Metal objects and methods for making metal objects using disposable molds
AssigneeGeneral Electric Company
InventorsRajendra Madhukar KELKAR, Pong Kwok CHAN, Singh PRABHJOT, Michael John MCCARREN, Arunkumar NATARAJAN, John T. LEMAN
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Abstract
Methods of making metal objects are provided. These methods generally involve adding a metal powder slurry into a sacrificial mold, such as a mold made by three dimensional printing, and heating the slurry/mold mixture. The heating steps may include curing the slurry to make a green part inside the mold, debinding to burn off the mold and binder to make a brown part, sintering, and hot isostatic pressing. Metal products, such as aircraft engine parts, are also provided.
Claims25
A method for making a metal object comprising:
- (a) introducing a metal powder slurry into a sacrificial mold;
- and
- (b) applying one or more heating steps to produce a solid metallic body and eliminate the sacrificial mold.
A method for making a metal object comprising:
- (a) creating a 3-D numerical model of a hollow component having an external wall;
- (b) creating a synthetic model of said component from said numerical model having a corresponding synthetic external wall;
- (c) introducing a metal powder slurry into the synthetic model;
- and
- (d) applying one or more heating steps to produce a solid metallic body;
- and
- (e) during or after step (d) removing the synthetic model.
A metal object comprising a non-linear, internal cavity and isotropic and/or equiaxed microstructures.
Dependencies are inferred from the claim text.