Method for manufacturing a metallic component by pre-manufactured bodies

1. A method for manufacturing a metallic component comprising the steps of:

providing a capsule which defines at least a portion of a shape of the metallic component;

arranging metallic material in the capsule;

sealing the capsule to be gas-tight; and

subjecting the capsule to Hot Isostatic Pressing for a predetermined time, at a predetermined pressure and at a predetermined temperature,

wherein the metallic material includes at least one pre-manufactured coherent body, the pre-manufactured coherent body includes at least a portion of metallic powder consolidated such that the metallic powder is held together into the pre-manufactured coherent body,

wherein at least one portion of the pre-manufactured coherent body is manufactured by Additive Manufacturing by sequentially superimposing layers of metallic powder,

wherein the metallic component is a valve spindle, the valve spindle including a valve disc and a valve stem,

wherein the capsule defines at least a portion of the valve disc, and the metallic material includes a valve seat and a core body having a core head, a cladding layer and a buffer layer arranged on the core head, and

wherein at least one of the valve seat, the buffer layer and the cladding layer are coherent pre-manufactured bodies of metallic powder.

2. The method according to claim 1 , wherein the entire pre-manufactured coherent body is manufactured by Additive Manufacturing.

3. The method according to claim 1 , wherein the metallic powder is consolidated by sintering.

4. The method according to claim 3 , wherein the entire pre-manufactured coherent body is sintered metallic powder.

5. The method according to claim 3 , wherein a surface portion of the pre-manufactured coherent body is consolidated metallic powder.

6. The method according to claim 1 , wherein the metallic powder in a surface portion of the pre-manufactured coherent body is consolidated by melting followed by cooling.

7. The method according to claim 5 , wherein the pre-manufactured coherent body is a shell which contains metallic powder, and wherein the shell is melted and solidified metallic powder.

8. The method according to claim 1 , wherein Additive Manufacturing is 3D-printing.

9. The method according to claim 1 , wherein the metallic material includes at least two pre-manufactured coherent bodies.

10. The method according to claim 1 , wherein the metallic material includes at least three pre-manufactured coherent bodies.

11. The method according to claim 1 , wherein the metallic material is loose metallic powder.

12. The method according to claim 1 , wherein at least two of the valve seat, the buffer layer and the cladding layer are coherent pre-manufactured bodies of metallic powder.

13. The method according to claim 1 , wherein any remaining metallic material is loose metallic powder.

14. The method according to claim 1 , wherein the core body is a forged body.

15. The method according to claim 1 , wherein the valve seat and/or the buffer layer and/or the cladding layer are pre-manufactured by sintering metallic powder, wherein sintering is performed at a temperature below the melting point of the metallic powder and at atmospheric pressure.

16. The method according to claim 1 , further comprising, subsequent to subjecting the capsule to Hot Isostatic Pressing, the step of cooling the capsule and removing the capsule.

17. A method for manufacturing a metallic component, the method comprising:

providing a capsule that defines at least a portion of a shape of the metallic component;

arranging metallic material in the capsule, wherein the metallic material includes at least two discreet components, wherein at least one of the at least two discreet components is a pre-manufactured coherent body at least a portion of which is formed of consolidated metallic powder;

sealing the capsule to be gas-tight; and

subjecting the capsule to Hot Isostatic Pressing for a predetermined time, at a predetermined pressure and at a predetermined temperature to densify the metallic material,

wherein the metallic component is a valve spindle, the valve spindle including a valve disc and a valve stem,

wherein the capsule defines at least a portion of the valve disc,

wherein the metallic material includes a valve seat and a core body having a core head, a cladding layer and a buffer layer arranged on the core head, and

wherein at least one of the valve seat, the buffer layer and the cladding layer is the pre-manufactured coherent body which is formed of consolidated metallic powder.

18. The method according to claim 17 , wherein the portion of the pre-manufactured coherent body which is formed of consolidated metallic powder is a surface portion of the pre-manufactured coherent body.

19. The method according to claim 18 , wherein the surface potion forms a coherent shell which encloses a volume.

20. The method according to claim 18 , wherein the surface potion forms a coherent shell which encloses a volume of the metallic powder.

21. The method according to claim 17 , wherein the pre-manufactured coherent body is manufactured by an Additive Manufacturing process.

22. The method according to claim 17 , further comprising manufacturing the pre-manufactured coherent body by an Additive Manufacturing process.

23. The method according to claim 17 , wherein the method includes sintering the metallic powder to form the pre-manufactured coherent body.

24. The method according to claim 17 , wherein, during Hot Isostatic Pressing, the discreet components and the capsule bond metallurgical to each to form a dense, diffusion bonded, coherent HIP:ed metallic component.

25. The method according to claim 24 , further comprising, subsequent to subjecting the capsule to Hot Isostatic Pressing, the step of cooling the capsule and removing the capsule.

26. The method according to claim 17 , wherein one of the at least two discreet components is a loose mixture of metallic powder.

27. The method according to claim 17 , including at least three discreet components, wherein two of the discreet components are pre-manufactured coherent bodies and one of the discreet components is loose metallic powder, and wherein materials forming the three discreet components are different.

28. The method according to claim 17 , wherein at least two of the valve seat, the buffer layer and the cladding layer are the pre-manufactured coherent body which is formed of consolidated metallic powder.

29. The method according to claim 28 , wherein any remaining metallic material is loose metallic powder.