Process for forming shapes from powder in a container

Abstract: A method of fabrication comprises partially filling a container (2), or a space between a container (2) having a core (4) therein, or a space between a substrate (5) having a container (2) therein, with a powdered or a granular material. Local pressure is applied to deform the container (2) and then it is heated under pressure to agglomerate the materials. The container (2) is removed to reveal a solid object having the desired shape, and the powdered or granular material (1) has a uniform thickness and density.

Description: The present invention relates to a method of fabrication and in particular to a method of forming a powdered or granular material into a shape prior to agglomerating the powdered or granular material. One known method for obtaining an object made of a powdered or a granular material, such as a metal or a ceramic, forms the powdered or granular material into a desired shaped, and then it is agglomerated by sintering or powder forging. In such methods, depending upon the material, the shaping or the sintering process, a container for sealing the material may be used. Some methods may include build-up welding, or sticking a wear-resistant, a heat-resistant or a corrosion-resistant material to an outer surface of a rod, and in which a container, made of a heat-resistant material such as a mild steel, covers a rod at certain intervals. A powdered or a granular material comprising a wear-resistant, a heat-resistant or a corrosion-resistant material is packed in a space between the container and the rod. A hot isostatic pressing step provides conditions of high temperature and high pressure and subjects it to the packed powdered or granular material. The powdered or granular material is then tightly stuck and sintered to the outer surface. This step is applicable in the same manner to that of a substrate which has a hollow body and the powdered or granular material is tightly stuck to the inner surface of the hollow body of the substrate. The step of agglomerating the powdered or granular material itself includes, the material being packed into the container and shaped to the desired shape and sealed. However, a gap in a top portion of the container cannot be avoided in practice, because the packing density of the material is smaller in a top portion. When the material is being stuck to an outer surface of a substrate using a hot isostatic pressing step, the space between the substrate and the container is often narrow, and it is difficult to pack a powdered or a granular material having uniform density, and may result in a non-uniform layer. Hitherto a container having a wide space, greater than the gap between the substrate and the container previously known is used, and a powdered or a granular material is easily packed with uniform density. However an excess is allowed for shrinkage caused by the low packing density, and this excess is then cut away. Therefore this method wasted both the material itself and time need for cutting which is especially time consuming since the sintered layer has a high strength. Further, the strength and other properties such as directionality can be enhanced by using a fibrous material mixed with the material for form a fibrous structure. The directionality of the fibrous structure is instilled in the product after agglomerating. However it is difficult to pack a powdered and a granular material when a fibrous structure is required. DE-A-36 33614 discloses a method for coating a rod whereby the rod is surrounded by a container, metallic powder mixture is filled between the rod and the container walls, the container is gas evacuated and sealed, isostatic pressure in an autoclave is applied and the container is removed. EP-A-O 248 783 discloses a method of filling a cylindrical container made of tinplate with metallic powder and sealing it thereafter subjecting the container to forming by hammering tools. The container is later removed. An object of the present invention is to provide a method, in which the aforementioned problems of the conventional techniques are solved. Another object of the present invention is to provide a method, in which the powdered or a granular material is uniform in terms of thickness and density, and which permits the provision of directional properties obtained from the powdered or granular material containing a fibrous material. Accordingly there is provided by the present invention a method of fabricating a solid body from powdered or granular material such as metal, ceramic, an alloy, or carbon, in which the material is initially formed into a desired shape, in a container and then is agglomerated to form a solid body, and removing the container, wherein, for initially forming the material, the container is partly filled with the powdered or granular material, the container is sealed, at least one solid tool is applied locally under pressure to the container, the container is rotated while the tool is or tools are applied, and the tool(s) and container are moved relative to one another so that the pressure is applied sequentially over the container surface. Also according to the present invention there is provided a method of fabricating a solid body from powdered or granular material such as metal, ceramic, an alloy, or carbon, in which the material is initially formed into a desired shape while confined by a container and then is agglomerated, wherein the container is inserted into a hollow of a substrate, the space between the substrate and the container is partly filled with the powdered or granular material, the container is sealed, at least one solid tool is applied locally under pressure to an inner surface of the container, the container is rotated while the tool is or tools are applied, and the tool(s) and container are moved relative to one another so that the pressure is applied sequentially over the container surface, the powdered or granular material being bonded to the substrate to form the said body. By the use of the invention, a body having a desired shape is easily obtained when forming a powdered or a granular material itself, or forming the material as a sintered layer on an inner surface of a hollow member, such that the density of the formed layers is uniform. Further features of the present invention are defined in the dependent claims. The present invention will now be described with reference to the accompanying schematic drawings, of which: Figure 1 is a schematic partial view of a container partially filled with a powdered material in accordance with a method of the present invention; figure 2 illustrates a container during a locally pressing process; Figure 3 illustrates a cross-section of the packed container having been locally pressed; Figure 4 illustrates a partial view of powdered material packed in the space between the core and the container being locally pressed; Figure 5 is a partial view of the powdered material stuck to the inner wall of a hollow substrate; Figures 6 - 10 each illustrate cross-sectional views of the packed container according to the present invention; Figure 11 illustrates a cross-section of a round-ended packed container; Figure 12 illustrates a cross-section of an hour-glass packed container; Figure 13 illustrates a cross-section of a container having a partially convex area on its surface; and Figure 14 is an enlargement of area as shown in Figure 13. The present invention is explained in detail as follows; A powdered or a granular material is formed into desired shape before it is agglomerated onto an outer surface or an inner surface of an object. After forming the desired shape by a method of the present invention, the formed powdered or granular material is agglomerated by an ordinary manner such as sintering or powder forging. Therefore, all of the raw material which is agglomerated is used. Metal (including alloys), ceramic, carbon or their composite, mixtures of various kinds of ceramics, glass may all be used for the raw material of a powdered or a granular material. A powdered or granular material 1 is put into a container 2, such as a metal alloy container as shown in Figure 1. The container 2 is kept transverse with respect to the axis of the cylindrical container and rotated as shown in Figure 2. The container 2 is locally pressed from an outer surface by using a small roller 3 whilst rotating the container 2. The container 2 is deformed by moving the pressed part of the roller 3 along a longitudinal direction as shown in Figure 3. Local pressing may be provided by a number of pressing tools such as a small roller, pushing with a spatula, or hitting with a hammer. There may not be just one pressing tool but multiple pressing tools arranged at appropriate positions and are used simultaneously. Also, local pressing is sometimes achieved by heating the whole of the container or only pressing part of the container. Figure 4 shows a container 2 having a core 4 inserted into an inner part. The edges are fixed by welding perhaps using a stopper. Preferably an outer surface of said core 4 and an inner wall of the container 2 are approximately the same distance apart at all times. A powdered or a granular material 1 is packed in the space between said outer surface of the core 4 and said inner wall of the container 2. The container 2 is then sealed and locally pressed by a small roller 3 in the same manner as shown in Figure 2. Figure 5 illustrates a metal cylindrical container 2 inserted into a hollow substrate 5, such that the space between the outer surface of said container 2 and the inner wall of the hollow substrate 5 are approximately the same distance apart at all times. The required parts of the container 2 and the substrate 5 are sealed so as not to leak out any powdered or granular material 1. An inner side of the container 2 is locally pressed by the small roller 3. By using the methods shown in Figure 4 and Figure 5, a powdered or a granular material 1 is formed into the desired shape using the container 2, or formed on an outer surface of the core 4 or an inner surface of the substrate 5. A product may be obtained using these methods even having, the deformation of the container 2 as shown in Figure 3. A powdered or a granular material 1 can also be arranged on an outer surface with almost uniform thickness even if the diameter of the core 4 varies as shown in Figure 6. A product may also be obtained, in which a groove 6 is provided in the outer surface of the core 4 as shown in Figure 7. Furthermore a powdered or a granular material 1 may be formed into the different shapes by local pressure by means of a variation in the deformation of the container 2 as shown in Figure 8. In the methods shown in Figure 2, Figure 4 and Figure 5, an open part of the container 2 or the space between the container 2 and the core 4 or the substrate 5 is wide enough for initial packing of the powdered or granular material 1 by a method of the present invention. The diameter of the container 2 can be reduced or extended during the local pressing treatment after packing the powdered or granular material 1, in which case the initial packing is very easily done since loose packing is sufficient. Even when the powdered or granular material 1 is finally formed into various kinds of shapes, the initial use of the container 2 is enough for it to have a simple cylindrical shape. A local pressing means such as a small roller etc. is used for tightening of the powdered or granular material 1 and for forming the desired shape in the method of the present invention. The diameter and the thickness of the formed powdered or granular material 1 may be changed by means of the local pressing. The method of the present invention does not pack the powdered or granular material 1 by way of feeding or forcing under pressure consequently a cavity naturally arises in the powdered or granular material and the unavoidable cavity appears at the upper edge part. Rotating the container 2 enables the powdered or granular material to flow. Non-uniform density is then solved by the terminating step of forming by local pressing. This step is enhanced by keeping the volume of the initially packed powdered or granular material 1 less than the volume of the space available for packing. The powdered or granular material 1 is kept in the fluid state and moves a little to the outside of the container 2 by centrifugal forces, when the container 2 is rotated. The density of the powdered or granular material 1 becomes uniform if the container 2 rotated at a constant rate. Furthermore, the powdered or a granular material 1 is easily formed because said powdered or said granular material 1 is easily moved during deformation of the container 2 by a local pressing and the density of the formed layer is almost uniform throughout. Also in the method of the present invention, said formed material is kept in the tightened state and this enables the density of said formed material to remain uniform when it is handled later. When a part or the whole of the powdered or granular material 1 comprises a fibrous or a cut wire shape, said powdered or said granular material is directed in the longitudinal direction as the space is progressly reduced during rotation of the container 2 and so said formed layer has a large directionability. Additionally, in the method of the present invention, transverse setting, vertical setting and oblique setting rotations may be selected for rotation of the container 2 during local pressing depending upon the shape of the container 2. Transverse setting rotation may be desirable when the packing density changes due to gravity and is alleviated in this case by the container 2 being considerably longer in the longitudinal direction. Vertical setting rotation is influenced by gravity but is not detrimental for short containers. Also vertical setting rotation is easier than transverse setting rotation. Furthermore, if a branch pipe is extended in the outer direction with respect to the container 2 it is desirable to rotate by vertical setting and to use gravity with centrifugal forces when it is necessary to pack the powdered or granular material 1 into the branch pipe. Accordingly, the shape of the container 2, the shape of the formed layer, and easiness of the rotation have to be predetermined, along with selection of a transverse setting, vertical setting or oblique setting. Examples of the method of the present invention are explained hereafter but the present invention is not limited to the following examples. Example 1 An austenitic stainless steel (sus316) powder, which occupied 80% of the volume of the internal space, was put into a cylindrical mild steel container (1mm thickness, 150mm internal diameter x 500mm). The internal space of the container was drawn in a vaccum, the open part was sealed, and the container put transversely on a rotary apparatus. A small roller provided a pressure to an outer surface of the container which was rotating. The whole region of the container was then locally spun. The formed body was kept at 1150°C, under the pressure of 100Kg/cm², for 2 hours in a hot isostatic pressing apparatus and then was taken out. The container was cut away and a stainless steel sintered body was obtained. Example 2 An edge plate, made of mild steel, having a 130mm internal diameter and a concentric hole was positioned with an edge open part of the container comprising the same material, shape and size with Example 1. A rodlike core, made of S45C steel and 495mm length having the outer diameter corresponding to the hole of said edge plate was inserted into the container such that the outer edge of the core was supported by the hole of the edge plate and the core positioned in the center of the container. The space between the external diameter of the edge plate and the container, and the space between the hole of the edge plate and the core are sealed by welding. A cobolt (Co) based heat-resistant alloy powder was packed from the other edge open part of the container occupying 80% of the volume of the space between the internal diameter of the container and the core. Next, an edge plate similar to the above edge plate, was welded to the other edge open part of the container, then the space of the container was drawn in a vaccum and was then sealed. The container was locally pressed whilst rotating with a transverse setting. Then the container was inserted into a hot isostatic pressing apparatus and was kept at 1150°C for 1 hour and then was taken out. The container was cut away, and a product having the Co based heat-resistant alloy sintered layer with uniform thickness and uniform density stuck to the surface of said core. Example 3 A mild steel container (2mm thickness, 120mm outer diameter, 500mm length) was inserted in a cylindrical substrate made of S45C steel (10mm thickness, 150mm inner diameter, 500mm length). An austenitic stainless steel (SUS316) powder was put into the space and occupies 80% of the volume of the space between the cylindrical substrate and the container. The internal space was drawn in a vacuum and both ends of the space were sealed. Then local pressing occurred by a small roller to an inner surface of the container whilst rotating with a transverse setting on a rotary apparatus, and local diameter-extending work was done to the whole region of the container. The formed body was sintered in a hot isostatic pressing apparatus as in Example 1, only the container on the inside was cut away. A product was obtained having a stainless steel sintered layer stuck to the inner surface of the substrate. Other examples are explained hereafter with reference to Figures 9 - 14. In Figure 9, there is shown the core 4 having a groove 6 in the outer surface and the powdered or granular material 1 is introduced to only the groove 6. This method is useful when a different property is required by the material 1 than by the core 4. Figure 10 illustrates the container 2 having been removed, to reveal a number of projecting bars 7 formed on the material layer after a process of deformating the container 2. Figure 11 shows an example, in which a powdered or a granular material 1 is also stuck to round-shaped top edges as well as the side surface. Figure 12 shows how two products in Figure 11 are formed simultaneously. This method is simple because a pipe-shaped container is used. Figure 13 illustrates a container having an increased diameter in one area a. Figure 14 shows an enlargement with extention 8 to area a shown in Figure 13. The present invention enables a powdered or a granular material to be easily packed compared with the conventional methods. Furthermore the present invention is best suited for forming a powdered or a granular material layer which becomes a thin coating by limiting the space at a later step. When the powdered or granular material is in its fluid state by rotating the container and in conjunction with local pressing it is also possible to avoid non-uniform packing density and to easily select the diameter and the thickness of the formed, powdered or granular material. It is also possible to obtain the desired shape by having the container, positioning at its center a core, or being positioned in the substrate and applying a local pressure whilst rotating the container. Furthermore, the cost is unexpensive. Since the powdered or granular material is sealed in the container at the time of local pressing, during the time until heat treatment is applied, there are no contaminations possible, such as oxidation. Furthermore, in the shapes shown in Figure 6 and Figure 13, hitherto two or three pieces container had to be used initially. The deformation step is not done using a wet treatment, such as water, and so the powdered or granular material is never contaminated, the apparatus is simple and expensive materials can be re-used. In the present invention, a powdered or a granular material is packed into the container or the space between the container and the core or the substrate, and then said powdered or said granular material is formed to the desired shape and thickness. Therefore, it is possible to determine the exact amount of powdered or granular material from calculating the weight or the size of the sintered body. The relative density of the powdered or granular material changes over a wide range e.g. 50-60%. Therefore, in the conventional method, various containers having various sizes fitting to every relative density have to be used but in the present invention, it is possible to determine the exact amount of powdered or granular material by calculating the weight, regardless of the relative density. The present invention has the advantage that the product size is exact and that the container size is almost constant. Additionally, if the powdered or granular material is rotated for a long time in the container and it also receives the local pressure force, and even if an active metal surface is exposed and the powdered or a granular material has a strong oxidizing layer on the outer surface which causes difficulties later during sintering, any oxidizing layer is broken up and the sinterability is improved. This is also applicable to the surface of the core and the substrate not just the powdered or granular material such that the binding force of the powered of granular material after agglomerating to the core or the substrate is enhanced. It is also possible to from a polygonal section type product by local pressing using a polygonal lathe.

Claims: A method of fabricating a solid body from powdered or granular material (1) such as metal, ceramic, an alloy, or carbon, in which the material is initially formed into a desired shape, in a container (2) and then is agglomerated to form a solid body, and removing the container, wherein, for initially forming the material, the container (2) is partly filled with the powdered or granular material (1), the container is sealed, at least one solid tool (3) is applied locally under pressure to the container, the container is rotated while the tool is or tools are applied, and the tool(s) and container are moved relative to one another so that the pressure is applied sequentially over the container surface. A method of fabrication in accordance with Claim 1 characterised in that said container (2) includes a core (4), in that said powdered or said granular material (1) fills a space between said core (4) and said container (2), and in that said solid body is fabricated from said core (4) and said powdered or said granular material (1) being stuck thereto. A method of fabricating a solid body from powdered or granular material (1) such as metal, ceramic, an alloy, or carbon, in which the material is initially formed into a desired shape while confined by a container (2) and then is agglomerated, wherein the container (2) is inserted into a hollow of a substrate (5), the space between the substrate and the container (2) is partly filled with the powdered or granular material (1), the container is sealed, at least one solid tool (3) is applied locally under pressure to an inner surface of the container, the container is rotated while the tool is or tools are applied, and the tool(s) and container are moved relative to one another so that the pressure is applied sequentially over the container surface, the powdered or granular material (1) being bonded to the substrate to form the said body. A method of fabrication according to any one of the preceding claims, characterized in that the method further comprises applying an isostatic treatment after applying said pressure. A method of fabrication according to any one of the preceding claims, characterized in that the method further comprises applying a vacuum to said powdered or granular material (1) after partially filling said container (2) or said space. A method of fabrication according to any one of the said preceding claims, characterized in that said pressure is applied locally in such a manner as to deform said container (2) into a desired shape. A method of fabrication according to Claim 6, characterized in that said pressure is applied locally by a plurality or pressing tools (3). A method of fabrication according to any preceding claim, characterized in that said tool or tools include any one of a roller, a spatula or a hammer. A method of fabrication according to any one of the preceding claims, characterized in that said container (2) is cylindrical. A method of fabrication according to Claim 9, characterised in that said container (2), or said substrate (5) and container (2), is rotated longitudinally, transversely or obliquely with respect to the cylindrical axis of the container (2) or any combination thereof. A method of fabrication according to any one of the preceding claims, characterised in that said container (2) is made of metal. A method of fabrication according to any one of the preceding claims, characterised in that said object is at least in part fibrous.

Inventors: KUROKI TAKANORI, KUROKI, TAKANORI
Applicants: KUROKI KOGYOSHO KK, KUROKI KOGYOSHO CO., LTD.
Application year: 1988
Main classification: B22F7
IPC codes: B22F3, B22F7