CN102712066B - 通过激光再填充和适度热等静压修复钛叶片的方法 - Google Patents

通过激光再填充和适度热等静压修复钛叶片的方法 Download PDF

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CN102712066B
CN102712066B CN201080056728.6A CN201080056728A CN102712066B CN 102712066 B CN102712066 B CN 102712066B CN 201080056728 A CN201080056728 A CN 201080056728A CN 102712066 B CN102712066 B CN 102712066B
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temperature
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杰拉德·德瑞恩
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Safran Aircraft Engines 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
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • 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
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
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    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/32—Bonding taking account of the properties of the material involved
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
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    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/32—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
    • B23K35/325—Ti as the principal constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/16—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of other metals or alloys based thereon
    • C22F1/18—High-melting or refractory metals or alloys based thereon
    • C22F1/183—High-melting or refractory metals or alloys based thereon of titanium or alloys based thereon
    • 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
    • F01D5/005—Repairing methods or devices
    • 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
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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
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    • 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
    • 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
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/14—Titanium or alloys thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/10—Manufacture by removing material
    • F05D2230/13—Manufacture by removing material using lasers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/80—Repairing, retrofitting or upgrading methods

Abstract

本发明涉及一种修复金属部件的方法，通过将所述金属的粉末喷涂到所述部件上而对受损的部件再填充，其中所述过程的特征在于，所述方法包括：使用所述粉末对所述受损的部件进行激光再填充的步骤；然后进行热等静压的步骤，在所述等静压过程中采用的最大温度不超过所述金属的再结晶温度。

Description

通过激光再填充和适度热等静压修复钛叶片的方法
技术领域
本发明的领域是航空涡轮引擎领域，特别是修复这些涡轮引擎的压缩机叶片的领域。
背景技术
航空涡轮引擎典型地包括一个或多个串联安置的压缩机，空气在喷射到燃烧室之前在压缩机中被压缩。在燃烧室中，空气与燃料混合并然后燃烧。燃烧气体经过一个或多个涡轮级，提取用于驱动一个或多个压缩机所必要的动力，然后燃烧气体经由喷嘴排放以产生所希望的冲力。在具有高旁通比的现代民用涡轮风扇引擎中，被称为风扇的额外压缩级被安置在第一压缩机(低压压缩机)的上游。这种风扇的叶片具有大尺度，并暴露于由于空气流(例如大气扰动)、灰尘或可能被引擎吸入的异物所致的侵袭。
由于这些侵袭导致腐蚀，因而风扇叶片或多或少地很快出现磨损，这些磨损需要消除，可通过尽量增加受损叶片容许工作寿命或者通过为这些叶片设计修整解决方案而实现。
已经提出许多解决方案以当压缩机叶片在使用过程中腐蚀之后再填补压缩机叶片的前缘或一些其他部分。例如，由霍尼韦尔(Honeywell)公司递交的国际专利申请WO2007/027177提出一种用于对钛合金制风扇叶片再填补的方法，其中采用被称为冷气动态喷涂的方法。这种方法涉及喷涂金属粉末，金属粉末的颗粒由于其动能而积聚在叶片上并由此形成可使叶片恢复到其初始轮廓的层。这种方法具有的缺点是，在喷涂层中最终留下相当多的气孔。为了解决这一问题，在所述专利申请中所述的方法提供热等静压(HIP)操作，HIP操作将在相对严格的条件下执行，这是因为有必要使待修复部件承受从700至1000巴的压力和从1400至1500℃的温度达1小时，然后使部件在900℃量级的温度下保持数小时。
与这种部件温度升高相关的缺点是，钛刚性丧失较多，因而叶片更易于变形。而且，所采用的使用冷气喷涂粉末形式金属的技术无法以足够精确的定位方式进行再填补。因此，这种技术不得不通过机加工修补以使叶片恢复到其精确的几何形状。
另一种可想到的解决方案是激光再填补，其可获得更精确的尺度并由此允许将最后的机加工操作省略或者至少减小至简单的人工执行的调整操作。激光再填补是利用焊接的再填补技术，其包括将金属层沉积到部件表面上。填料金属以丝或粉末形式使用惰性气体供应，然后沿侧向或共轴地被喷射到激光束中。通过这种系统，由激光束传输的一些能量用于预加热束内粉末，而通过粉末射流传送的能量部分可较薄地再熔化衬底表面。熔化区通过激光能量供应被维持。
这种解决方案可将叶片直接翻新(refurbish)至其最后形状，但其并未完全消除与紧凑性不足相关的问题。虽然通过适合的激光调整，所观察到的气孔显著少于之前情况的气孔，不过仍有必要借助于在再填补之后消除气孔的方法确保在采用钛合金压缩机叶片的情况下具有足够的疲劳强度。
还提出其它再填补方法，其中喷涂金属并之后进行诸如HIP加压之类的压密操作，例如在通用电气(GeneralElectric)公司的专利申请EP1643011和EP1743729、或者联合科技(UnitedTechnologies)的专利申请EP1897972中所述方法。应注意，这些热等静压操作在高温条件下执行，这是因为这些条件下通常超过700℃的温度，例如，对于钛合金TA6V而言该温度对应于其再结晶温度。在第一个文献D1中，所用温度在“大致700℃”至“大致950℃”之间，而在第三个文献中，温度在800至1000℃的范围内；在第二个文献中并未指明温度。
同样地，在这些HIP加压操作过程中施加的压力(对于第一个文献在14至28巴之间变化，对于第三个文献在10巴的量级)通常在这种情况下保持相对较低，这对于消除气孔而言是非常不利的。本发明的目的是，通过提供一种修复方法克服这些缺陷，这种修复方法不具有现有技术缺陷中至少一些缺陷，而且这种修复方法特别是消除在再填补过程中可能形成的气孔，而没有叶片轮廓变形的风险。
发明内容
对此，本发明涉及一种修复金属部件的方法，通过将所述金属的粉末喷涂到所述部件上而对受损的部件再填补，其特征在于，所述方法包括：借助于所述粉末对所述受损的部件进行激光再填补(laser-refilling)的步骤；然后进行热等静压的步骤，在所述等静压过程中采用的最大温度不超过所述金属的再结晶温度。
通过保持处于金属再结晶温度之下，避免金属部件变形，金属部件可在激光再填补操作过程中被形成至最后尺度。因而在HIP加压之后不需要用于使部件恢复到其精确几何形状的磨制操作。
优选地，这种方法可对由钛合金制成的涡轮引擎压缩机叶片执行。
在此情况下，所述最大温度最高等于680℃。
在一个特定实施例中，所述部件在所述最大温度下保持至少等于2小时的时间。
增加在最大温度下的保持时间可补偿所述最大温度的降低和获得相似的结果。
优选地，等静压的压力至少等于970巴。
在特定实施例中，所述温度的升高不超过350℃/小时。
在另一特定实施例中，在等静压结束时所述温度的降低不超过100℃/小时。
有利地，在等静压结束时所述压力的降低不超过20巴/分钟。
附图说明
通过以下利用仅示例性的非限制性示例并参照附图给出的本发明实施例的详细描述，本发明将被更好地理解，且本发明的其它目的、细节、特征和优点将更显而易见。
图1是根据本发明实施例的用于修复钛合金叶片的方法的各实施步骤的序列图。
具体实施方式
根据本发明的方法通过以下方式执行：
首先以完全传统的方式使用本领域技术人员已知的方法制备所述部件的将被修复的表面。
所述部件然后布置在激光再填补设备中，被侵蚀的部件在该激光再填补设备中被修整。这种再填补在不施加掩护模板的情况下执行，这是因为所述方法足够精确以将金属加到缺陷位置，而不会延伸超出再填补区域。
以这种方式获得的部件仍然包括具有较小尺寸(在10至40微米之间)的气孔，而这种气孔仍足以激发疲劳裂纹的源发点，这因而阻碍叶片实现与再填补之前尚具有工作寿命相等的剩余工作寿命。这就是为什么有必要通过密化操作而补充进行这种再填补。
如前可见，在传统使用的热条件下通过热等静压进行的传统密化操作，将导致叶片几何形状变形，从而使其不适合于重新使用。
本发明提出，在比传统上所采用HIP方法低的温度条件下执行热等静压操作。通过增加在此温度下的保持温度，于是依照密化获得类似结果。
在叶片由诸如TA6V之类的钛合金制成的情况下，在诸如氩气氛之类的中性气氛中，部件首先被加热到最高等于700℃的温度并持续约2小时时间。同时，装容所述部件的室的压力升高到1000巴±30巴。执行这种HIP加压的优选温度是665℃，容差为±15℃。
所述部件在这些条件下保持约2小时时间。
当在最高700℃下进行这样的保持之后，室温度在另外的约2小时30分钟的时间内逐渐降低到400℃。
最后，根据一定的降低方式(恒定保持小于20巴/分钟的速率)，压力降低到大气压值。
优选地，所述温度以350℃/小时的梯度进行升高，并且以100℃/小时的梯度降低。
显示出当对风扇叶片执行此方法之后获得的结果(密化之前和之后)：
-通过对部件进行摄影测量，使叶片的几何形状不变；
-通过对经历相同方法的样品进行断层摄影，借助于所用的方式使气孔消失或变为具有无法检测出的尺寸。
机械表征测试已经确证，再填补后的叶片如同非再填补叶片那样作用，因而可以为叶片提供与叶片在不需修复时应尚具有的工作寿命相同的剩余工作寿命。
应注意，在HIP加压过程中使用的最高温度在700℃以下，也就是说，在用于退火操作的钛合金TA6V再结晶温度以下。本发明因而要求保护在所涉及材料的再结晶温度以下的温度下执行热等静压而执行的对金属材料的密化操作。

Claims (8)

1.一种修复钛合金部件的方法，通过将钛合金的粉末喷涂到所述部件上而对受损的部件再填补，其特征在于，所述方法包括：
借助于所述钛合金的粉末对所述受损的部件进行激光再填补的步骤；然后
进行热等静压的步骤，在所述热等静压过程中采用的最大温度不超过所述钛合金的再结晶温度。
2.如权利要求1所述的方法，其中，
所述部件是由所述钛合金制成的涡轮引擎压缩机叶片，所述钛合金是TA6V钛合金。
3.如权利要求1所述的方法，其中，
所述最大温度最高等于680℃。
4.如权利要求1所述的方法，其中，
所述部件在所述最大温度下保持至少等于2小时的时间。
5.如权利要求1所述的方法，其中，
所述热等静压的压力至少等于970巴。
6.如权利要求1所述的方法，其中，
在热等静压过程中，温度的升高不超过350℃/小时。
7.如权利要求1所述的方法，其中，
在热等静压结束时温度的降低不超过100℃/小时。
8.如权利要求1所述的方法，其中，
在热等静压结束时压力的降低不超过20巴/分钟。
CN201080056728.6A 2009-12-14 2010-12-08 通过激光再填充和适度热等静压修复钛叶片的方法 Expired - Fee Related CN102712066B (zh)

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