherein each of the first adjustable tool and the second adjustable tool is a pneumatic device. 
     
     
         9 . The method of  claim 1 , wherein each of the first adjustable tool and the second adjustable tool is a hydraulic device. 
     
     
         10 . The method of  claim 1 , wherein each of the first adjustable tool and the second adjustable tool is active through one or more of a gear, a sprocket, a lever, a toggle, a clamp, or a press.