benefits of hot isostatic pressing for cast and advanced ... · pdf filecast and advanced...
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Benefits of Hot Isostatic Pressing for Cast and Advanced Manufactured
Products
Presented by Tony Alderton & Stewart Griffiths
Aalberts Industries
Revenue : €2,040 M Operating profit : €225 M 12,300 employees
Building
Installations
Climate
Control Industrial
Controls
Industrial
Services
Precision
Stamping
Precision
Casting
Heat Treatment Surface
Treatment
Regulation and distribution of
water and gas systems
Complete hydronic
systems for heating &
cooling systems
Regulation & control
systems of fluids and
gases in more severe
conditions
Aalberts Heat Treatment Locations
27 Locations
1100 Employees
European Sales of €150M
Providing a range of Heat Treatment Services
Surface Engineering & Heat Treatment Specialists
TTI Group Ageing Annealing Brazing Case Hardening CarboNitriding Duplex Treatments Low Pressure Carburising Harden & Tempering Hipping Induction Martempering Nitriding Nitrocarburising Nitrotec Nitreg Normalising Oxidation Plasma Nitriding Precipitation Hardening PVD Coating Stainitec Salt Bath Hardening Stress Relieving Tufftride QPQ Vacuum Brazing Vacuum Hardening
Surface Engineering & Heat Treatment Specialists
TTI Letchworth
• Size Floor Space in 3,000m2
• Employees 38
• Equipment: o Vacuum Furnaces
o Sealed Quench Furnaces
o Nitriding Furnaces
o Cryogenic Unit
o Salt Bath Processes (Cyanide and Neutral)
o Hot Isostatic Presses
• Continuous Improvement / Quality Programmes
Surface Engineering & Heat Treatment Specialists
HIP Overview o The Hot Isostatic Pressing (HIP) process uses the
simultaneous application of temperature and pressure. o Specially-designed pressure vessel. o To remove internal voids from materials. o Usually either cast or in the form of encapsulated
powders. o Removal of internal voids through a combination of
creep, plastic deformation and diffusion bonding.
Surface Engineering & Heat Treatment Specialists
HIP Materials/Applications
o Ni-based Superalloys
o Co-Cr alloys
o Nickel alloys
o Titanium alloys
o Steel alloys
o Aluminum alloys
Surface Engineering & Heat Treatment Specialists
HIP Materials/Applications
o Ni-based Superalloys
o Co-Cr alloys
o Nickel alloys
o Titanium alloys
o Steel alloys
o Aluminum alloys
o Industrial gas-turbine blade components
o Medical implants-knee, hip etc
o Motor racing & high end automotive components
o Powder/MMC billets for motorsport and aerospace
o Oil & Gas/Petrochem-valve & tool components
o Metal matrix cutting tools
o Oil valve cladding for wear resistance
o Joining of dissimilar materials
Surface Engineering & Heat Treatment Specialists
Casting Densification
Diffusion Bonding
PM
Additive Manufacturing
HIP Processes
Surface Engineering & Heat Treatment Specialists
Casting Densification
Diffusion Bonding
PM
Additive Manufacturing
HIP Processes
• Uses: o Removal of shrinkage porosity o Mitigate risk of exposing internal pores during machining
• Benefits: o Improved mechanical properties o Superior Fatigue strength o Post machining surface finish enhanced
Surface Engineering & Heat Treatment Specialists
Casting Densification
Examples of HIP castings
Surface Engineering & Heat Treatment Specialists
Additive Manufacturing
Examples of AM parts
Picture Courtesy Renishaw
Surface Engineering & Heat Treatment Specialists
Casting Densification
Diffusion Bonding
PM
Additive Manufacturing
Powder
HIP Processes
Solid To
Solid
Powder To
Solid
Surface Engineering & Heat Treatment Specialists
Casting Densification
Diffusion Bonding
PM
Additive Manufacturing
Powder
HIP Processes
Examples
Solid To
Solid
Powder To
Solid
Surface Engineering & Heat Treatment Specialists
Powder HIP Examples
Sacrificial container Consolidated powder
Near Net Shape
Surface Engineering & Heat Treatment Specialists
Casting Densification
Diffusion Bonding
PM
Additive Manufacturing
Powder To
Solid
HIP Processes
Example
Powder Solid
To Solid
Surface Engineering & Heat Treatment Specialists
Powder to Solid Example
o Solid tube Steel – Proprietary Ni based powder core
o 5 flute spiral involute o 100 mm bore size x 2 mtrs long
o All within tolerance
o No machining required
o Industry – Pumping – Oil & Gas
Picture Courtesy AIMS
Surface Engineering & Heat Treatment Specialists
Casting Densification
Diffusion Bonding
PM
Additive Manufacturing
Solid To
Solid
HIP Processes
Case Study
Powder To
Solid Powder
Surface Engineering & Heat Treatment Specialists
ACQUIRE RAW MATERIALS
MANUFACTURE, FILL AND SEAL SHEET METAL CANISTER
UNDERTAKE HOT ISOSTATIC PRESSING
REMOVE CANISTER
MACHINE PART
HOT ISOSTATIC PRESSING OF METAL CANISTER
TRANSPORT INSPECT
SIMULATE MODELLING CAN DESIGN
Surface Engineering & Heat Treatment Specialists
Surface Engineering & Heat Treatment Specialists
Solid to Solid Case Study
• Component currently produced by Thermal Spray
o High porosity
o Low yield
o Long lead time
o Manual process
Surface Engineering & Heat Treatment Specialists
Surface Engineering & Heat Treatment Specialists
Solid to Solid Case Study
• Proposed Method Diffusion Bonding Solid Solid
o Encapsulation / Canning
o Degassing
o Crimping
o Hot Isostatic Pressing
o Near Net Shape Part
Surface Engineering & Heat Treatment Specialists
Surface Engineering & Heat Treatment Specialists
Can Diagram
Evacuation pipe
Aluminium
Mild steel can (tube stock)
Leaded Bronze
Mild steel disc
Weld
Surface Engineering & Heat Treatment Specialists
Surface Engineering & Heat Treatment Specialists
Solid to Solid Case Study Benefits
• Increased joint strength
• Improved yield through better process control
• Batch process vs. piece part process – improved repeatability/consistency
• Cost competitive solution
• Reduction in lead time NNS
Questions?
Stand Number G63 - TTI GROUP LTD