Abstract: A method of forming a fully consolidated joint between first and second components comprising the steps of forming a slot in the first component; inserting at least part of the second component into the slot; inserting a powder material into the slot; heating the powder material to form a pressure tight skin; and applying hot isostatic pressure to the pressure tight skin to form a fully consolidated joint. Also a method of repairing a component.

Abstract: A component is manufactured from a powdered material such as a titanium alloy, by performing a first hot isostatic pressing HIP operation on the powdered material 14 while the powdered material is in contact with a molding surface 8 of a rigid, usable molding tool 2. The first HIP operation creates a non-porous shaped surface 16 on a partially consolidated component 14, but avoids bonding or reaction between the partially consolidated component 14 and the molding tool 2. After separation of the partially consolidated component 14 from the molding tool 2, the partially consolidated component 14 is subjected to a second HIP operation in which the powdered material is fully consolidated.

Abstract: A method of manufacturing an article by diffusion bonding, the method comprising the steps of assembling first and second component parts having a joint therebetween; sealing the joint against infiltration by solid particulate material, without causing phase change of the component parts; and applying heat and isostatic pressure via a solid particulate material to form a consolidated joint by diffusion bonding.

Abstract: A method of repairing a component comprising: removing a damaged portion of the component to expose a region of the component; providing a patch having a rim exceeding the dimensions of the exposed region; placing the patch on the exposed region of the component such that the exposed region is covered by the patch and the rim is spaced apart from the exposed region; joining the patch to the component around the rim of the patch; and diffusion bonding the patch and the component together. The rim may be spaced apart from the exposed region such that the step of joining the patch to the component does not affect the exposed region. The method may further comprise machining a recess in the damaged region of the component.

Abstract: The invention relates to a mould assembly for a hot isostatic pressing, HIP, process, comprising: an insert comprising a plurality of pieces which combine to provide a recess in which a protrusion of the component can be formed; and, a holding piece having at least one cavity in which the insert is mateably received.

Abstract: A component is manufactured from a powdered material such as a titanium alloy, by performing a first hot isostatic pressing HIP operation on the powdered material 14 while the powdered material is in contact with a moulding surface 8 of a rigid, usable moulding tool 2. The first HIP operation creates a non-porous shaped surface 16 on a partially consolidated component 14, but avoids bonding or reaction between the partially consolidated component 14 and the moulding tool 2. After separation of the partially consolidated component 14 from the moulding tool 2, the partially consolidated component 14 is subjected to a second HIP operation in which the powdered material is fully consolidated.

Abstract: In a hot isostatic pressing (HIP) process, for example for securing blades (5) to a disc (3) to form a blisk (1), the temperature of the powder (6) to be consolidated is raised to a predetermined temperature, which may be the eventual required pressing temperature, before the pressure rise to the pressing pressure is initiated. If the powder is a titanium alloy and the process employs steel tooling pieces, the application of pressure occurs only when the temperature has risen to the extent that the steel is harder than the titanium alloy.

Abstract: A method of forming a fully consolidated joint between first and second components comprising the steps of forming a slot in the first component; inserting at least part of the second component into the slot; inserting a powder material into the slot; heating the powder material to form a pressure tight skin; and applying hot isostatic pressure to the pressure tight skin to form a fully consolidated joint. Also a method of repairing a component.

Abstract: A method of manufacturing an article by diffusion bonding, the method comprising the steps of assembling first and second component parts having a joint therebetween; sealing the joint against infiltration by solid particulate material, without causing phase change of the component parts; and applying heat and isostatic pressure via a solid particulate material to form a consolidated joint by diffusion bonding.

Abstract: A method of manufacturing a fan blade (26) for a gas turbine engine by powder metallurgy comprises the steps of forming a container (52) and placing at least one metal insert (52) at a predetermined position within the container (52) and filling the container (52) with metal powder (60). The at least one metal insert (62) has a predetermined pattern of stop off material (68,70) on at least one surface of the metal insert (64,66). The container (52) is evacuated and then sealed. The container (52) is hot pressed to consolidate the metal powder (60) into a consolidated metal powder preform (72). The container (52) is removed from the consolidated metal powder preform (72). The consolidated metal powder preform (72) is heated and a fluid is supplied to the predetermined pattern of stop off material (68,70) to hot form at least a portion of the consolidated metal powder preform (72) to form the hollow metal fan blade (26).

Abstract: A method of manufacturing a fan blade (26) for a gas turbine engine by powder metallurgy comprises the steps of forming a container (52) and placing at least one metal insert (52) at a predetermined position within the container (52) and filling the container (52) with metal powder (60). The at least one metal insert (62) has a predetermined pattern of stop off material (68,70) on at least one surface of the metal insert (64,66). The container (52) is evacuated and then sealed. The container (52) is hot pressed to consolidate the metal powder (60) into a consolidated metal powder preform (72). The container (52) is removed from the consolidated metal powder preform (72). The consolidated metal powder preform (72) is heated and a fluid is supplied to the predetermined pattern of stop off material (68,70) to hot form at least a portion of the consolidated metal powder preform (72) to form the hollow metal fan blade (26).

Abstract: A sealing element for a turbine of a gas turbine engine includes a radially inner surface region provided with an integrally formed seal structure comprising a plurality of radially inwardly projecting walls. The walls may be abradable and may define cells for receiving an abradable sealing material.

Abstract: A method of manufacturing an article by consolidating powder material comprises forming a non-deformable tool (12) and a deformable tool (14). The non-deformable tool (12) comprises a plurality of tool parts (16,18). The non-deformable tool (12) defines a first cavity (20) having an open end (22) and the first cavity (20) corresponds in shape to that of the article. The non-deformable tool (12) is encapsulated in the deformable tool (14) and the non-deformable tool (12) and the deformable tool (14) define a second cavity (24) interconnected with the first cavity (20). The first and second cavities are filled with powder material (26). The deformable tool (14) is evacuated and sealed. Heat and pressure are applied to the deformable tool (14) and non-deformable tool (12) to consolidate the powder material (26) to form an article (30) in the first cavity (20) of the non-deformable tool (12). The method is used to make compressor blades, compressor vanes or compressor blisks for gas turbine engines.

Abstract: A sealing element for a turbine of a gas turbine engine includes a radially inner surface region provided with an integrally formed seal structure comprising a plurality of radially inwardly projecting walls. The walls may be abradable and may define cells for receiving an abradable sealing material.