Method for manufacturing a metal based component having a cavity, and a metal based component having a cavity

Abstract

The inventive concept relates to a method for manufacturing a metal based component (100, 200) having a cavity (103, 203). The method comprises the steps of: providing a plurality of individual segments (110, 210) corresponding to different portions of the metal based component; arranging the plurality of segments in a stack (120, 220) in such a way that the shape of the stack corresponds to the shape of the metal based component, and that a void (130, 230) is formed in the stack, wherein the shape of at least a portion of the void corresponds to the shape of the cavity; filling at least the first 10 portion of the void with an incompressible filler (140, 240); removing gas from the stack; subjecting the stack to a hot pressing process to form the metal based component comprising the cavity; removing at least a part of the incompressible filler from the metal based component.

Claims

1. A metal based component having a cavity, said metal based component comprising a body formed by a plurality of segments arranged in a stack, said body having an envelope comprising an opening fluidly connected to said cavity, and having internal wall portions defining said cavity, wherein said plurality of segments have metallurgically bonded to each other during a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature, wherein said metal based component comprises metallurgical detectable traces of said plurality of segments, wherein said metallurgical detectable traces are formed by crystallographic mismatch at interfaces between different segments in said plurality of segments, wherein a surface of said internal wall portions of the body comprises diamond powder particles or traces of diamond powder particles embedded in said surface.

2. A metal based component according to claim 1, wherein said opening is a first opening, and the envelope of said body comprises: a second opening fluidly connected to said cavity, and fluidly connected to said first opening, and wherein the cavity between said first and second openings is formed as a flow channel.

3. A metal based component according to claim 1, wherein said flow channel comprises at least one bend.

4. The metal based component according to claim 1, wherein said metal based component has been manufactured by a method comprising the steps of: providing the plurality of segments corresponding to different portions of the metal based component; arranging said plurality of segments in the stack in such a way that the shape of said stack corresponds to the shape of the metal based component, and such that a void is formed in said stack, wherein the shape of at least a portion of said void corresponds to the shape of said cavity, under conditions at which the segments in the stack do not form any metallurgical bonds with each other; filling at least said portion of the void with an incompressible filler; removing gas from said stack; subjecting said stack to the hot pressing process for the determined time at the predetermined pressure and the predetermined temperature such that said segments bond metallurgically to each other to form said metal based component comprising said cavity; and removing at least a part of said incompressible filler from said metal based component.

5. A metal based component according to claim 1, wherein the surface of said internal wall portions of the body comprises the diamond powder particles embedded in said surface.

6. A metal based component according to claim 5, wherein an average particle size of the diamond powder particles is between 1 micron and 1000 microns.

7. A metal based component according to claim 6, wherein an average particle size of the diamond powder particles is between 50 microns and 500 microns.

8. A metal based component according to claim 5, wherein the diamond powder particles embedded in the surface of said internal wall portions of the body provide said surface with an increased wear-resistance.

9. A metal based component according to claim 8, wherein an average particle size of the diamond powder particles is between 1 micron and 1000 microns.

10. A metal based component according to claim 9, wherein an average particle size of the diamond powder particles is between 50 microns and 500 microns.

11. A metal based component according to claim 1, wherein the surface of said internal wall portions of the body comprises the traces of diamond powder particles embedded in said surface.

12. A metal based component according to claim 11, wherein the traces of diamond powder particles embedded in the surface of said internal wall portions of the body provide said surface with an increased wear-resistance.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above objects, as well as additional objects, features and advantages of the present inventive concept, will be more fully appreciated by reference to the following illustrative and non-limiting detailed description of embodiments of the present invention, when taken in conjunction with the accompanying drawings, wherein:

(2) FIG. 1a shows an exploded perspective view of a stack in accordance with at least one example embodiment of the invention;

(3) FIG. 1b shows an enlarged view of a side portion, or a top portion, of the stack of FIG. 1a;

(4) FIG. 1c shows a metal based component form by said stack of FIG. 1a and FIG. 1b;

(5) FIG. 2a shows a schematic cross-sectional view of a metal based component and an incompressible filler, in accordance with at least one example embodiment of the invention;

(6) FIG. 2b shows a cross-sectional view of at least some segments used to manufacture the metal based component of FIG. 2a;

(7) FIG. 2c shows a perspective view of the segments of FIG. 2b;

(8) FIG. 2d shows a cress-sectional view of a stack used to manufacture the metal based component of FIG. 2a, in accordance with at least one example embodiment of the invention;

(9) FIG. 3 shows a flow-chart explaining the steps of a method in accordance with at least one embodiment of the invention;

(10) FIG. 4 shows a schematic, top view of at least some diamond powder particles used in accordance with at least one example embodiment of the invention;

(11) FIG. 5 shows a micrograph of a trace in a metal based component in accordance with at least one example embodiment of the invention.

(12) FIGS. 6a, 6b, 6c and 6d show different embodiments of metal based components having a cavity in accordance with at least some example embodiments of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

(13) In the present detailed description, embodiments of the present invention will be discussed with reference to the accompanying figures. It should be noted that this by no means limits the scope of the invention, which is also applicable in other circumstances for instance with other types or variants of methods for manufacturing a metal based component having a cavity encompassed by the scope of the claims, then the embodiments shown in the appended drawings. Further, that specific features are mentioned in connection to an embodiment of the invention does not mean that those features cannot be used to an advantage together with other embodiments of the invention.

(14) FIG. 1a shows an exploded perspective view of a stack 120 in accordance with at least one example embodiment of the invention. The stack 120 comprises a plurality of segments 110, in FIG. 1a being a first segment 112, a second segment 114, a third segment 116, and a fourth segment 118 (hereafter sometimes referred to the four segments 112, 114, 116, 118). The first segment 112 and the fourth segment 118 are end segments. For example, the first segment 112 may be a bottom segment 112 and the fourth segment may be a top segment 118. As seen in FIG. 1a, the plurality of segments 110 are arranged in the stack 120, such that the second segment 114 and the third segment 116 are arranged in between the first segment 112 and the fourth segment 118. The four segments 112, 114, 116, 118 of FIG. 1a are arranged such that a void 130 is formed in the stack 120. Each one of the four segments 112, 114, 116, 118 is typically metal based, and is e.g. made out of a wrought material. At least one of the four segments 112, 114, 116, 118 may be made out of a material which is different compared to at least another one of the segments 112, 114, 116, 118.

(15) Moreover, in FIG. 1a the metal tube 150 is arranged inside of the void 130 such that the void 130 is divided into at least two portions 132, 134, or void portions 132, 134, or sub-voids 132, 134 (hereafter referred to as void portions 132, 134), better shown in FIG. 1b. A first void portion 132 is arranged inside of the metal tube 150, and a second void portion 134 is arranged outside of the metal tube 150. More specifically, the second void portion 134 is defined by internal segment wall portions (i.e. internal wall portions of the four segments 112, 114, 116, 118) defining the void 130, and an outer surface of the metal tube 150. Moreover, the first void portion 132 is defined by the internal volume of the metal tube 150.

(16) The metal tube 150 of FIG. 1a, is shaped to have at least two bends 150A, 150B, forming a U-shape, and the two bends 150A, 150B are arranged in the void 130 at corresponding bends of the void 130A, 130B. However, the shape of the void 130 needs not to completely correspond to the shape of the metal tube 150, as long as the metal tube 150 can be arranged in the void 130. For example, the bends of the void 130A, 1308 may not need to be rounded, but may be straight or square-shaped.

(17) The four segments 112, 114, 116, 118 are arranged in the stack 120 such that a first opening 136 and a second opening 138 distant from the first opening 136, are provided in the envelope of the stack 120. Correspondingly, the metal tube 150 comprises a first tube opening 156, and a second tube opening 158 distant from the first tube opening 156. Thus, the void 130, and in particular the metal tube 150 is arranged as a flow channel 157, and is configured to enable a fluid to flow from the first tube opening 156 to the second tube opening 158.

(18) As shown in FIG. 1a, a filler material 140, and more specifically an incompressible filler 140, is provided, and may be inserted into the first void portion 132 via the first opening 136 and more specifically, via the first tube opening 156 to fill the first void portion 132. The second tube opening 158 may also be used to fill the first void portion 132 with the incompressible filler 140. That is, in FIG. 1a, the incompressible filler 140 is inserted into the metal tube 150 arranged in the void 130. The incompressible filler 140 in FIG. 1a is a powder 142, and more specifically a diamond powder 142. The diamond powder may e.g. have an average powder size of between 1 micron and 1000 microns, preferably between 50 microns and 500 microns.

(19) Prior to subjecting the stack to a hot pressing process, as is described further below, the first opening 136 and the second opening 138, or at least the first tube opening 156 and the second tube opening 158 are closed from the surroundings by a first closing member 160 and second closing member 162, respectively.

(20) FIG. 1c shows a metal based component 100 having a body 101 and a cavity 103 formed in the body 101. The body 101 of the metal based component 100 has been formed by the stack 120 of FIG. 1a and FIG. 1b, during a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature wherein the four segments 112, 114, 116, 118 and the metal tube 150 have metallurgically bonded to each other. Stated differently, the plurality of segments 110 of FIG. 1a and FIG. 1b are arranged in the stack 120 such that the stack 120 corresponds to the body 101 of the metal based component 100, or such that the shape of the stack 120 is the same as the shape of the body 101 of the metal based component 100. Thus, the plurality of segments 110 corresponds to, or are shaped equally to, different portions of the body 101 of the metal based component 100.

(21) As seen in FIG. 1c, the body 101 comprises a first body opening 156′ arranged in the envelope of the body 101, the first body opening 156′ corresponding to the first tube opening 156, and comprises a second body opening 158′ arranged in the envelope of the body 101, the second body opening 158′ corresponding to the second tube opening 158. The first body opening 156′ and the second body opening 158′ are in fluid contact with the cavity 103, and the cavity 103 may thus be referred to as a flow channel 107 configured to enable a fluid to flow from the first body opening 156′ to the second body opening 158′.

(22) During the hot pressing process, the shape and dimensions of the first void portion 132, which is filled with the incompressible filler 140, 142, will be maintained. Hereby, the first void portion 132 holding the incompressible filler 140, 142 will form the cavity 103 of the metal based component 100 in a desired manner. That is, the shape and dimensions of the cavity 103 will be the same, or substantially the same as, (i.e. will correspond to) the shape and dimensions of the first void portion 132. Hence, the flow channel 107 will in a corresponding manner comprise at least two bends 107A, 107B.

(23) The second void portion 134 on the other hand, which is not filled with an incompressible filler 140, 142, will instead be filled with material from one or more of the four segments 112, 114, 116, 118. That is, for example, when the hot pressing process is carried out by placing the stack 120 of FIG. 1a and FIG. 1b in a canister, and the subsequently subjecting the canister to the predetermined pressure and the predetermined temperature for the predetermined time, at least one of the plurality of segments 110 will be compressed into the second void portion 134, up to the outer surface of the metal tube 150, which metal tube 150 will withstand any further compression inwardly, as the incompressible filler 140, 142 is arranged inside of the metal tube 150, i.e. in the first void portion 132. Hereby, an efficient method for manufacturing a metal based component 100 having a cavity 103 is provided.

(24) After the hot pressing process, the incompressible filler 140, 142 is at least partly removed from the cavity 103, which is enabled by that the first and second closing members 160, 162 are removed from the first and second body openings 156′, 158′, respectively. As indicated by the gathering of the diamond powder 142 in a tube 190, the diamond powder 142 may be collected and possibly be reused.

(25) The cavity 103 is defined at least partly by internal wall portions 105, and is, in FIG. 1c, defined at least partly by the first and second body openings 156′, 158′. As a trace or as a residue, a surface of the internal wall portions 105 of the body 101 comprises diamond powder particles 143 which is embedded in the surface of the internal wall portions 105.

(26) According to at least one example embodiment, the internal wall portions 105 are coated with a metal carbide layer, such as an Iron Carbide layer. Such metal carbide layer may e.g. origin from a reaction between diamond powder particles and internal segment wall portions, or an internal surface of the metal tube 105.

(27) Turning to FIG. 2a showing a cross section of a metal based component 200 comprising a body 201 and a cavity 203 formed in the body 201. The metal based component 200 has been manufactured in a similar manner as the metal based component 100 of FIG. 1c. Thus, in short, and with reference to FIG. 2d, the body 201 of the metal based component 200 has been manufactured by a plurality of segments 210 arranged in a stack 220, wherein the plurality of segments 210 have metallurgically bonded to each other during a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature.

(28) In FIG. 2b and FIG. 2c, only a sub-set 210′ of the plurality of segments 210 of FIG. 2d is shown, and more specifically, three segments 212, 214, 216, wherein each one of the three segments 212, 214, 216 comprises a through hole 212A, 214A, 216A. The three segments 212, 214, 216 are arranged in such a way that a stack 220′ is formed, and such that the through holes 212A, 214A, 216A align. The aligned through holes 212A, 214A, 216A thus form at least a part of a void 230 (of which only a part of the void 230 is shown in FIG. 2b and FIG. 2c, complete void is shown in FIG. 2d, but in FIG. 2d). As mentioned above, FIG. 2b and FIG. 2c only discloses a sub-set 210′ of the plurality of segments 210 used for manufacturing the metal based component 200 of FIG. 2a, thus more segments than the three segments 212, 214, 216 with a respective through hole are typically used for manufacturing the metal based component 200 of FIG. 2a, however the stacking principle, and the alignment of the through holes for forming the void 230, are equivalent to the shown three segments 212, 214, 216 of FIG. 2b, and FIG. 2c. Such configuration of a stack 210 is shown in FIG. 2d.

(29) In FIG. 2d, the void 230 is not divided in the same way as the void 130 of FIG. 1a, and the void 230 consists of the portion 232 of the void housing the incompressible filler 240. In other words, the above referred to first void portion corresponds to the only portion 232 of the void 230, or alternatively described, a first part 232 of the void 230, or a first void part 232 is the only part of the void 230. As also shown in FIG. 2d a filler material 240, and more specifically an incompressible filler 240, is arranged in the void 230 to fill the void 230. The incompressible filler 240 in FIG. 2d comprises a powder 242, such as a diamond powder 242 as described with reference to FIG. 1a, and a solid insert 244, such as a solid metal insert 244, The diamond powder may e.g. have an average powder size of between 1 micron and 1000 microns, preferably between 50 microns and 500 microns. As shown in FIG. 2d, the solid metal insert 244 is embedded in the diamond powder 242, such that the solid metal insert 244 is prevented from being in contact with any one of the plurality of segments 210. Hereby bonding between any one of the plurality of segments 210 and the solid metal insert 244 during the hot pressing process is prevented. Moreover, as shown in FIG. 2d, a metal foil 250 is arranged inside of the void 230 between the plurality of segments 210 and the incompressible filler 240. Thus, contact between the plurality of segments 210 and the incompressible filler 240 is prevented. In more detail, the metal foil 250 is arranged between the diamond powder 242 and internal segment wall portions. Thus, the diamond powder 242 is prevented from undesirably entering any gaps or spaces within the stack 220.

(30) During the hot pressing process, similar to that described with reference to FIGS. 1a-1c, the shape and dimensions of the void 230, which is filled with the incompressible filler 240, 242, 244 will be maintained. Hereby, the void 230 holding the incompressible filler 240, 242, 244 will form the cavity 203 of the metal based component 200 in a desired manner. That is, the shape and dimensions of the cavity 203 will be the same, or substantially the same as, (i.e. will correspond to) the shape and dimensions of the void 230. Correspondingly, the body 201 of the metal based component 200 has been formed by the stack 220 of FIG. 2d, during the hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature wherein the plurality of segments 210 has metallurgically bonded to each other. Hence, each one of the plurality of segments 210 is typically metal based, and is e.g. made out of a wrought material. Stated differently, the plurality of segments 210 of FIG. 2d and are arranged in the stack 220 such that the stack 220, or the shape of the stack 220, corresponds to the body 201 of the metal based component 200, or the shape of the body 201 of the metal based component 200. Thus, the plurality of segments 210 corresponds to different portions of the body 201 of the metal based component 200.

(31) Turning back to FIG. 2a, the metal based component 200 comprises a first elongated portion 200A, and a second elongated portion 200B, wherein the second elongated portion 200B is branched with an angle to the first elongated portion 200A thus forming the metal based component in a y-shape having at least one bend 207A. The body 201 is in common for the first elongated portion 200A and the second elongated portion 200B. Furthermore, as the body 201 comprises the cavity 203, also the cavity will be y-shaped corresponding to the shaped of the first elongated portion 200A and the second elongated portion 200B. Moreover, a first body opening 256, a second body opening 258, and a third body opening 259 are formed in the envelope of the body 201. All of the body openings 256, 258, 259 corresponds to respective openings in the stack 220, and have been closed by a first, second and third closing arrangement 260, 262, 264 respectively during the hot pressing process.

(32) As shown in FIG. 2a, the second closing arrangement 262 has been removed, and thus the cavity 203 is opened to the surroundings, and the compressible filler 240 is, i.e. the diamond powder 242 and the solid metal insert 244 are, being removed from the cavity 203 via the second body opening 258. When the incompressible filler 240 has been removed, all of the first, second and third body openings 256, 258, 259 will be in fluid contact with each other, and the cavity 203, thus forming a flow channel 207 which is y-shaped within the body 201.

(33) The cavity 203 is defined at least partly by internal wall portions 205, and is, in FIG. 2a, defined at least partly by the first, second and third body openings 256, 258, 259. The internal wall portions 205 defining the cavity will stem from the metal foil 250, as the metal foil 250 has been metallurgically bonded to the plurality of segments 210 during the hot pressing process. As a trace or as a residue, a surface of the internal wall portions 205 of the body 201 comprises diamond powder particles 243 which is embedded in the surface of the internal wall portions 205.

(34) According to at least one example embodiment, the internal wall portions 205 are coated with a metal carbide layer, such as an Iron Carbide layer. Such metal carbide layer may e.g. origin from a reaction between diamond powder particles and internal segment wall portions, or a surface of the metal foil 250.

(35) Turning to FIG. 3 showing a flow chart of the steps in a method 300 for manufacturing a metal based component 100, 200 having a cavity 103, 203, according to at least one embodiment of the inventive concept. The metal based components 100, 200 of FIG. 1c and FIG. 2a are examples of the result of the method described in relation to FIG. 3. Thus reference numerals used to describe structures and features in FIGS. 1a-1c and FIGS. 2a-2d will used when describing the method 300 of FIG. 3.

(36) The method 300 comprises the steps of (steps are abbreviated with the capital “S”):

(37) S1: providing a plurality of segments 110, 210 corresponding to different portions of the metal based component 100, 200;

(38) S2: arranging the plurality of segments 110, 210 in a stack 120, 220 in such a way that the shape of the stack 120, 220 corresponds to, or are the same as, the shape of the metal based component 100, 200, and such that a void 130, 230 is formed in the stack 120 220, wherein a the shape of at least a portion 132, 232 of the void 130, 230 corresponds to, or are the same as, the shape of the cavity 103, 203;

(39) S3: arranging a metal foil 250 inside of the void 230 such that the metal foil 250 prevents contact between the segments 210 and the incompressible filler 240.

(40) S4: arranging a metal tube 150 inside of the void 130 such that the void 130 is divided into at least two portions 132, 134, a first portion 132 inside of the metal tube 150, and a second portion 134 outside of the metal tube 150. The first portion 132 being the portion of the void 130 which shape corresponds to, or are the same as, the shape of the cavity 103.

(41) It should be noted that steps S3 and S4 are optional. However, the void 130, 230 may be a single void 230 of the stack 220, or the void 130 may be divided into at least two portions 132, 134 or parts 132, 134.

(42) S5: filling the first portion 132 of the void 130, or filling the void 230 (i.e. at least the portion 132, 232 of the void 130, 230 which shape corresponds to, or are the same as, the shape of the cavity 103, 203) with an incompressible filler 140, 240;

(43) In step S5, for embodiments in which the incompressible filler 140, 240 comprises a diamond powder 142, 242 and a solid metal insert 244, the step S5 comprises embedding the solid metal insert 244 in the diamond powder 242.

(44) It should be noted that the step S2 of arranging the plurality of segments 110, 210 in a stack 120, 220 may comprise arranging the segments 110, 210 such that an opening 136, 236 to the void 130, 230 is formed in the envelope of the stack 110, 210, and that the step S5 of filling at least the first portion 132 of the void 130, or filling the void 230, with an incompressible filler 140, 240 comprises introducing the incompressible filler 140, 240 to the first portion 132 of the void 130, or the void 230, via at least the opening 136, 236. The method may further comprise the step of

(45) S6: closing at least the first portion 132 of the void 130, or closing the void 230, from the surroundings by closing at least a portion of the opening 136, 236.

(46) S7: removing gas from the stack 120, 220;

(47) S8: subjecting the stack 120, 220 to a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature such that the segments 110, 210 bond metallurgically to each other to form the metal based component 100, 200 comprising the cavity 103, 203;

(48) S9: opening the cavity 103, 203 of the metal based component 100, 200 to the surroundings.

(49) S10: removing at least a part of the incompressible filler 140, 240 from the metal based component 100, 200.

(50) In step S10, for embodiments in which the incompressible filler comprises diamond powder 142, 242, the step S10 comprises removing at least a part of the diamond powder 142, 242 from the metal based component 100, 200.

(51) S11: at least partly reusing the incompressible filler 140, 240 subsequent to the step S10 of removing the incompressible filler 140, 240 from metal based component 100, 200.

(52) The method 300 may further comprise the following three steps prior to the step S1 of providing a plurality of segments 110, 210:

(53) S01: making a 3D model of the desired metal based component 100, 200;

(54) S02: discretizing the 3D model into model segments 112′, 114′, 116′, 118′; 212′, 214′, 216′, the model segments 112′, 114′, 116′, 118′; 212′, 214′, 216′ are indicated in FIG. 1a and FIG. 2b;

(55) S03: manufacturing the segments 112, 114, 116, 118; 212, 214, 216 in the plurality of segments 110, 210 based on the model segments 112′, 114′, 116′, 118′; 212′, 214′, 216′, wherein each one of the segments 112, 114, 116, 118; 212, 214, 216 in the plurality of segments 110, 210 corresponds to a model segment 112′, 114′, 116′, 118′; 212′, 214′, 216′.

(56) Turning to FIG. 4 showing a schematic, top view of at least some diamond powder particles 343 of the diamond powder 142, 242, as the diamond powder 142, 242 is arranged in the first portion 132 of the void 130 (i.e. the first void portion 132) or in the void 230. As seen in FIG. 4, the diamond powder particles 343 are formed in well-defined shapes as squares 344 and hexagons 345 with crystal facets having straight edges. The crystal facets of different diamond powder particles 343 are in contact with each other, and thus withstand compression when being subject to an external load (indicated by arrows in FIG. 4), such as an external load stemming from the hot pressing process and the predetermined pressure.

(57) FIG. 5 shows a micrograph of a trace 1100, e.g. a metallurgical detectable trace, of the interface between two different segments in the plurality of segments 110, 210, which trace is visible in the metal based component 100, 200 after it is manufactured by the hot pressing process. In the micrograph, the line 1102, along which line a crystallographic mismatch of metal grains 1106 is clearly visible. Thus, the traces are formed by crystallographic mismatch at interfaces between different segments in the plurality of segments 110, 210.

(58) FIGS. 6a, 6b, 6c and 6d show different embodiments of metal based components 400, 500, 600, 700 formed in accordance with the method of the invention (as e.g. method 300 of FIG. 3) by a hot pressing process of stack (not shown) with a principle structure as the stacks 120, 220 in FIGS. 1a-1b and FIG. 2d but where the arrangement of the plurality of segments 110, 210 have been arranged and stacked to correspond to the shape of the present metal based components 400, 500, 600, 700. Thus, an incompressible filler has been used in the formation of each one of the metal based components 400, 500, 600, 700 to form a respective cavity 403, 503, 603, 703 from a void, or a first void portion. Thus each one of the metal based components 400, 500, 600, 700 of FIGS. 6a, 6b, 6c and 6d, comprise a body 401, 501, 601, 701 formed by a plurality of segments arranged in a stack, wherein the plurality of segments have metallurgically bonded to each other during a hot pressing process (e.g. a HIPping process) for a predetermined time at a predetermined pressure and a predetermined temperature.

(59) In FIG. 6a the metal based component 400 is a manifold in which the cavity 403 comprises a large pipe portion which is divided into three smaller pipe portions. In FIG. 6b, the metal based component 500 is another manifold in which the cavity 503 comprises a relatively large pipe which ends into a common pipe from which four relatively small pipes extends. In FIG. 6c, the metal based component 600 is a reducer in which a relatively large portion of the cavity 603 (i.e. having a relatively large cross sectional area) extends into a relatively small portion of the cavity 603 (i.e. having a relatively small cross sectional area). In FIG. 6d, the metal based component 700 is a fluid diode with a relatively complex geometry of the cavity 703. For the fluid diode, the cavity has a varying cross section alternating between relatively small cross sections and relatively larger cross sections.

(60) The person skilled in the art realizes that the present invention by no means is limited to the embodiments described above. The features of the described embodiments may be combined in different ways, and many modifications and variations are possible within the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting to the claim. The word “comprising” does not exclude the presence of other elements or steps than those listed in the claim. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements.

ITEMIZED LIST OF EMBODIMENTS

(61) 1. A method for manufacturing a metal based component (100, 200) having a cavity (103, 203), said method comprising the steps of: providing a plurality of segments (110, 210) corresponding to different portions of the metal based component; arranging said plurality of segments in a stack (120, 220) in such a way that the shape of said stack corresponds to the shape of the metal based component, and such that a void (130, 230) is formed in said stack, wherein the shape of at least a portion of said void corresponds to the shape of said cavity; filling at least said portion of the void with an incompressible filler (140, 240); removing gas from said stack; subjecting said stack to a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature such that said segments bond metallurgically to each other to form said metal based component comprising said cavity; removing at least a part of said incompressible filler from said metal based component.

(62) 2. The method according to item 1, wherein said incompressible filler comprising at least diamond powder (142, 242), and wherein said step of removing at least a part of said incompressible filler comprises removing at least a part of said diamond powder from said metal based component.

(63) 3. The method according to item 2, wherein an average powder size of said diamond powder is between 1 micron and 1000 microns, preferably between 50 microns and 500 microns.

(64) 4. The method according to any one items 2-3, wherein said incompressible filler further comprises a solid metal insert (244), and wherein said step of filling at least said portion of the void with an incompressible filler comprises embedding said solid metal insert in said diamond powder.

(65) 5. The method according to any one of the preceding items, comprising the step of arranging a metal foil (250) inside of said void such that said metal foil prevents contact between said segments and said incompressible filler.

(66) 6. The method according to any one of the preceding items, said portion of the void is a first portion (132) of the void, and the method comprises the step of arranging a metal tube (150) inside of said void such that said void is divided into at least two portions (132, 134), said first portion (132) inside of said metal tube, and a second portion (134) outside of said metal tube, and wherein the material of said metal tube is the same or different compared to the material of at least one of the segments.

(67) 7. The method according to any one of the preceding items, further comprising the step of at least partly reusing the incompressible filler subsequent to said step of removing the incompressible filler from metal based component.

(68) 8. The method according to any one of the preceding items, wherein said step of arranging said plurality of segments in a stack comprising arranging said segments such that an opening (136, 236) to said void is formed in the envelope of said stack, and wherein said step of filling at least said portion of the void with an incompressible filler comprises introducing said incompressible filler to said portion of the void via at least said opening, said method further comprising the steps of: closing at least said portion of the void from the surroundings by closing at least a portion (156, 236) of said opening; opening said cavity of the metal based component to the surroundings prior to removing said incompressible filler from said metal based component.

(69) 9. The method according to any one of the preceding items, further comprising the steps of: making a 3D model of the desired metal based component; discretizing the 3D model into model segments (112′, 114′, 116′, 118′; 212′, 214′, 216′); manufacturing the segments (112, 114, 116, 118; 212, 214, 216) in said plurality of segments based on said model segments, wherein each one of the segments in said plurality of segments corresponds to a model segment.

(70) 10. The method according to any one of the preceding items, each one of the segments in the plurality of segments is metal based, e.g. made out of a wrought material, and wherein the material of at least one of the segments is different from the material of at least another segment.

(71) 11. A metal based component (100, 200, 300, 400, 500, 600) having a cavity (103, 203, 303, 403, 503, 603), said metal based component comprising a body (101, 201, 301, 401, 501, 601) formed by a plurality of segments (110, 210) arranged in a stack (120, 220), said body having an envelope comprising an opening (156′, 256) fluidly connected to said cavity, and having internal wall portions (105, 205) defining said cavity, wherein said plurality of segments have metallurgically bonded to each other during a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature, wherein said metal based component comprises metallurgical detectable traces (1100) of said plurality of segments, wherein said metallurgical detectable traces are formed by crystallographic mismatch at interfaces (1102) between different segments in said plurality of segments.

(72) 12. A metal based component according to item 11, wherein said opening is a first opening, and the envelope of said body comprises: a second opening (158′, 258) fluidly connected to said cavity, and fluidly connected to said first opening, and

(73) wherein the cavity between said first and second openings is formed as a flow channel (107, 207).

(74) 13. A metal based component according to item 11, wherein said flow channel comprises at least one bend (107A, 107B, 207A).

(75) 14. The metal based component according to any one of items 11-13, wherein said metal based component has been manufactured by the method according to any one of items 1-10.

(76) 15. The metal based component according to any one of items 11-14, wherein a surface of said internal wall portions of the body comprises traces, or residues (143, 243), of an incompressible filler.

(77) 16. Use of an incompressible filler when manufacturing a metal based component having a cavity, wherein said incompressible filler is used in said cavity to maintain the desired shaped of said cavity during manufacturing of said metal based component by a hot pressing process.

(78) 17. Use of an incompressible filler in which said incompressible filler comprises diamond powder wherein the powder size of said diamond powder is between 1 micron and 1000 microns, preferably between 50 microns and 500 microns.