Hot Isostatic Pressing Fusible Closure for Hollow Module Manufacturing
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Solution Overview
Problem
Current methods for manufacturing hollow zone modules by hot isostatic compression face challenges such as significant degradation of the structure, unacceptable loss of dimensional precision, and high manufacturing costs due to the difficulty in sealing and maintaining the geometry of channels with complex shapes, especially when bends are pronounced or channels are not straight.
Innovation Solution
A method involving a sealed assembly with a fusible closure member that ruptures during hot isostatic compression, allowing pressurization gas to penetrate the hollow zone, enabling higher pressure without crushing the channels, and ensuring strong mechanical resistance at the interfaces, thus simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the inlets and outlets of the channels are sealed to avoid crushing during hot isostatic compression, then the channels retain their geometry, but the pressurizing gas cannot penetrate the interfaces between elements and welding cannot proceed
Solution Approach 1:
The sealing system is divided into two functional parts: permanent seals at channel inlets/outlets and temporary fusible seals at assembly interfaces. This segmentation allows different regions to have different sealing characteristics during the manufacturing process, enabling welding at interfaces while maintaining channel geometry through permanent seals.
Solution Approach 2:
The fusible closure members are pre-installed to seal the hollow zone before hot isostatic compression begins. This preliminary sealing action prevents gas penetration during the initial stages of compression, allowing welding to proceed without interference from pressurized gas.
Solution Approach 3:
The fusible closure members undergo a phase transition from solid to liquid/melted state during hot isostatic compression when temperature and pressure reach specific thresholds. This phase transition automatically opens the sealing, allowing pressurizing gas to penetrate and complete the welding process while maintaining channel geometry throughout.
2Ease of manufacture
If conventional sealing methods are used to prevent gas penetration during hot isostatic compression, then welding can proceed, but the channels are crushed by pressure leading to loss of dimensional precision
Solution Approach 1:
The sealing system is designed to respond to changes in temperature and pressure parameters during hot isostatic compression. The fusible closure members are selected with specific melting points and pressure resistance characteristics that allow them to maintain sealing at lower pressures while opening when parameters reach welding completion thresholds.
3Manufacturing precision
If multiple hot isostatic compression stages are used to maintain channel geometry, then dimensional precision is improved, but manufacturing time and complexity increase
Solution Approach 1:
The fusible closure members are pre-installed to provide automatic protection against channel crushing during the entire hot isostatic compression process. This preliminary protective action eliminates the need for multiple compression stages with intermediate cooling and reopening operations, reducing manufacturing cycle time while maintaining dimensional precision.
Solution Approach 2:
The fusible closure members enable continuous hot isostatic compression without interruption. By maintaining channel geometry protection throughout the entire compression cycle, the process avoids repeated heating-cooling-reopening cycles, thereby reducing total manufacturing time and simplifying the process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides a cost-effective and reliable way to produce modules with complex channel geometries, maintaining desired dimensions and thermal performance, while avoiding the need for multiple hot isostatic compression stages and reducing the risk of errors associated with drilling operations.
Implementation Method 1
the pressurizing gas penetrates inside the tubes, so that they are subjected to the same pressure as that of the exterior surfaces of the assembly
Implementation Method 2
diffusion welding of its elements
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for manufacturing a module (2) having a hollow area by means of hot isostatic pressing, including: a step of making an assembly including vertically adjacent elements defining the hollow area, said assembly being made so as to form a sealed casing containing said hollow area, comprising at least one fusible blocking member (12) separating the hollow area from the outside of the assembly; and a step of hot isostatic pressing said assembly, carried out so as to achieve a diffusion welding of the elements thereof, said step being carried out by varying the temperature and pressure conditions such that the latter cause, during said step, a breakage of the fusible blocking member (12) enabling the pressurizing gas to enter into the hollow area (2).