Abstract: This invention relates to a mould assembly for a hot isostatic pressing, HIP, process for fabricating a component, comprising: a first part which includes a shaped surface for forming a first surface of the component, the shaped surface having at least one recess; a second part arranged to move relative to the first part during the HIP process so as to compress a powder in-fill held therebetween, wherein the second part includes a formation configured to focus pressure toward the recess so as to aid consolidation of the powder in-fill at a distal end thereof.

Abstract: The present method creates a relatively thin in situ brazing alloy layer upon first and second component edges which are brought together in order to create a component joint. This in situ brazing alloy layer is created by deposition of brazing elements, such as copper or nickel, from an electrical discharge cutting process electrode depletion utilized in order to cut the component edges, and then a subsequent brazing technique creates through interstitial migration between that brazing alloy layer and the underlying material substrate of the components a robust component joint wherein the in situ brazing alloy layer penetrates the respective component cut edge surface to only a limited depth such that the geometric effect is similarly limited, and the properties of the underlying component material structure are maintained.

Abstract: A method of forming a component (30) by isostatic pressing, the method comprising: providing a canister (4) suitable for isostatic pressing, the canister comprising first and second membranes (14, 16) which, in use, are disposed within the canister (4); the first and second membranes (14, 16) defining a component cavity (24) disposed between the first and second membranes (14, 16), a first tool cavity (26) disposed between the first membrane (14) and an adjacent wall (10) of the canister (4), and a second tool cavity (28) disposed between the second membrane (16) and another adjacent wall (12) of the canister (4); filling the component cavity (24) with the component powder for forming the component (30); filling the first and second tool cavities (26, 28) with a second tool powder; and isostatically pressing the canister (4) to form the component (30).

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 pocket (6) is machined into the surface of a component (9) by pressurising a fluid (1) and directing a jet (11) of the pressurized fluid (1) at the surface to be machined. Continuous relative movement is provided between the component (9) and the pressurized jet (11) of fluid (1) during machining. Material is removed from the component (9) in a series of layers, whereby the path of the fluid jet (11) in one of the layers is perpendicular to the path of the fluid jet (11) in the subsequent layer. The fluid jet (11) operates continuously until the required amount of material has been removed from the component (9).

Abstract: A method of manufacturing a metal component from metal powder comprises preparing (12) a metal powder, providing (14) gallium on at least part of the surface of at least some of the metal powder particles, encapsulating (16) the metal powder in a container, evacuating (18) the container to remove air and/or gas from the container, sealing (20) the container, hot isostatically pressing (22) the container to consolidate the metal powder particles to produce the metal component and removing (24) the container from the metal component. The process is used to produce gas turbine engine metal components, for example turbine discs with improved fatigue properties.

Abstract: A method of correcting the shape of a brittle cast component such as a low pressure turbine blade. The method includes steps of placing the component against a creep mold having a surface defining the desired profile of the component and HIP treating it to creep deform the component to the desired shape whilst consolidating it and removing gas and shrinkage porosity.

Abstract: This invention relates to a mould assembly for a hot isostatic pressing, HIP, process for fabricating a component, comprising: a first part which includes a shaped surface for forming a first surface of the component, the shaped surface having at least one recess; a second part arranged to move relative to the first part during the HIP process so as to compress a powder in-fill held therebetween, wherein the second part includes a formation configured to focus pressure toward the recess so as to aid consolidation of the powder in-fill at a distal end thereof.

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 method of manufacturing a blisk comprising a disc joined to an aerofoil, wherein a union piece of partially sintered powder and having an alignment feature is provided. The union piece is connected between the disc and the aerofoil, which is aligned relative to the disc by the alignment feature of the union piece. Heat and pressure is subsequently applied to consolidate the first workpiece, union piece and second workpiece.

Abstract: A powder and/or polyhedral grains of a solid material are produced by directing one or more jets of liquid at a body of the solid material, thereby causing the ablation of powder particles from the solid material. The jet or jets of liquid may be controlled to cut polyhedral grains from the solid material. The liquid within which the powder particles and/or grains are entrained is then collected and the powder particles and/or grains are separated from the liquid.

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: A method of manufacturing a metal component from metal powder comprises preparing (12) a metal powder, providing (14) gallium on at least part of the surface of at least some of the metal powder particles, encapsulating (16) the metal powder in a container, evacuating (18) the container to remove air and/or gas from the container, sealing (20) the container, hot isostatically pressing (22) the container to consolidate the metal powder particles to produce the metal component and removing (24) the container from the metal component. The process is used to produce gas turbine engine metal components, for example turbine discs with improved fatigue properties.

Abstract: A method of forming a component (30) by isostatic pressing, the method comprising: providing a canister (4) suitable for isostatic pressing, the canister comprising first and second membranes (14, 16) which, in use, are disposed within the canister (4); the first and second membranes (14, 16) defining a component cavity (24) disposed between the first and second membranes (14, 16), a first tool cavity (26) disposed between the first membrane (14) and an adjacent wall (10) of the canister (4), and a second tool cavity (28) disposed between the second membrane (16) and another adjacent wall (12) of the canister (4); filling the component cavity (24) with the component powder for forming the component (30); filling the first and second tool cavities (26, 28) with a second tool powder; and isostatically pressing the canister (4) to form the component (30).

Abstract: A method of manufacturing a blisk comprising a disc joined to an aerofoil, wherein a union piece of partially sintered powder and having an alignment feature is provided. The union piece is connected between the disc and the aerofoil, which is aligned relative to the disc by the alignment feature of the union piece. Heat and pressure is subsequently applied to consolidate the first workpiece, union piece and second workpiece.

Abstract: A manufacturing process that comprises placing an article within a particulate medium (4), the article being provided with a molded body (8) of small ceramic particles. On application of heat and pressure the small ceramic particles are pushed between the particulate medium (4) to permit localized deformation of the article (2).

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 gamma titanium aluminide alloy consisting of 46 at % aluminium, 8 at % tantalum and the balance titanium plus incidental impurities has an alpha transus temperature T? between 1310° C. and 1320° C. The gamma titanium aluminide alloy was heated to a temperature T1=1330° C. and was held at T1=1330° C. for 1 hour or longer. The gamma titanium aluminide alloy was air cooled to ambient temperature to allow the massive transformation to go to completion. The gamma titanium aluminide alloy was heated to a temperature T2=1250° C. to 1290° C. and was held at T2 for 4 hours. The gamma titanium aluminide alloy was air cooled to ambient temperature. The gamma titanium aluminide alloy has a fine duplex microstructure comprising differently orientated alpha plates in a massively transformed gamma matrix. The heat treatment reduces quenching stresses and allows larger castings to be grain refined.