Powder Sorting and Metering for Uniform Packing Density
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Solution Overview
Problem
The manufacturing of gas turbine engine casings through hot isostatic pressing of powder materials faces challenges due to uneven packing density and shrinkage variations, caused by inconsistent powder metal size distribution and flow properties, leading to inconsistent final product density and shape.
Innovation Solution
A method involving sorting powder materials by size, shape, and flow characteristics, storing them in different hoppers, and controlling their proportions to fill a canister with specific regions requiring different types of powder for uniform packing density, combined with a metering device to manage voidage and shrinkage during the hot isostatic pressing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If powder material is supplied directly into the canister without sorting, then the filling process is simpler and faster, but the packing density becomes uneven and the final article quality is inconsistent
Solution Approach 1:
The powder material supply system is segmented into multiple hoppers, each containing powder of specific size ranges. This segmentation allows different particle sizes to be directed to appropriate regions within the canister, ensuring uniform packing density while maintaining efficient filling operations.
Solution Approach 2:
Different regions of the canister receive different particle size distributions tailored to local requirements. This local quality approach ensures that each region achieves optimal packing density, resulting in consistent final article quality throughout the entire canister volume.
2Adaptability or versatility
If the canister has complex shape with recesses for flanges and bosses, then the finished article functionality is improved, but the powder metal flow becomes blocked and packing density becomes non-uniform
Solution Approach 1:
The invention applies local quality by supplying different particle sizes to different regions of the canister. Smaller particles are directed to recessed areas such as flange and boss regions where flow blockages commonly occur, while larger particles are supplied to open areas. This regional differentiation ensures uniform packing density throughout the complex canister geometry.
Solution Approach 2:
Smaller powder particles act as intermediaries that fill the voids and blockages in recessed regions caused by larger particles. This intermediary approach allows powder to successfully fill complex geometric features without creating flow blockages, maintaining packing density uniformity throughout the article.
3Loss of substance
If powder material with varying size distribution is used, then the material cost is reduced, but the shrinkage variation increases and final article dimensions become inconsistent
Solution Approach 1:
The powder material is segmented into distinct size categories stored in separate hoppers. This segmentation enables controlled mixing and regional distribution of different particle sizes, allowing the use of varied powder materials while maintaining consistent packing density and minimizing shrinkage variation in the final article.
Solution Approach 2:
The invention changes the particle size parameter distribution in a controlled manner by selecting specific size ranges for different canister regions. This parameter optimization ensures consistent packing density and predictable shrinkage behavior, maintaining dimensional consistency in the final article while utilizing cost-effective powder materials.
4Device complexity
If a single hopper supplies all powder material, then the device complexity is reduced, but the control over voidage and shrinkage in different canister regions is insufficient
Solution Approach 1:
The hopper system is segmented into multiple independent units, each controlling powder supply to specific canister regions. This segmentation provides the necessary control over voidage and shrinkage in different areas, achieving manufacturing precision while keeping each individual hopper unit relatively simple in design.
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 approach ensures consistent and predictable powder metal articles with controlled shrinkage and density, reducing material and machining costs by optimizing the filling process and final product quality.
Implementation Method 1
supplying the powder material from one or more of the different hoppers into the canister to fill the canister
Implementation Method 2
Hot isostatic pressing of powder material to net-shape is being developed as an alternative method for manufacturing a gas turbine engine casing
Data Source
AI summary
An apparatus for manufacturing an article from powder material includes a canister, a sorter, a plurality of hoppers and at least one valve. The canister has a predetermined internal shape to define the shape of the powder metal article. The sorter sorts the powder material by the size of the powder particles, the shape of the powder particles and/or the flow characteristics of the powder particles. The hoppers contain powder material with different sizes of powder particles, different shapes of powder particles and/or powder particles with different flow characteristics. The hoppers are arranged to supply the sorted powder material to the canister. The at least one valve controls the proportions of the different powder materials supplied from the one or more of the different hoppers into the canister to control the packing density of the powder material in the canister at all positions in the canister.