CN110732637A - turbine blade air film hole precision forming method - Google Patents

turbine blade air film hole precision forming method Download PDF

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Publication number
CN110732637A
CN110732637A CN201910913889.5A CN201910913889A CN110732637A CN 110732637 A CN110732637 A CN 110732637A CN 201910913889 A CN201910913889 A CN 201910913889A CN 110732637 A CN110732637 A CN 110732637A
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film hole
ceramic
air film
turbine blade
blade
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鲁中良
李涤尘
陈义
苗恺
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Xian Jiaotong University
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Xian Jiaotong University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • B22C9/04Use of lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C7/00Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02Lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/22Moulds for peculiarly-shaped castings
    • B22C9/24Moulds for peculiarly-shaped castings for hollow articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045Directionally solidified castings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
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    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
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Abstract

The invention discloses a turbine blade air film hole precise forming method, which belongs to the field of rapid casting based on a photocuring forming technology and comprises the steps of 1) manufacturing a turbine blade resin mold by using the photocuring rapid forming technology, 2) pouring ceramic slurry into a resin mold prototype of a turbine blade by using a gel injection molding method to obtain a casting mold blank to realize the forming of an air film hole ceramic core, 3) strengthening the air film hole ceramic core by using vacuum freeze drying and high-temperature sintering in steps to realize the forming of different ceramic-based air film hole ceramic cores, and 4) combining the directional solidification technology for the air film hole ceramic cores of different types of ceramic bases to realize the air film hole casting forming of various high-temperature alloys, and finally removing the ceramic cores remained in the metal blade and the air film hole by using a decoring process to realize the high-quality casting air film hole forming.

Description

turbine blade air film hole precision forming method
Technical Field
The invention belongs to the field of rapid casting based on a photocuring molding technology, and relates to a precise forming method of turbine blade air film holes.
Background
The efficient air film cooling technology for the hollow turbine blade is which is the core technology of heavy-duty gas turbine development, and the air film holes are developed towards the direction of size micronization, structural abnormity and distribution densification.
The laser drilling technology is characterized in that high temperature at a laser focusing point is utilized to instantly melt and vaporize a blade material, the melted material and a vaporized material are explosively sprayed out, but the surface roughness and the roundness of a machined air film hole are low, a remelted layer and even micro-cracks are inevitably generated after machining, the electric spark drilling technology is used for removing the material by utilizing potential energy generated by discharge between a conductive part material and a tool electrode, the production efficiency is low, meanwhile, because electric spark machining belongs to thermal machining, the remelted layer with fixed thickness of is generated on the machined surface, the problems of uncontrollable machining size precision, uncontrollable machining taper, low surface roughness, more burrs, low machining quality and the like exist, the problem that the remelted layer, the micro-cracks and a heat affected zone are not generated in the machining of the air film hole machined by the electric spark beam, but the machining efficiency is low, the repeatability of the size precision is poor, only a circular hole with a size range of can be machined, and a special-shaped hole and a multi-angle inclined hole cannot be machined.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide turbine blade air film hole precision forming methods, which start from ceramic casting materials and structures, combine light curing forming and gel casting technology to form air film hole ceramic cores with complete structures, excellent precision and perfect surface quality, and realize turbine blade air film hole precision casting forming through directional solidification technology.
In order to achieve the purpose, the invention adopts the following technical scheme to realize the purpose:
A turbine blade air film hole precision forming method, comprising the following steps:
1) and (2) forming a hollow turbine blade resin mold prototype with a gas film hole structure by adopting a photocuring rapid forming method, pouring ceramic slurry into the resin mold prototype of the turbine blade through a gel casting method to obtain a casting mold blank, and performing vacuum freeze drying and high-temperature sintering reinforcement on the casting mold blank to obtain the blade ceramic casting mold with the gas film hole ceramic core.
2) Pouring high-temperature alloy into the porous ceramic casting mold at a specific temperature by a directional solidification technology, realizing the molding of the gas film hole of the blade by a casting method, and finally obtaining the blade with the gas film hole structure by core removal treatment.
The sizes of the resin prototype air film hole, the air film hole ceramic core and the cast air film hole are , the minimum structure size is smaller than 0.5mm, the gel injection molding method can realize the complete mold filling of the fine air film hole structure, and the freeze drying and high-temperature sintering strengthening process can ensure the structural integrity of the formed air film hole ceramic core.
The ceramic mold includes an alumina ceramic mold, a silica ceramic mold, a calcia ceramic mold, a yttria ceramic mold, and the like. The formable turbine blades include hollow turbine blades, double-walled blades, cascade blades, and the like. The cast gas film hole structure comprises a round hole gas film hole, a wedge-shaped gas film hole, an opposite-type gas film hole and the like.
The directional solidification process can realize the molding of isometric crystal, directional crystal and single crystal blade. The high-temperature alloy depends on the material of the matrix ceramic mold and comprises iron-based high-temperature alloy, nickel-based high-temperature alloy, cobalt-based high-temperature alloy, titanium-aluminum alloy and the like, and the pouring temperature is determined by the high-temperature alloy material and the mold material.
The core removing process adopts a strong alkali corrosion process to remove ceramic cores remained in the metal blades, the core removing liquid is KOH solution with the concentration of 50-70 wt.%, and the core removing process does not influence the surface quality and precision of the air film holes.
The turbine blade air film hole is formed by times through a casting method, and post-processing treatment is not needed.
Compared with the prior art, the invention has the following beneficial effects:
the invention discloses a turbine blade air film hole precision forming method, compared with the traditional processes such as electric spark processing, electric liquid beam processing and laser drilling, the method starts from ceramic casting mold materials and structures, combines light curing forming and gel casting technology to form an air film hole ceramic core with complete structure, excellent precision and complete surface quality, and realizes turbine blade air film hole precision casting forming through directional solidification technology.
Drawings
FIG. 1 is a light-cured resin prototype blade containing gas film holes;
FIG. 2 is a ceramic mold for a blade comprising a film hole ceramic core;
FIG. 3 turbine blade and film holes;
wherein: 1, photo-curing a resin blade prototype; 2 is a gas film hole; 3, a blade ceramic casting mold; 4 is a gas film hole ceramic core; 5 is a metal blade; 6 is a casting air film hole;
Detailed Description
For those skilled in the art to better understand the technical solution of the present invention, the technical solution in the embodiment of the present invention will be clearly and completely described below with reference to the drawings in the embodiment of the present invention, and it is obvious that the described embodiment is only a partial embodiment of of the present invention, rather than a complete embodiment.
Furthermore, the terms "comprises" and "comprising," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a series of steps or elements of is not necessarily limited to the expressly listed steps or elements, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
The invention is described in further detail with reference to the drawings in which:
the invention provides a precise forming method of turbine blade air film holes, which is designed as follows:
the resin mold for manufacturing the hollow turbine blade casting mold is manufactured by utilizing photocuring rapid molding equipment, the gel casting technology is combined to realize the molding of a ceramic casting blank body containing a gas film hole ceramic core, the ceramic casting mold is subjected to freeze drying and high-temperature sintering to obtain a porous ceramic casting mold, meanwhile, the gas film hole ceramic core is completely molded, the molding of a metal blade and a gas film hole is realized through the directional solidification technology, finally, the ceramic core remained in the gas film hole is removed by utilizing a core removing method, and finally, times of molding of the gas film hole is realized.
According to the selection of the base material, various ceramic casting molds can be manufactured, including an aluminum ceramic casting mold, a silicon oxide ceramic casting mold, a calcium oxide ceramic casting mold, a yttrium oxide ceramic casting mold and the like, and the requirement of casting and forming of various blades and gas film holes is met. The alloy material for directional solidification includes: iron-based superalloys, nickel-based superalloys, cobalt-based superalloys, titanium-aluminum alloys, and the like.
The sizes of the resin prototype air film hole, the air film hole ceramic core and the cast air film hole are , the minimum structure size is smaller than 0.5mm, the gel injection molding method can realize the complete mold filling of the air film hole ceramic core, the freeze drying and high-temperature sintering strengthening process can ensure the complete molding structure of the air film hole ceramic core, and the resin prototype air film hole ceramic core is finally applied to directional solidification molding of hollow turbine blades, double-wall blades, cascade blades and the like, the cast air film hole structure comprises a circular hole air film hole, a wedge-shaped air film hole, an opposite air film hole and the like, and the minimum structure size of the air film hole is smaller than 0.5 mm.
Finally, a strong alkali decoring process is adopted to remove ceramic cores remained in the metal blade and the gas film hole, times of molding of the cast gas film hole is realized, post-processing treatment is not needed, and the surface quality and precision of the gas film hole meet the requirements.
Example 1
The precise forming method for the turbine blade air film hole comprises the following steps:
1) resin mould for manufacturing turbine blade
The invention utilizes the light-cured rapid prototyping technology to manufacture the resin mould, firstly utilizes commercial three-dimensional software to design a resin mould CAD model, generates a two-dimensional slice file with the layered thickness of 0.07mm, and rapidly and automatically manufactures a light-cured prototype of the resin mould under the control of the slice file, referring to figure 1, wherein 1 is a leaf body, and 2 is a gas film hole structure. The manufactured turbine blade resin mold has high precision, high rigidity and good surface quality, and can be completely used as a ceramic ligand forming mold.
2) Preparing ceramic slurry
Firstly, dissolving organic matters in deionized water, sequentially adding a dispersing agent, uniformly mixed alumina ceramic powder and mineralizer powder to prepare ceramic slurry, adding an initiator and a catalyst before pouring, uniformly mixing, and simultaneously vacuumizing to remove bubbles in the ceramic slurry to prepare the ceramic slurry with the viscosity of less than 1 Pa.S; the ceramic slurry was poured into the cavity of the hollow turbine blade prototype resin mold shown in fig. 1 by a gating system and the air film holes in fig. 1 were filled.
Wherein, the ceramic powder is alumina powder with the grain diameter of 2 μm, 5 μm or 40 μm; the mineralizer is added into the ceramic powder, and the added mineralizer is zirconia, wherein the zirconia powder accounts for 5% of the mass of the ceramic powder.
3) Freeze drying and high temperature sintering
After the ceramic slurry is solidified and formed in situ, removing the peripheral structures of the ceramic slurry pouring system and the resin mold, transferring the ceramic blank into a vacuum drying oven, controlling the vacuum degree to be between 1pa and 10pa, drying the blade ceramic casting mold for 48 to 72 hours according to the drying time of the blank, and taking out the blank after drying. The temperature rise process is controlled to burn out the resin mold and the organogel, and the ceramic particles are sintered at high temperature to obtain a complete ceramic casting mold as shown in fig. 2, wherein 3 is the integral ceramic casting mold and 4 is the air film hole core. According to the invention, through high-temperature sintering, under the action of a mineralizer, the room-temperature bending strength of the ceramic casting mold is higher than 70MPa, and the high-temperature bending strength at 1500 ℃ is 15-25 MPa.
4) Directional solidification and blade decoring
After a ceramic casting mold meeting the directional solidification requirement is obtained, the ceramic casting mold is placed in a three-chamber vacuum directional solidification furnace to carry out directional solidification casting on a hollow turbine blade, the ceramic casting mold is preheated to about 1500 ℃, heat is preserved for 30-60 min, high-temperature metal is poured, after the blade is cooled, the ceramic casting mold on the surface of the blade is directly removed, a ceramic core remained in the blade is subjected to a strong base corrosion decoring process, the selected decoring solution is KOH with the concentration of 50-70 wt.%, the decoring process does not influence the surface quality and precision of a gas film hole, the complete forming of the turbine blade shown in the figure 3 is realized, wherein 5 is a complete turbine blade, and 6 is a formed gas film hole.
In summary, the turbine blade air film hole precise forming method disclosed by the invention combines the light curing forming technology and the gel injection molding technology to realize the casting mold forming of the air film hole-containing ceramic core, and comprises the steps of 1) manufacturing a turbine blade resin mold by using the light curing rapid forming technology, 2) pouring ceramic slurry into a resin mold prototype of the turbine blade through the gel injection molding method to obtain a casting mold blank to realize the forming of the air film hole ceramic core, 3) performing steps of strengthening the air film hole ceramic core by vacuum freeze drying and high-temperature sintering to realize the forming of different ceramic-based air film hole ceramic cores, and 4) combining the directional solidification technology for the air film hole ceramic cores of different types of ceramic-based air film holes to realize the air film hole casting forming of various high-temperature alloys, and finally removing the ceramic cores remained in the metal blade and the air film holes by using the core removing technology to realize the high-quality forming of the cast.
The method of the invention optimizes according to material design, the formed ceramic casting materials are various, including alumina base, silica base, calcium oxide base and yttrium oxide base, can be used for casting various alloy materials, such as iron-based high-temperature alloy, nickel-based high-temperature alloy, cobalt-based high-temperature alloy, titanium-aluminum alloy and the like, turbine blades with structures of round holes, wedges, opposite gas film holes and the like are formed, and the gas film holes are formed by times of casting without secondary processing.
The above-mentioned contents are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical idea of the present invention falls within the protection scope of the claims of the present invention.

Claims (8)

  1. The precise forming method of the air film hole of the turbine blade is characterized by comprising the following steps of:
    1) forming a turbine blade resin mold prototype with a gas film hole structure by adopting a photocuring rapid forming method, pouring ceramic slurry into the turbine blade resin mold prototype with the gas film hole structure by a gel casting method to obtain a casting mold blank, and performing vacuum freeze drying and high-temperature sintering strengthening treatment on the casting mold blank to obtain a blade ceramic casting mold with a gas film hole ceramic core;
    2) and pouring high-temperature alloy into the blade ceramic casting mold containing the ceramic core with the air film holes by a directional solidification method at a specific temperature, realizing the formation of the air film holes of the turbine blade by a casting method, and finally obtaining the turbine blade with the air film hole structure by core removal treatment.
  2. 2. The method for precisely forming the air film hole of the turbine blade as claimed in claim 1, wherein the minimum size of the air film hole of the resin mold prototype of the turbine blade, the air film hole ceramic core of the ceramic mold of the blade, and the air film hole of the turbine blade is mm.
  3. 3. The method for precisely forming the air film hole of the turbine blade as claimed in claim 1, wherein the blade ceramic mold is an alumina ceramic mold, a silica ceramic mold, a calcium oxide ceramic mold or a yttrium oxide ceramic mold.
  4. 4. The method for precisely forming the air film hole of the turbine blade as claimed in claim 3, wherein in the step 2), the material of the cast high-temperature alloy is determined by the ceramic casting material of the blade.
  5. 5. The method for precisely forming the air film hole of the turbine blade as claimed in claim 3, wherein the specific temperature during the operation of the directional solidification method in the step 2) is determined by the high-temperature alloy material and the ceramic casting material of the blade.
  6. 6. The method of claim 1, wherein the turbine blade is a hollow turbine blade, a double-walled blade or a cascade blade.
  7. 7. The turbine blade film hole precision forming method of claim 1, wherein the shape of the film hole is a round hole, a wedge-shaped hole or a special-shaped hole.
  8. 8. The turbine blade air film hole precise forming method according to claim 1, wherein in the step 2), KOH solution with mass concentration of 50-70% is adopted as a core removing solution for removing the ceramic core remained in the metal blade in the core removing treatment.
CN201910913889.5A 2019-09-25 2019-09-25 turbine blade air film hole precision forming method Pending CN110732637A (en)

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111843081A (en) * 2020-07-31 2020-10-30 成都和鸿科技有限公司 Turbine blade exhaust edge air film hole machining method
CN112592187A (en) * 2020-12-14 2021-04-02 西安鑫垚陶瓷复合材料有限公司 Aviation blade forming tool and technology based on carbon ceramic material
CN112916811A (en) * 2021-01-22 2021-06-08 成都航宇超合金技术有限公司 Casting method of hollow turbine blade with air film hole
CN113461412A (en) * 2021-06-25 2021-10-01 西安交通大学 Core-shell integrated casting mold with controllable gap and preparation method and application thereof
CN114178484A (en) * 2021-11-30 2022-03-15 清华大学 Integrated casting method of hollow turbine blade
CN115042301A (en) * 2022-05-30 2022-09-13 西安交通大学 Integrated ceramic casting preparation method based on photocuring surface exposure forming
CN115570105A (en) * 2022-11-21 2023-01-06 中国航发四川燃气涡轮研究院 Method for manufacturing double-wall turbine blade

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Cited By (11)

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Publication number Priority date Publication date Assignee Title
CN111843081A (en) * 2020-07-31 2020-10-30 成都和鸿科技有限公司 Turbine blade exhaust edge air film hole machining method
CN111843081B (en) * 2020-07-31 2021-05-11 成都和鸿科技有限公司 Turbine blade exhaust edge air film hole machining method
CN112592187A (en) * 2020-12-14 2021-04-02 西安鑫垚陶瓷复合材料有限公司 Aviation blade forming tool and technology based on carbon ceramic material
CN112592187B (en) * 2020-12-14 2022-05-13 西安鑫垚陶瓷复合材料有限公司 Aviation blade forming tool and technology based on carbon ceramic material
CN112916811A (en) * 2021-01-22 2021-06-08 成都航宇超合金技术有限公司 Casting method of hollow turbine blade with air film hole
CN113461412A (en) * 2021-06-25 2021-10-01 西安交通大学 Core-shell integrated casting mold with controllable gap and preparation method and application thereof
CN114178484A (en) * 2021-11-30 2022-03-15 清华大学 Integrated casting method of hollow turbine blade
CN115042301A (en) * 2022-05-30 2022-09-13 西安交通大学 Integrated ceramic casting preparation method based on photocuring surface exposure forming
CN115042301B (en) * 2022-05-30 2023-08-15 西安交通大学 Preparation method of integrated ceramic casting mold based on photo-curing surface exposure forming
CN115570105A (en) * 2022-11-21 2023-01-06 中国航发四川燃气涡轮研究院 Method for manufacturing double-wall turbine blade
CN115570105B (en) * 2022-11-21 2023-05-05 中国航发四川燃气涡轮研究院 Manufacturing method of double-wall turbine blade

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