Rolls-royce Corporation

Junfa Mei

Wayne Eric Voice

Xinhua Wu

Joanne M Shipton, Legal Representative

Thomas P Jarvis

Nicholas Wain

Martin Tuffs

Thomas Peter Jarvis

A method of forming a fully consolidated joint between first and second components comprising the steps of forming a slot in the first component; inserting at least part of the second component into the slot; inserting a powder material into the slot; heating the powder material to form a pressure tight skin; and applying hot isostatic pressure to the pressure tight skin to form a fully consolidated joint. Also a method of repairing a component.

Joining and a repair method

A component is manufactured from a powdered material such as a titanium alloy, by performing a first hot isostatic pressing HIP operation on the powdered materialwhile the powdered material is in contact with a molding surfaceof a rigid, usable molding tool. The first HIP operation creates a non-porous shaped surfaceon a partially consolidated component, but avoids bonding or reaction between the partially consolidated componentand the molding tool. After separation of the partially consolidated componentfrom the molding tool, the partially consolidated componentis subjected to a second HIP operation in which the powdered material is fully consolidated.

Method of manufacturing a component

A method of manufacturing an article by diffusion bonding, the method comprising the steps of assembling first and second component parts having a joint therebetween; sealing the joint against infiltration by solid particulate material, without causing phase change of the component parts; and applying heat and isostatic pressure via a solid particulate material to form a consolidated joint by diffusion bonding.

Joining method and resultant article

A method of manufacturing a fan blade () for a gas turbine engine by powder metallurgy comprises the steps of forming a container () and placing at least one metal insert () at a predetermined position within the container () and filling the container () with metal powder (). The at least one metal insert () has a predetermined pattern of stop off material () on at least one surface of the metal insert (). The container () is evacuated and then sealed. The container () is hot pressed to consolidate the metal powder () into a consolidated metal powder preform (). The container () is removed from the consolidated metal powder preform (). The consolidated metal powder preform () is heated and a fluid is supplied to the predetermined pattern of stop off material () to hot form at least a portion of the consolidated metal powder preform () to form the hollow metal fan blade ().

Method of manufacturing a metal article by powder metallurgy

A sealing element for a turbine of a gas turbine engine includes a radially inner surface region provided with an integrally formed seal structure comprising a plurality of radially inwardly projecting walls. The walls may be abradable and may define cells for receiving an abradable sealing material.

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Birmingham, United Kingdom

Junfa Mei