CN103402691B - 用于制造金属部件,诸如涡轮发动机叶片加强件的方法 - Google Patents
用于制造金属部件,诸如涡轮发动机叶片加强件的方法 Download PDFInfo
- Publication number
- CN103402691B CN103402691B CN201280010947.XA CN201280010947A CN103402691B CN 103402691 B CN103402691 B CN 103402691B CN 201280010947 A CN201280010947 A CN 201280010947A CN 103402691 B CN103402691 B CN 103402691B
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- metal parts
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- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
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Classifications
-
- 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
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- 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
- 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
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
- B23K20/021—Isostatic pressure welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C11/00—Propellers, e.g. of ducted type; Features common to propellers and rotors for rotorcraft
- B64C11/16—Blades
- B64C11/20—Constructional features
- B64C11/205—Constructional features for protecting blades, e.g. coating
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/02—Pretreatment of the fibres or filaments
- C22C47/04—Pretreatment of the fibres or filaments by coating, e.g. with a protective or activated covering
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/02—Pretreatment of the fibres or filaments
- C22C47/06—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
- C22C47/062—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element from wires or filaments only
- C22C47/064—Winding wires
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/20—Making alloys containing metallic or non-metallic fibres or filaments by subjecting to pressure and heat an assembly comprising at least one metal layer or sheet and one layer of fibres or filaments
-
- 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
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- 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
- F04D29/02—Selection of particular materials
- F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
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- 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
-
- 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
- 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
-
- 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
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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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- 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
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- 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
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- 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
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- 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
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/124—Tongue and groove joints
- B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
- B29C66/12463—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being tapered
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- 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
- B29C66/05—Particular design of joint configurations
- B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
-
- 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
- B29C66/50—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
- B29C66/53—Joining single elements to tubular articles, hollow articles or bars
-
- 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
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
-
- 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
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- B29L2031/082—Blades, e.g. for helicopters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B64D27/00—Arrangement or mounting of power plants in aircraft; Aircraft characterised by the type or position of power plants
- B64D2027/005—Aircraft with an unducted turbofan comprising contra-rotating rotors, e.g. contra-rotating open rotors [CROR]
-
- 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
- F01D5/288—Protective coatings for blades
-
- 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
- F05D2220/00—Application
- F05D2220/30—Application in turbines
- F05D2220/36—Application in turbines specially adapted for the fan of turbofan engines
-
- 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
- F05D2230/20—Manufacture essentially without removing 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
- F05D2230/40—Heat treatment
- F05D2230/42—Heat treatment by hot isostatic pressing
-
- 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
- F05D2240/00—Components
- F05D2240/20—Rotors
- F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
- F05D2240/303—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the leading edge of a rotor blade
-
- 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
- F05D2240/00—Components
- F05D2240/20—Rotors
- F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
- F05D2240/304—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the trailing edge of a rotor blade
-
- 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
- F05D2300/00—Materials; Properties thereof
- F05D2300/10—Metals, alloys or intermetallic compounds
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Abstract
本发明涉及一种用于生产金属部件,诸如金属涡轮发动机叶片加强件的方法,连续地包括:生产由插件(301)和多个金属丝(302)所组成的三维金属结构(310)的步骤,该插件(301)具有允许超塑性成形和扩散焊接的特性,该多个金属丝(302)围绕所述插件(301)的周围,所述金属结构(310)形成所述金属部件(30)的预制件;在成形工具中定位所述金属结构(310)的步骤;和所述三维金属结构(310)的热压步骤,这引起所述金属结构(310)的聚集,以获得所述致密金属部件(30)。
Description
本发明涉及用于制造金属部件,诸如用于复合或金属涡轮发动机叶片的金属加强件的方法。
更特别地,本发明涉及用于制造用于涡轮发动机叶片的前缘或后缘的金属加强件的方法。
本发明的领域是涡轮发动机的领域,更特别地是复合或金属材料制造的和其前缘包括金属结构加强件的涡轮发动机风扇叶片的领域。
然而,本发明也可以应用于金属加强件的制造,该金属加强件用于增强任何类型涡轮发动机叶片的前缘或后缘,在地面上使用或航空使用的涡轮发动机和特别地直升机涡轮轴发动机或航空器喷气涡轮发动机,也用于螺旋桨的制造,诸如双扇反转非减阻螺旋桨或开放转子螺旋桨。
本发明也可以应用于具有复杂几何形状的所有整体金属部件的制造。
应该想到前缘对应于空气动力学轮廓的前部,其遇到气流和将气流分成拱腹或下表面气流和拱背或上表面气流。后缘对应于空气动力学轮廓的后部,在这里拱腹和拱背流重聚。
涡轮发动机叶片,并且特别地风扇叶片受到高水平的机械应力,这特别地与转速有关,并且它们必须满足严格的重量和总尺寸条件。因此,使用更轻的由复合材料所制造的叶片。
安装到涡轮发动机的风扇叶片是已知的,其由复合材料制造,并且其中金属结构的加强件在它们前缘的任一侧上延伸整个高度,如文献EP1908919中所述。在外面物体,诸如,例如小鸟、冰雹甚或石头撞击风扇期间,这种加强件保护复合叶片。
特别地,金属结构的加强件通过防止由于纤维/基体接合破坏而引起的脱层、纤维破裂或损坏的可能性,保护复合风扇的前缘。
通常地,涡轮发动机叶片包括空气动力学表面,其在第一方向上在前缘和后缘之间延伸,并且在基本上垂直于第一方向的第二方向上,其在叶片的根部和顶端之间延伸。金属结构的加强件符合叶片的空气动力学表面的前缘形状,并且在叶片的空气动力学表面的前缘的任一侧上的第一方向上延伸,以符合叶片拱腹和拱背的轮廓,并且在叶片根部和顶端之间的第二方向上延伸。
在已知的方式中,金属结构的加强件是由钛制造的金属部件,后者完全通过由一块材料的铣削来制造的。
然而,叶片前缘的金属加强件是制造复杂的部件,需要大量再加工操作和复杂刀具加工,这涉及高的制造成本。
在本发明的上下文中目的是通过提出用于制造用于涡轮发动机叶片的前缘或后缘的金属加强件的方法,解决上述问题,这显著地减少用于这种部件的制造成本以及简化制造过程。
为此,本发明提出了用于制造金属部件的方法,诸如涡轮发动机叶片金属加强件的方法,其连续地包括:
-用于制造由插件和多个金属丝所组成的三维金属结构的步骤,该插件具有允许进行超塑性成形和扩散焊接的特性,该多个金属丝围绕所述插件的周围,其中所述金属结构形成所述金属部件的预制件;
-其中所述金属结构定位在成形工具中的步骤;
-所述三维金属结构的热压步骤,这引起所述金属结构的聚集,以获得所述致密金属部件。
由于本发明,通过制造金属构造,简单和快速地制造金属部件诸如,例如,包括沿着两个不同平面的两条曲线(或扭曲绕着轴线)的金属结构加强件,其中通过插件和金属丝成形以产生绕着插件的金属缠绕,由此产生绕着插件的金属骨架,以及允许获得致密部件的热压和/或压制成型方法的组合,事先形成该金属结构。有利地,热压方法是等压压制或压制成型方法(HIP或热等压压制),这允许通过塑性变形、蠕变和扩散焊接的组合来获得致密非多孔的部件。
使用模具生产金属丝,该模具的截面可以恰好地等于圆形、方形或六边形等。
有利地,制造插件以符合待要制造部件的中轴线的形式,这样所制造的金属结构形成待要制造部件的预制件,其容易地能够定位在成形工具中。
所制造的金属结构因此是容易运输和容易定位在成形工具中的结构,与待要制造的部件,诸如叶片加强件,显示渐开非可展开形状的部件,甚或具有包覆形状的部件诸如,例如,部分地重叠叶片端部的部件的复杂形状无关。
有利地,用于制造金属结构的金属丝的长度和直径是变化的,并且取决于待要制造部件的形状,诸如,例如叶片加强件的形状。
因此,这种制造方法克服了使用对平台的铣削或拉削类型的块机械加工,对叶片加强件的复杂制造的要求,所述机械加工需要使用大体积材料,以及由此高原料供应成本。该方法也允许容易地制造金属加强件,后者满足严格的质量和/或几何要求。
有利地,金属部件是涡轮发动机的风扇叶片前缘或后缘的金属加强件。
单独地考虑或根据所有技术可能的组合,根据本发明用于制造金属部件的方法也显示了下面一个或多个特征。
-所述方法是用于制造用于涡轮发动机叶片前缘或后缘的金属加强件的方法,或者是螺旋桨的金属加强件的方法,这样所述热压步骤期间所获得的所述金属部件是金属加强件。
-所述热压步骤是等压压制步骤或等热锻造步骤;
-所述用于制造三维金属结构的步骤连续地包括:
-用于制造插件的第一子步骤;
-用于绕着所述插件缠绕多个金属丝的第二子步骤;
-所述用于制造三维金属结构的步骤连续地包括:
-用于制造插件的第一子步骤;
-弯曲所述多个金属丝这样每个金属丝都显示至少一个环的第二子步骤;
-将所述插件插入到所述多个金属丝的所述环的每个环中的第三子步骤;
-通过锻造或机械加工,或者通过铸造或通过三维编织方法获得用于制造所述插件的所述子步骤;
-所述插件是金属插件;
-所述多个金属丝的所述金属丝弯曲成A形状;
-所述金属丝是钛基金属丝和/或SiC-钛丝;
-所述方法连续地包括:
-用于多个三维金属结构制造的步骤,该三维金属结构由插件和环绕所述插件的多个金属丝所组成,其中所述多个金属结构形成所述金属部件的预制件;
-用于在成形工具中定位所述多个金属结构的步骤;
-所述三维多个金属结构的热压步骤,这引起所述多个金属结构的聚集以获得所述金属部件。
通过示意目的和以任何非限制性方式,参考附图所给出的下面说明,本发明的其它特征和优点将会更清楚地呈现,其中:
图1是叶片的侧视图,其包括通过本发明的制造方法所获得的前缘金属结构加强件。
图2图1中所示叶片沿着截面AA平面的部分截面图。
图3是概括性示意图,其表示本发明制造方法的涡轮发动机的叶片前缘的金属结构加强件制造的主要步骤。
图4a、4b、4c表示涡轮发动机的叶片前缘的金属加强件的长度,其表示图3中所示方法的第一步骤中各个的阶段。
图5表示图3中所示方法的第二步骤期间,涡轮发动机的叶片前缘的金属加强件的长度。
图6表示图3中所示方法的第三步骤期间,涡轮发动机的叶片前缘的金属加强件的视图。
除非另外说明,所有图中共同的元件都具有相同的附图标记。
图1是叶片的侧视图,其包括通过本发明的制造方法所获得的前缘金属结构加强件。
所示例的叶片10是,例如涡轮发动机(未示出)的动风扇叶片。
叶片10具有航空动力学表面12,后者沿着第一轴向方向14在前缘16和后缘18之间延伸以及沿着基本上垂直于第一方向14的第二径向方向20在根部22和顶端24之间延伸。
空气动力学表面12形成叶片10的拱背13和拱腹11表面。图1中示出了仅仅叶片10的拱背13表面。拱腹11和拱背13形成叶片10的侧向表面,它们连接叶片10的前缘16和后缘18。
在这个实施方式中,叶片10是通常通过编织纤维织物的成形而获得的复合叶片。举例说明,所用的复合材料可以由编织碳纤维和树脂基基体的组合而组成,使用RTM(“树脂转移模塑”)或VARTM(“真空树脂转移模塑”)类型的树脂注塑方法,通过模塑形成整个系统。
叶片10包括金属结构加强件30,其粘合到其前缘16,并且其在叶片10的空气动力学表面12的前缘16的任一侧面上在第一方向14上和沿着第二方向在叶片的根部22和顶端24之间延伸。
如图2中所示,结构加强件30符合叶片10的空气动力学表面12的前缘16的 形状,它延伸形成前缘31,称为加强件的前缘。
通常地,结构加强件30是整体部件,其包括基本上V形截面,具有形成前缘31的基部39和延伸有两个侧翼35和37,它们分别符合叶片的空气动力学表面12的拱腹11和拱背13。侧翼35、37在叶片后缘的方向上显示了锥形或渐细的轮廓。
基部39包括磨圆的内轮廓33,其匹配叶片10前缘16的圆形形状。
结构加强件30是金属的,并且优选地钛基的。这种材料实际上显示了吸收由于撞击而引起的能量的高吸收力。使用本领域技术人员已知的粘合剂,诸如,例如环氧树脂粘合剂,加强件通过粘合连接到叶片10。
在专利申请EP1908919中更详细地描述了用于增强涡轮发动机的复合叶片的这种类型金属结构加强件30。
根据本发明的方法特别地允许制造如图2中所示待要制造的结构加强件,其中图2表示最终状态的加强件30。
图3表示概括性示意图,其示例了金属部件制造方法200的主要步骤,该制造方法能够,例如生产,诸如图1和2中所示例的叶片10前缘的金属结构加强件30。
制造方法200的第一步骤210是用于制造金属结构310的步骤,其形成根据本发明方法所要制造的部件的预制件。这个步骤210特别地如图4a、4b和4c中所示,其表示该第一步骤210的各个阶段。
通过插件301以及由环绕插件301周围的多个金属丝302所形成的金属骨架303的组合形成金属结构310(图4c)。
根据第一实施方式,制造方法200的第一步骤210由用于制造插件301的第一子步骤和用于绕着插件301缠绕多个金属丝302的第二子步骤组成,以制造包覆插件301的金属骨架303。
如图4a所示的第一子步骤是用于制造插件301的步骤,其形状根据待要制造部件的最终形状而确定。在涡轮机前缘的金属加强件的制造实施例中,插件301具有金属加强件的基部39(图2)的形状,并且显示了在两个不同平面中的两条曲线(或绕着轴线的扭曲),这遵循叶片前缘的中轴线。为此,插件301基本上是三角形形式,其具有两个侧翼304、305和基部306。
插件301可以是刚性插件,诸如整体插件,例如由锻造、机械加工或铸造方法制造的,或者是弹性插件,诸如使用三维编织方法制造的编织插件。
与用于制造插件的方法类型无关,插件301可以直接制造成期望的形状(即, 没有附加的变形步骤),或者可以在两个连续的操作中制造(如果插件材料的性质允许这样):第一操作包括制造基本上直线部件和第二操作包括成形直线部件,以制造期望形状的插件(即,具有用于制造涡轮发动机叶片加强件的两条曲线)。
为了制造用于涡轮发动机叶片的加强件,插件301有利地是钛基金属插件。
当通过编织方法制造金属插件301时,使用金属丝,例如使用钛丝和/或碳化硅和钛基(SiC-Ti)丝,和/或涂覆有硼(SiC-硼)的丝编织插件。丝也可以是由碳化硅(SiC-SiC)所制造的非金属丝。
无论什么材料用于制造插件301,所述材料必须显示允许进行超塑性成形和扩散焊接的特性。在制造用于涡轮机叶片的金属加强件的实施例中,金属插件301有利地由钛制造。
为了制造中空金属加强件(未示出),通过由不同于用于制造金属加强件的材料的材料所制造的“过渡插件”代替金属插件。术语“过渡插件”指一种插件,其不意指永久性的和仅仅对于制造前缘的中空金属加强件是必要的。因此,过渡插件不存在于最终状态的金属插件中,并且不会以任何方式对金属加强件的机械特性做出贡献。
过渡插件,例如,由能够抵靠900℃数量级高温,1000巴数量级高压的材料制造,并且与制造金属加强件中所用的材料相容,以不产生杂质或氧化。
过渡插件的材料也必须能够承受化学侵蚀,包括化学试剂的溶解。
有利地,过渡插件由铜、石英或硅石制造。
过渡插件的形状取决于金属加强件的最终内腔室的期望形状。
第二子步骤是用于绕着插件301缠绕多个金属丝的步骤,该金属丝开始是直线形。
根据图4b中所示的缠绕的一个实施例,金属丝302缠绕到插件301上,以制造绕着插件301的至少一个环。根据图4b和4c中所示缠绕的实施例,包括金属丝缠绕的步骤以这样的一种方式进行,对于绕着插件301缠绕的金属丝,插件301在其侧翼304、305上显示两次金属丝通过,并且在其基部306上只有一次金属丝通过。
因此,缠绕开始于插件301的第一侧翼305上。然后,金属丝在插件301的顶峰弯曲,这样金属丝与插件301的第二侧翼304接触。然后,金属丝在第二侧翼304和基部306之间的连接处再次弯曲,这样它符合插件301的基部形状。通过金属丝再次通过第一侧翼305,然后通过第二侧翼304,终止缠绕。
因此,围绕插件301的五条直线部件形成缠绕丝302。
然后,由多个缠绕金属丝302围绕插件301,这形成金属结构310的金属骨架303。图4c特别地表示缠绕子步骤的结束。
从一旦完成缠绕就剪切到期望长度的连续直线丝或者从剪切到期望长度的多个直线金属丝可以进行缠绕子步骤。
待要制造的部件的厚度可以变化;所使用金属丝的厚度可以沿着部件长度变化。
根据金属丝302的厚度和根据需要制造部件的材料要求确定间隔两个缠绕金属丝302的间隙(即,金属丝之间的定位间距)。待要制造的金属部件可以具有可变厚度,金属丝的定位间距可以是变量,并且金属丝的厚度也可以不同于部件的长度,以匹配部件的可变厚度。
图4b和4c中所示用金属丝缠绕的实施例不是限制性的,并且绕着插件301的其它类型缠绕也是可能的。
缠绕的子步骤也可以包括绕着插件301缠绕几层金属丝302。
这种金属结构310制造的第一实施例特别地适于使用刚性插件301。
根据制造金属结构310的第二实施例,制造方法200的第一步骤210包括用于制造前述插件301的子步骤,用于弯曲多个金属丝302基本上成A形的第二子步骤,该A形显示了基本上插件301形状的环,以及将第一子步骤期间所制造的插件引入到第二子步骤期间事先形成的每个金属丝的每个环中,以产生包覆插件301的金属骨架。
该第二制造实施例特别地适于使用弹性插件,诸如编织插件。
绕着插件所缠绕的金属丝302主要是钛丝。然而,也可以将碳化硅和钛(SiC-Ti)基的丝、硼涂覆的丝(SiC-硼丝)或碳化硅丝(SiC-SiC丝)掺入到基于钛丝的金属结构310中,以通过分离和局部方式,在待要制造的部件中产生结构加强件。
制造方法200的第二步骤220是包括前步骤中所制造的金属结构310在成形工具400中定位的步骤。
成形工具400包括模具440,其具有对应于金属加强件30的最终外部形状(图1)的腔室410和对应于前缘的金属加强件的最终内部形状的冲头420。
通过在成形工具400的模具440的腔室410中定位金属结构310进行定位步骤220。
因为三维金属结构310基本上具有补充腔室410形状的形状,通过安装金属结 构简单地进行定位步骤,该金属结构形成待要制造部件的预制件。通过金属丝302的直线端部所形成的金属骨架端部的可能弹性变形也可以有助于该步骤。
根据另一个制造的实施例,待要制造部件的预制件可以由上述多个金属结构310制造。在制造的实施例中,通过将各个三维金属结构310定位在成形工具400的腔室410中然后进行定位步骤。通过沿着腔室410的长度(即,沿着腔室的纵向轴线)各个金属结构310的连续定位完成定位。因此,将预制件分成金属结构的多个部分意指工具的腔室410中复杂形状预制件的定位更便利。
制造方法200中第三步骤230是包括热压定位在工具400中的金属结构310。
根据制造的第一实施例,热压是等压压制(HIP或热等压压制)。
热等压压制是广泛使用和公知的用于减少金属孔隙率和用于对许多材料的密度具有影响的一种制造方法。等压压制方法还改进了材料的机械特性和使用性能。在高温(通常400℃和1400℃之间,对于钛是在1000℃数量级的温度)和等压压力下进行等压压制。
因此,通过塑性变形、蠕变和扩散焊接的组合,接合内部压力的热应用移除了堆叠中空的间隙以及微孔率。
在用于涡轮发动机叶片的金属加强件的制造上下文中,由等压压制步骤所产生的整体部件430具有接近金属加强件30的最终形状的形状。然后从成形工具400的模具移除整体部件430。
在真空下进行等压压制步骤,有利地在次级真空下进行,或者在产生次级真空的焊接工具中或者在高压釜真空袋子中进行,方法的选择取决于待要生产部件的数量。次级真空防止钛的等压压制阶段的期间,氧气存在于工具中和金属结构中。
根据制造的第二个实施例,热压制也可以是使用抽真空套中压制的等温锻造方法。
工具由称为超级合金或高温合金的机械合金制造。
热压步骤230可以包括涉及清洁、脱脂和/或化学侵蚀金属结构310的在先步骤,以从各个金属丝302移除残留的杂质。有利地,通过在清洗剂或化学试剂的槽中浸泡金属结构310完成杂质清洗步骤。
在中空金属加强件的制造上下文中,本发明的方法可以包括从模具释放金属部件后,对插件进行化学侵蚀的附加步骤,该插件是致密金属部件430的整体部分。通过已知与制造插件的材料反应的化学试剂进行化学反应。对过渡插件的化学侵蚀 溶解了过渡插件,这样由溶解插件以前所占据的空间形成中空金属加强件的内部腔室。有利地,通过在包含已知溶解插件的化学试剂的槽中浸泡整体部件430完成化学侵蚀步骤。化学试剂是,例如酸或碱。
有利地,化学试剂能够溶解铜、石英或者甚至硅石。
在这些主要制造步骤的组合中,本发明的方法也可以包括精加工步骤和再加工步骤,涉及从工具所获得的整体金属部件的机械加工,以获得加强件30。该再加工步骤包括:
-用于再加工加强件30基部39的轮廓以对它进行精加工的步骤,和特别地再加工前缘31的空气动力学轮廓;
-用于再加工侧翼35、37的步骤,其中该步骤特别地包括侧翼35、37的修整以及拱腹和拱背侧翼的修磨。
-精加工步骤,其允许获得所要求表面的精加工。
在这些主要制造步骤的组合中,本发明的方法也可以包括对加强件30的非破坏性检测步骤以检查所获得组件的几何和冶金的柔度。举例说明,使用X射线方法可以进行非破坏性检测。
本发明已经主要地描述了钛基金属丝的使用。然而,制造方法也可以应用于使用显示特性的任何金属材料,该特性允许进行超塑性成形和/或扩散焊接,诸如铝基金属丝。
已经描述了特别地用于涡轮发动机复合叶片前缘的金属加强件的制造的本发明。然而,本发明也可应用于涡轮发动机叶片后缘的金属加强件的制造,或者甚至用于复合或金属螺旋桨的金属加强件的制造。
本发明的其它优点是特别地如下:
-制造成本的减低;
-制造时间的减少;
-制造过程的简化;
-材料成本的降低。
Claims (10)
1.一种用于制造金属部件(30)的方法(200),其连续地包括:
-用于制造由插件(301)和多个分开的金属丝(302)所组成的三维金属结构(310)的步骤(210),该插件(301)具有允许进行超塑性成形和扩散焊接的特性,每个金属丝(302)围绕所述插件(301)的周围,其中所述金属结构(310)形成所述金属部件(30)的预制件;
-其中所述金属结构(310)定位在成形工具(400)中的步骤(220);
-所述三维金属结构(310)的热压步骤(230),这引起所述金属结构(310)的聚集,以获得致密的所述金属部件(30)。
2.根据权利要求1所述的用于制造金属部件(30)的方法(200),其特征在于:所述方法是用于制造用于涡轮发动机叶片前缘或后缘的金属加强件的方法,或者用于制造螺旋桨的金属加强件的方法,这样在所述热压步骤(230)期间所获得的所述金属部件是金属加强件。
3.根据权利要求1所述的用于制造金属部件(30)的方法(200),其特征在于:所述热压步骤是等压压制步骤或等温锻造步骤。
4.根据权利要求1所述的用于制造金属部件(30)的方法(200),其特征在于:所述用于制造三维金属结构(310)的步骤(210)连续地包括:
-用于制造插件(301)的第一子步骤;
-用于绕着所述插件(301)缠绕多个金属丝的第二子步骤。
5.根据权利要求1所述的用于制造金属部件(30)的方法(200),其特征在于:所述用于制造三维金属结构(310)的步骤(210)连续地包括:
-用于制造插件(301)的第一子步骤;
-弯曲所述多个金属丝(302),这样每个金属丝都显示至少一个环的第二子步骤;
-将所述插件(301)插入到所述多个金属丝(302)的所述环的每个环中的第三子步骤。
6.根据权利要求4至5的一个权利要求所述的用于制造金属部件(30)的方法(200),其特征在于:通过锻造或机械加工,或者通过铸造或通过三维编织方法进行用于制造所述插件(301)的所述第一子步骤。
7.根据权利要求1所述的用于制造金属部件(30)的方法(200),其特征在于:所述插件是金属插件。
8.根据权利要求1所述的用于制造金属部件(30)的方法(200),其特征在于:所述多个丝的所述金属丝(302)弯曲成A形。
9.根据权利要求1所述的用于制造金属部件(30)的方法(200),其特征在于:所述金属丝(302)是钛基丝。
10.根据权利要求1所述的用于制造金属部件(30)的方法(200),其特征在于:所述方法连续地包括:
-用于多个三维金属结构(310)制造的步骤(210),该三维金属结构(310)由插件(301)和环绕所述插件(301)的多个金属丝(302)所组成,其中所述多个金属结构(310)形成所述金属部件(30)的预制件;
-在成形工具(400)中定位所述多个金属结构(310)的步骤(220);
-所述多个三维金属结构(310)的热压步骤(230),这引起所述多个金属结构(310)的聚集,以获得所述金属部件(30)。
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WO2015069335A2 (en) * | 2013-09-09 | 2015-05-14 | United Technologies Corporation | Fan blades and manufacture methods |
FR3025735B1 (fr) * | 2014-09-17 | 2016-12-09 | Europe Tech | Procede de traitement d'une piece composite |
FR3040902B1 (fr) | 2015-09-10 | 2017-09-01 | Snecma | Procede de fabrication d'un renfort de protection pour une aube (p) presentant un bord d'attaque ou de fuite courbe |
FR3045710B1 (fr) | 2015-12-21 | 2018-01-26 | Safran Aircraft Engines | Bouclier de bord d'attaque |
GB2549113A (en) * | 2016-04-05 | 2017-10-11 | Rolls Royce Plc | Composite bodies and their manufacture |
DE102016120480A1 (de) | 2016-10-27 | 2018-05-03 | Man Diesel & Turbo Se | Verfahren zum Herstellen eines Strömungsmaschinenlaufrads |
US11286782B2 (en) | 2018-12-07 | 2022-03-29 | General Electric Company | Multi-material leading edge protector |
CN111893405B (zh) * | 2020-06-23 | 2021-08-06 | 西安理工大学 | 一种钛纤维韧化冷镦模具及其制备方法 |
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CN113751976B (zh) * | 2021-09-29 | 2022-11-18 | 上海交通大学 | 航空发动机复材风扇叶片前缘钛合金加强边的制造方法 |
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CA2828778C (en) | 2019-04-09 |
US9346134B2 (en) | 2016-05-24 |
BR112013022129B1 (pt) | 2018-11-27 |
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