Methods of forming powdered metal articles

Claim 1

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable ceramic material having inner side surface areas disposed in engagement with outer side surfaces of the container, transmitting heat and fluid pressure through the rigid body of fluid permeable ceramic material to the container, said step of providing a container includes the step of providing a container having sufficient structural strength to be self-supporting during filling of the container and insufficient structural strength to be self-supporting without sagging during performance of the step of transmitting heat and fluid pressure to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable ceramic material without deforming the rigid body of fluid permeable ceramic material, said step of compacting the heated metal powder including the steps of maintaining the size and configuration of the rigid body of fluid permeable ceramic material constant, reducing the size of the container to provide space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable ceramic material, and inducing in the container stresses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the inner side surface areas of the rigid body of fluid permeable ceramic material while maintaining the configuration of the inner side surface areas of the rigid body of fluid permeable ceramic material constant to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 2

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable ceramic material having inner side surface areas disposed in engagement with outer side surfaces of the container, transmitting heat and fluid pressure through the rigid body of fluid permeable ceramic material to the container, said step of providing a container includes the step of providing a container having sufficient structural strength to be self-supporting during filling of the container and insufficient structural strength to be self-supporting without sagging during performance of the step of transmitting heat and fluid pressure to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable ceramic material without deforming the rigid body of fluid permeable ceramic material, said step of compacting the heated metal powder including the steps of maintaining the size and configuration of the rigid body of fluid permeable ceramic material constant, reducing the size of the container to provide space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable ceramic material, and inducing in the container stresses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the inner side surface areas of the rigid body of fluid permeable ceramic material while maintaining the configuration of the inner side surface areas of the rigid body of fluid permeable ceramic material constant to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 7

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material having inner side surface areas disposed in engagement with outer side surfaces of the container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the container, compacting and diffusion bonding the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material while maintaining the container intact, said step of compacting and diffusion bonding the heated metal powder including the steps of providing space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material and inducing in the container stresses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said step of providing a metal container includes the step of providing a container having sufficient structural strength to be self-supporting during filling of the container and insufficient structural strength to be self-supporting without deformation during performance of said step of transmitting heat and fluid pressure to the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting and diffusion bonding of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the rigid body of fluid permeable material to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 8

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material having inner side surface areas disposed in engagement with outer side surfaces of the container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the container, compacting and diffusion bonding the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material while maintaining the container intact, said step of compacting and diffusion bonding the heated metal powder including the steps of providing space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material and inducing in the container stresses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said step of providing a metal container includes the step of providing a container having sufficient structural strength to be self-supporting during filling of the container and insufficient structural strength to be self-supporting without deformation during performance of said step of transmitting heat and fluid pressure to the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting and diffusion bonding of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the rigid body of fluid permeable material to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 13

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the step of shaping the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 14

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the step of shaping the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 16

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable ceramic material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable ceramic material being performed after said steps of filling and sealing the container and including the step of shaping the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of at least portions of the outer side surfaces of the container, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable ceramic material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable ceramic material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body fluid permeable ceramic material by moving said surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable ceramic material, said method further including the step of supporting the container with the rigid body of fluid permeable ceramic material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable ceramic material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 17

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable ceramic material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable ceramic material being performed after said steps of filling and sealing the container and including the step of shaping the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of at least portions of the outer side surfaces of the container, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable ceramic material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable ceramic material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body fluid permeable ceramic material by moving said surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable ceramic material, said method further including the step of supporting the container with the rigid body of fluid permeable ceramic material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable ceramic material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 18

A method of forming an article from metal powder by compacting the powder under heat and pressure comprising the steps of: providing a self supporting pressure responsive, metal container of a predetermined shape having an interior cavity which is determinative of the final shape configuration of the article and having wall portions whose outer surfaces define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container against the entry of a pressurizing fluid, enclosing a portion of the filled and sealed container with a rigid body of fluid permeable material having contoured wall portions that conform generally to the outer surfaces of the shaped metal container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the filled and sealed container, compacting the heated metal powder in the sealed container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer surfaces of the container wall portions and the contoured wall portions of the rigid body of fluid permeable material by a controlled collapsing of container wall portions into spaced apart relationship with the rigid body of fluid permeable material and inducing stresses into the container tending to distort said predetermined shape beyond the initial spatial boundary, said method further including the step of maintaining the performed shape of the container while under the influence of stresses induced in the container during the compacting of the metal powder by selectively restricting movement of the portions of the container to within the spatial boundary and permitting a controlled collapse of the container to thereby effect compaction of the metal powder in the container to the predetermined shape configuration.

Claim 19

A method of forming an article from metal powder by compacting the powder under heat and pressure comprising the steps of: providing a self supporting pressure responsive, metal container of a predetermined shape having an interior cavity which is determinative of the final shape configuration of the article and having wall portions whose outer surfaces define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container against the entry of a pressurizing fluid, enclosing a portion of the filled and sealed container with a rigid body of fluid permeable material having contoured wall portions that conform generally to the outer surfaces of the shaped metal container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the filled and sealed container, compacting the heated metal powder in the sealed container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer surfaces of the container wall portions and the contoured wall portions of the rigid body of fluid permeable material by a controlled collapsing of container wall portions into spaced apart relationship with the rigid body of fluid permeable material and inducing stresses into the container tending to distort said predetermined shape beyond the initial spatial boundary, said method further including the step of maintaining the performed shape of the container while under the influence of stresses induced in the container during the compacting of the metal powder by selectively restricting movement of the portions of the container to within the spatial boundary and permitting a controlled collapse of the container to thereby effect compaction of the metal powder in the container to the predetermined shape configuration.

Claim 20

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material having inner side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material includes the steps of providing a body of ceramic slurry, surrounding the filled and sealed container with the body of ceramic slurry, and hardening the body of ceramic slurry around the container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material and inducing in the container stresses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the rigid body of fluid permeable material to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 21

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material having inner side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material includes the steps of providing a body of ceramic slurry, surrounding the filled and sealed container with the body of ceramic slurry, and hardening the body of ceramic slurry around the container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material and inducing in the container stresses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the rigid body of fluid permeable material to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 27

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material having inner side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material includes the step of providing first and second rigid members formed of a fluid permeable material and placing the members in engagement with side surfaces of the filled and sealed container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material and inducing in the container stesses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the rigid body of fluid permeable material to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 28

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material having inner side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material includes the step of providing first and second rigid members formed of a fluid permeable material and placing the members in engagement with side surfaces of the filled and sealed container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material and inducing in the container stesses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the rigid body of fluid permeable material to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 35

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material having inner side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material includes the steps of providing a body of ceramic slurry, repetitively dipping the filled and sealed container in the body of ceramic slurry to build up layers of ceramic slurry over the container, and hardening layers of the ceramic slurry built up over the container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material and inducing in the container stresses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the rigid body of fluid permeable material to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 36

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces which define an initial spatial boundary of the container, filling the cavity in the container with metal powder, sealing the filled container so that fluid pressing against the outer side surfaces of the container cannot enter the cavity, thereafter, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material having inner side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material includes the steps of providing a body of ceramic slurry, repetitively dipping the filled and sealed container in the body of ceramic slurry to build up layers of ceramic slurry over the container, and hardening layers of the ceramic slurry built up over the container, transmitting heat and fluid pressure through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material and inducing in the container stresses tending to deflect the container to a configuration in which at least a portion of the container would be outside the initial spatial boundary of the container, said method further including the step of maintaining the container within the initial spatial boundary of the container against the influence of stresses induced in the container during the compacting of the metal powder by blocking movement of portions of the container out of the initial spatial boundary of the container with the rigid body of fluid permeable material to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 39

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the steps of providing a body of ceramic slurry, enclosing at least a portion of the container with the body of ceramic slurry, hardening the body of ceramic slurry around the container to shape the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 40

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the steps of providing a body of ceramic slurry, enclosing at least a portion of the container with the body of ceramic slurry, hardening the body of ceramic slurry around the container to shape the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 42

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the steps of providing a body of ceramic slurry, repetitively dipping at least a portion of the container in the body of ceramic slurry, and hardening layers of the ceramic slurry built up over the outside of the container during performance of said step of repetitively dipping the container in the body of ceramic slurry to shape the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 43

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the steps of providing a body of ceramic slurry, repetitively dipping at least a portion of the container in the body of ceramic slurry, and hardening layers of the ceramic slurry built up over the outside of the container during performance of said step of repetitively dipping the container in the body of ceramic slurry to shape the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 45

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the steps of providing first and second members formed of a fluid permeable material, shaping surface areas of first and second members to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, and placing the first and second members in engagement with said surfaces of the container, said method further including the steps of heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 46

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the steps of providing first and second members formed of a fluid permeable material, shaping surface areas of first and second members to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, and placing the first and second members in engagement with said surfaces of the container, said method further including the steps of heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 47

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, said step of removing the pattern from the layer of metal includes the step of conducting the pattern material through a first opening in the layer of metal, filling the container with metal powder, said step of filling the container including the step of conducting a flow of metal powder into the container through a second opening, sealing the filled container so that fluid pressing against the container cannot enter the cavity, said step of sealing the container including the step of sealing the first opening prior to filling of the container, said step of sealing the container further including the step of sealing the second opening, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the step of shaping the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 48

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article and having side walls with outer side surfaces having a configuration which is different than the configuration of the article, said step of providing a metal container including the steps of electroplating a thin layer of metal over a pattern and then removing the pattern from the layer of metal to form a container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, said step of removing the pattern from the layer of metal includes the step of conducting the pattern material through a first opening in the layer of metal, filling the container with metal powder, said step of filling the container including the step of conducting a flow of metal powder into the container through a second opening, sealing the filled container so that fluid pressing against the container cannot enter the cavity, said step of sealing the container including the step of sealing the first opening prior to filling of the container, said step of sealing the container further including the step of sealing the second opening, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, said step of enclosing the container with a rigid body of fluid permeable material including the step of shaping the inside surface areas of the rigid body of fluid permeable material to have a configuration which corresponds to the configuration of the outer side surfaces of the container and differs from the configuration of the article, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, said step of compacting the heated metal powder including the steps of providing space between portions of the outer side surfaces of the container and inner side surface areas of the rigid body of fluid permeable material by moving side surface areas of the container into a spaced apart relationship with the inner side surface areas of the rigid body of fluid permeable material, said method further including the step of supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 54

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, thereafter, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure by transmitting fluid pressure through the rigid body of fluid permeable material while maintaining intact the structure of the rigid body of fluid permeable material, and supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder.

Claim 55

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, thereafter, enclosing at least a portion of the container with a rigid body of fluid permeable material having side surface areas disposed in engagement with outer side surfaces of the container, heating the container and metal powder in the container to a temperature sufficient to promote diffusion bonding of the particles of metal powder by transmitting heat through the rigid body of fluid permeable material to the container, compacting the heated metal powder in the container under the influence of the fluid pressure by transmitting fluid pressure through the rigid body of fluid permeable material while maintaining intact the structure of the rigid body of fluid permeable material, and supporting the container with the rigid body of fluid permeable material during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder.

Claim 74

An apparatus for use in forming an article of metal powder, said apparatus comprising a metal container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without sagging after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, means for heating said container of metal powder to a temperature sufficient to promote diffusion bonding of the particles of metal powder in said container, a plurality of rigid members formed of fluid permeable material, said rigid members of fluid permeable material having inner side surfaces for engaging outer side surface areas of said container with a space between said members, and means for pressing said rigid members of fluid permeable material against outer side surface areas of the container during the application of heat and fluid pressure to said container, said means for pressing said rigid members against the outer side surface areas of said container including means for decreasing the space between said members during the application of heat and fluid pressure to said container.

Claim 75

An apparatus for use in forming an article of metal powder, said apparatus comprising a metal container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without sagging after the container has been filled with metal powder and heated to a temperature sufficient to promote diffusion bonding of the particles of metal powder in the container, means for heating said container of metal powder to a temperature sufficient to promote diffusion bonding of the particles of metal powder in said container, a plurality of rigid members formed of fluid permeable material, said rigid members of fluid permeable material having inner side surfaces for engaging outer side surface areas of said container with a space between said members, and means for pressing said rigid members of fluid permeable material against outer side surface areas of the container during the application of heat and fluid pressure to said container, said means for pressing said rigid members against the outer side surface areas of said container including means for decreasing the space between said members during the application of heat and fluid pressure to said container.

Claim 79

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article, said step of providing a metal container including the steps of forming a metal container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to cause diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material, said step of enclosing the container with a rigid body of fluid permeable material including providing a first block of rigid fluid permeable material having a side surface area with a configuration which is a function of the desired configuration of a first side of the article, providing a second block of rigid fluid permeable material having a side surface area with a configuration which is a function of the desired configuration of a second side of the article, placing the side surface area on the first block in engagement with one side of the container, and placing the side surface area on the second block in engagement with a side of the container opposite from the one side, heating the container and the metal powder in the container to a temperature sufficient to cause diffusion bonding of the metal powder in the container by transmitting heat through the rigid blocks of fluid permeable material to the container, compacting the metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, and supporting the container with the first and second blocks during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 80

A method of forming an article from metal powder, said method comprising the steps of providing a thin metal container having an interior cavity with a configuration corresponding to the configuration of the article, said step of providing a metal container including the steps of forming a metal container having sufficient structural strength to be self-supporting during filling of the container with metal powder and having insufficient structural strength to be self-supporting without deformation after the container has been filled with metal powder and heated to a temperature sufficient to cause diffusion bonding of the particles of metal powder in the container, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material, said step of enclosing the container with a rigid body of fluid permeable material including providing a first block of rigid fluid permeable material having a side surface area with a configuration which is a function of the desired configuration of a first side of the article, providing a second block of rigid fluid permeable material having a side surface area with a configuration which is a function of the desired configuration of a second side of the article, placing the side surface area on the first block in engagement with one side of the container, and placing the side surface area on the second block in engagement with a side of the container opposite from the one side, heating the container and the metal powder in the container to a temperature sufficient to cause diffusion bonding of the metal powder in the container by transmitting heat through the rigid blocks of fluid permeable material to the container, compacting the metal powder in the container under the influence of the fluid pressure transmitted through the rigid body of fluid permeable material, and supporting the container with the first and second blocks during the transmitting of heat and fluid pressure through the rigid body of fluid permeable material and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article.

Claim 90

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material, said step of enclosing the container with a rigid body of fluid permeable material including providing a first block of rigid fluid permeable material having a side surface area with a configuration which is a function of the desired configuration of a first side of the article, providing a second block of rigid fluid permeable material having a side surface area with configuration which is a function of the desired configuration of a second side of the article, placing the side surface area on the first block in engagement with one side of the container, and placing the side surface area on the second block in engagement with a side of the container opposite from the one side, urging the first and second blocks toward each other with a clamping force which is applied against the blocks by a metal clamping element, thereafter, heating the first and second blocks, clamping element, container and metal powder in the container to a temperature sufficient to cause diffusion bonding of the metal powder in the container by transmitting heat through the first and second blocks to the container, thermally expanding the metal clamping element in a manner which tends to decrease the clamping force applied against the first and second blocks during performance of said heating step, compacting the metal powder in the container under the influence of the fluid pressure transmitted through the first and second blocks, and supporting the container with the first and second blocks during the transmitting of heat and fluid pressure through the first and second blocks and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article, said step of supporting the container with the first and second blocks includes compensating for the thermal expansion of the clamping element to maintain a clamping force against the first and second blocks by thermally expanding a compensating element which is connected with the clamping element and has a coefficient of thermal expansion which is greater than the coefficient of thermal expansion of the clamping element, said step of thermally expanding the compensating element includes heating the compensating element along with the clamping element during performance of said heating step and increasing the size of a unit dimension of the compensating element by a greater amount than the size of a unit dimension of the clamping element during performance of said heating step.

Claim 91

A method of forming an article from metal powder, said method comprising the steps of providing a metal container having an interior cavity with a configuration corresponding to the configuration of the article, filling the container with metal powder, sealing the filled container so that fluid pressing against the container cannot enter the cavity, enclosing at least a portion of the filled and sealed container with a rigid body of fluid permeable material, said step of enclosing the container with a rigid body of fluid permeable material including providing a first block of rigid fluid permeable material having a side surface area with a configuration which is a function of the desired configuration of a first side of the article, providing a second block of rigid fluid permeable material having a side surface area with configuration which is a function of the desired configuration of a second side of the article, placing the side surface area on the first block in engagement with one side of the container, and placing the side surface area on the second block in engagement with a side of the container opposite from the one side, urging the first and second blocks toward each other with a clamping force which is applied against the blocks by a metal clamping element, thereafter, heating the first and second blocks, clamping element, container and metal powder in the container to a temperature sufficient to cause diffusion bonding of the metal powder in the container by transmitting heat through the first and second blocks to the container, thermally expanding the metal clamping element in a manner which tends to decrease the clamping force applied against the first and second blocks during performance of said heating step, compacting the metal powder in the container under the influence of the fluid pressure transmitted through the first and second blocks, and supporting the container with the first and second blocks during the transmitting of heat and fluid pressure through the first and second blocks and during the compacting of the metal powder to thereby effect compaction of the metal powder in the container to a configuration which at least closely approximates the desired configuration of the article, said step of supporting the container with the first and second blocks includes compensating for the thermal expansion of the clamping element to maintain a clamping force against the first and second blocks by thermally expanding a compensating element which is connected with the clamping element and has a coefficient of thermal expansion which is greater than the coefficient of thermal expansion of the clamping element, said step of thermally expanding the compensating element includes heating the compensating element along with the clamping element during performance of said heating step and increasing the size of a unit dimension of the compensating element by a greater amount than the size of a unit dimension of the clamping element during performance of said heating step.