Abstract: There is provided a method of treating a nickel base super alloy (NiSa) article. First, the NiSa article having fine grains is obtained. The NiSa article has a uniform distribution of the fine grains and substantially uniform mechanical properties throughout. One or more regions within the NiSa article are mechanically deformed. Then, the NiSa article is heat treated to obtain coarse grains in the one or more regions, the coarse grains having a size that is larger than that of the fine grains of the NiSa article outside of the one or more regions.

Abstract: A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.

Abstract: A method of forming a component from a part in the green state, including selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion to obtain the component. The green part is provided with the first portion(s) having a first solid loading and the second portion(s) having a second solid loading different from the first solid loading, then debound and sintered to obtain the component. The different first and second solid loadings produce the different local volume reduction in the first portion(s). The first portion(s) can be selected by determining a resulting final shape obtained from debinding and sintering a green part having a uniform first volumetric proportion of binder, and selecting the first portion(s) requiring a different local deformation than that producing the resulting final shape to obtain a desired final shape.

Abstract: There is provided a method of treating a nickel base super alloy (NiSa) article. First, the NiSa article having fine grains is obtained. The NiSa article has a uniform distribution of the fine grains and substantially uniform mechanical properties throughout. One or more regions within the NiSa article are mechanically deformed. Then, the NiSa article is heat treated to obtain coarse grains in the one or more regions, the coarse grains having a size that is larger than that of the fine grains of the NiSa article outside of the one or more regions.

Abstract: A method of sizing a cavity in a part and a part made from such method. The method includes forming the part having the cavity, including forming a plurality of protrusions extending within the cavity from at least one internal surface of the cavity, the protrusions having distal ends bordering an unobstructed portion of the cavity, the unobstructed portion having an initial dimension at least partially defined by a position of the distal ends, pressing a deforming element against the distal ends of the protrusions to plastically deform the protrusions toward the at least one internal surface of the cavity and increase the initial dimension to a final dimension, and disengaging the deforming element from the distal ends.

Abstract: A method of forming a component from a part in the green state, including selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion to obtain the component. The green part is provided with the first portion(s) having a first solid loading and the second portion(s) having a second solid loading different from the first solid loading, then debound and sintered to obtain the component. The different first and second solid loadings produce the different local volume reduction in the first portion(s). The first portion(s) can be selected by determining a resulting final shape obtained from debinding and sintering a green part having a uniform first volumetric proportion of binder, and selecting the first portion(s) requiring a different local deformation than that producing the resulting final shape to obtain a desired final shape.

Abstract: A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.

Abstract: A mold assembly for powder injection molding of a shaped element includes a first mold portion having a first surface defining a first portion of the mold cavity and releasably engageable to the feedstock and a second mold portion having a second surface defining a second portion of the mold cavity and releasably engageable to the feedstock. The first mold portion has a first thermal capacity and a first thermal conductivity, and the second mold portion has a second thermal capacity and a second thermal conductivity. At least one of the first thermal capacity and the first thermal conductivity is lower than a respective one of the second thermal capacity and the second thermal conductivity and/or than a respective one of the thermal conductivity and thermal capacity of solid metal. A method of molding a green part is also discussed.

Abstract: A method of manufacturing a part, including providing a green body made of powder injection molding material and connected to a solid support member partially contained in the green body. The support member is engaged with a retaining fixture of a machine tool. While supporting the green body through the engagement between the support member and the retaining fixture, the green body is machined to obtain a machined green part. The machined green part is debound and sintered. A method of forming a powder injection molding part in a green state including machining a molded body using a machine tool while supporting the blank with a retaining fixture, and a machining blank having a green body and a solid support member including one locating feature of a pair of complementary locating features snuggly engageable with one another are also discussed.

Abstract: A method of sizing a cavity in a part and a part made from such method. The method includes forming the part having the cavity, including forming a plurality of protrusions extending within the cavity from at least one internal surface of the cavity, the protrusions having distal ends bordering an unobstructed portion of the cavity, the unobstructed portion having an initial dimension at least partially defined by a position of the distal ends, pressing a deforming element against the distal ends of the protrusions to plastically deform the protrusions toward the at least one internal surface of the cavity and increase the initial dimension to a final dimension, and disengaging the deforming element from the distal ends.

Abstract: A method for machining a rotor having a disc and a plurality of integral airfoils projecting outwardly from the disc, according to one aspect of the invention, comprises a step of machining each airfoil with a disc tool having a grinding periphery thereof adapted for removing material from the airfoils. The grinding periphery has a thickness greater than a thickness of an adjacent supporting portion of the disc to permit the grinding periphery to pass a surface of an airfoil in a multi-axis simultaneous motion, thereby matching the grinding periphery with a predetermined geometry of a portion of the airfoil.