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