US 11,883,882 B2
Method of forming a component from a green part
Orlando Scalzo, Montreal (CA); Marc Campomanes, Longueuil (CA); and Guillaume Poitras, Longueuil (CA)
Assigned to PRATT & WHITNEY CANADA CORP., Longueuil (CA)
Filed by PRATT & WHITNEY CANADA CORP., Longueuil (CA)
Filed on Jul. 21, 2021, as Appl. No. 17/381,483.
Application 17/381,483 is a continuation of application No. 16/382,481, filed on Apr. 12, 2019, granted, now 11,097,343.
Application 16/382,481 is a continuation of application No. 14/656,342, filed on Mar. 12, 2015, abandoned.
Prior Publication US 2021/0346953 A1, Nov. 11, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B22F 3/22 (2006.01); B22F 3/10 (2006.01); B22F 7/02 (2006.01); B22F 7/06 (2006.01); F01D 9/04 (2006.01); F01D 25/24 (2006.01); B22F 3/105 (2006.01); B22F 5/00 (2006.01); B22F 3/02 (2006.01)
CPC B22F 3/225 (2013.01) [B22F 3/105 (2013.01); B22F 3/1021 (2013.01); B22F 5/009 (2013.01); B22F 7/02 (2013.01); B22F 7/06 (2013.01); F01D 9/04 (2013.01); F01D 25/246 (2013.01); B22F 3/02 (2013.01); B22F 2003/023 (2013.01); B22F 2999/00 (2013.01); F05D 2230/22 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of forming a component of an aircraft engine from a part in a green state through a powder injection molding process, the method comprising:
forming the part having an initial shape of a flat panel in the green state, including:
injection-molding at least one first portion of the part in the initial shape of the flat panel with a first feedstock;
injection-molding at least one second portion of the part in the initial shape of the flat panel with a second feedstock;
wherein:
the at least one first portion having a first volume of powder material VP1 and a first volume of binder VB1, the at least one first portion having a first solid loading defined as VP1/(VP1+VB1), and
the at least one second portion having a second volume of powder material VP2 and a second volume of binder VB2, the at least one second portion having a second solid loading defined as VP2/(VP2+VB2), the first solid loading greater than the second solid loading; and
curving the part having the initial shape of the flat panel in the green state by debinding and sintering the part to obtain the component, wherein the curving includes obtaining a final shape of a curved panel after the sintering by having the first and second solid loadings producing a different local volume reduction in the at least one first portion with respect to the at least one second portion.