Method for manufacturing sintered component

Abstract

The present invention comprises: a step for preparing a container having a storage part, an object that is to be processed and stored in the storage part, and a lid for covering the storage part; a step for storing the object in the storage part and covering the storage part with the lid; a step for producing a sealing body by welding the container in which the object is stored and the lid, at least part of said welding being performed in a vacuum; and a step for subjecting the sealing body to hot isostatic pressing. In the method for manufacturing a sintered component, the container is manufactured by feed forward processing.

Description

Manufacturing method for sintered parts

[0001] This disclosure relates to a method for manufacturing a sintered part. This application claims priority to Japanese Application No. 2024-064371, filed April 12, 2024, and incorporates by reference all of the contents of said Japanese application.

[0002] Patent Literature 1 discloses a method for manufacturing sintered parts by hot isostatic pressing (HIP). This manufacturing method includes the steps of: preparing a capsule having a storage portion; storing an object to be hot isostatically pressed in the storage portion; creating a vacuum inside the capsule; and hot isostatically pressing the evacuated capsule. The capsule manufacturing step includes the steps of preparing a component, which is a T-shaped pipe, using a 3D printer; and welding multiple steel plates to the component so as to form a storage portion between the component and the outer surface of the component.

[0003] JP 2023-76470 A

[0004] The method for manufacturing a sintered part according to the present disclosure includes the steps of preparing a container having a storage section, an object to be stored in the storage section, and a lid that covers the storage section, storing the object in the storage section and covering it with the lid, welding the container containing the object to the lid at least partially in a vacuum to produce a sealed body, and hot isostatically pressing the sealed body. The container is manufactured by progressive processing.

[0005] FIG. 1 is an explanatory diagram illustrating progressive processing for producing a container used in the method for manufacturing a sintered part of embodiment 1. FIG. 2 is an explanatory diagram illustrating steps A to B in the method for manufacturing a sintered part of embodiment 1. FIG. 3 is an explanatory diagram illustrating step C in the method for manufacturing a sintered part of embodiment 1. FIG. 4 is an explanatory diagram illustrating step D in the method for manufacturing a sintered part of embodiment 1. FIG. 5 is an explanatory diagram illustrating a manufacturing apparatus for a sintered part used in the method for manufacturing a sintered part of embodiment 2. FIG. 6 is an explanatory diagram illustrating a manufacturing apparatus for a sintered part used in the method for manufacturing a sintered part of embodiment 3. FIG. 7 is an explanatory diagram illustrating the operation of the first pass box and the fifth conveying path provided in the manufacturing apparatus for a sintered part of FIG. 6.

[0006] The production time of components using 3D printers is very long, which reduces the productivity of sintered parts, and the cost of producing components using 3D printers is very high.

[0007] An object of the present disclosure is to provide a method for manufacturing a sintered part that improves the productivity of the sintered part.

[0008] The method of manufacturing a sintered part of the present disclosure improves the productivity of sintered parts.

[0009] First, embodiments of the present disclosure will be listed and described.

[0010] (1) A method for manufacturing a sintered part according to an embodiment of the present disclosure includes the steps of preparing a container having a storage section, an object to be stored in the storage section, and a lid that covers the storage section, storing the object in the storage section and covering it with the lid, welding the container containing the object to the lid at least partially in a vacuum to produce a sealed body, and hot isostatically pressing the sealed body. The container is manufactured by progressive processing.

[0011] Progressive processing improves the productivity of containers, allowing containers to be manufactured at low cost. Therefore, the manufacturing method for sintered parts described above in (1) improves the productivity of sintered parts, allowing sintered parts to be manufactured at relatively low cost.

[0012] (2) In the method for producing a sintered part according to (1) above, the thickness of the container may be 20 μm or more and 2 mm or less.

[0013] In progressive processing, it is easy to produce a container with a thickness of 20 μm or more. When the thickness of the container is 2 mm or less, it is relatively easy to form the container in progressive processing, it is easy to produce a sintered part using the container in the hot isostatic pressing step, and it is easy to reduce the processing cost when cutting and removing a part of the container after hot isostatic pressing.

[0014] (3) In the method for manufacturing a sintered part according to (1) or (2), the material of the container and the lid may be one selected from the group consisting of iron, iron alloy, titanium, and titanium alloy. The thickness of the welded portion of the container and the welded portion of the lid may be 20 μm or more and 150 μm or less. The welding may be seam welding.

[0015] When the thickness of the welded portion of the container and the welded portion of the lid made of the above material is 20 μm or more and 150 μm or less, seam welding is easy.

[0016] (4) In any of the methods for manufacturing a sintered part described above in (1) to (3), the shape of the container may correspond to the shape of the final product of the sintered part manufactured in the hot isostatic pressing process.

[0017] In the manufacturing method of sintered parts described above in (4), hot isostatic pressing is performed using a container having a shape corresponding to the final product shape of the sintered part, so that near-net shaping, which is a finishing process close to the shape of the final product, is possible.

[0018] (5) In the method for manufacturing a sintered part according to any one of (1) to (4) above, the container may include a plurality of the storage sections.

[0019] In the method for producing a sintered part described above in (5), the use of a plurality of storage sections shortens the time required for evacuation per object to be processed, thereby further improving the productivity of sintered parts.

[0020] (6) In the method for producing a sintered part according to any one of (1) to (5) above, the preparing step, the housing step, and the sealing body fabricating step may be performed in-line.

[0021] The manufacturing method of a sintered part described above in (6) can produce sintered parts with high productivity because the preparing step, the storing step, and the sealing body manufacturing step are performed in-line, thereby shortening the time required from the preparation to the manufacturing of the sealing body.

[0022] (7) In any one of the methods for manufacturing a sintered part described in (1) to (6), the object to be processed may be one or more selected from the group consisting of powder, a powder compact, a sintered body, and an ingot material.

[0023] In the method for producing a sintered part described above in (7), any of powder, green compact, sintered body, and ingot material can be used as the processing object.

[0024] <Details of the Embodiments of the Present Disclosure> Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. The same reference numerals in the drawings indicate the same objects. The shapes, sizes, positional relationships, etc. shown in each drawing are depicted for the purpose of clarifying the description and do not necessarily represent the actual shapes, sizes, positional relationships, etc. The same reference numerals in the drawings indicate the same objects. Note that the present invention is not limited to the configurations shown in the embodiments, but is defined by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0025] First Embodiment [Method for Manufacturing a Sintered Part] A method for manufacturing a sintered part according to the first embodiment will be described with reference to FIGS. 1 to 4. The method for manufacturing a sintered part according to the first embodiment is a method for manufacturing a sintered part by the HIP process. The method for manufacturing a sintered part according to the first embodiment includes the following steps A to D. In step A, as shown in FIG. 2, a container 11, a lid 12, and an object to be processed 13 are prepared. In step B, the object to be processed 13 is placed in the storage section 11a of the container 11, and the lid 12 is placed thereon. In step C, as shown in FIG. 3, the container 11 and the lid 12 are welded together in a vacuum to form a sealed body 10b. In step D, as shown in FIG. 4, the sealed body 10b is hot isostatically pressed. One of the features of the method for manufacturing a sintered part is that in step A, a container 11 manufactured by progressive machining is prepared.

[0026] [Step A] (Container) The container 11 has a storage section 11a. The storage section 11a stores the objects to be processed 13. One container 11 may have one or more storage sections 11a. If one container 11 has multiple storage sections 11a, multiple objects to be processed 13 can be hot isostatically pressed together, further improving the productivity of sintered parts.

[0027] As shown in FIG. 1 , the container 11 is manufactured by progressive machining. Progressive machining uses a single die (not shown) in which multiple press processes are arranged at equal intervals. The plate-shaped material is fed through the progressive die by the pitch length, thereby sequentially performing multiple press processes on the same location of the material. Examples of press processes include bending and drawing. FIG. 1 shows an example in which the plate-shaped material is fed from left to right, one pitch at a time, for a total of four pitches. The cylindrical storage portion 11a is formed by sequentially performing four press processes on the same location of the material, with the depths increasing sequentially. The number of press processes performed on the same location of the material is not particularly limited and is not limited to the example shown in FIG. 1 . Progressive machining improves the productivity of the container 11. Therefore, the container 11 can be manufactured at low cost. Therefore, the sintered part manufacturing method of this example improves the productivity of sintered parts. Therefore, sintered parts can be manufactured at relatively low cost.

[0028] The shape of the container 11 may be, for example, a single cylindrical or columnar shape with a uniform diameter, a combination of multiple cylindrical and columnar shapes with different diameters, or a shape with different cross-sectional shapes. The shape of the container 11 may correspond to the final product shape of the sintered part manufactured by hot isostatic pressing, for example. The outer shape may remain the same before and after hot isostatic pressing, but the dimensions may be smaller. A shape corresponding to the shape of the sintered part means that the dimensions are different but the outer shape is the same. By having the container 11 correspond to the final product shape, near-net shape finishing, which is similar to the shape of the final product, is possible.

[0029] The thickness of the container 11 is, for example, 20 μm or more. A container 11 having a thickness of 20 μm or more is easily manufactured by progressive machining. The thickness of the container 11 is, for example, 2 mm or less. A container 11 having a thickness of 2 mm or less is relatively easy to form in progressive machining, facilitates the production of a sintered part using the container 11 in the hot isostatic pressing process, and facilitates reducing the processing cost when cutting and removing a portion of the container 11 after hot isostatic pressing. The thickness of the container 11 may be 50 μm or more. A container 11 having a thickness of 50 μm or more is easily manufactured by progressive machining. The thickness of the container 11 may be 1 mm or less. The thickness of the container 11 may be 20 μm or more and 2 mm or less, 50 μm or more and 1 mm or less, 50 μm or more and 200 μm or less, or 80 μm or more and 150 μm or less. The thickness of the container 11 is measured with a micrometer. For example, 10 points are selected arbitrarily from the areas excluding the areas to be welded, and measurements are taken at 10 points. The minimum thickness of the 10 points is 20 μm or more, and the maximum thickness is 2 mm or less.

[0030] When seam welding is performed in step C described below, the thickness of the weld 110 of the container 11 shown in FIG. 2 is, for example, 150 μm or less. The thickness of the weld 110 of the container 11 refers to the thickness of the portion of the container 11 that is to be welded when the container 11 and the lid 12 are combined before welding. If the thickness of the weld 110 of the container 11 is 150 μm or less, seam welding is easy. When seam welding is performed, the thickness of the weld 110 of the container 11 is, for example, 20 μm or more. When seam welding is performed, the thickness of the weld 110 of the container 11 may be 20 μm or more and 150 μm or less, 30 μm or more and 150 μm or less, or 80 μm or more and 120 μm or less. The thickness of the weld 110 of the container 11 is measured with a micrometer. For example, 10 locations are randomly selected from the portions that are to be welded, and measurements are taken at 10 points. The minimum thickness among these 10 points is 20 μm or more and the maximum thickness is 150 μm or less. The roughness Ra of the portion to be welded may be 0.5 mm or less. The thickness of the container 11 other than the weld 110 may be the same as or different from the weld 110. Progressive processing may be performed to thin only the portion that will become the weld 110. After progressive processing, only the portion that will become the weld 110 may be ground to a predetermined thickness. In this way, even if the process for manufacturing the container 11 includes a process for manufacturing a very complex shape, such as deep drawing press processing, the container 11 can be easily manufactured without cracking. From the same perspective, the process for manufacturing the container 11 may include at least one of warm pressing and hot pressing.

[0031] The material of the container 11 is, for example, one selected from the group consisting of pure iron, iron alloy, pure copper, copper alloy, pure titanium, titanium alloy, pure aluminum, and aluminum alloy. The iron alloy is, for example, stainless steel or carbon steel. When seam welding is performed in step C described below, the material of the container 11 is, for example, one selected from the group consisting of pure iron, iron alloy, pure titanium, and titanium alloy.

[0032] (Lid) The lid 12 covers the storage section 11a of the container 11. When there are multiple storage sections 11a, the lid 12 is, for example, a single lid 12 large enough to cover all of the storage sections 11a. The material of the lid 12 is, for example, one selected from the group consisting of pure iron, iron alloy, pure copper, copper alloy, pure titanium, titanium alloy, pure aluminum, and aluminum alloy. The material of the lid 12 may be the same as or different from that of the container 11. The shape of the lid 12 is, for example, a single rectangular plate or disk shape with a uniform thickness, a shape combining a plate shape with at least one of a cylinder and a columnar shape, or a shape combining multiple cylinders and columns.

[0033] The thickness of the lid 12 may be the same as or different from that of the container 11. The thickness of the lid 12 is, for example, 20 μm or more. A thickness of 20 μm or more makes the lid 12 easier to weld. The thickness of the lid 12 is, for example, 500 μm or less. A thickness of 500 μm or less makes it easier to manufacture a sintered part using the lid 12 in a hot isostatic pressing process. The thickness of the lid 12 may be 50 μm or more and 200 μm or less, or 80 μm or more and 150 μm or less. The thickness of the lid 12 is measured with a micrometer. For example, measurements are taken at 10 arbitrary points on the lid 12. The minimum thickness of these 10 points is 20 μm or more and the maximum thickness is 500 μm or less.

[0034] When seam welding is performed in step C described below, the thickness of the weld 120 of the lid 12 shown in FIG. 2 is, for example, 150 μm or less. The thickness of the weld 120 of the lid 12 refers to the thickness of the portion of the lid 12 to be welded when the lid 12 and the container 11 are assembled before welding. If the thickness of the weld 120 of the lid 12 is 150 μm or less, seam welding is easy. When seam welding is performed, the thickness of the weld 120 of the lid 12 is, for example, 20 μm or more. When seam welding is performed, the thickness of the weld 120 of the lid 12 may be 20 μm or more and 150 μm or less, 30 μm or more and 150 μm or less, or 80 μm or more and 120 μm or less. The thickness of the weld 120 of the lid 12 is measured with a micrometer. For example, measurements are taken at 10 points at the portions to be welded. Among these 10 points, the minimum thickness is 20 μm or more and the maximum thickness is 150 μm or less.

[0035] (Object to be Processed) The object to be processed 13 is stored in the storage section 11a of the container 11 and is hot isostatically pressed. The material of the object to be processed 13 is, for example, a metal, a ceramic, or a composite material. The composite material includes, for example, a metal and a ceramic. The metal constituting the object to be processed 13 is, for example, one selected from the group consisting of pure iron, an iron alloy, pure copper, a copper alloy, pure titanium, a titanium alloy, pure aluminum, and an aluminum alloy. The metal constituting the object to be processed 13 may be the same as or different from the material of the container 11. The object to be processed 13 is one or more selected from the group consisting of a powder, a powder compact, a sintered compact, and an ingot material. A powder compact is formed by compacting a powder. A sintered compact is formed by sintering a powder compact. An ingot material is formed by melting and solidifying a material. Hereinafter, the powder compact, the sintered compact, and the ingot material may be collectively referred to as a compact. The shape of the molded body may be, for example, a single cylindrical or columnar body with a uniform diameter, a combination of multiple cylindrical and columnar bodies with different diameters, or a shape with different cross-sectional shapes. The shape of the molded body may correspond to the storage section 11a of the container 11. The shape of the molded body may also correspond to the shape of the final product.

[0036] [Step B] In step B, as shown in the upper diagram of Fig. 2, the object to be treated 13 is stored in the storage section 11a, and the lid 12 is placed on the container 11. The thin arrows extending downward from the object to be treated 13 and the lid 12 in the upper diagram of Fig. 2 indicate that the object to be treated 13 is moved to the storage section 11a of the container 11, and the lid 12 is moved onto the container 11. By placing the lid 12 on the container 11, an assembly 10a is produced, as shown in the lower diagram of Fig. 2, of the container 11 in which the object to be treated 13 is stored in the storage section 11a, and the lid 12 that covers the storage section 11a.

[0037] The processing object 13 stored in one storage section 11a is one or more types selected from the group consisting of powder, powder compact, sintered body, and ingot material. That is, one storage section 11a stores only powder, only powder compact, only sintered body, only ingot material, two types of powder and powder compact, two types of powder and sintered body, two types of powder and ingot material, two types of powder and sintered body, two types of powder and ingot material, two types of powder, powder compact, and sintered body, three types of powder, powder compact, and ingot material, three types of powder, sintered body, and ingot material, three types of powder, powder compact, sintered body, and ingot material, three types of powder, powder compact, sintered body, and ingot material, or four types of powder, powder, powder compact, sintered body, and ingot material. The powder may be one type of powder or multiple types of powders made of different materials. The powder molded body may be one type of powder molded body or multiple types of powder molded bodies made of different materials. The sintered body may be one type of sintered body or multiple types of sintered body made of different materials. The ingot material may be one type of ingot material or multiple types of ingot material made of different materials.

[0038] For example, when only powder is stored in one storage section 11a, only one type of powder or multiple types of powder made of different materials is stored in one storage section 11a. When only powder compacts, sintered compacts, or ingots are stored in one storage section 11a, the same applies as when only powder is stored in one storage section 11a. Furthermore, when two types of materials, powder and powder compacts, are stored in one storage section 11a, one storage section 11a may store one type of powder and one type of powder compact, multiple types of powders made of different materials and one type of powder compact, one type of powder and multiple types of powder compacts made of different materials, or multiple types of powders made of different materials and multiple types of powder compacts made of different materials. The same applies to cases where one storage section 11a stores two types of materials: powder and sintered body, two types of powder and ingot material, two types of powder compacts and sintered body, two types of powder compacts and ingot material, two types of sintered body and ingot material, three types of powder, powder compact, and sintered body, three types of powder, powder compact, and ingot material, three types of powder, sintered body, and ingot material, three types of powder compact, sintered body, and ingot material, or four types of powder, powder compact, sintered body, and ingot material. Depending on the shape of the storage section 11a, even if a compact is placed in the storage section 11a, a gap may be formed between the inner surface of the storage section 11a and the compact. In such cases, if at least one of a powder compact, a sintered body, and an ingot material and a powder are stored in one storage section 11a, the gap can be filled with powder. Therefore, the gap in the storage section 11a can be minimized. The compact is produced by typical uniaxial press molding. It is technically difficult to provide a curved or inclined surface on the pressed surface of a compact produced by uniaxial press molding without cutting. In contrast, progressive processing can include drawing, which forms the container 11 by pressing a punch, and therefore it is easy to provide a curved or inclined surface on the surface of the container 11 that is pressed by the punch. By using a container 11 with a curved surface or the like, and adding powder to the pressed surface of the compact inside the container 11, a curved surface or the like can be easily formed on the pressed surface of the compact.

[0039] [Step C] In step C, as shown in FIG. 3, the container 11 and the lid 12 are welded together in a vacuum to form a sealed body 10b. The black squares in FIG. 3 are weld marks 15. Welding in a vacuum means that at least a portion of the welding between the container 11 and the lid 12 is performed in a vacuum. The entire welding between the container 11 and the lid 12 may be performed in a vacuum. A portion of the welding between the container 11 and the lid 12 may be performed in the atmosphere, and the remaining portion may be performed in a vacuum. When one container 11 has multiple storage sections 11a, the outer periphery of the container 11 and the outer periphery of the lid 12 are welded together to surround all of the storage sections 11a. The degree of vacuum is, for example, 0.1 Pa or less. The atmosphere is an inert gas atmosphere. The inert gas is, for example, argon gas or nitrogen gas.

[0040] The welding may be, for example, seam welding, laser welding, electron beam welding, or TIG (Tungsten Inert Gas) welding. Seam welding is particularly suitable for welding the container 11 and the lid 12 entirely in a vacuum. The welding conditions may be set appropriately depending on the materials of the container 11 and the lid 12. A commercially available welding device may be used for welding.

[0041] [Step D] In step D, the sealed body 10b is hot isostatically pressed, as shown in Fig. 4. The white arrows in Fig. 4 indicate the application of pressure. A sintered part is produced by hot isostatically pressing the sealed body 10b. The conditions for hot isostatic pressing may be set appropriately depending on the material of the workpiece 13. A commercially available HIP apparatus can be used for hot isostatic pressing.

[0042] [Other Steps] After step D, the sintered part may be subjected to a finishing process, if necessary. Finishing is not essential. Finishing is, for example, a mechanical process for removing a portion of the sintered part or for adjusting the dimensions to the design dimensions. The portion of the sintered part that is removed is, for example, at least one of the portion corresponding to the lid 12 and the portion corresponding to the container 11. The mechanical process is, for example, a cutting process or a polishing process.

[0043] Second Embodiment [Method for Manufacturing a Sintered Part] A method for manufacturing a sintered part according to the second embodiment will be described with reference to Fig. 5. Fig. 5 shows a sintered part manufacturing apparatus used in the method for manufacturing a sintered part according to the second embodiment, viewed obliquely from above. The method for manufacturing a sintered part according to the second embodiment differs from the method for manufacturing a sintered part according to the first embodiment in that steps A to C described in the first embodiment are performed in-line. The following description of the second embodiment will focus on the differences from the first embodiment.

[0044] "Performed inline" means that processes A to C are performed in a continuous, serial production line. "Processes A to C being continuous" does not mean that the conveyance path, such as a belt conveyor, that transports the transported object is continuous, but rather that even if the conveyance path is divided into processes, there is a transport device, such as a manipulator, that moves the transported object at the divided point of the conveyance path to the conveyance path of the next process. In the manufacturing method of sintered parts in this example, processes A to C are performed inline, which shortens the time required from process A to process C, and therefore sintered parts can be manufactured with high productivity.

[0045] The manufacturing apparatus for sintered parts includes, for example, a first conveying path 21 , a first transfer device 31 , a second transfer device 32 , and a welding device 6 .

[0046] [First Conveying Path] The first conveying path 21 conveys a molded body, which is the processing object 13. The molded body is a powder compact, a sintered body, or an ingot material. The powder compact is manufactured by a molding apparatus (not shown) and conveyed to the first conveying path 21. The sintered body is manufactured by a sintering apparatus (not shown) and conveyed to the first conveying path 21. The ingot material is manufactured by an ingot equipment (not shown) and conveyed to the first conveying path 21. The molding apparatus, sintering apparatus, or ingot equipment may be connected to the first conveying path 21, or a conveying device (not shown) separate from the first conveying device 31 may move the molded body from the molding apparatus, sintering apparatus, or ingot equipment to the first conveying path 21. The first conveying path 21 may run continuously at a constant speed or may run intermittently by repeatedly running and stopping. The molded body is conveyed from upstream to downstream of the first conveying path 21 to a predetermined position where it is gripped by the first conveying device 31. The first conveying path 21 is, for example, a fixed belt conveyor.

[0047] [First Transfer Device] The first transfer device 31 moves the compacts transported to a predetermined position on the first transport path 21 so that they are placed in the storage section 11a of the container 11. Instead of transporting the compacts, powder may be loaded directly into the container. The container 11 is placed on the mounting table 4. For example, the first transfer device 31 or a transfer device other than the first transfer device 31 (not shown) moves the container 11 from a first storage location (not shown) onto the mounting table 4 in advance. Multiple containers 11 are stored together in the first storage location. The mounting table 4 is located downstream of the first transfer device 31. When one container 11 has multiple storage sections 11a, the first transfer device 31 repeatedly moves the compacts until all storage sections 11a of one container 11 are filled with compacts. When powder is filled into the storage section 11a in addition to the compacts, a powder feeder (not shown) supplies powder to the storage section 11a.

[0048] When the transfer of the molded bodies to all of the storage sections 11a is completed, the first transfer device 31 or a transfer device (not shown) different from the first transfer device 31 moves the lid 12 so that it is placed on the container 11. By placing the lid 12 on the container 11, an assembly 10a in which the storage sections 11a are covered with the lid 12 is produced. The lid 12 is moved, for example, from the second storage location. A plurality of lids 12 are stored together in the second storage location.

[0049] The first transfer device 31 is, for example, a manipulator such as a robot hand that grips a molded body, or an electromagnet or vacuum pad that can attract a molded body, etc. A transfer device other than the first transfer device 31 is also, for example, a manipulator, an electromagnet, or a vacuum pad.

[0050] [Second Transfer Device] The second transfer device 32 transfers the assembly 10a to the welding device 6. The second transfer device 32 may transfer only the assembly 10a, or may transfer the mounting table 4 on which the assembly 10a is placed. The second transfer device 32 is, for example, a manipulator such as a robot hand that grasps the assembly 10a or the mounting table 4.

[0051] [Welding Device] The welding device 6 produces the sealed body 10b by welding the container 11 and the lid 12 together in a vacuum. The welding device 6 is not particularly limited as long as it is a welding device 6 that can draw a vacuum. The welding device 6 in this example is a seam welding device. The welding device 6 in this example has a pair of roller electrodes 61. The pair of roller electrodes 61 are energized while rotating, for example, sandwiching the container 11 and the lid 12 between them, thereby welding the container 11 and the lid 12 together by resistance heating.

[0052] The produced sealed body 10b is removed from the welding device 6 by, for example, the second transfer device 32 or a transfer device different from the second transfer device 32. The removed sealed body 10b is sent to a HIP device and subjected to hot isostatic pressing.

[0053] Third Embodiment [Method for Manufacturing Sintered Part] A method for manufacturing a sintered part according to the third embodiment will be described with reference to FIGS. 6 and 7 . FIG. 6 shows a top view of a manufacturing apparatus for a sintered part used in the manufacturing method for a sintered part according to the third embodiment. FIG. 7 shows a side view of the first pass box 51, the fifth conveying path 25, and the welding device 6, which are mainly included in the manufacturing apparatus for a sintered part shown in FIG. 6 . The manufacturing method for a sintered part according to the third embodiment is the same as the manufacturing method for a sintered part according to the second embodiment in that steps A to C are performed in-line. The manufacturing apparatus for a sintered part used in the manufacturing method for a sintered part according to the third embodiment includes conveying paths for conveying the container 11, the lid 12, and the assembly 10a, as well as a first pass box 51 and a second pass box 52 located upstream and downstream of the welding device 6, respectively. This is what distinguishes it from the manufacturing apparatus for a sintered part used in the manufacturing method for a sintered part according to the second embodiment. The following description of the third embodiment will focus on the differences from the second embodiment.

[0054] The manufacturing apparatus for sintered parts according to the third embodiment includes a first conveying path 21, a second conveying path 22, a third conveying path 23, a fourth conveying path 24, a fifth conveying path 25, a sixth conveying path 26, a seventh conveying path 27, a first transfer device 31, a first pass box 51, a second pass box 52, and a welding device 6. The first conveying path 21 is the same as the first conveying path 21 used in the second embodiment.

[0055] [Second Conveyor Path] The second conveyor path 22 conveys the containers 11. The containers 11 are moved onto the second conveyor path 22 from the first storage location (not shown) described above, for example, by a conveyor (not shown). This conveyor is, for example, a manipulator such as a robot hand that grasps the containers 11. The downstream side of the second conveyor path 22 is, for example, located near the upstream side of the fourth conveyor path 24 described below. In the example shown in FIG. 6 , the second conveyor path 22 is arranged perpendicular to the fourth conveyor path 24. The second conveyor path 22 may run continuously at a constant speed, or may run intermittently by repeatedly running and stopping. The second conveyor path 22 is, for example, a fixed belt conveyor.

[0056] [Third Conveyor Path] The third conveyor path 23 conveys the lids 12. The lids 12 are moved onto the third conveyor path 23 from the second storage location (not shown) by, for example, a conveyor (not shown). This conveyor is, for example, a manipulator such as a robot hand that grasps the lids 12. The downstream side of the third conveyor path 23 is located, for example, near the upstream side of the fourth conveyor path 24 (described later). In the example shown in FIG. 6 , the third conveyor path 23 is located opposite the second conveyor path 22 across the fourth conveyor path 24, perpendicular to the fourth conveyor path 24, and aligned in the same straight line as the second conveyor path 22. The third conveyor path 23 may run continuously at a constant speed or may run intermittently by repeatedly running and stopping. The third conveyor path 23 is, for example, a fixed belt conveyor.

[0057] [First Transfer Device] In this example, the first transfer device 31 transfers the container 11, the molded body, and the lid 12. The first transfer device 31 transfers the container 11 from the second conveying path 22 to the fourth conveying path 24. After the container 11 has been moved to the fourth conveying path 24, the first transfer device 31 moves the molded body from the first conveying path 21 to the fourth conveying path 24 so that it is placed in the storage unit 11a of the container 11. If one container 11 has multiple storage units 11a, the first transfer device 31 repeats the movement of the molded body until the molded body is placed in all of the storage units 11a of one container 11. After the movement of the molded body to all of the storage units 11a is completed, the first transfer device 31 moves the lid 12 from the third conveying path 23 to the fourth conveying path 24 so that it is placed on the container 11. The combination 10a is produced by the movement of the container 11, the movement of the molded body, and the movement of the lid 12. The first transfer device 31 is, for example, a manipulator, an electromagnet, or a vacuum pad.

[0058] Unlike this example, the first transfer device 31 may only transfer the compacts. In this case, the sintered part manufacturing apparatus may include, in addition to the first transfer device 31, one transfer device that moves both the container 11 and the lid 12, or a transfer device that moves the container 11 and a transfer device that moves the lid 12. Instead of transporting the compacts, powder may be loaded directly into the container.

[0059] [Fourth Conveyor Path] The fourth conveyor path 24 conveys the set 10a. The upstream of the fourth conveyor path 24 is located near the downstream of the first conveyor path 21. In the example shown in FIG. 6 , the fourth conveyor path 24 is aligned in the same straight line as the first conveyor path 21. In this example, the set 10a is made on the fourth conveyor path 24. Therefore, the fourth conveyor path 24 does not run until the set 10a is made, and runs intermittently, repeatedly running and stopping, so that it starts running after the set 10a is made. The fourth conveyor path 24 may be provided with a stopper portion that prevents the container 11 from moving on the fourth conveyor path 24. In this case, the fourth conveyor path 24 continuously travels at a constant speed, but the container 11 is held by the stopper portion and slides on the fourth conveyor path 24, and is held in a predetermined position on the fourth conveyor path 24. After the set 10a is produced, the stopper portions are released from preventing the containers 11 from moving forward so that the set 10a can be transported. The fourth transport path 24 is, for example, a fixed belt conveyor.

[0060] Unlike this example, the manufacturing apparatus for sintered parts may be provided with a separate stage for preparing the set 10a between the first conveying path 21 and the fourth conveying path 24. In this case, the set 10a may be moved from the stage to the fourth conveying path 24 by the first conveying device 31 or a conveying device (not shown) different from the first conveying device 31. The fourth conveying path 24 may run continuously at a constant speed.

[0061] [First Pass Box] The first pass box 51 changes the internal air pressure from atmospheric pressure to vacuum. The degree of vacuum inside the first pass box 51 is the same as the degree of vacuum inside the welding device 6. The entrance and exit of the first pass box 51 are provided with slide doors 515 that can be opened and closed freely. The entrance of the first pass box 51 is located near the downstream side of the fourth conveying path 24. The exit of the first pass box 51 may also serve as the entrance of the welding device 6.

[0062] [Fifth Conveying Path] The fifth conveying path 25 conveys the set 10a from the fourth conveying path 24 through the first pass box 51 to the welding device 6. The fifth conveying path 25 in this example conveys the set 10a placed on the fifth conveying path 25 by moving itself. The fifth conveying path 25 in this example is, for example, a movable belt conveyor. The fifth conveying path 25 includes, for example, a moving belt and casters.

[0063] An example of the operation of the first pass box 51 and the fifth conveying path 25 will be described with reference to FIG. 7 . The welding device 6 is not shown in the left and center views of FIG. 7 . The fifth conveying path 25, without the combined workpieces 10a loaded thereon, is disposed inside the first pass box 51. With the sliding doors 515 at the entrance and exit of the first pass box 51 closed, the air pressure inside the first pass box 51 is adjusted to atmospheric pressure. As shown in the left view of FIG. 7 , the sliding door 515 at the entrance of the first pass box 51 is opened. The fifth conveying path 25 passes through the entrance of the first pass box 51 and moves to a position close to the downstream side of the fourth conveying path 24. The combined workpieces 10a transported on the fourth conveying path 24 are placed on the belt of the fifth conveying path 25. The fifth conveying path 25, with the combined workpieces 10a loaded thereon, moves inside the first pass box 51 through the entrance of the first pass box 51. As shown in the center view of FIG. 7 , the sliding door 515 at the entrance of the first pass box 51 is closed. The inside of the first pass box 51 is evacuated. Once the inside of the first pass box 51 is evacuated, the sliding door 515 at the exit of the first pass box 51 is opened, as shown in the right diagram of FIG. 7 . The exit of the first pass box 51 also serves as the entrance of the welding device 6. The fifth conveying path 25 with the pair 10a loaded thereon moves to a position close to a turntable 62 of the welding device 6, which will be described later. As the belt of the fifth conveying path 25 runs, the pair 10a is transported from above the belt of the fifth conveying path 25 to the turntable 62 of the welding device 6. The fifth conveying path 25 without the pair 10a loaded thereon moves into the inside of the first pass box 51. The sliding door 515 at the exit of the first pass box 51 is closed. When the air pressure inside the first pass box 51 is adjusted to atmospheric pressure and the sliding door 515 at the entrance of the first pass box 51 is opened as shown in the left diagram of Figure 7, the fifth conveying path 25 is moved to a position close to the downstream of the fourth conveying path 24.

[0064] [Welding Apparatus] The welding apparatus 6 shown in FIG. 6 produces a sealed body 10b by welding the container 11 and the lid 12 together in a vacuum. The welding apparatus 6 in this example is a seam welding apparatus. The welding apparatus 6 in this example includes a pair of roller electrodes 61, a rotating table 62, and a conveyor (not shown). The rotating table 62 is rotatable. The assembly 10a is placed on the rotating table 62. The rotation of the rotating table 62 rotates the assembly 10a. The rotation of the assembly 10a eliminates the need to move the pair of roller electrodes 61 of the seam welding apparatus, making it easy to weld the assembly 10a. The conveyor moves the produced sealed body 10b from the rotating table 62 onto the sixth transport path 26, which will be described later. This conveyor is a manipulator, an electromagnet, or a vacuum pad.

[0065] Unlike this example, welding device 6 may include a fixed table instead of rotating table 62. That is, welding device 6 may include a pair of roller electrodes 61, a fixed table, and a conveyor. In this case, the conveyor changes the orientation of assembly 10a on the fixed table and moves fabricated sealed body 10b from the fixed table onto sixth conveying path 26, which will be described later.

[0066] The entrance of the welding device 6 is the entrance for the assembly 10a. The exit of the welding device 6 is the exit for the sealed body 10b. The exit of the welding device 6 may also serve as the entrance for a second pass box 52, which will be described later. A sliding door 525 that can be opened and closed is provided at the exit of the welding device 6.

[0067] [Second Pass Box] The second pass box 52 changes the internal air pressure from atmospheric pressure to vacuum. The degree of vacuum inside the second pass box 52 is the same as the degree of vacuum inside the welding device 6. The entrance and exit of the second pass box 52 are provided with slide doors 525 that can be opened and closed freely. The exit of the second pass box 52 is located near the upstream of the seventh conveying path 27, which will be described later.

[0068] [Sixth Conveyor Path] The sixth conveyor path 26 conveys the sealed bodies 10b from the welding device 6 through the second pass box 52 to the seventh conveyor path 27. In this example, the sixth conveyor path 26 itself moves to convey the sealed bodies 10b arranged on the sixth conveyor path 26. In this example, the sixth conveyor path 26 is, for example, a movable belt conveyor. The sixth conveyor path 26 is equipped with, for example, a moving belt and casters, the same as the fifth conveyor path 25.

[0069] Although not shown, an example of the operation of the second pass box 52 and the sixth conveying path 26 will be described. The sixth conveying path 26 is disposed inside the second pass box 52, and the second pass box 52 is evacuated with the entrance and exit sliding doors 525 closed. After the second pass box 52 is evacuated and the sealed body 10b is produced by the welding device 6, the exit of the welding device 6, i.e., the entrance sliding door 525 of the second pass box 52, is opened. The sixth conveying path 26 passes through the exit of the welding device 6 and moves to a position close to the turntable 62 of the welding device 6. A transfer device provided in the welding device 6 moves the sealed body 10b from the turntable 62 onto the belt of the sixth conveying path 26. The sixth conveying path 26 carrying the sealed body 10b moves into the second pass box 52. The entrance sliding door 525 of the second pass box 52 is closed. The air pressure inside the second pass box 52 is adjusted to atmospheric pressure. Once the pressure inside the second pass box 52 reaches atmospheric pressure, the sliding door 525 at the exit of the second pass box 52 is opened. The sixth conveying path 26 carrying the sealed bodies 10b passes through the exit of the second pass box 52 and moves to a position close to the upstream of the seventh conveying path 27. The belt of the sixth conveying path 26 runs, and the sealed bodies 10b are conveyed from the sixth conveying path 26 to the seventh conveying path 27. The sixth conveying path 26 passes through the exit of the second pass box 52 and moves inside. The sliding door 525 at the exit of the second pass box 52 is closed.

[0070] The sintered part manufacturing apparatus of this example is equipped with a first pass box 51 connected to the entrance of the welding device 6 and a second pass box 52 connected to the exit of the welding device 6, so that the welding device 6 can always maintain a vacuum state inside.

[0071] [Seventh Conveyor Path] The seventh conveyor path 27 conveys the sealed bodies 10b. The upstream of the seventh conveyor path 27 is located near the exit of the second pass box 52. The seventh conveyor path 27 runs continuously at a constant speed, for example. The seventh conveyor path 27 is, for example, a fixed belt conveyor.

[0072] The sealed body 10b transported by the seventh transport path 27 is sent to the HIP device and is subjected to hot isostatic pressing.

[0073] 10a Assembled body 10b Sealing body 11 Container 110 Welded part 11a Storage part 12 Lid 120 Welded part 13 Processing object 15 Weld mark 21 First conveying path 22 Second conveying path 23 Third conveying path 24 Fourth conveying path 25 Fifth conveying path 26 Sixth conveying path 27 Seventh conveying path 31 First conveying device 32 Second conveying device 4 Placement table 51 First pass box 515 Sliding door 52 Second pass box 525 Sliding door 6 Welding device 61 Roller electrode 62 Rotating table

Claims

1. A method for manufacturing a sintered part, comprising the steps of: preparing a container having a storage section, an object to be stored in the storage section, and a lid that covers the storage section; storing the object to be processed in the storage section and covering it with the lid; producing a sealed body by performing at least a portion of the welding between the container containing the object to be processed and the lid in a vacuum; and hot isostatically pressing the sealed body, wherein the container is produced by progressive processing.

2. The method for producing a sintered part according to claim 1, wherein the thickness of the container is between 20 μm and 2 mm.

3. A method for manufacturing a sintered part according to claim 1 or claim 2, wherein the material of the container and the lid is one selected from the group consisting of iron, iron alloy, titanium, and titanium alloy, the thickness of the welded portion of the container and the welded portion of the lid is 20 μm or more and 150 μm or less, and the welding is seam welding.

4. A method for manufacturing a sintered part as described in any one of claims 1 to 3, wherein the shape of the container corresponds to the final product shape of the sintered part manufactured by performing the hot isostatic pressing process.

5. A method for manufacturing a sintered part according to any one of claims 1 to 4, wherein the container has a plurality of the storage sections.

6. A method for producing a sintered part according to any one of claims 1 to 5, wherein the steps of providing, encasing and making the encapsulation are carried out in-line.

7. A method for manufacturing a sintered part according to any one of claims 1 to 6, wherein the object to be processed is one or more selected from the group consisting of powder, green compact, sintered compact, and ingot material.

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