WO2001071056A2 - Nickel vapour deposition manufacture of aircraft engine parts - Google Patents
Nickel vapour deposition manufacture of aircraft engine parts Download PDFInfo
- Publication number
- WO2001071056A2 WO2001071056A2 PCT/CA2001/000356 CA0100356W WO0171056A2 WO 2001071056 A2 WO2001071056 A2 WO 2001071056A2 CA 0100356 W CA0100356 W CA 0100356W WO 0171056 A2 WO0171056 A2 WO 0171056A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mould
- nickel
- vapour deposition
- sheet metal
- blank
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/01—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes on temporary substrates, e.g. substrates subsequently removed by etching
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02K—JET-PROPULSION PLANTS
- F02K1/00—Plants characterised by the form or arrangement of the jet pipe or nozzle; Jet pipes or nozzles peculiar thereto
- F02K1/46—Nozzles having means for adding air to the jet or for augmenting the mixing region between the jet and the ambient air, e.g. for silencing
- F02K1/48—Corrugated nozzles
Definitions
- the invention concerns a method of manufacturing a seamless self-supporting sheet metal part using the nickel carbonyl vapour deposition process to replace conventional sheet metal parts that are formed from flat blanks and welded or brazed together.
- Finished sheet metal components for various uses are conventionally bent, roll-formed, stamped and formed into shapes that are combined with other shapes and welded or brazed into a final sheet metal assembly.
- the complex shapes constructed of sheet metal for aircraft engines involve a high degree of precision, skill, quality control, rework, part rejection and the necessary expenditure of time and money to produce acceptable results.
- An example of a complex sheet metal component is an exhaust mixer for an aircraft engine.
- This component is an annular ring with a pleated or accordion-like skirt which serves to mix the cold engine bypass flow and hot engine exhaust gasses at the tail of the engine.
- Such complex shapes are generally fabricated by cutting and forming smaller segments in a sheet metal die press then assembling the components together in a complex welding jig.
- the fitting and assembly of multiple components inherently involves a degree of inaccuracy.
- the introduction of heat to thin sheet metal components during welding introduces inaccuracies and heat distortion as the adjacent metal expands and contracts.
- Welding of aerodynamic shapes is less than ideal since the surface of welded areas must be ground, polished or finished to preserve the surface aerodynamic properties of the part.
- the heat from welding induces residual stresses which are locked into the structure and require heat treating to relieve these built-in stresses, that introduces distortion.
- the inventors have recognised that nickel vapour deposition may be utilised to produce complex sheet metal surfaces despite the relatively high cost involved and the long periods of time required to deposit pure nickel on a mould surface.
- the 99.9% pure nickel deposited in this process has limited capacity for heat resistance making it unsuitable for applications where operating temperatures exceed 900°F.
- Nickel vapour deposition is commonly utilised for low temperature nickel plating of electrodes or other metal clad components as illustrated in the following U.S. patents: U.S. Patent No. 4,687,702 to Monsees for applying a metal layer on one surface of a polyamide foam; and U.S. Patent No. 5,362,580 to Ferrando et al . for a nickel coated lightweight battery electrode.
- the nickel deposition process is used to apply a thin very accurate plating or coating on a substrate.
- the nickel coating layer conventionally
- Nickel vapour deposition is well known and will be described here only in general terms.
- U.S. Patent No. 5,766,683 to Waibel describes a nickel deposition system with a carbon monoxide and vapour recovery system. Pure nickel on exposure to carbon monoxide produces nickel carbonyl vapour, which is contained within an enclosed deposition chamber.
- the substrate to be coated with a nickel layer is positioned within the chamber and exposed to the nickel carbonyl vapour. When the substrate is heated to a predetermined temperature, the nickel carbonyl vapour decomposes on the substrate. Elemental nickel is plated on the substrate and carbon monoxide gas is emitted.
- Nickel vapour deposition systems generally include means to withdraw the carbon monoxide gas and recycle the CO gas to produce a continuous supply of nickel carbonyl vapour for deposition.
- nickel vapour deposition generally progresses at a rate much greater than conventional plating to build up a thin plated layer on the substrate at a rate of up to 0.010 inches per hour.
- a negative mould surface with a nickel plating layer accurately reproduces the positive master.
- the intent of forming nickel plated moulds is to produce a single side, which is used as an accurate negative of the component to be moulded.
- the side of the nickel shell opposite the negative mould side is often -encased in resins or reinforced in various ways to produce the final nickel-lined mould. Therefore, the opposite side of the nickel plated layer is given no consideration except to the extent that it provides a base for reinforcing the thin nickel mould surface.
- the nickel layer is thin and prone to distortion if removed from the master. Therefore mould making includes encasing or reinforcing the deposited side in resins before removal from the master.
- the invention provides a novel method of manufacturing a seamless self-supporting metal part using nickel vapour deposition, where the part has a selected minimum thickness, a first aerodynamically contoured surface and a second substantially parallel surface.
- the method replaces labour intensive welding of individually manufactured sheet metal segments for complex aerodynamic shapes, and produces a part with higher accuracy, less cost, controlled strength and hardness properties.
- Nickel vapour deposition is commonly used for plating electronic components, and for producing a relatively thick metallic lining on plastic injection moulds.
- the seamless sheet metal part is manufactured by: fabricating a mould with at least one mould surface being a negative of the first surface of the part; enclosing the mould in a nickel vapour deposition chamber; heating the mould continuously while depositing nickel on the mould surface by nickel vapour deposition until a blank of nickel is deposited having at least the minimum thickness required and an external deposition surface; and separating the blank from the mould.
- the invention therefore provides an alternative means to produce complex sheet metal parts .
- Conventional methods of forming parts from flat plates and welding segments together involves a significant compromise in that the efficient design of sheet metal components is limited by the manufacturing methods that are currently economical .
- Cutting flat blanks from flat metal sheets and forming the blanks, assembling the formed segments in a jig and welding involves significant expenditure of time and skilled labour and inevitably results in heat distortion and inaccuracies due to the inherent difficulty in applying heat to thin sheet metal during welding and accurate fitting and assembling.
- Nickel vapour deposition as well results in a pure nickel coating, which has limited application due to its relatively low resistance to heat.
- the inventors have recognised that nickel vapour deposition despite its limitations may provide an economic means for manufacturing specific components which in an aircraft engine are not exposed to high heat such as an exhaust mixer for an aircraft engine.
- the invention therefore provides means to manufacture a seamless one-piece sheet metal component which is free from thermally induced distortions and stresses, mechanical stresses from cold working and the inherent increased risk of fatigue failure due to cold working of sheet metal.
- the invention ensures smooth aerodynamic shapes without the need to grind welds or otherwise finish the external and internal surfaces.
- the nickel vapour deposition chamber provides a contaminant free environment in which a pure nickel homogenous material may be deposited.
- the pure nickel component has enhanced strength, hardness and improved durability as a result of manufacture in a seamless manner .
- Figure 1 is a top perspective view of an assembled mould with exterior mould surface configured to nickel vapour deposit a sheet metal exhaust mixer for an aircraft engine.
- Figure 2 is a plan top view of the mould shown in Figure 1 comprised of alternating block segments showing one block segment with parallel sides in dotted outline indicating the means by which the annular assembly of blocks are withdrawn from the finished sheet metal part.
- Figure 3 is a side perspective view of a mould block segment having parallel side surfaces.
- Figure 4 is a like side perspective view of a second mould block segment having surfaces disposed at an acute angle relative to each other.
- Figure 5 is a perspective view of the completed sheet metal part .
- Figure 1 illustrates one embodiment of the mould where the mould surface 1 is an exterior surface of the assembled annular mould built up of alternating first block segments 2 having parallel side surfaces 3 and second block segments 4 having side surfaces 5 abutting the parallel surfaces 3 of the first block and being disposed at an acute angle relative to each other as best seen in Figure 2.
- the segments 2 and 4 are inwardly removable after the nickel deposition process is completed to permit the deposited nickel blank to be separated from the mould.
- portions of the mould can be masked to prevent deposition of nickel on unwanted areas of the mould.
- the first step is to fabricate a mould with at least one mould surface 1 that represents a negative of a first surface of the desired part.
- the seamless sheet metal part has a minimum wall thickness with a first aerodynamically contoured surface in a second substantially parallel surface.
- the first contoured surface of the seamless part is formed by deposition on the negative mould surface 1 of the assembled mould.
- the second parallel contoured surface of the part represents the exposed or external surface of the part blank on which nickel vapour deposition has occurred in the deposition chamber.
- the mould or mandrill is heated in a controlled manner by various means such' electrical induction heaters or circulation of heated oil.
- the temperatures at the surface of the mould 1 and at the exposed surface of the nickel deposition layer determine the rate of nickel carbonyl decomposition and the rate of formation of metallic nickel on the mould.
- Choice of mandrel material and geometry is carefully made to ensure even temperature distribution and hence uniform deposition rate.
- nickel is deposited on the mould surface 1 by nickel vapour deposition until a blank of nickel is deposited having at least the predetermined minimal thickness and a external surface generally parallel to the internal surface of the blank adjacent the mould surface 1. After the desired minimum thickness has been obtained, the mould and blank are removed from the deposition chamber and the blank is separated from the mould.
- the mandrel is made of a material allowing easy separation of the part from the mould.
- the blank is removed from the mould by disassembling the mould.
- the first blocks 2 are removed inwardly and thereafter the second blocks 4 can be easily removed inwardly.
- the blocks 2 and 4 are cleaned if necessary and reassembled for repetition of the deposition process.
- a one piece seamless component can be formed to virtually any configuration desired by the designers and it is not limited to fabrications which can be assembled by sheet metal forming and welding techniques as conventionally used.
- the amount of deformation that a sheet metal component can withstand during forming is limited.
- the shapes that can be formed and the extent to which material flows predictably during the forming process impose severe limitations on the shapes that can be practically fabricated.
- the introduction of heat and surface discontinuities resulting from welding are completely avoided by the invention as well as the thermally induced stresses from welding and the mechanical stresses from cold working during forming.
- the nickel vapour deposition process produces an extremely smooth aerodynamically superior surface within an absolutely clean controlled atmosphere.
- the hardness, strength and composition of the nickel deposited can be strictly controlled and reproduced.
- the results from fitting and welding individual components are highly dependent on the skill of welders and those involved in forming the individual components prior to welding.
- nickel deposition is a relatively slow process, compared to conventional sheet metal forming and welding, the manufacturing process can be adapted to compensate for longer residence times in the nickel vapour deposition chambers since the end result is a sheet metal product which is highly accurate, less costly to manufacture, has superior aerodynamic surface finish, and is produced in an absolutely controllable environment where parameters can be set and reproduced with extreme accuracy.
- the ability to form more than one part in the deposition chamber at a time also exists.
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE60120933T DE60120933T2 (en) | 2000-03-22 | 2001-03-21 | MANUFACTURE OF AIRCRAFT COMPONENTS THROUGH NICKEL COATING FROM THE GAS PHASE |
EP01916787A EP1266044B1 (en) | 2000-03-22 | 2001-03-21 | Nickel vapour deposition manufacture of aircraft engine parts |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/532,302 US6463992B1 (en) | 2000-03-22 | 2000-03-22 | Method of manufacturing seamless self-supporting aerodynamically contoured sheet metal aircraft engine parts using nickel vapor deposition |
US09/532,302 | 2000-03-22 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2001071056A2 true WO2001071056A2 (en) | 2001-09-27 |
WO2001071056A3 WO2001071056A3 (en) | 2002-01-24 |
Family
ID=24121215
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/CA2001/000356 WO2001071056A2 (en) | 2000-03-22 | 2001-03-21 | Nickel vapour deposition manufacture of aircraft engine parts |
Country Status (4)
Country | Link |
---|---|
US (1) | US6463992B1 (en) |
EP (1) | EP1266044B1 (en) |
DE (1) | DE60120933T2 (en) |
WO (1) | WO2001071056A2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1664372A1 (en) * | 2003-08-08 | 2006-06-07 | Weber Manufacturing Limited | Hollow nickel shapes by vapor deposition |
DE102006021539A1 (en) * | 2006-05-08 | 2007-11-15 | Eads Space Transportation Gmbh | Method for producing components for rocket construction |
Families Citing this family (10)
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US7401638B2 (en) * | 2002-03-28 | 2008-07-22 | Delta Electronics, Inc. | Heat-dissipating device and its manufacturing process |
US7229249B2 (en) * | 2004-08-27 | 2007-06-12 | Pratt & Whitney Canada Corp. | Lightweight annular interturbine duct |
US7389635B2 (en) * | 2004-12-01 | 2008-06-24 | Honeywell International Inc. | Twisted mixer with open center body |
US7909569B2 (en) * | 2005-06-09 | 2011-03-22 | Pratt & Whitney Canada Corp. | Turbine support case and method of manufacturing |
US7909570B2 (en) * | 2006-08-25 | 2011-03-22 | Pratt & Whitney Canada Corp. | Interturbine duct with integrated baffle and seal |
US7882696B2 (en) * | 2007-06-28 | 2011-02-08 | Honeywell International Inc. | Integrated support and mixer for turbo machinery |
US9616484B2 (en) * | 2008-12-18 | 2017-04-11 | Pratt & Whitney Canada Corp. | Method and apparatus for forming a turbofan mixer |
US8236163B2 (en) * | 2009-09-18 | 2012-08-07 | United Technologies Corporation | Anode media for use in electroplating processes, and methods of cleaning thereof |
US9950382B2 (en) * | 2012-03-23 | 2018-04-24 | Pratt & Whitney Canada Corp. | Method for a fabricated heat shield with rails and studs mounted on the cold side of a combustor heat shield |
FR3071765B1 (en) * | 2017-10-03 | 2020-11-20 | Safran Ceram | COMPOSITE MATERIAL REALIZATION OF A FLOW MIXER LOBE STRUCTURE |
Citations (2)
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US3024506A (en) * | 1959-07-31 | 1962-03-13 | Budd Co | Mold and method of making metalfaced foundry patterns thereon |
US3135044A (en) * | 1959-06-04 | 1964-06-02 | United Aircraft Corp | Lightwight porous structures and methods of making same |
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US4294303A (en) * | 1980-03-13 | 1981-10-13 | Caterpillar Tractor Co. | Sand core pattern and method of forming a sand mold |
US4447466A (en) * | 1981-08-14 | 1984-05-08 | General Electric Company | Process for making plasma spray-cast components using segmented mandrels |
DE3321231C2 (en) | 1983-06-11 | 1985-10-31 | MTU Motoren- und Turbinen-Union München GmbH, 8000 München | Process for the production of wear protection layers on the surfaces of components made of titanium or titanium-based alloys |
US4567066A (en) | 1983-08-22 | 1986-01-28 | Enthone, Incorporated | Electroless nickel plating of aluminum |
US4840820A (en) | 1983-08-22 | 1989-06-20 | Enthone, Incorporated | Electroless nickel plating of aluminum |
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2000
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-
2001
- 2001-03-21 DE DE60120933T patent/DE60120933T2/en not_active Expired - Lifetime
- 2001-03-21 EP EP01916787A patent/EP1266044B1/en not_active Expired - Lifetime
- 2001-03-21 WO PCT/CA2001/000356 patent/WO2001071056A2/en active IP Right Grant
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1664372A1 (en) * | 2003-08-08 | 2006-06-07 | Weber Manufacturing Limited | Hollow nickel shapes by vapor deposition |
JP2007501897A (en) * | 2003-08-08 | 2007-02-01 | ウェーバー・マニュファクチュリング・リミテッド | Hollow nickel molded product by vapor deposition |
EP1664372A4 (en) * | 2003-08-08 | 2008-09-10 | Weber Mfg Technologies Inc | Hollow nickel shapes by vapor deposition |
DE102006021539A1 (en) * | 2006-05-08 | 2007-11-15 | Eads Space Transportation Gmbh | Method for producing components for rocket construction |
Also Published As
Publication number | Publication date |
---|---|
DE60120933T2 (en) | 2007-01-04 |
EP1266044A2 (en) | 2002-12-18 |
DE60120933D1 (en) | 2006-08-03 |
EP1266044B1 (en) | 2006-06-21 |
WO2001071056A3 (en) | 2002-01-24 |
US6463992B1 (en) | 2002-10-15 |
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