Patent ID: 6517773
Filing Date: 2003-02-11
Classification: B22F,B23H,B33Y

Abstract:
A method of directly fabricating a metal part having no re-entrant angles at the part's side faces, comprising the steps of:providing a part negative cavity of a metal part to be fabricated, said metal part having no re-entrant angles at the part's side faces; pouring a powder blend into said part negative cavity, said powder blend comprising: a base metal in powder form, a lower melting temperature alloy of said base metal in powder form, and a polymer binder in powder form; heating said part negative cavity until said polymer binder melts and adheres the metal particles to form a green part, said step of heating of said part negative cavity performed immediately after said step of pouring said powder blend into said cavity; removing said green part from said part negative cavity; placing said green part in a heat-resistant container and packing loose ceramic powder around it to provide support; and heating said green part to vaporize said binder and consolidate said part via transient liquid phase sintering.