Shrouded wheel method of manufacture

The method of sinter-fusing moulded parts using metal injection moulding addresses the challenges of manufacturing shrouded wheels by enabling high-volume production of strong, complex, and accurately sized turbomachine components with improved surface finish and reliability.

WO2025059090A1 Publication Date: 2025-03-20GARRETT TRANSPORTATION I INC
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Patent Information

Application Number
PCT/US2024/046061
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2024-03-25
Filing Date
2024-09-11
Publication Date
2025-03-20

AI Technical Summary

Technical Problem

Current methods for manufacturing shrouded wheels for turbomachines are complex, costly, and limited in producing high volumes of small, strong, durable, and complex structures with fine tolerances.

Method used

A method involving the use of metal injection moulding (MIM) to create two moulded parts that are then sinter-fused together to form a unitary, monolithic shrouded wheel, eliminating the need for overt melting and allowing for high-volume production of complex parts.

Benefits of technology

This method enables the efficient and cost-effective manufacturing of small, strong, and complex shrouded wheels with fine tolerances, achieving a high surface finish and reducing the need for post-processing, while also providing a uniform microstructure and improved reliability.

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Abstract

A method for manufacturing a turbomachine shrouded wheel involves separately moulding a first green, moulded part forming a hub and blades, and a second green, moulded part forming a shroud, using a feedstock comprising a metal powder and a binder. The green, moulded parts are adjoined in a mated configuration, with additional feedstock placed between respective connection-surfaces on the moulded parts. The adjoined moulded parts are sintered to fuse them into a single unitary, monolithic structure. The moulded parts' connection-surfaces form conforming protrusions and depressions, which have surface discontinuities spaced at intervals along their respective lengths.
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