Rolls-Royce Deutschland Ltd & Co. Kg

Alexander Schult

Dan Roth-Fagaraseanu

Gerald Hechler-Stabbert

A method for manufacturing thermally stressed engine components having a geometrically complex structure includes metal injection molding metal powder mixed with a binder to form green compacts of individual parts, which are debindered to form brown compact sections which are joined together to form a multi-part brown compact which are sintered in the assembled state. The brown compact sections have differing shrinkage properties in the sintering process, depending on the metal powder used, with a greater shrinking first brown compact section being automatically pressed against a second brown compact section during sintering. Connecting elements having positively engaging projections and recesses are provided at joining surfaces of the brown compact sections and have differing shrinkage such that during sintering of the assembled brown compact, the brown compact section with projections undergoes a greater shrinkage than the brown compact section with recesses.

Method for producing engine components with a geometrically complex structure

Injection molding tool for the manufacture of a plastic element sheathed with a sheet-metal shell (), where the gate () which is designed as an integral part of the lower mold half () for correct positioning and supply of the plastic melt projects beyond the inner surface of the mold half () into the sheet-metal shell having a positioning opening (), such that the plastic melt is discharged inside the sheet-metal shell and does not flow past it. A sealing groove () adjoining the gate and integral with the mold half, said groove receiving a sealing ring () elastically deformable under the effect of the internal pressure on the sheet-metal shell, forming a rigid sealing edge () to the sheet-metal shell and at the same time performing the function of a labyrinth seal together with a gap () remaining between the positioning opening and the gate, also ensures that the plastic melt does not flow past the sheet-metal shell and that the sheet-metal shell is sealed to the outside such that the high internal pressure required to shape the sheet-metal shell can be generated by the continued flow of the plastic melt.

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Berlin, Germany

Alexander Schult