Method of forming a component from a green part

Abstract

A method of forming a component from a part in the green state, including selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion to obtain the component. The green part is provided with the first portion(s) having a first solid loading and the second portion(s) having a second solid loading different from the first solid loading, then debound and sintered to obtain the component. The different first and second solid loadings produce the different local volume reduction in the first portion(s). The first portion(s) can be selected by determining a resulting final shape obtained from debinding and sintering a green part having a uniform first volumetric proportion of binder, and selecting the first portion(s) requiring a different local deformation than that producing the resulting final shape to obtain a desired final shape.

Description

TECHNICAL FIELD[0001]The application relates generally to the manufacturing of components from green parts and, more particularly, to powder injection molding processes.BACKGROUND OF THE ART[0002]When manufacturing complex parts using powder injection molding, the volume reduction of the part occurring during sintering is often anisotropic, i.e. the deformations caused by the volume reduction are often more important in one direction when compared to the other. Accordingly, the shape of the part may change during sintering, which may prevent parts from being manufactured within tight dimensional tolerances.[0003]Moreover, some gas turbine engine panel components, such as for example some combustor heat shield panels, may have features which are relatively hard to mold. Such features may include, for example, a curved shape, angled retention elements and / or angled cooling holes. Accordingly, manufacturing these components using a molding process while being able to easily remove the ...

AI Technical Summary

Benefits of technology

[0004]In one aspect, there is provided a method of forming a component from a part in a green state, the method comprising: selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion of the part to obtain the component; providing the part in the green state including: the at least one first portion having a first volume of powder material VP1 and a first volume of binder VB1, the at least one first portion having a first solid loading defined as VP1 / (VP1+VB1), and the at least one second portion having a second volume of powder material at least one second portion VP2 and a second volume of binder VB2, the at least one second portion having a second solid loading defined as VP2 / (VP2+VB2), the first and second solid loadings having different values from one another; and debinding and sintering the part to obtain the component, the different values of the first and second solid loadings producing the different local volume reduction in the at least one first portion with respect to the at least one second portion.

Problems solved by technology

Moreover, some gas turbine engine panel components, such as for example some combustor heat shield panels, may have features which are relatively hard to mold.

Accordingly, manufacturing these components using a molding process while being able to easily remove the component from the mold cavity may require the use of a mold with a complex configuration, which may render the use of a molding process such as powder injection molding to manufacture these components undesirable and / or impractical.

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