Method for bonding powder metallurgical parts
AssigneePrecision Castparts Corp.
InventorsJedidiah David Rust, Michael Charles Watt, Laxmappa Hosamani, Jason Joseph Schmertman
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Abstract
Method for forming a unitary component from a plurality of powder metallurgy compacts. The method in some embodiments includes fluidizing first and second surfaces, wherein a first powder metallurgy compact defines the first surface and a second powder metallurgy compact defines the second surface. The method also includes joining the fluidizing first and second surfaces to form a bonded structure and thermally treating the bonded structure to fuse the first and second compacts into a unitary component.
Claims33
A method for forming a unitary component from at least first and second powder metallurgy compacts, the method comprising:
- injection molding a first powder metallurgy compact having a first surface that is formed by a mold;
- injection molding a second powder metallurgy compact having a second surface that is formed by a mold;
- fluidizing the first and second surfaces by applying thermal energy to the first and second surfaces;
- while the first and second surfaces are fluidized, placing the first and second surfaces directly in contact with each other, wherein additional material is not applied to the first or second surfaces prior to placing the first and second surfaces in contact with each other;
- wherein after the fluidized first and second surfaces are placed in contact with each other, the fluidized first and second surfaces solidify to form a bonded structure;
- and
- thermally treating the bonded structure to fuse the first and second compacts into a unitary component.
A method for joining first and second powder compacts to form an object, the method comprising:
- forming first and second powder compacts, each comprising an inorganic powder and a binder;
- applying thermal energy to respective surfaces of the first and second compacts to fluidize the surfaces;
- placing the fluidized surfaces of the compacts in contact with each other while the surfaces are still fluidized and without applying any material to either surface after the compacts are formed and prior to placing the fluidized surfaces in contact with each other;
- cooling the compacts to form an object having a bond at the interface of the joined surfaces;
- and
- thermally treating the object to remove at least a portion of the binder from the compacts.
A method of forming a hermetically sealed member, comprising:
- injection molding a first powder metallurgy compact having a first surface that is formed by a mold;
- injection molding a second powder metallurgy compact having a second surface that is formed by a mold;
- fluidizing a region of the first surface and a region of second surface;
- placing the fluidized regions into contact with each other without applying any material to either surface before placing the fluidized regions into contact with each other;
- allowing the fluidized regions to solidify, thereby forming a bonded structure;
- and
- thermally treating the bonded structure to fuse the first and second compacts into a unitary component having an internal cavity that is hermetically sealed where the first and second compacts are fused to each other.
Dependencies are inferred from the claim text.