专利摘要:
A method of manufacturing a turbomachine part, said method comprising a step (101) for producing said piece by metallurgy of the powders with a material forming the substrate of said part, then a finish comprising at least a first step (103) in a specific material is deposited on at least one surface (S1) of the substrate of said part after the step (101) of metallurgical production of the powders and a second step (104) corresponding to a heat treatment, so as to form a smooth coating of said surface (S1), characterized in that said determined material is a metallic material, so as to form a metal coating.
公开号:FR3062324A1
申请号:FR1750709
申请日:2017-01-30
公开日:2018-08-03
发明作者:Stephane KNITTEL;Philippe Bayard;Pierre Jacques Colas Cedric
申请人:Safran Aircraft Engines SAS;
IPC主号:
专利说明:

© Holder (s): SAFRAN AIRCRAFT ENGINES.
O Extension request (s):
Agent (s):
GEVERS & ORES Public limited company.
(54) PROCESS FOR MANUFACTURING PARTS MADE OF POWDER METALLURGY INCLUDING THE APPLICATION OF A COATING.
FR 3 062 324 - A1 (57) Method for manufacturing a turbomachine part, said method comprising a step (101) of producing said part by powder metallurgy with a material forming the substrate of said part, then a finish comprising at least a first step (103) in which a determined material is deposited on at least one surface (S1) of the substrate of said part after the step (101) of production by powder metallurgy and a second step (104) corresponding to a heat treatment, so as to form a smooth coating of said surface (S1), characterized in that said determined material is a metallic material, so as to form a metallic coating.
j 101 Make the part by | powder technology! 102 Clean the surface S1
............... I ................
10s Apply the metal powder i on the surface S1 i 131 Coat the surface SL; i d an adhesive product
1s2 Apply powder to the piece coated with adhesive
1104 Carry out first treatment '. thermal: 105 Perform a second treatment;
; thermal: 10b Perform mechanical or chemical finishing i
METHOD FOR MANUFACTURING PARTS MADE OF POWDER METALLURGY INCLUDING THE APPLICATION OF A COATING
TECHNICAL AREA
The field of the present invention is that of the manufacture of metal parts and more particularly that of the finishing treatment for obtaining a good surface condition on parts produced by powder metallurgy.
STATE OF THE ART
The production of parts by powder metallurgy is of definite economic interest in terms of production rate, reduction of the times of the machining steps and cost of production.
The powder metallurgy manufacturing methods include in particular additive or direct manufacturing methods, such as laser sintering, powder injection molding or electron beam melting, for example. These processes have the advantage of being able to produce metallic parts with a geometry close to the final geometry of the part from metallic powders.
However, the surface finish at the end of the process does not allow direct use of the parts. Indeed, surface states with high and irregular roughness levels are generally obtained according to the method of production, the parameters and the construction orientation and the nature of the powders used (grain size, particle size distribution and chemical composition) . These surface conditions prove to be incompatible with the requirements of design offices in terms of roughness (impact on aerodynamic performance in flow passage areas), but also mechanical abatements (parts subject to vibration stresses in service ) linked to these degraded surface conditions.
In addition, the surfaces of the parts produced in additive manufacturing are generally polluted (oxides, grains of powder with low adhesion) or have metallurgical defects which can affect the microstructure of the part on thicknesses generally between 50 and 200 μm.
Techniques exist which make it possible to improve the surface conditions of parts produced by additive manufacturing by removing material from the surface of the parts so as to obtain surfaces compatible with the requirements imposed by the design offices. These processes can be mechanical (process for modifying surface conditions by machining, or tribofinishing) or chemical (chemical or electrochemical machining) or, alternatively, can be a combination of processes belonging to the two previous families. For parts with complex geometries, these processes may have limitations in terms of efficiency and accessibility.
Another family of processes can, as described in document FR-B129786878 of the depositor, comprise the manufacture of a part by powder metallurgy with an under-thickness, followed by a finishing operation with the deposition of a coating in epoxy paint to form a film to obtain the desired positioning of the surface of the part. The deposition of epoxy paint is easier to carry out and makes it possible to achieve good surface finish after manufacture. However, this method has the disadvantage that the coating does not have the same qualities of mechanical, thermal and chemical resistance as the substrate of the part obtained by powder metallurgy. It is rather reserved for prototyping parts but it does not necessarily have the characteristics allowing to produce a part intended to function in operational use. Indeed, the application of a layer of organic paint of epoxy type can make it possible to smooth the surface, even to bring a certain resistance to corrosion to the substrate. However, use is limited to 150/200 ° C maximum. In addition, in flow passage areas, organic paints based on epoxy resin have poor erosion behavior.
The object of the present invention is to remedy these drawbacks by proposing a method for producing parts with rapid construction from metal powders, which does not have some of the drawbacks of the prior art and which, in particular, makes it possible to obtain high quality surface finish and effective protection of the part during its use.
STATEMENT OF THE INVENTION
To this end, the subject of the invention is a method for manufacturing a turbomachine part, said method comprising a step of producing said part by powder metallurgy with a material forming a substrate for said part, then a finish comprising at at least a first step in which a determined material is deposited on at least one surface of the substrate of said part after the step of production by powder metallurgy and a second step corresponding to a first heat treatment, so as to form a smooth coating of said surface, characterized in that said determined material is a metallic material so as to form a smooth metallic coating.
The use of a metallic material makes it possible to form a metallic coating conferring on the part an improved surface topography compared to a part without treatment and an increased mechanical resistance due to said improvement of the surface topography (better vibratory resistance for example )
Preferably, said metallic material is deposited in powder form during said first finishing step.
Advantageously, a binder or adhesive agent is used during said first finishing step, so as to promote the adhesion of the metallic powder material to said surface of the substrate.
Advantageously, the substrate material being a metal or a determined metal alloy, said powdered metallic material comprises at least a first set of grains composed of a first metal or of a first alloy of the same kind as the material of the substrate. This makes it possible to obtain metallurgical continuity between the substrate and the coating, thus making it possible to obtain equivalent properties between the substrate and the coating, promoting the operational efficiency of the part.
Preferably, the heat treatment of said second finishing step is carried out so as to melt at least one set of grains of the same kind in said metallic powder material.
Advantageously, the first set of grains is different from the set of grains melted in said second finishing step.
Advantageously, said surface of the substrate having a determined roughness, said first set of grains has a particle size of size less than said roughness, preferably less than 53 μm, so as to form drops of liquid material correctly filling the roughness of the surface of the substrate during said second finishing step.
Preferably, the method comprises a step of cleaning said surface of the substrate before said first finishing step, so as to promote adhesion to the substrate of said metallic material.
In a first embodiment of the method, said first finishing step comprises at least one phase of depositing an adhesive agent on said surface of the substrate prior to a phase of applying the powder of said metallic material on said surface, so that the powder adheres to said surface.
In a second embodiment of the method, said first finishing step comprises a phase of producing a slip with the powder of said metallic material, using at least a binding agent and a solvent, and a phase applying said slip on said surface of the substrate, so that the powder deposit reaches the desired thickness to form the coating
DESCRIPTION OF THE FIGURES
The invention will be better understood, and other objects, details, characteristics and advantages thereof will appear more clearly during the detailed explanatory description which follows, of embodiments of the invention given by way of examples. purely illustrative and not limiting, with reference to the accompanying schematic drawings.
In these drawings:
- Figure 1 is a schematic sectional view of the surface of a part made from metal powders, after the additive manufacturing step;
- Figure 2 is a schematic sectional view of the surface of the same part as Figure 1 after depositing a layer of metal powder in a first embodiment according to the invention;
- Figure 3 is a schematic sectional view of the surface of the same part as Figure 1 after depositing a layer of metal powder with a slip, in a second embodiment according to the invention;
- Figures 4a, 4b and 4c are schematic sectional views of a detail of the surface of Figure 1 on which are hung drops of different sizes of metal powder brazed to form a layer as in Figure 5;
- Figure 5 is a schematic sectional view of the surface of the same part as Figure 3 after a first heat treatment according to the invention;
- Figure 6 is a schematic sectional view of the surface of the same part as Figure 5 after a second heat treatment according to the invention;
- Figure 7 shows the flow diagram of a first embodiment of the method according to the invention;
- Figure 8 shows the flow diagram of a second embodiment of the method according to the invention.
DETAILED DESCRIPTION
The invention relates to the production of a part by powder metallurgy by additive manufacturing, for example manufacturing by laser with powder spraying (Additive Laser Manufacturing or ALM), selective laser melting (Selective Laser Melting or SLM), metal injection molding (Metal Injection Molding or MIM), powder injection molding (Powder Injection Molding or PIM), electron beam fusion (Electron Beam Melting or EBM), etc. As has been said previously, additive manufacturing thus makes it possible to form a part with a metallic material forming a substrate whose surface has a geometry close to the desired final shape. The substrates concerned by the invention can be:
- Nickel, Cobalt, NiCr, CoCr, NiCo, CoNi, CoNiCr, nickel base alloys, cobalt base or nickel base superalloys or cobalt base superalloys;
- steels (martensitic, austenitic, cast iron, etc.), FeCrAI, etc ...;
- Titanium and titanium alloys;
- Intermetallic materials (TiAI, etc ...).
Referring to Figure 1, there is seen in section and at very high magnification a surface element S1 of the substrate 1 of such a part. This surface S1 has a certain number of peaks and hollows which extend perpendicular to the average surface of the part and whose amplitude between the highest peak and the deepest hollow, which characterizes the roughness of the surface, is equal to a so-called Rt value. This roughness Rt also provides a dimension characteristic of the size of the patterns Mi forming the asperities of the surface S1, typically a peak between depressions.
We will now describe the rest of the process according to the invention, which makes it possible to achieve low roughness on the surface element S1 while following the shapes of the final part. This process applies a metallic coating on the surface element S1, the thickness of which is generally between 25 and 3000 μm, depending on whether one simply wants to smooth the surface S1 or also make up for a deviation in dimensions from the specified shape. for the room.
With reference to FIG. 7, a first embodiment of the method uses the application of an adhesive or glue on the surface S1 to maintain a metallic powder or a mixture of metallic powders which will serve to form the metallic coating on the surface S1 .
The powder or the powder mixture advantageously comprises a first powder of a first metal, of the same kind as that of the substrate 1, or of a first alloy, of the same shade or of a shade similar to the alloy of the substrate 1 This makes it possible to form a coating having the same qualities as the substrate 1 of the part and to ensure metallurgical continuity between the part and the coating. Said first powder, generally non-meltable during heat treatments such as brazing used in the process, preferably has a fine particle size. The grain size is preferably determined as a function of the characteristic dimension Rt of the roughness and of the distance between the patterns, so that the powder grains can be distributed over the patterns Mi forming the roughness of the surface S1. Typically the grain size is less than 53 µm.
Taking into account the heat treatments forming part of the process according to the invention, the powder or the mixture of powders preferably comprises a second powder of a second metal, here fusible, intended for brazing. Advantageously, the solidus temperature of the second metal, of brazing, is lower than the solidus temperatures of the first metal and of the substrate 1. Examples of metal alloys which can be used for the second metal are given below with their melting temperatures. . The table below further includes mixtures of first and second powders or metals and their melting temperatures.
Alloy type(second metal) or mixture (first metal and second metal) Temperaturefusion NiCrB1055 1100 ° C NiCoSiB1060 1125 ° C RBD61 (Astroloy 75% and NiCoSiB1060 25%) 1170-1220 ° C RBD121 (Astroloy70% and NiCoSiB1060 30%) 1170 ° C- 1220 ° C
Advantageously, the powder mixture is placed in a kneader for a time necessary for good homogenization, before its use in the steps described below.
Preferably, the method comprises, after the step 101 of additive manufacturing of the part and before the deposition of the metal powder or mixture of powders, a preliminary cleaning step 102 so that the surface S1 to be treated is clean, non-greasy and not oxidized. This cleaning step 102 advantageously includes a range of degreasing and deoxidation. It is possible to add a vapor phase cleaning of the fluorinated cleaning type.
Then, the first step 103 of producing the metallic coating, here the application of a layer of metallic powder on the surface S1, comprises two phases.
A first phase 131 consists in depositing on the surface S1 an adhesive such as glue, charcoal lacquer or hair lacquer, for example. This can be achieved by spraying the adhesive in the form of a spray or by any other means (e.g. painting or spraying, brush, brush, soaking).
This is immediately followed by a second phase 132 of depositing a thin layer of the powder or the mixture of powders, on the surface S1 bonded. For this, the powder can be sprinkled on the surface S1 from a salt-type powder distributor in which it has been previously placed. The powder is then distributed homogeneously over the entire area to be treated before eliminating the excess non-adherent so as to have a very fine thickness of powder on the part. The thickness of the powder layer is between 30pm and 150pm.
In a variant, the second phase 132 can be carried out by immersing the part in a powder mixture bath (type tribofinishing bowl), so as to adhere the powder to the surface of the part.
With reference to FIG. 2, at the end of the second phase 132, the mixture 3 of metal powders sticks to a layer of adhesive agent 2 which clings itself to the surface S1. The assembly can cover the patterns Mi of the roughness of the surface S1, the adhesive agent 2 filling the hollows between the patterns Mi and the powder layer of this mixture 3 not penetrating into the hollows. The external surface of the powder or powder mixture deposited is smoother than the surface S1 but it does not necessarily have sufficient polish and the whole does not yet form a coating having the desired properties.
The two phases 131, 132, of the powder deposition step 103 can be repeated the number of times necessary for the powder layer to reach a determined thickness, making it possible to carry out, thanks to the heat treatments applied in the rest of the process, the metal coating with the desired thickness.
The method then comprises a heat treatment 104 in order to reduce the roughness and obtain a coating smoothing the surface S1. Here, this consists of an energy supply to the surface of the metal powder layer, for example by heat treatment in an oven. The heat supply can also be local using a laser, to melt at least part of the powder deposited, for example the grains of the brazing powder, composed of the second fusible metal. With reference to FIG. 5, a metallic coating 5 is obtained which, on the one hand has a smoother external surface S2 and with better mechanical properties, on the other hand conforms to the surface S1 of the substrate 1, the adhesive agent having been evacuated.
This treatment can be followed by heat treatments 105 for diffusion and structural homogenization. With reference to FIG. 6, the second heat treatments 105 can in particular make it possible to homogenize the thickness of the metal coating 5.
More generally, the part can undergo a brazing-diffusion cycle, in order to optimize the smoothing of the surface S1 by the coating, as in the example described below:
degassing between 400 and 600 ° C for 15 minutes (step not shown in Figure 7), homogenization at 950 ° C for 15 minutes (step not shown in Figure 7), soldering with a temperature to choose between 960 ° C and 1220 ° C for 10 to 20 minutes (step 104 represented in FIG. 7), diffusion with a temperature to be chosen beyond 1100 ° C for a duration depending on the substrate / coating couple, lasting, for example, 2 hours to 8 hours) ( step 105 shown in FIG. 7).
Such a heat treatment cycle can be carried out under vacuum, under a neutral atmosphere or a reducing atmosphere to limit the oxidation phenomena.
To finalize the improvement in the surface finish, a finishing treatment 106 can be carried out. This treatment can be mechanical, for example tribofinishing, light grooming or sanding, or chemical, for example chemical machining.
With reference to FIG. 8, a second embodiment of the method uses, after the additive manufacturing 101 of the part, the application of a slip in which is suspended a metallic powder or a mixture of metallic powders which will serve to form the metallic coating on the surface S1. This second embodiment can be advantageous in the case of parts with complex geometries where it is necessary to cover areas of complex shapes and difficult to access.
As in the first embodiment, the powder or mixture of metallic powders advantageously comprises a first powder of a first metal of the same kind as that of the substrate 1 or of a first alloy of the same shade or a shade close to that the alloy of the substrate 1.
Likewise, the powder or mixture of powders preferably comprises a second powder formed from a second alloy having a solidus temperature lower than the solidus temperatures of the first metal or first alloy and of the substrate 1, with a view to heat treatments of the type brazing which are applied in the process. For the second embodiment, said second alloy is preferably formed by using an alloy of the same family as the first alloy or the same metal as the first metal but by modifying its composition for example by using bodies such as Si, B , P or precious metals such as Cu, Ag, Au, Pd.
Preferably, the second embodiment also comprises, before depositing the powder or the mixture of metal powders, a preliminary cleaning step 202 so that the surface S1 to be treated is clean, non-greasy and non-oxidized. As in the previous embodiment, this cleaning step 202 can include a range of degreasing and deoxidation. It is possible to add a vapor phase cleaning of the fluorinated cleaning type. Advantageously, this step 202 is similar to decontamination and can be carried out using a chemical pickling of the surface S1 so as to deoxidize it and activate it. By way of example, for a substrate 1 made of a nickel base alloy, a deoxidation bath containing a mixture: HNO3 / HCl / HF and FeCI3 can be used to pickle the surface S1. The above step 102 can be replaced by this step 202.
This cleaning improves the efficiency of the process by promoting the good wettability of the alloys constituting the powder or the mixture of powders on the surface S1 of substrate 1. In fact, it is known that a metallic material in the liquid state has good wettability on a solid substrate made of the same material.
In the second embodiment, step 203 of depositing the powder or mixture of metal powders begins with a first phase 231, of manufacturing a slip. This consists of suspending the mixture of metallic powders in a solution or a paste, adding a binder and solvents to it. The binder can be an aqueous organic binder, such as a polyethylene oxide (PEO) or acrylic materials, or a metal binder such as NiCr or NiCrSi. Solvents are generally organic solvents.
Agents such as a wetting agent can also be added to the mixture to allow good adhesion and better spreading of the slip over the entire part.
The second phase 232 of the deposition step 203 consists of an application of the slip on the surface S1. This can be done by known methods, for example by spraying (spraying, spraying), dipping or brushing.
With reference to FIG. 3, at the end of step 203, the layer 4 of the slip material penetrates into the hollows around the patterns Mi of the surface S1, promoting its grip and the homogenization of the coating during the subsequent steps. of the process.
A steaming step, not shown in FIG. 8, can be carried out so as to consolidate the deposit on the part and allow its easier handling. The drying time can range from 10 min to a few hours, with a temperature between 50 and 150 ° C, for example.
In the second embodiment, the method also includes a heat treatment 204 to obtain, as shown in FIG. 5, a homogeneous metallic coating 5, which matches the surface S1 of the substrate 1 and which has a smooth surface S2 on the outside . Here, the treated part is placed in the oven to assemble the coating on the part. The temperature and the duration of the treatment for assembling the coating on the part may vary depending on the nature of the substrate and the coating. In all cases, the treatment temperature must be higher than the solidus temperature of the second alloy. Intermediate temperature steps can be achieved at temperatures below the final treatment. The purpose of these bearings is to evaporate the binder and the solvents contained in the slip. Typically for the application of the process on a nickel-based alloy, the treatment temperatures are between 800 and 1300 ° C. and the hold times from 20 min to 2 h.
It will be noted at this stage that, to promote good wettability and good adhesion of the powder mixture, it is necessary that the metal particles have a size compatible with the surface state to be covered. As indicated in FIG. 4, this makes it possible to obtain, during the heat treatment, drop sizes 6 of molten slip allowing good filling of the roughness during the setting in temperature and the melting of the mixture applied to the surface of the part. . It can be seen in FIG. 4a that the drops 6 have a dimension comparable to the roughness Rt and therefore are distributed correctly over the patterns Mi of the surface S1. On the other hand, in FIG. 4b, the drops 6 are too small and do not form a homogeneous film, while, in FIG. 4c, drops 6 which are too large do not wet the hollows between the patterns Mi. The use of powders of fine particle size, with grains of size less than or equal to 53 μm makes it possible to obtain adequate drop sizes. This remark is also valid for the drops of molten material from the powder bonded to the surface S1, during the heat treatment 131 of the first embodiment.
In the context of a reduction in the costs of implementing the process, the heat treatment can be carried out at the same time as a heat treatment intended to obtain a particular microstructure for the base alloy (e.g. treatment of returned). The heat treatments can be carried out under vacuum, under neutral gas or even in a reducing atmosphere (presence of H2 for example).
To promote good adhesion, heat treatments 205 for diffusion and / or containment can optionally be carried out after the initial assembly treatment. With reference to FIG. 6, following this step 205, the interface between the substrate 1 and the metal coating 5 follows a substantially smooth surface S’1.
As in the first embodiment, a mechanical or chemical finishing treatment 206 can be carried out to finalize the improvement in the surface finish.
The examples of implementation of the method have been presented on a portion of surface S1 with reference to small-scale structures. It is obvious that the method can be used to manufacture a part of which a determined portion of surface must be treated, for example to work under particular conditions, or even the entire surface of which must be treated.
权利要求:
Claims (11)
[1" id="c-fr-0001]
1. A method of manufacturing a turbomachine part, said method comprising a step (101) of producing said part by powder metallurgy with a material forming the substrate of said part, then a finish comprising at least a first step (103 ) in which a determined material is deposited on at least one surface (S1) of the substrate of said part after the step (101) of production by powder metallurgy, and a second step (104) corresponding to a heat treatment, so forming a smooth coating of said surface (S1), characterized in that said determined material is a metallic material, so as to form a smooth metallic coating.
[2" id="c-fr-0002]
2. Method according to claim 1, in which said metallic material is deposited in the form of powder during said first finishing step (103).
[3" id="c-fr-0003]
3. Method according to claim 2, in which a binder or adhesive agent is used during said first finishing step (103), so as to promote the adhesion of the metallic powder material on said surface (S1) of the substrate.
[4" id="c-fr-0004]
4. The method of claim 2 or 3, wherein the substrate material is a metal or a determined metal alloy and wherein said metallic powder material comprises at least a first set of grains composed of a first metal or a first alloy of the same kind as the substrate material.
[5" id="c-fr-0005]
5. Method according to one of claims 2 to 4, wherein the heat treatment of said second finishing step (104) is carried out so as to melt at least one set of grains of the same kind in said metallic powder material.
[6" id="c-fr-0006]
6. Method according to claims 4 and 5, wherein the first set of grains is different from the set of grains melted in said second finishing step (104).
[7" id="c-fr-0007]
7. The method as claimed in claim 6, in which, said surface (S1) of the substrate having a determined roughness (Rt), said first set of grains has a particle size smaller than said roughness, preferably less than or equal to 53 μm, so as to form drops of liquid material correctly filling the roughness of the surface (S1) of the substrate during said second finishing step (104).
5
[8" id="c-fr-0008]
8. Method according to one of claims 2 to 7, comprising a step (102) of cleaning said surface (S1) of the substrate before said first finishing step (103), so as to promote adhesion to the substrate of said material metallic.
[9" id="c-fr-0009]
9. Method according to one of claims 2 to 8, wherein said first finishing step (103) comprises at least one phase (131) of depositing an agent
[10" id="c-fr-0010]
10 adhesive on said surface (S1) of the substrate prior to a phase (132) of applying the powder of said metallic material to said surface (S1), so that the powder adheres to said surface (S1).
10. Method according to one of claims 2 to 8, wherein said first finishing step (203) comprises a phase (231) of making a slip
[11" id="c-fr-0011]
15 with the powder of said metallic material, using at least a binding agent and a solvent, and a phase (232) of application of said slip on said surface (S1) of the substrate, so that that the powder deposit reaches the desired thickness to form the coating.
1/2
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同族专利:
公开号 | 公开日
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法律状态:
2017-12-18| PLFP| Fee payment|Year of fee payment: 2 |
2018-08-03| PLSC| Publication of the preliminary search report|Effective date: 20180803 |
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优先权:
申请号 | 申请日 | 专利标题
FR1750709|2017-01-30|
FR1750709A|FR3062324B1|2017-01-30|2017-01-30|PROCESS FOR MANUFACTURING PARTS PRODUCED IN METALLURGY OF POWDERS COMPRISING THE APPLICATION OF A COATING|FR1750709A| FR3062324B1|2017-01-30|2017-01-30|PROCESS FOR MANUFACTURING PARTS PRODUCED IN METALLURGY OF POWDERS COMPRISING THE APPLICATION OF A COATING|
EP18153781.2A| EP3354769A1|2017-01-30|2018-01-27|Method for manufacturing parts made by powder metallurgy comprising the application of a coating|
CN201810084788.7A| CN108372303A|2017-01-30|2018-01-29|For manufacturing the method including applying coating for passing through part made from powder metallurgy|
US15/884,244| US20180214953A1|2017-01-30|2018-01-30|Method for manufacturing parts made by powder metallurgy comprising the application of a coating|
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