# US 11,305,348 B2 · Methods for producing gas turbine engine rotors and other powdered metal articles having shaped internal cavities

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- Number: US 11,305,348 B2
- Document ID: US11305348B2
- Status: Granted
- Kind: B2
- Application number: 16/996,569
- Filed: 2020-08-18
- Published: 2020-12-03
- Granted: 2022-04-19
- Earliest claimed: 2014-09-22
- Assignees: Honeywell International Inc.
- Applicants: Honeywell International Inc.
- Inventors: Deanna Pinar Chase; Amandine Miner; Harry Lester Kington; Anthony Martinez
- Web page: https://patentgrep.com/patent/US11305348B2

## CPC

- B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)}
- B22F 3/15: Hot isostatic pressing
- B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)}
- B23P 15/006: {turbine wheels}
- B22F 2003/247: {Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface}
- B22F 2005/103: {Cavity made by removal of insert}
- F01D 5/02: Blade-carrying members, e.g. rotors (rotors of non-bladed type F01D1/34; stators F01D9/00 {; selecting particular materials F01D5/28})
- F01D 5/043: {of the axial inlet- radial outlet, or vice versa, type}
- F01D 5/28: Selecting particular materials; {Particular measures relating thereto;} Measures against erosion or corrosion
- F01D 5/34: Rotor-blade aggregates of unitary construction {, e.g. formed of sheet laminae; (discs formed of sheet laminae F01D5/028; ceramic materials F01D5/284, composite materials F01D5/282)}
- F05D 2230/22: by sintering
- F05D 2260/94: Functionality given by mechanical stress related aspects such as low cycle fatigue [LCF] of high cycle fatigue [HCF]
- F05D 2260/941: particularly aimed at mechanical or thermal stress reduction
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS

## Abstract

Embodiments of a methods for producing gas turbine engine rotors and other powdered metal articles having shaped internal cavities are provided. In one embodiment, the method includes consolidating a powdered metal body utilizing a hot isostatic pressing process to produce a rotor preform in which elongated sacrificial tubes are embedded. Acid or another solvent is directed into solvent inlet channels provided in the elongated sacrificial tubes to chemically dissolving the elongated sacrificial tubes and create shaped cavities within the rotor preform. The rotor preform is subject to further processing, such as machining, prior to or after chemical dissolution of the elongated sacrificial tubes to produce the completed gas turbine engine rotor.

## Claims

### Claim 1

A method for manufacturing a Powdered Metal (PM) component, the method comprising:
positioning elongated sacrificial tubes in a PM body, the elongated sacrificial tubes twisting about an axis of the PM body and converging toward the axis when moving along the axis, the elongated sacrificial tubes comprising solvent inlet channels and longitudinal axes along which the solvent inlet channels extend;
consolidating the PM body utilizing a Hot Isostatic Pressing (HIP) process to produce a component preform in which the elongated sacrificial tubes are embedded;
chemically dissolving the elongated sacrificial tubes by directing a solvent into the solvent inlet channels to create shaped cavities within the component preform; and
prior to or after chemical dissolution of the elongated sacrificial tubes, further processing the component preform to produce the PM component.

### Claim 2 (depends on 1)

The method of claim 1 further comprising providing internal reinforcement structures within the solvent inlet channels, which resist collapse of the elongated sacrificial tubes during the HIP process.

### Claim 3 (depends on 1)

The method of claim 1 further comprising filling the solvent inlet channels with a non-compressible material prior to consolidating the PM body.

### Claim 4 (depends on 1)

The method of claim 1 further comprising dimensioning the solvent inlet channels to have diameters at least one half outer diameters of the elongated sacrificial tubes.

### Claim 5 (depends on 1)

The method of claim 1 further comprising applying a coating material over an exterior of the sacrificial tubes prior to consolidating the powdered metal body, the coating material comprising zirconia, silica, zircon, or a combination thereof.

### Claim 6 (depends on 1)

The method of claim 1 further comprising pressurizing the solvent inlet channels during the HIP process to prevent collapse of the solvent inlet channels.

### Claim 7 (depends on 6)

The method of claim 6 wherein the PM body is disposed within a container during the HIP process, and wherein pressurizing comprises maintaining fluid communication between the solvent inlet channels and an exterior environment of the container during the HIP process.