HIP Container Deformation Control for Billet Shape
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Solution Overview
Problem
The existing hot isostatic pressing (HIP) process results in significant deformation of containers and material loss, leading to undesirable shapes and costly removal of billet material, as the container becomes joined to the billet and deforms during high temperature and pressure processing, making it difficult to achieve predetermined billet shapes like parallel, convex, or concave sides without losing valuable material.
Innovation Solution
A container design with angled or tapered top and bottom portions that deform during the HIP process to control the shape of the billet, allowing for predetermined shapes by selecting a non-zero angle α, which minimizes material loss and enables retention of the container material on the billet, thereby optimizing material use and achieving desired billet shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional container is used in HIP process, then the container provides sealing and containment, but the container deforms dramatically and joins to the billet surface, requiring machining and material removal
Solution Approach 1:
The container is pre-formed with an hourglass shape before the HIP process. This preliminary geometric configuration is designed to deform in a controlled manner during pressing, allowing the container walls to move inward and join to the billet surface in a predictable way that produces the desired final billet shape without requiring subsequent machining.
Solution Approach 2:
The invention changes the geometric parameters of the container by introducing an hourglass shape with specific wall angle characteristics. This parameter modification allows the container to deform controllably under HIP conditions, transforming from a conventional cylindrical shape to a shape that produces precise billet geometry while maintaining sealing functionality.
2Strength
If the container walls are made straight and rigid, then the container maintains structural integrity during HIP, but the billet develops hourglass shape requiring material removal
Solution Approach 1:
Instead of making the container walls straight and rigid to prevent deformation, the invention inverts the approach by designing the walls to be intentionally angled and deformable. The hourglass shape with specific wall angles allows controlled inward movement during HIP, transforming the problem from preventing deformation to managing controlled deformation that produces the desired billet shape.
Solution Approach 2:
The container walls are designed with varying local properties - the hourglass shape creates regions of different wall thickness and angle. The walls are thinner and more compliant in the mid-section to allow controlled deformation, while maintaining sufficient strength in the top and bottom regions to maintain sealing and contain the powder throughout the HIP process.
3Quantity of substance
If the container is designed to deform freely during HIP, then the billet can achieve compacted density, but the container joins to the billet and requires cutting away
Solution Approach 1:
The container is pre-formed with an hourglass shape that is designed to deform in a controlled manner during pressing. This preliminary geometric configuration is calculated to allow the container walls to move inward and join to the billet surface in a predictable way that produces the desired final billet shape without requiring subsequent machining operations.
Solution Approach 2:
The invention converts the harmful effect of container deformation and joining to the billet into a beneficial process feature. By designing the container to deform controllably, the joining that would normally be considered a defect becomes the mechanism by which the desired billet shape is achieved, eliminating the need for post-process machining.
4Manufacturing precision
If machining is performed to remove container material, then the desired billet shape is achieved, but valuable billet material is lost
Solution Approach 1:
The container is pre-formed with an hourglass shape that is designed to deform in a controlled manner during pressing. This preliminary geometric configuration is calculated to allow the container walls to move inward and join to the billet surface in a predictable way that produces the desired final billet shape without requiring subsequent machining operations.
Solution Approach 2:
The invention converts the harmful effect of container deformation and joining to the billet into a beneficial process feature. By designing the container to deform controllably, the joining that would normally be considered a defect becomes the mechanism by which the desired billet shape is achieved, eliminating the need for post-process machining and the associated material loss.
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
The solution effectively reduces material loss and allows for the retention of container material on the billet, enabling the production of billets with precise shapes such as parallel, convex, or concave sides, while minimizing the need for costly machining and material removal.
Implementation Method 1
the powders are placed into a container (sometimes referred to as a 'can') that has been sealed and its contents placed under a vacuum. The container is also subjected to an elevated temperature and pressurized on the outside using an inert gas such as e.g., argon to avoid chemical reaction. By pressurizing the container that is enclosing the powder, the selected fluid medium (e.g., an inert gas) applies pressure to the powder at all sides and in all directions.
Implementation Method 2
the container is substantially deformed or crushed as the volume of the powder decreases during the HIP process and the container becomes joined to the surface of the billet created by the compacted powder. temperatures as high as 480° C. to 1315° C. and pressures from 51 MPa to 310 MPa or even higher may be applied to process the metal powder.
Data Source
AI summary
An improved method and container for forming billets using hot isostatic pressing is provided. The improved method and container have features that control the deformations of the container during the high temperatures and pressures experienced in such processing so as to provide a billet having a predetermined shape such as, for example, substantially parallel, convex, and/or concave sides. Conservations of the powder used for the billet and more efficient use of the container upon the resulting billet can be achieved.