CN103030416A - Cmc构件、功率发生系统和形成cmc构件的方法 - Google Patents

Cmc构件、功率发生系统和形成cmc构件的方法 Download PDF

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CN103030416A
CN103030416A CN2012103689869A CN201210368986A CN103030416A CN 103030416 A CN103030416 A CN 103030416A CN 2012103689869 A CN2012103689869 A CN 2012103689869A CN 201210368986 A CN201210368986 A CN 201210368986A CN 103030416 A CN103030416 A CN 103030416A
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P.德迪戈
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Abstract

本发明涉及CMC构件、功率发生系统和形成CMC构件的方法。一种用于功率发生系统(10)的陶瓷基质复合构件(100)包括陶瓷泡沫芯体(120)和包围陶瓷泡沫芯体(120)的至少一部分的陶瓷基质复合材料(130)。陶瓷泡沫芯体(120)在功率发生系统(10)中的构件(100)的运行期间保持就位。另外，提供一种形成陶瓷基质复合构件(100)的方法(700)。

Description

CMC构件、功率发生系统和形成CMC构件的方法
技术领域
本发明大体涉及功率发生系统，并且更具体而言，涉及用于功率发生系统的陶瓷基质复合构件。
背景技术
已经提出基于碳化硅(SiC)的陶瓷基质复合(CMC)材料作为燃气轮机发动机的某些构件(诸如涡轮叶片和导叶)的材料。已知用于制造基于SiC的CMC构件的多种方法，包括熔渗(MI)、化学气相渗透(CVI)和聚合物热解(PIP)工艺。虽然这些制造技术彼此有显著的不同，但是各自都包括使用工具或模具，以通过包括在多种处理阶段应用热的工艺来产生近净形状的部件。如同由较传统的超合金材料形成的涡轮叶片和导叶一样，CMC叶片和导叶主要配备有腔体和冷却通道，这有两个主要原因，其一是为了降低重量，降低重量会减小离心载荷，而其二是降低它们的运行温度。使用可移除且易耗的工具的组合来使这些特征典型地形成于CMC构件中。
典型地使用在大多数情况下可再次使用的可移除的工具来形成空心的CMC构件的外部轮廓。也可使用可移除的工具来形成内部腔体，但是传统的硅石(SiO2)和氧化铝(Al2O3)芯体广泛地与也已经使用过的熔模铸造法一起使用。
硅石和氧化铝芯体需要用浸出化合物(其包括盐、氟化氢(HF)和碱金属，诸如氢氧化钠(NaOH)和氢氧化钾(KOH)来移除。在一些情况下，金属熔模铸件的暴露表面涂有掩蔽材料，以防止浸出化合物造成表面侵蚀——由于存在芯体的原因，不能掩蔽铸件的内表面。因此，铸件的关键的外表面得到保护，而不那么关键的内表面则会经受浸出化合物的轻微侵蚀。但是，在传统上用来从熔模铸件中移除硅石芯体的浸出化合物会剧烈地侵蚀许多CMC材料，而且特别是包含硅和硼(典型地分别呈SiC和氮化硼(BN)的形式)的那些。因此，从易于被浸出化合物侵蚀的CMC构件中移除硅石芯体的尝试会使构件的内表面遭受无法接受的侵蚀，这会降低CMC构件的结构完整性。
因此，一种没有以上缺陷的CMC构件和形成用于功率发生系统的陶瓷基质复合物的方法在本领域中是合乎需要的。
发明内容
根据本公开的示例性实施例，提供一种用于功率发生系统的陶瓷基质复合(CMC)构件。该CMC构件包括陶瓷泡沫芯体和包围陶瓷泡沫芯体的至少一部分的陶瓷基质复合(CMC)材料。陶瓷泡沫芯体在构件的运行期间保持就位。
根据本公开的另一个示例性实施例，提供一种功率发生系统。该功率发生系统包括涡轮叶片。涡轮叶片包括陶瓷泡沫芯体和包围陶瓷泡沫芯体的至少一部分的陶瓷基质复合材料。陶瓷泡沫芯体在功率发生系统中的构件的运行期间保持就位。
根据本公开的另一个示例性实施例，提供一种形成陶瓷基质复合构件的方法。该方法包括提供陶瓷泡沫芯体，陶瓷泡沫芯体材料具有预定几何构造。该方法包括对陶瓷泡沫芯体应用增强层。该方法包括用基质材料浸渍增强层。该方法包括使陶瓷泡沫芯体、增强层和基质材料固化，以形成陶瓷基质复合构件。
根据结合附图得到的优选实施例的以下更加详细的描述，本发明的其它特征和优点将显而易见，附图以示例的方式示出了本发明的原理。
附图说明
图1是本公开的功率发生系统的示意图。
图2是具有本公开的陶瓷泡沫芯体的组装好的构件的透视图。
图3是本公开的构件的沿着图2的线2-2的横截面图。
图4是本公开的经预处理的构件的放大视图。
图5是在加工之前的、包括陶瓷泡沫芯体的预成形CMC构件的分解图。
图6显示了用来制造叶片组件的工具的示例性实施例的透视图。
图7是形成本公开的构件的方法的流程图。
在可能的情况下，将在所有图中使用相同的参考标号来表示相同部件。
部件列表
10　功率发生系统
12　压缩机区段
14　燃烧器区段
16　涡轮区段
18　固定翼型件
20　叶片
22　盘
24　转子
26　叶片尖部
28　导叶托架
30　内周缘表面
32　压力侧预成形件
34　吸力侧预成形件
100　CMC构件
120　陶瓷泡沫芯体
122　陶瓷泡沫芯体的外部
124　陶瓷泡沫芯体中的气穴/腔体
130　CMC材料-陶瓷基质复合物
132　增强纤维
133　增强层
134　基质材料(陶瓷基质)
136　层压层/多个片层
138　中间层(应用于陶瓷泡沫芯体的可选的额外的CMC层压层)
150　后缘
152　前缘
156　杆部分
160　侧壁
500　预成形构件。
具体实施方式
提供的是没有现有技术中的缺陷的CMC构件、功率发生系统和形成CMC构件的方法。根据本公开的CMC构件最大程度地减少或消除CMC材料属性和制造约束的限制性方面，并且改进机械载荷能力。在图2和3中显示了本公开的实施例，但是本公开不限于示出的结构。
功率发生系统包括(但不限于)燃气轮机、蒸汽轮机和其它涡轮组件。
图1显示了功率发生系统10的示例，即燃气轮机发动机，其具有压缩机区段12、燃烧器区段14和涡轮区段16。在涡轮区段16中，存在成交错的排的固定翼型件18(通常称为导叶)和旋转翼型件20(通常称为叶片)。各排叶片20由多个翼型件20形成，翼型件20附连到设置在转子24上的22盘上。叶片20可从盘22沿径向向外延伸，并且在称为叶片尖部26的区域中终止。通过将多个导叶18附连到导叶托架28上来形成各排导叶18。导叶18可从导叶托架28的内周缘表面30沿径向向内延伸。导叶托架28附连到外壳32上，外壳32封闭发动机10的涡轮区段16。在功率发生系统10的运行期间，高温且高速的气体流过涡轮区段16中的成排的导叶18和叶片20。
图2是加工之后的功率发生系统10的陶瓷基质复合(CMC)构件100的透视图。在一个实施例中，构件100是(但不限于)燃气轮机发动机构件，其包括燃烧器构件、高压涡轮导叶和叶片，以及其它热区段构件，诸如(但不限于)翼型件、导叶、陶瓷壳护罩和喷嘴应用。如图2-3中显示的，CMC构件100是叶片20。构件100包括陶瓷泡沫芯体120和包围陶瓷泡沫芯体120的至少一部分的陶瓷基质复合(CMC)材料130。陶瓷泡沫芯体120在功率发生系统10中的CMC构件100的运行期间保持就位。陶瓷泡沫芯体120由能经受住CMC固化过程的材料形成，并且成为最终CMC构件100的一部分。
在一个实施例中，用于陶瓷泡沫芯体120的材料包括(但不限于)莫来石、硅石、氧化锆、锆石及它们的组合。在另一个实施例中，使用模子用碳化硅(SiC)或硼化硅(SiB)材料来构建陶瓷泡沫芯体120。模子为陶瓷泡沫芯体120提供期望的几何构造。陶瓷泡沫芯体120是开孔泡沫芯体或闭孔泡沫芯体。
CMC构件100包括基于氧化物的CMC，诸如可从加利福尼亚圣地亚哥的COI陶瓷公司获得的AN-720(基于氧化物-氧化物)，或者混合氧化物CMC材料，诸如美国专利No. 6,733,907中公开的一种，该专利通过引用而以其整体结合在本文中。
如图3中显示的那样，构件100是具有前缘152、后缘150和杆部分156的叶片20。叶片20的CMC材料130包围陶瓷泡沫芯体120的至少一部分。在一个实施例中，CMC材料130完全包围陶瓷泡沫芯体120。CMC材料130的侧壁160在陶瓷泡沫芯体120附近，并且大体由陶瓷泡沫芯体120连结(参见图4)。通过形成整体式CMC构件100，陶瓷泡沫芯体120对CMC构件100提供额外的硬度或稳定性。另外，陶瓷泡沫芯体120提供改进的振动属性。
在一个实施例中，陶瓷泡沫芯体120在制造CMC构件100时起心轴的作用。陶瓷泡沫芯体120接收增强纤维132，或者被增强纤维132包裹。增强纤维132布置和设置成形成叶片20。增强纤维132包括以单轴向或双轴向定向的材料以及一般的材料，诸如(但不限于)以四轴向定向的材料、无摺皱的织物(NCF)、砍碎的绳垫和编织织物。
如图4中显示的那样，提供CMC材料130的一个实施例使用被基质材料134浸渍且被进一步加工而形成CMC材料130的增强纤维132。在备选实施例中，CMC材料130由预浸渍的CMC材料构建而成。
如图4中的放大视图所显示的那样，CMC构件100的经预处理的CMC材料130包括陶瓷基质134和在基质134内的包括多个增强纤维132(在图4中显示了仅几个纤维，以有利于论述)的至少一个增强层133，以及应用于陶瓷泡沫芯体120的可选的中间层138。中间层138是由CMC片层构建而成的层压层。增强纤维132选自诸如金属纤维、陶瓷纤维、碳纤维及它们的组合的材料。
另外，如图4中显示的那样，在应用多个增强纤维132之前，CMC材料130可以可选地包括应用于陶瓷泡沫芯体120的中间层138。CMC材料130包括任何适当的纤维体系结构。CMC130的增强纤维132可定向成提供期望的强度属性。例如，增强纤维132可定向成提供各向异性、正交各向异性或面内各向同性属性。在一个实施例中，增强纤维132可布置成相对于彼此基本90度，诸如0-90度定向或+/-45度定向。增强纤维132也可设置在多个层或层压片层136中。在一个实施例中，在应用之前预先浸渍增强纤维132。陶瓷基质134是选自诸如Sic、SiN、SiB及它们的组合的材料
在一个实施例中，使用传统的陶瓷基质材料处理来得到CMC构件100。在处理期间，陶瓷泡沫芯体120不会从CMC构件100中熔出。即使在燃烧或刚性化循环之后，陶瓷泡沫芯体120也继续存在。在一个实施例中，对陶瓷泡沫芯体120使用高温CMC SiC泡沫。在烧尽循环期间，即在将预成形构件500(参见图4-5)置于处于预先设定的温度处的烤箱中以去除CMC材料130中的所有粘合剂(挥发性气体)而形成CMC构件100时，CMC材料130(或预成形部件32和34)和陶瓷泡沫芯体120两者均经受烧掉所有挥发性物质(诸如硅)的过渡阶段。在烧尽阶段或循环之后，产生的CMC构件100具有主要包括碳的CMC材料130和陶瓷泡沫芯体120。陶瓷泡沫芯体120位于CMC材料130的侧壁160之间。产生的CMC构件100(其包括CMC材料130和陶瓷泡沫芯体120两者)包括具有烤面包片状的纹理或结构的易碎的多孔碳材料。
如图5中显示的那样，在备选实施例中，使用预成形CMC构件500来形成CMC构件100。预成形CMC构件500(在这里是经预处理的叶片20)由包围陶瓷泡沫芯体120的压力侧部件32和吸力侧部件34形成。使用呈不同组合和厚度(这取决于待生产的构件)的CMC片层的层压序列来产生用来产生部件32和34的CMC材料130。另外，部件32和34包括必要的强度特性，这取决于最终构件100的结构。部件32和34可包括在部件的外侧上的最终基质片层。
如图6中显示的那样，可使用工具200来制造包括被压力侧预成形件32和吸力侧预成形件34包围的陶瓷泡沫芯体120的CMC构件100。使预成形叶片20(诸如图5中的一个)位于或铺叠在工具200中，以使复合物刚性化或密实。大体上，工具200包括构造成邻接彼此且紧固在一起的第一组相反的侧部202、204。如所显示的那样，可将侧部202、204布置成构件100的模子或用于保持叶片代用品的区段。侧部202、204可包括设计成容许将叶片10制造成期望的形状的第一铺叠表面206。工具200进一步包括构造成分别在翼型件和鸠尾上(或者，在备选实施例中，在叶片代用品上)提供压力的第二组相反的侧部208、210。工具200可包括鸠尾模具212和/或桥214，或者用以提供用于铺叠预成形材料(诸如陶瓷纤维材料)的可选择性地构造的表面的其它结构。在一个实施例中，鸠尾模具212可进一步限定铺叠表面，例如第一铺叠表面。在另一个实施例中，针对待共同刚性化的翼型件和鸠尾预成形以及一体式平台预成形件来构造鸠尾模具212。
接下来，使用熔渗(MI)工艺来完成CMC构件100的构建。使用芯吸、浇口或其它适当的工艺来使硼化硅材料(诸如四硼化物(SiB4)、六硼化硅(SiB6)或它们的组合)熔融到包括陶瓷泡沫芯体120和CMC材料120的CMC构件100中。在MI工艺期间，硼化硅材料被毛细吸收作用吸收到存在于CMC构件100和陶瓷泡沫芯体120中的所有碳腔体中。
在图7中显示了形成陶瓷基质复合构件100的方法700。方法700包括提供陶瓷泡沫芯体120，即步骤702(参见图2)。在一个实施例中，陶瓷泡沫芯体120具有预定几何构造，并且用作用于形成构件100的心轴。接下来，可选地，对陶瓷泡沫芯体120应用中间层138或CMC层压层，即步骤704(参见图4)。接下来，通过用压力侧预成形件32和吸力侧预成形件34包围陶瓷泡沫芯体120来在工具200中组装CMC预成形500(参见图6)，即步骤706(参见图5-6)。备选地，在工具200中对陶瓷泡沫芯体120应用多个增强层133，即步骤706(参见图4和6)，以得到期望的预成形构件形状。在一个实施例中，用基质材料134浸渍增强层133，或者在应用之前预先浸渍纤维。接下来，可选地使用工具200来对包括陶瓷泡沫芯体120的预成形构件500进行高压处理，即步骤708。接下来，使包括陶瓷泡沫芯体120的预成形构件500在适当的温度处固化，诸如(但不限于)大约2700℉至大约3400℉，或者备选地大约2750℉至大约3300℉，或者备选地大约2800℉至大约3200℉，即步骤710。固化会使预成形构件500和陶瓷泡沫芯体120刚性化，并且烧掉多余的有机材料，而留下具有几乎烤面包片状的纹理或结构以及具有构件100的一般的期望形状的易碎的多孔碳材料。接下来，通过使用利用硼化硅材料的熔渗或其它适当的芯吸技术来使预成形构件和陶瓷泡沫芯体120密实，以形成CMC构件100，即步骤712(参见图2)。
本公开的实施例的一个优点包括一种不需要与形成CMC构件相关联的额外的移除步骤和清洁步骤的方法。
本公开的实施例的另一个优点包括一种消除清洁和再熔化在形成CMC构件时使用的心轴的方法。
本公开的实施例的另一个优点在于，构件在保持重量轻和空心的同时，容许构件的内部腔体有气体流或加压。
本公开的实施例的又一个优点在于，构件具有提供完整的整体式结构系统的统一侧壁，从而在重量减小的情况下类似于实心CMC叶片而改进振动和硬度。
本公开的实施例的又一个优点在于，其减少层压层建立时间和片层组装，从而降低成本。
本公开的实施例的又一个优点在于CMC叶片重量减小以及离心载荷降低，从而允许接收CMC叶片的转子的大小和重量减小。
另一个优点包括叶片重量与实心的单块式构件相比有所减小。
本公开的实施例的另一个优点在于，构件与空心的CMC构件相比具有改进的硬度属性。
虽然参照优选实施例对本发明进行了描述，但本领域技术人员将理解，可在不偏离本发明的范围的情况下做出多种改变，而且等效物可代替本发明的元件。另外，可在不偏离本发明的实质范围的情况下作出许多改良，以使具体情况或材料适于本发明的教导。因此，意图的是本发明不限于被公开为为了执行本发明而构想的最佳模式的特定实施例，相反，本发明将包括落在所附权利要求的范围内的所有实施例。

Claims (10)

1.一种用于功率发生系统(10)的陶瓷基质复合构件(100)，包括：
陶瓷泡沫芯体(120)；以及
包围所述陶瓷泡沫芯体(120)的至少一部分的陶瓷基质复合材料(130)，其中，所述陶瓷泡沫芯体(120)在所述构件(100)的运行期间保持就位。
2.根据权利要求1所述的陶瓷基质复合构件(100)，其特征在于，所述陶瓷泡沫芯体(120)包括选自氧化铝、莫来石、硅石、氧化锆、锆石、碳化硅、硼化硅及它们的组合的材料。
3.根据权利要求2所述的陶瓷基质复合构件(100)，其特征在于，所述陶瓷泡沫芯体(120)选自开孔泡沫或闭孔泡沫。
4.根据权利要求1所述的陶瓷基质复合构件(100)，其特征在于，陶瓷基质复合(100)包括至少一个增强纤维(132)和基质材料(134)。
5.根据权利要求4所述的陶瓷基质复合构件(100)，其特征在于，所述至少一个增强纤维(132)包括选自金属纤维、陶瓷纤维、碳纤维及它们的组合的材料。
6.根据权利要求4所述的陶瓷基质复合构件(100)，其特征在于，所述基质材料(134)选自SiC、SiN及它们的组合。
7.根据权利要求1所述的陶瓷基质复合构件(100)，其特征在于，中间层(138)在所述陶瓷泡沫芯体(120)附近，并且在所述陶瓷基质复合材料(130)附近。
8.一种形成陶瓷基质复合构件(100)的方法(700)，包括：
提供陶瓷泡沫芯体(120)，所述陶瓷泡沫芯体(120)具有预定几何构造；
组装包括所述陶瓷泡沫芯体(120)的陶瓷基质复合构件(100)预成形件；
使所述陶瓷基质复合构件(100)预成形件和陶瓷泡沫芯体(120)固化；
渗透固化的陶瓷基质复合构件(100)预成形件和陶瓷泡沫芯体(120)，以形成所述陶瓷基质复合构件(100)。
9.根据权利要求8所述的方法，其特征在于，提供陶瓷泡沫芯体(120)的步骤包括对所述陶瓷泡沫芯体(120)添加中间层(138)。
10.根据权利要求8所述的方法，其特征在于，使用具有期望的几何构造的模子来形成所述芯体(120)。
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