Method for Thermal Treatment of Metal Powder Injection Molding Components, a Metal Powder Injection Molding Component and an Aircraft Engine

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This patent describes a new method for the thermal treatment of metal injection molded (MIM) components, specifically those made with nickel-based superalloys such as (modified) CM247LC. The process involves subjecting the components, after sintering, to a carefully controlled heat treatment at temperatures just below the sintering temperature for a set period. This results in a significantly enlarged grain size in the material, which greatly improves the component's resistance to creep at high temperatures. The method can be applied to critical parts in aircraft engines and other machinery exposed to extreme thermal loads.

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• Turbine blades, compressor components, dampers, seals, and fasteners in aircraft jet engines, especially in regions exposed to high temperatures.
• Parts for turbochargers and stationary gas turbines that require high-temperature mechanical stability.
• Automotive turbocharger components for heavy-duty applications.
• Specialized industrial machinery where thermal and mechanical loads are extreme.
• Production of additively manufactured or powder binder-based metal components where improved grain size is beneficial.

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• Enables much greater grain size in MIM components compared to traditional processes, significantly improving creep resistance at high temperatures.
• Increases the long-term durability and life span of parts used in thermally demanding environments such as aircraft engines.
• Allows manufacturing of complex-shaped metal parts with improved mechanical performance using cost-effective powder metallurgy or additive manufacturing techniques.
• Provides a process window that is industrially practical, requiring only a controlled heat step after sintering without significant process complications.
• Reduces the need for conventional forging or pre-treatment steps to obtain large grain size and high creep resistance.

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Patent Abstract

A method for the thermal treatment of a component, in particular a metal powder injection molded component (MIM component) including a nickel base alloy, wherein, after sintering, in particular immediately after sintering, in the injection molding process, the component is exposed for a predetermined holding time to at least one treatment temperature below the sintering temperature. A component, in particular an MIM component, and to an aircraft engine.