CN102686356A - 制造用于涡轮引擎叶片的金属加固件方法 - Google Patents

制造用于涡轮引擎叶片的金属加固件方法 Download PDF

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Publication number
CN102686356A
CN102686356A CN2010800593929A CN201080059392A CN102686356A CN 102686356 A CN102686356 A CN 102686356A CN 2010800593929 A CN2010800593929 A CN 2010800593929A CN 201080059392 A CN201080059392 A CN 201080059392A CN 102686356 A CN102686356 A CN 102686356A
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China
Prior art keywords
metal reinforced
turbine engine
girth member
instrument
engine blade
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CN2010800593929A
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CN102686356B (zh
Inventor
蒂里·吉恩·埃米尔·弗莱什
吉恩-弗朗索瓦·弗朗蒙特
斯特凡·安德鲁·莱韦克
利蒂希亚·桑切斯
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Safran Aircraft Engines SAS
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SNECMA SAS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/64—Treatment of workpieces or articles after build-up by thermal means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0053—Seam welding
    • B23K15/006—Seam welding of rectilinear seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
    • B23K37/047—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C14/00—Alloys based on titanium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/32—Rotors specially for elastic fluids for axial flow pumps
    • F04D29/321—Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
    • F04D29/324—Blades
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    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
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    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/248—Thermal after-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/001—Turbines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/484—Moisture curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
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    • B29C66/124—Tongue and groove joints
    • B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12461—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being rounded, i.e. U-shaped or C-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/12463—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being tapered
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种制造用于涡轮引擎叶片(10)的前缘或后缘的金属加固件(30)的方法，所述金属加固件包含一加固件脚(32)和头(34)。所述方法连续地包含：制造多个V形锥形元件(30a，30b，30c，30d)的步骤，所述元件形成所述金属加固件(30)的不同部分，以使所述金属加固件(30)分成分布于所述脚(32)与所述头(34)之间的多个部分；将所述部分定位在一工具上的步骤，该工具的形状与所述涡轮引擎叶片的所述前缘或后缘相似；将所述不同部分刚性连接的步骤，以通过重新结合所述不同部分形成所述单件金属加固件(30)的所述完整轮廓。

Description

制造用于涡轮引擎叶片的金属加固件方法
技术领域
本发明涉及一种制造用于合成或金属涡轮引擎叶片的金属加固件的方法。
更具体地，本发明涉及一种制造用于涡轮引擎叶片前缘的金属加固件的方法。
背景技术
本发明的领域是涡轮引擎领域，更具体为由合成或金属材料制成的涡轮引擎的风扇叶片领域，其中前缘包括一金属结构性加固件。
然而，本发明也可应用于制造对涡轮引擎叶片的前缘进行加固的金属加固件。
回忆所述前缘对应于空气动力学轮廓的前部分，其面对气流，将气流分为下表面气流和上表面气流。后缘对应于空气动力学轮廓的后部分，其中下面流和上面流合并。
已知提供由合成材料制成的涡轮引擎的风扇叶片，带有一延伸超过所述叶片的整个高度并越过它们前缘的金属结构性加固件，如文献EP1908919中所记载的那样。这样的加固件使所述合成叶片可在例如鸟、冰雹或其他石头这样的外来物体对风扇造成冲击过程中得到保护。
特别是，该金属金属结构性加固件通过防止由于纤维/基体分离而造成分层、纤维断裂或损坏的风险而保护该合成叶片的前缘。
通常，涡轮引擎叶片包含一空气动力学表面，该空气动力学表面沿第一方向在前缘与后缘之间延伸，并沿大致垂直于所述第一方向的第二方向在该叶片的脚与头之间延伸。该金属结构性加固件呈现该叶片的空气动力学表面的前缘的形状，并沿所述第一方向延伸超过呈现该叶片的下面和上面轮廓形状的所述叶片的空气动力学表面的前缘，并沿所述第二方向在所述叶片的脚与头之间延伸。
该金属结构性加固件以已知方式为完全通过铣削材料块而制成的金属部件。
然而，叶片前缘的金属加固件是一个制造复杂的部件，需要许多复杂的再加工和加工操作，消耗较高的制造成本。
发明内容
在此上下文中，本发明旨在通过提出一种制造用于涡轮引擎叶片的前缘或后缘的金属加固件的方法而解决前述问题，使此部件的制造成本大大降低，生产范围简化。
为此目的，本发明提出一种制造用于涡轮引擎叶片的前缘或后缘的金属加固件的方法，所述金属加固件包含一加固件脚和一加固件头，所述方法连续地包含：
-制造多个V形锥形元件的步骤，所述元件形成所述金属加固件的不同区段，以使所述金属加固件分成分布于所述脚与所述头之间的多个区段；
-将所述区段定位在一工具上的步骤，该工具的形状与所述涡轮引擎叶片的所述前缘或所述后缘相似；
-将所述不同区段刚性连接的步骤，以通过重新结合所述不同区段形成所述单件金属加固件的所述完整轮廓。
由于本发明，该金属结构性加固件由多个区段以直接、迅速的方式制造，所述区段随后刚性连接以形成一单件完整加固件。
通过重新结合所述单独制造的多个区段而进行的所述金属加固件的制造使得可避免与此部件的单件制造相联系的偏差，特别是在该加固件的倾向于扭曲的薄侧。
制造所述加固件的多个区段的步骤实际上使得可限制在制造过程中在该部件上产生的应力，因此可限制在该部件从该工具移除过程中在薄壁侧的变形。
该制造方法从而使得可通过由需要使用大体积材料并因此初始材料的供应成本较高的单件平棒在主体内铣削而避免该加固件的复杂制造。
根据本发明的方法还使得可大大减少此部件的制造成本。
根据本发明的该制造用于涡轮引擎叶片的金属加固件的方法还可包括一个或多个下列特征，以单独或所有可能技术组合考虑：
-在所述制造形成所述金属加固件的所述区段的多个元件的所述步骤过程中，每个区段通过激光熔合工艺制造；
-所述刚性连接不同区段的步骤通过扩散硬钎焊工艺进行；
-该方法包括与所述刚性连接步骤同时进行的热成型步骤；
-该方法包括从所述工具脱模所述金属加固件的步骤，所述工具由多个可移动区段形成，所述脱模通过连续退出所述可移动区段来进行；
-该方法包括最后加工所述金属加固件的步骤，该步骤包括抛光所述加固件表面的子步骤和/或再加工所述加固件侧部的子步骤；
-所述刚性连接不同区段的步骤通过焊接工艺来进行；在此例中，所述刚性连接不同区段的步骤之后有利地连续包括：
-定位所述经刚性连接的区段的步骤，其中所述刚性连接的区段在一工具上形成所述加固件，该工具的形状与所述涡轮引擎叶片的所述前缘或所述后缘相似；
-减轻应力的热处理步骤；
-热成型步骤；
-从所述工具脱模所述金属加固件的步骤，所述工具由分布在所述加固件的所述脚与所述头之间的多个可移动区段形成；
-最后加工所述金属加固件的步骤，该步骤包括抛光所述加固件表面的子步骤和/或再加工所述加固件侧部的子步骤。
本发明的主题名称还是一种维修涡轮引擎叶片的方法，所述叶片包含所述叶片的前缘或后缘的磨损的金属加固件，所述方法包括：
-从所述叶片拆下所述磨损的金属加固件的步骤；
-根据本发明制造涡轮引擎叶片的前缘或后缘的金属加固件的步骤；
-将在前面步骤过程中制造的所述金属加固件刚性连接到所述涡轮引擎叶片的步骤。
本发明的主题名称还是一个用于执行制造根据本发明的制造涡轮引擎叶片的金属加固件的方法的工具，该工具包含多个可移动区段。
根据本发明的工具还可具有一个或多个下列特征，单独考虑或以所有可能的技术性结合：
-所述工具包含大于加固件区段数量的多个可移动区段；
-所述工具以一种膨胀系数大于所述加固件材料的膨胀系数的材料制造。
附图说明
本发明的其他特征和优点通过下面参照附图的非限定性描述将更清楚地呈现，其中：
图1是包含通过根据本发明的制造方法获得的前缘的金属结构性加固件的叶片的侧视图；
图2是图1的在截面AA的平面图中的部分截面图；
图3是显示根据本发明的制造涡轮引擎叶片的前缘的金属结构性加固件的主要步骤的方块图；
图4是在图3中所示的该方法的第一步骤过程中涡轮引擎叶片的前缘的金属加固件的视图；
图5是在图3中所示的该方法的第二步骤过程中涡轮引擎叶片的前缘的金属加固件的视图；
图6是在图3中所示的通过根据本发明的制造方法获得的涡轮引擎叶片的前缘的金属加固件的在其最终状态的视图。
具体实施方式
在所有视图中，除另有说明外，公共元件具有相同的附图标记。
图1是包含通过根据本发明的制造方法获得的前缘的金属结构性加固件的叶片的侧视图。
图中所示的叶片10例如为涡轮引擎(未示出)的移动风扇叶片。
叶片10包含一空气动力学表面12，该空气动力学表面在前缘16与后缘18之间沿第一轴向方向14延伸，在脚22与头24之间沿大致与第一方向14垂直的第二轴向方向20延伸。
空气动力学表面12形成叶片10的一上表面13与一下表面11，叶片10的上表面13显示在图1中。下表面11与上表面13形成叶片10的将叶片10的前缘16与后缘18相连的侧面。
在此实施例中，叶片10通常为通过编织织物合成材料而获得的合成叶片。在例中，该使用的合成材料可包含编制碳纤维与一树脂基体的组件，该组件通过利用在RTM型(代表“树脂变换成型”)真空下的树脂注射工艺的模制而形成。
叶片10包含金属结构性加固件30，该金属结构性加固件粘合于叶片10的前缘16，并沿第一方向14延伸超过叶片10的空气动力学表面12的前缘16，以及沿第二方向20在该叶片的脚22与头24之间延伸。
如图2中所示，结构性加固件30采用叶片10的空气动力学表面12的前缘16的形状，其延伸以形成一前缘31，即所称的该加固件的前缘。
通常，结构性加固件30是一单件零件，包含大致V形的截面，该截面具有基底39，该基底39形成前缘31，并分别由两个采用叶片空气动力学表面12的下表面11和上表面13形状的横向侧部35和37延伸。侧部35、37的轮廓沿该叶片的后缘方向逐渐变细或变薄。
基底39具有一圆形内轮廓33，其可采用叶片10的前缘16的圆形。
结构性加固件30是金属的，优选为钛基的。实际上此材料具有很大的吸收冲击能的能力。该加固件通过本领域技术人员已知的胶，例如氰基丙烯酸胶(cyanoacrylic glue)或环氧胶而被粘合到叶片10上。
用于该合成涡轮引擎叶片加固件的此类型的金属结构性加固件30更具体地记载在专利申请EP 1908919中。
根据本发明的方法使得可制造例如图1、2和6所示的结构性加固件，图2和图6显示在其最终状态的加固件。
图3为表示如图1和2所示的叶片10的前缘的金属结构性加固件30的制造方法100的主要原理的的方块图。
制造方法100的第一步骤110为制造金属加固件30的多个区段30a，30b，30c，30d的步骤。
图4具体表示在第一步骤110过程中获得的不同区段30a，30b，30c，30d。
为此，金属加固件30在设计或建造数字模型的过程中预先分成多个区段。
根据本发明的一优选实施例，加固件30的不同区段通过快速原型工艺，更具体是通过激光熔合工艺而分别制造。实际上激光熔合是一种使得可通过沉积多个连续材料层来制造加固件30的各区段的工艺，其使得可以容易的方式制造复杂的形状，具体为在侧部35、37具有较小厚度的金属加固件30的逐渐变细的V形。
该激光熔合工艺，或通过激光熔合进行烧结的工艺，是一种对于本领域技术人员来说已知的工艺，在许多专利中涉及，具体例如专利EP 2060343或EP 2125339；因此，我们不进一步详细描述该制造方法的功能性原理。
通过重新结合多个区段30a，30b，30c，30d来制造金属加固件30使得可避免与从单件平棒合成一零件的制造相联系的偏差，特别是避免小厚度的侧部35、37的扭曲。
每个在第一步骤110中制成的区段30a，30b，30c，30d形成最终加固件30的基底39、前缘31和侧部35、37的一个部分。
制造方法100的第二个步骤120是将不同区段30a，30b，30c，30d定位在一用于重新结合的特定模制工具40上的步骤。此用于定位的第二步骤120如图5所示。
工具40由多个区段40a，40b，40c，40d，40e，40f的结合形成，所述区段以共同协作的方式形成与加固件30的内轮廓33互补的模腔43。当不同区段40b，40c，40d，40e，40f组装时，工具40的模腔43大致对应于叶片10的轮廓。
这样，在第二步骤的过程中，加固件30的不同区段30a，30b，30c，30d区段挨区段地定位在工具40上，以在该工具上构建该加固件的整体轮廓。工具40的形状，以及特别是模腔43的轮廓的制造方式使得可形成所要求的金属加固件30形状，以及金属加固件30的下表面和上表面。
优选地，工具40包含大于加固件30的区段数量的多个区段。
制造方法100的第三步骤130是通过扩散硬钎焊工艺组装或刚性连接加固件30的不同区段30a，30b，30c，30d的步骤。为此，在各相邻区段30a，30b，30c，30d之间的接缝31被钎焊线所填充，所述钎焊线通过从以条形式或以粉末形式的填充金属进行扩散硬钎焊而获得。此填充金属使得可刚性连接不同区段30a，30b，30c，30d以形成具有其最终轮廓的单件加固件30。
可回忆扩散硬钎焊是使得填充金属完全移入基底材料，直到熔化的填充金属零件消失的操作。
扩散硬钎焊特别使得可获得相对较小并具有复杂轮廓的加工后零件的组装的良好结果。
制造方法100的第四步骤140是热成型步骤，在与前面步骤相同的成型工具40中进行，该工具随后被放入一被加热至所使用材料锻造温度的炉中。
此热成型步骤使得可形成为了获得其最终形状的加固件30。
工具40优选用具有膨胀系数大于该加固件材料膨胀系数的材料制造。在例中，工具40在该加固件在钛基底上制造时可用钢来制造。工具40的轮廓和工具40的尺寸设计为考虑所使用的不同材料的退出。
根据本发明的优选实施例，热成型步骤140在扩散硬钎焊步骤130的过程中进行。
第五步骤150是所述加固件30从工具40脱模的步骤。为此，工具40的不同区段40a，40b，40c，40d，40e，40f是可移动的，并能够单独拆除，以利于加固件30的脱模。
为了有利于脱模，可通过最初在工具40的模腔43上沉积一保护层来准备工具40，以避免加固件30粘到工具40上。在例中，此保护层可以是铝层。
最后，制造方法100的第六步骤160是通过加工来最后加工和再加工加固件30的步骤。此最后加工步骤160具体为：
-再加工侧部35、37；该步骤具体包括修剪侧部35、37，并使下表面和上表面侧部35、37变薄；
-抛光加固件30以获得所要求的表面状态。
图6显示通过根据本发明的制造方法获得的在其最终状态的加固件30。
与这些主要制造步骤联合，根据本发明的该方法还可包括非破坏性地控制加固件30、允许该获得的组件的几何和冶金学的一致性得到确保的步骤。在例中，该非破坏性控制可通过X射线方法来进行。
根据本发明的第二实施例，通过扩散硬钎焊而进行的不同加固件的组装或刚性连接的步骤被通过焊接，例如利用电子束而进行的不同加固件的组装步骤所取代。
在此第二实施例中，通过焊接组装的步骤不使用模制工具而进行。此步骤在制造该加固件的不同区段的步骤之后进行。
因此，在此第二实施例中，如图1和2所示的制造叶片10前缘的金属结构性加固件30的方法包括：
-通过例如激光熔合工艺，制造该金属加固件的多个区段30a，30b，30c，30d的第一步骤；
-通过焊接而组装构成该加固件不同部分的不同区段30a，30b，30c，30d的第二步骤；
-将在一工具上刚性连接到一起的所述区段30a，30b，30c，30d定位的第三步骤，所述工具形成该加固件的内模腔，并具有所述涡轮引擎叶片的前缘的轮廓；
-放松应力的第四热处理步骤；
-第五热成型步骤；
-将金属加固件30从该工具脱模的第六步骤，该工具分成不同可移动区段，以利于加固件30的脱模；
-最后加工金属加固件30的步骤，包括抛光该加固件表面的子步骤和/或再加工加固件30侧部的子步骤。
根据本发明的方法已主要针对在钛基上的金属结构性加固件进行了描述；然而，根据本发明的方法还可应用镍基或钢基上的材料进行。
本发明已具体针对合成涡轮引擎叶片的金属加固件的制造而进行了描述；然而，本发明还可应用于金属涡轮引擎叶片的金属加固件的制造。
本发明已具体针对涡轮引擎叶片的前缘的金属加固件的制造而进行了描述；然而，本发明还可应用于涡轮引擎叶片的后缘的金属加固件的制造。
本发明已描述了使用激光熔合工艺而实施第一步骤；然而，第一步骤可通过例如另一原型工艺或通过一种加工工艺来实施。
通过激光熔合该利用多个单独区段的加固件而执行的好处使得可限制在通过激光熔合的制造方法过程中在该零件中累积的应力，因而可限制在该零件从该工具退出的过程中所述薄壁侧部的变形。实际上该加固件具有薄壁侧部，该零件的尺寸越大，在该零件从该工具退出的过程中倾向于变形。
该根据本发明的制造金属加固件的方法优选可并入维修合成或金属涡轮引擎叶片的总体工艺中。维修涡轮引擎叶片的方法因此包括：
-通过高温分解方法分离磨损的金属加固件的第一步骤，使胶或树脂加热到100℃-400℃量级的温度以软化和/或退化所使用的将该金属加固件刚性连接到该涡轮引擎叶片上的胶；
-根据本发明的方法制造新的金属加固件的第二步骤；
-使用本领域技术人员已知的将加固件粘合到叶片上的胶(例如氰基丙烯酸胶(cyanoacrylic glue)或环氧胶)通过粘合而将在前面步骤中所制得的金属加固件刚性连接的最终的第三步骤。
本发明的其他优点具体如下：
-削减制造成本；
-减少制造时间；
-简化制造范围；
-减少材料成本。

Claims (12)

1.一种制造用于涡轮引擎叶片(10)的前缘或后缘的金属加固件(30)的方法，所述金属加固件包含一加固件脚(32)和一加固件头(34)，所述方法连续地包含：
-制造多个V形锥形元件(30a，30b，30c，30d)的步骤(100)，所述元件形成所述金属加固件(30)的不同区段，以使所述金属加固件(30)分成分布于所述脚(32)与所述头(34)之间的多个区段；
-将所述区段(30a，30b，30c，30d)定位在一工具(40)上的步骤(120)，该工具的形状与所述涡轮引擎叶片(10)的所述前缘或所述后缘相似；
-将所述不同区段刚性连接的步骤(130)，以通过重新结合所述不同区段(30a，30b，30c，30d)而形成所述单件金属加固件(30)的所述完整轮廓。
2.如权利要求1所述的制造用于涡轮引擎叶片的金属加固件(30)的方法，其中在制造形成所述金属加固件(30)的所述区段(30a，30b，30c，30d)的多个元件的所述步骤(100)过程中，每个区段(30a，30b，30c，30d)通过激光熔合工艺进行制造。
3.如权利要求1或2所述的制造用于涡轮引擎叶片的金属加固件(30)的方法，其中所述刚性连接不同区段(30a，30b，30c，30d)的步骤(120)通过扩散硬钎焊工艺进行。
4.如权利要求3所述的制造用于涡轮引擎叶片的金属加固件(30)的方法，其中该方法包括与所述刚性连接步骤(130)同时进行的热成型步骤(140)。
5.如权利要求3或4所述的制造用于涡轮引擎叶片的金属加固件(30)的方法，其中该方法包括从所述工具(40)脱模所述金属加固件(30)的步骤(150)，所述工具(40)由多个可移动区段(40a，40b，40c，40d，40e，40f)形成，所述脱模通过连续退出所述可移动区段(40a，40b，40c，40d，40e，40f)来进行。
6.如权利要求5所述的制造用于涡轮引擎叶片的金属加固件(30)的方法，其中该方法包括最后加工所述金属加固件(30)的步骤(160)，该步骤包括抛光所述加固件表面的子步骤和/或再加工所述加固件(30)的侧部(35，37)的子步骤。
7.如权利要求1或2所述的制造用于涡轮引擎叶片的金属加固件(30)的方法，其中刚性连接所述不同区段(30a，30b，30c，30d)的所述步骤(110)通过焊接工艺来进行。
8.如权利要求7所述的制造用于涡轮引擎叶片的金属加固件(30)的方法，其中在刚性连接所述不同区段(30a，30b，30c，30d)的所述步骤(110)之后连续包括：
-定位所述经刚性连接的区段(30a，30b，30c，30d)的步骤，其中所述经刚性连接的区段在一工具上形成所述加固件，该工具的形状与所述涡轮引擎叶片(10)的所述前缘(31)或所述后缘相似；
-减轻应力的热处理步骤；
-热成型步骤；
-从所述工具脱模所述金属加固件(30)的步骤，所述工具由分布在所述加固件的所述脚(32)与所述头(34)之间的多个可移动区段形成；
-最后加工所述金属加固件(30)的步骤，该步骤包括抛光所述加固件(30)的表面的子步骤和/或再加工所述加固件(30)的侧部(35，37)的子步骤。
9.一种维修涡轮引擎叶片的方法，所述叶片包含所述叶片的前缘或后缘的磨损的金属加固件，所述方法包括：
-从所述叶片拆下所述磨损的金属加固件的步骤；
-制造根据权利要求1-8中任何一项所述的涡轮引擎叶片(10)的前缘或后缘的金属加固件(30)的步骤；
-将在前面步骤过程中制造的所述金属加固件(30)刚性连接到所述涡轮引擎叶片(10)的步骤。
10.一种用于执行制造根据权利要求1-9中任何一项所述的涡轮引擎叶片的金属加固件(30)的方法的工具(40)，其中所述工具(60)由多个可移动区段(40a，40b，40c，40d，40e，40f)形成。
11.如权利要求10所述的工具(40)，其中它包括数量大于所述加固件(30)的区段(30a，30b，30c，30d)数量的多个可移动区段(40a，40b，40c，40d，40e，40f)。
12.如权利要求10或11所述的工具(40)，其中所述工具(60)以一种膨胀系数大于所述加固件材料(30)的膨胀系数的材料制造。
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CN106514149B (zh) * 2016-11-29 2018-08-10 沈阳黎明航空发动机(集团)有限责任公司 一种整体式导向器的加工方法
CN107674959A (zh) * 2017-09-25 2018-02-09 哈尔滨汽轮机厂有限责任公司 一种用于大叶片热处理定型工具
CN109590192A (zh) * 2018-11-27 2019-04-09 中国航空制造技术研究院 一种复合材料叶片保护壳体制造方法
CN111687606A (zh) * 2019-03-11 2020-09-22 中国航发商用航空发动机有限责任公司 复合材料风扇叶片前缘金属加强边的制备方法

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EP2516107B1 (fr) 2016-07-06
RU2012130953A (ru) 2014-01-27
CA2785374C (fr) 2018-02-27
EP2516107A1 (fr) 2012-10-31
WO2011076890A1 (fr) 2011-06-30
JP2013527359A (ja) 2013-06-27
BR112012015720A2 (pt) 2021-01-26
BR112012015720B1 (pt) 2021-08-17
RU2551741C2 (ru) 2015-05-27
US9199345B2 (en) 2015-12-01
CA2785374A1 (fr) 2011-06-30
CN102686356B (zh) 2016-05-11

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