Composite metallic and non-metallic articles
AssigneeROLLS-ROYCE plc
InventorRalph I. Conolly
Life of this patent
Estimating the term…
Abstract
The invention is concerned with the problem of joining ceramic components to metal components. A composite ceramic-metal component is proposed, e.g. a rotor disc for a gas turbine engine (see FIG. 2), in which the main body of the component is made from a ceramic, e.g. Silicon Nitride, but the areas at which attachment is to be made to a metal component is formed from metal compacted onto the ceramic by a hot isostatic pressing process. The method of manufacture described is to form a ceramic core with holes appropriately positioned in it where a connection is to be made to another component, surround the core with a powdered metal, e.g. a Nickel-based superalloy, ensuring that the holes also fill with powder, compacting the powder by hot isostatic pressing, and then machining away unwanted metal.
Claims20
A method for manufacturing a composite component having a pre-formed body made from a base material chosen from the group consisting of a ceramic, a high temperature glass/ceramic composite and a carbon-in-carbon composite, and a metallic component bonded to a selected area on the pre-formed body, comprising the steps of:
- placing the pre-formed body in a peripherally walled can, with the pre-formed body spaced throughout substantially its entire extent, from the can wall, to define a space therebetween;
- filling the space between the pre-formed body and the can wall with a powdered metal, thereby completely surrounding the pre-formed body with the powdered metal;
- sealing and evacuating the can;
- applying hot isostatic pressure to the can to compact and sinter the metal powder and to bond the metal powder to the pre-formed body;
- removing the can from the exterior of the completely coated body;
- and
- removing the bonded metal powder from selected areas on the surface of the pre-formed body to expose areas of the base material and to leave the bonded metal powder at other areas, whereby the composite component can be directly connected to another metal component through a portion of the bonded metal powder.
A composite component comprising a pre-formed body made from a base material chosen from the group consisting of a ceramic, a high temperature glass/ceramic composite and a carbon-in-carbon composite and a metallic component bonded to a selected area upon the pre-formed body, the method for making the composite component comprising:
- placing the pre-formed body in a peripherally walled can, with the pre-formed body spaced throughout its entire extent, from the can wall, to define a space therebetween;
- filling the space between the pre-formed body and the can wall with a powdered metal, thereby completely surrounding the pre-formed body with the powdered metal;
- sealing and evacuating the can;
- applying hot isostatic pressure to the can to compact and sinter the metal powder, and to bond the metal powder to the pre-formed body;
- removing the can from the exterior of the completely coated body;
- and
- removing the bonded metal powder from selected areas on the surface of the pre-formed body to expose areas of the base material and to leave the bonded metal powder at other areas, whereby the composite component can be directly connected to another metal component through a portion of the bonded metal powder.
Dependencies are inferred from the claim text.