CN103476544B - 制作金属部件的方法 - Google Patents

制作金属部件的方法 Download PDF

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Publication number
CN103476544B
CN103476544B CN201180056092.XA CN201180056092A CN103476544B CN 103476544 B CN103476544 B CN 103476544B CN 201180056092 A CN201180056092 A CN 201180056092A CN 103476544 B CN103476544 B CN 103476544B
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metal
bundle
making
forming
metal parts
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CN103476544A (zh
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布鲁诺·杰克斯·杰拉德·达姆布瑞恩
蒂里·戈登
艾伦·罗伯特·伊夫斯·佩罗科斯
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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
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/03—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal otherwise than by folding
    • B21D39/031—Joining superposed plates by locally deforming without slitting or piercing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/78—Making other particular articles propeller blades; 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
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • 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
    • F01D5/12—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
    • F04D29/02—Selection of particular materials
    • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
    • 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
    • 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
    • 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
    • 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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2241/00—Treatments in a special environment
    • C21D2241/01—Treatments in a special environment under pressure
    • 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
    • F05D2240/00—Components
    • F05D2240/10—Stators
    • F05D2240/12—Fluid guiding means, e.g. vanes
    • F05D2240/121—Fluid guiding means, e.g. vanes related to the leading edge of a stator vane
    • 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
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    • F05D2250/10—Two-dimensional
    • F05D2250/18—Two-dimensional patterned
    • F05D2250/185—Two-dimensional patterned serpentine-like
    • 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
    • F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
    • F05D2300/133—Titanium
    • 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
    • F05D2300/70—Treatment or modification of materials
    • F05D2300/702—Reinforcement
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/00—Metal working
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    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • Y10T29/49337—Composite blade
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Architecture (AREA)
  • Composite Materials (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Forging (AREA)

Abstract

本发明涉及制作金属部件的方法，按顺序包括如下步骤：在至少一块挠性金属箔(101)上切割多个缺口(110)的步骤(220)，以便在金属箔纵向边缘(103,104)每一侧形成交错排列的开口，从而形成至少一个金属盘卷(102,102’)；在成形工具上定位至少一个金属盘卷(102,102’)的步骤，所述至少一个金属盘卷在冷态时可沿空间三个方向(X,Y,Z)手工变形；热等静压压制步骤，即在工具内压制所述至少一个金属盘卷(102,102’)的步骤，使得所述金属盘卷(102,102’)得以压紧，从而获得所述金属部件。

Description

制作金属部件的方法
技术领域
本发明涉及一种制作金属部件的方法，例如， 涡轮机复合材料或金属叶片的金属加强件。
本发明特别涉及到制作涡轮机叶片前缘金属加强件的方法。
背景技术
本发明领域为涡轮机，特别是采用复合材料或金属制成的风扇涡轮机叶片，所述叶片前缘包括金属结构加强件。
然而，本发明还适用于制作金属加强件，该加强件可增强陆用或航空用任何类型涡轮机（特别是直升机涡轮机或飞机涡轮喷气发动机）的叶片前缘或后缘，但也适用于螺旋桨，诸如双反转开式转子螺旋桨（open rotor propellers）。
应该注意的是，前缘对应于面对气流的航空动力面的前部，该航空动力面将气流分为拱内气流和拱背气流。后缘对应于航空动力面的后部，在此处，拱内和拱背气流汇合。
涡轮机叶片，特别是风扇叶片，会受到与转速相关的很高的机械应力，且又必须满足严格的重量和尺寸条件。于是，人们采用复合材料制成的重量较轻的叶片。
众所周知，复合材料制成的涡轮机风扇叶片可以安装金属结构加强件，加强件沿叶片整个高度延伸，且一直延伸过其前缘，如EP 1908919 专利文件所公开的那样。这种加强件可在外物，诸如鸟，冰雹或石块，撞击风扇时来保护复合材料叶片。
特别是，金属结构加强件可防止出现分层、纤维失效或纤维/基底分离所带来的损坏等任何风险，从而保护复合材料叶片前缘。
传统上，涡轮机叶片包括航空动力面，沿前缘和后缘之间的第一方向和在叶片根部和顶部之间沿大体垂直于第一方向的第二方向延伸。金属结构加强件与叶片航空动力面的前缘形状相匹配，并沿越过叶片航空动力面前缘的第一方向延伸，与叶片的拱背和拱内轮廓相匹配，并沿叶片根部和叶片顶部之间的第二方向延伸。
众所周知，金属结构加强件是一种金属部件，完全采用一整块材料铣削而成。
然而，叶片前缘用的金属加强件的制造非常复杂，必须进行多次复杂的重复作业，并涉及复杂的工装，生产成本很大。
人们知道，也可采用不同的方法，特别是专利文件WO 2009/039282所介绍的方法，其使用了扩散粘结的原理来制作涡轮机前缘用金属加强件。然而，这些方法都不是完全令人满意。
发明内容
在这种情况下，本发明的目的是提出一种生产方法从而解决上述问题，这种生产方法可以制作涡轮机叶片前缘或后缘金属加强件，以便简化这种部件的制作程序，同时降低生产成本。
为此，本发明提出了一种制作金属部件的方法，所述方法依次包括如下步骤：
- 在至少一块挠性金属箔上切割多个缺口的步骤，从而在金属箔纵向边缘每边上形成交错排列的开口，以便形成至少一个金属盘卷（metallic coil）；
- 将至少一个金属盘卷固定在成形工具上的步骤，所述至少一个金属盘卷在冷态时可沿空间三个方向手动变形；
- 在工具内对所述至少一个金属盘卷进行热等静压压制步骤，使得所述金属盘卷压紧，从而获得所述金属部件。
根据本发明，复杂成形的金属部件，例如，包括沿两个不同平面（围绕轴线扭转）两个弯曲度的金属结构加强件，就可方便迅速地采用至少一个挠性金属盘卷来制成，所述金属盘卷可沿三个方向变形，通过对薄板或金属箔的简单切割就可获得，热等静压(HIP)压制或压紧方法，通过塑性变形、蠕变和扩散粘结的结合形式来获得压制件，不带任何孔眼。
在薄的金属箔上形成切口而构成金属盘卷，其几何形状大体对应于要制造的金属部件的几何形状。由此制成的金属盘卷很容易变形，并也容易置放在成形模板上，诸如模型，或直接置放在成形工具的凸模上。
为此，这种制造方法则不再需要采用铣削来从实心部件上或从使用大量材料的板材上加工生产叶片加强件这种复杂技术，因为现有技术会增加原材料的采购成本。该方法还可用来制造金属加强件，后者对质量要求和/或几何尺寸要求都很严格。
根据本发明的方法还包括一个或多个如下特性，不论是单独考虑还是从技术上可能的所有结合形式考虑：
- 所述至少一个金属盘卷是由在所述切割多个缺口的步骤期间切割而成的两个金属箔组合而构成；
- 在所述定位步骤之前，所述方法包括从至少一个挠性金属盘卷中制作至少一个金属小袋(metallic pouch)的步骤，所述至少一个金属盘卷是在所述至少一个挠性金属小袋中切割多个缺口的步骤中形成的；
- 所述切割缺口的步骤是通过以给定切割节距来切割出多个缺口，这些缺口沿所述金属盘卷长度排列；
- 在所述切割多个缺口的步骤之前，所述方法包括从至少一个金属薄板中切割至少一个挠性金属盘卷的步骤，所述金属薄板厚度小于0.3mm;
- 在所述的等静压压制步骤之前，所述方法包括在所述成形工具上置放的所述第一金属盘卷上堆积至少一个第二金属盘卷的步骤；
- 在所述堆积步骤期间按顺序堆放的两个金属盘卷的切口节距彼此偏移。
- 所述金属部件是涡轮机叶片前缘或后缘的金属加强件或螺旋桨的金属加强件；
- 所述成型工具是成型模板或等静压压制工具凸模或所述等静压压制工具的凹模。
在阅读了作为信息给出的且非限定性的如下说明后，本发明的其它特性和优点就会更清楚地显现出来，
附图说明
图1是叶片的侧视图，包括使用本发明方法获得的前缘的空心金属结构加强件；
图2为图1的局部剖面图，所示沿剖面AA平面剖开；
图3为方框图，示出了根据本发明所公开的制作方法制作涡轮机叶片前缘金属结构加强件的主要步骤；
图4为在图3所示方法第一步骤期间涡轮机叶片前缘金属加强件的侧视图；
图5为在图3所示方法第二步骤期间涡轮机叶片前缘金属加强件的侧视图；
图6为在图3所示方法第三步骤期间涡轮机叶片前缘金属加强件的侧视图；
图7为在图3所示方法第四步骤期间涡轮机叶片前缘金属加强件的侧视图；
在所有附图中，共同部件使用相同的附图标记，除非另有说明。
具体实施方式
在本说明的其它部分中，前缘或后缘的金属加强件均指加强件或金属加强件。
图1为叶片的侧视图，包括了使用本发明制造方法获得的前缘金属结构加强件。
例如，图示叶片10为涡轮机风扇(图中未示)动叶片。
叶片10包括空气动力面12，沿前缘16和后缘18之间的第一轴向方向14和沿叶根22和叶顶24之间大体垂直于第一方向14的第二径向方向20延伸。
空气动力面12构成叶片的拱背面13和拱内面11， 图1仅示出了叶片10的拱背面13。拱内面11和拱背面13构成叶片10的侧面，将叶片的前缘16连接到后缘18上。
在这个实施例中，叶片10为复合材料叶片，通常采用铺层或对编织纤维织构进行成形而获得。例如，所使用的复合材料可以是编织碳纤维和树脂基组件制成，该组件通常采用RTM (树脂传递模塑) 类型树脂注入法模塑而成。
叶片10包括金属结构加强件30，其胶结在其前缘16处，并沿叶片10空气动力面12前缘16之外的第一方向14和沿叶片根部22和顶部24之间的第二方向延伸。
如图2所示，结构加强件30与叶片10空气动力面12前缘16形状相吻合，其延伸而构成前缘31，称之为加强件的前缘。
通常，结构加强件30为整体部件，包括带有底部39的呈大体V形的截面，底部构成前缘31，并通过两个侧翼35和37延伸，两个侧翼分别与叶片空气动力面12拱内面11和拱背面13相吻合。侧翼35, 37的外形越接近叶片后缘越呈锥形或越薄。
结构加强件30的底部39还包括一个内部腔室40，从叶片根部至顶部，沿结构加强件30的高度延伸。
结构加强件30是一种金属且优选钛基加强件。钛具有很高的能量吸收能力，可吸收因冲击而产生的能量。加强件采用所属领域技术人员所熟知的胶粘结到叶片10上，例如，氰基丙烯酸盐粘合剂或环氧胶。
专利申请文件EP 1908919特别公开了涡轮机复合材料叶片增强用的这种金属结构加强件30。
根据本发明的方法可以用来制造图2所示的结构加强件，该图示出了其最终状态的加强件30。
图3为方框图，示出了制造图1和图2所示叶片10前缘金属结构加强件30的方法200的主要步骤。
制造方法200的第一步骤210是从金属薄板或薄的挠性钛基金属条带上切割出多个挠性金属部件101的步骤，以形成金属箔。
图4所示金属箔101是采用切割金属薄板的传统装置切割而成，换句话说，所述板材的厚度小于0.3mm。为此，例如，金属箔101可以采用冲模切割装置、剪切切割装置或水射流切割装置等切割。
切割出来的金属箔101的几何形状大体上对应于叶片10前缘金属加强件30端面的基本形状，如图1和图2所示。
制造方法200的第二步骤220是在每个金属箔101上切割出多个缺口110。
缺口10可方便制成，从而在金属箔101纵向边缘103，104每一边上形成交错排列的开口。
沿金属箔101纵向的缺口110的节距和缺口110的形状都适合满足要制作的金属部件的需求。
金属箔101沿其长度带有交错排列的多个缺口，从而形成了图5所示的挠性金属盘卷（metallic "coil"）102, 102’。由此得到的金属盘卷102, 102’可以很容易地沿三个尺寸X, Y, Z进行变形，并能满足所有几何形状。
根据本发明的另一个实施例，第一切割步骤和第二切割步骤可以在同一工具上同时进行，分两次操作或一次操作完成。
第三步骤230是对一个或几个金属盘卷102, 102’进行定位的步骤。
根据第一实施例，定位步骤230是通过在成型模板(图中未示)上确定一个或几个金属盘卷的位置，该成型模板带有要制造部件的阴模（negative impression）。在我们的实施例中，成型模板的几何形状与涡轮机叶片前缘相同。
金属盘卷102, 102’通过在每个缺口110处的成型模板上叠放金属盘卷而使其定位。
沿金属盘卷整个长度排列的多个缺口使得金属盘卷可适合任何复杂的成型模板形状。
有利的是，定位步骤也可以是堆放多个金属盘卷102, 102’的步骤。
为此，金属盘卷102, 102’可按两种不同的类别来制造，这两个类别不同，但在切割节距上是互补的。换句话说，这两种金属盘卷在制作时采用切割节距抵消方式，这样，当堆放每一种金属盘卷时，下层金属盘卷缺口110所出现的材料损失就可以得以覆盖。
有利的是，不同层的金属盘卷102, 102’可以通过胶结或焊接装置而保持定位。
用钛制成的两层金属盘卷102, 102’在稍稍加压环境下只要对两个叠加金属盘卷加热便可胶结在一起。
所述焊接采用已知的焊接装置来进行，以便将两个薄的钛金属板焊接在一起。例如，金属盘卷102, 102’可以采用点焊、放电焊接方法或任何其它固定两个钛薄板的方法来装配到一起。
根据本发明该第一实施例，必须进行附加作业，以便将金属盘卷102, 102’堆栈放于成型工具400内，如图6所示。该工具400包括对应于金属加强件30最终外部形状的凹模410和对应于前缘金属加强件最终内部形状的凸模420。
根据第二实施例，定位步骤230直接在成型工具400的凸模420上制成，如图6所示。
根据本发明的第三实施例，定位步骤230通过对不同金属盘卷的连续定位而直接在工具的凹模410内进行。
有利的是，由金属箔101制成的金属盘卷102, 102’，金属箔宽度L不一，这样，不同层的金属盘卷102, 102’所形成的堆栈就反映了制作最终部件（即金属加强件30）所必需的材料厚度要求。
另外，还可设想，通过制作不同厚度挠性金属盘卷可优化堆栈的厚度，换句话说，厚度可在大约0.05到0.3mm的范围内。
根据另一个实施例，本发明的方法可以包括附加步骤，即由在第一切割步骤210期间切割的一个或多个金属箔101来制作金属小袋。
这样，在该制作步骤期间，金属小袋可以从一个金属箔中制成，该金属箔折叠成V形，然后切割成近似与需制作部件的几何尺寸。
另外，金属小袋也可采用叠加第一箔材101，对应于金属加强件30拱内面几何形状与对应于金属加强件30拱背面几何形状的第二箔材101叠加而制成。两个箔材101然后，例如，通过胶结或焊接装置，在至少一个公共边缘上组合，该边缘大体上相当于加强件30前缘31外形，从而形成金属小袋。
用钛制成的两片金属箔101在稍稍加压环境下只要通过对两片金属箔101加热便可胶结而成。
在公共边缘处的焊接可以采用已知焊接装置来将两个钛金属薄板焊接在一起。例如，两个金属箔101可以采用点焊、放电焊方法或任何其它固定方法来装配到一起。
因此，制造方法200的第二切割步骤220用来在金属小袋上制造出多个缺口，从而能够获得V形的金属盘卷。
缺口110可以很方便地制成，从而获得金属小袋纵向边缘每一侧上的交错排列的开口。
根据本发明方法的另一个实施例，制造金属小袋的这一步骤是在第二步骤220之后进行，在第二步骤期间，在金属箔上切割出多个缺口。
在这个实施例中，V形金属盘卷是在公共边缘处采用一个折叠金属盘卷或两个金属盘卷102, 102’制成，如图5所示，采用上述胶结或焊接装置装配在一起。
在用来制作V形金属盘卷的各种实施例中，定位步骤230是通过在成形工具400凸模420上或成形工具400凹模410内对一个或几个金属V形盘卷直接定位来实施。
金属V形盘卷优选置于凸模420的边缘上（形成叶片前缘），以便有利于不同金属盘卷的定位操作。
根据另一个实施例，例如，嵌入件可嵌入在两个连续的金属盘卷102, 102’之间，从而形成更为确切的材料厚度，一种由不同材料制成的专门加强件，或制作成空心金属加强件。
例如，嵌入件可用是采用锻造、机加工或铸造工艺而成的实心嵌入件，或者可使用金属丝编织而成的嵌入件，例如，使用钛丝和/或碳化硅和钛基丝(SiC-Ti)，和/或涂硼丝(SiC-Bore)，或涂碳化硅(SiC-SiC)丝。
不论用来制作置放在金属盘卷之间的嵌入件的材料特性如何，这种材料都必须与制作金属盘卷所用材料特性相匹配，并具有能够进行超塑成形和扩散粘结的特性。
在制作空心金属加强件(图中未示)时，该嵌入件是一种临时嵌入件，采用与金属箔101所用材料不同的一种材料。
“临时嵌入件”是一种不作为永久使用且又必须只能制作前缘空心金属加强件的嵌入件。因此，临时嵌入件在其最终状态中不出现在金属加强件中，不会以任何方式参与金属加强件的机械特性。
例如，临时嵌入件可采用能够抵抗大约900°C高温，高压大约1000巴的材料制成，并能与制作金属箔101的材料相兼容，从而不会在预制件110内产生任何杂质或氧化。
另外，还可以采用化学制剂进行溶解的形式对临时嵌入件制成的材料进行化学侵袭。
有利的是，临时嵌入件可采用铜、石英或硅制成。
植入金属箔101堆栈内的临时嵌入件的形状取决于所期望的最终内部腔室的形状。
制造方法200的第四步骤240为在工具400内形成的堆栈的热等静压压制(HIP)步骤，如图7所示。
热等静压压制是一种常用的制作方法，因其可降低金属孔隙率以及其对许多金属密度，诸如陶瓷的影响，所以为人们所熟知。热等静压压制方法还可改善机械特性和材料的可用性。
等静压压制是在高温（一般在400°C至1400°C之间，对于钛，大约1000°C）和高静压压力下进行。
为此，与内部压力结合使用的热量会通过塑性变形、蠕变和扩散粘结的结合形式来消除堆栈内的空隙和微孔隙率，从而形成实心部件430。
等静压压制步骤后形成的实心部件430包括金属加强件30的内部和外部轮廓。而后，从工具400内取出实心部件430。
等静压步骤可在真空环境下，特别是在二次真空环境下进行，即在建立二次真空的焊接工具内，或者是在高压釜的袋内实施，具体方法的选择取决于所要生产的部件数量。二次真空可以避免在钛等静压压制步骤期间所述工具和纤维结构内存留氧气。
工具400采用一种称之为超合金或高性能合金的机械合金制成。
等静压压制步骤240可以包括不同金属盘卷102, 102’的初步清洁、去油步骤和/或化学侵蚀步骤，清除堆栈上的残余杂质。
有利的是，杂质清除步骤是将纤维组件浸入到清洁剂或化学制剂的槽内。
在制作空心金属加强件时，根据本发明的方法可以包括一个附加步骤，即对在不同金属小袋堆积步骤期间所嵌入的嵌入件进行化学侵蚀，并形成实心部件430的组成部分。化学侵蚀是采用能够对制成嵌入件的材料进行侵蚀的一种化学制剂。临时嵌入件的化学侵蚀可对临时嵌入件进行溶解，这样，被溶解的嵌入件所释放的空间就在金属加强件中形成内部腔室。有利的是，化学侵蚀步骤是将实心部件430浸入含有适合溶解嵌入件的化学制剂的槽内。例如，化学制剂可以是酸或碱。
有利的是，化学制剂可以溶解铜、石英或硅。
结合这些主要制作步骤，根据本发明的方法还可包括表面加工和再加工步骤，通过对在从工具出口获得的实心部件的空心进行加工，从而获得加强件30。这个再加工步骤包括：
- 对加强件30基本外形39的再加工步骤，以便使其逐渐缩小，特别是前缘31的空气动力外形；
- 侧翼35,37的再加工步骤；该步骤特别包括了对侧翼35,37的修整和对拱内面和拱背面的削薄处理；
- 表面加工步骤，以获得所期望的表面状态。
根据本发明的方法还包括结合这些主要制作步骤对加强件30进行无损检验的步骤，以确保所获得的组件的几何和冶金一致性。例如，可使用X射线工艺来进行无损检验。
上面具体介绍了本发明用于涡轮机复合材料叶片金属加强件的制作方法；然而，本发明同样适用于制作涡轮机金属叶片的金属加强件。
上面具体介绍了本发明用于涡轮机叶片前缘金属加强件的制作方法；然而，本发明还适应于涡轮机叶片后缘金属加强件的制作，或者适应于制作复合材料或金属螺旋桨的金属加强件。
本发明的其它主要优点是：
- 降低制作成本；
- 缩短制作时间；
- 简化制作程序；
- 降低材料成本。

Claims (9)

1.制作金属部件(30)的方法(200)，按顺序包括如下步骤：
在至少一个挠性金属箔(101)中切割多个缺口(110)以形成至少一个金属盘卷(102,102’)的步骤；
在成形工具(410,420)上定位至少一个金属盘卷(102,102’)的步骤(230)，所述至少一个金属盘卷冷态时可沿空间三个方向(X,Y,Z)手工变形，
热等静压压制步骤(240)，在工具(400)内压制所述至少一个金属盘卷(102,102’)，使得所述金属盘卷(102,102’)得以压紧，从而获得所述金属部件(30)。
2.根据权利要求1所述的制作金属部件(30)的方法(200)，其特征在于，所述至少一个金属盘卷是由在所述切割多个缺口(110)的步骤(220)期间所切割的两块金属箔(101)组装而成。
3.根据权利要求1所述的制作金属部件(30)的方法(200)，其特征在于，在所述定位步骤(230)之前，所述方法包括从至少一个挠性金属箔(101)上制作至少一个金属小袋的步骤，所述至少一个金属箔是在所述至少一个挠性金属小袋切割多个缺口(110)的步骤(220)中形成的。
4.根据权利要求1到3其中一项权利要求所述的制作金属部件(30)的方法(200)，其特征在于，所述切割缺口(110)的步骤(220)是通过以给定切割节距切割多个缺口(101)来进行的，所述多个缺口在所述至少一个金属箔的纵向边缘的每一侧上或沿所述金属箔(101)长度的排列,或者在所述至少一个金属箔的纵向边缘的每一侧上和沿所述金属箔(101)长度的排列。
5.根据权利要求1到3其中一项权利要求所述的制作金属部件(30)的方法(200)，其特征在于，在所述切割多个缺口(110)的步骤(220)之前，所述方法包括从厚度小于0.3mm的至少一个金属薄板中切割至少一块挠性金属箔(101)的步骤(210)。
6.根据权利要求1到3其中一项权利要求所述的制作金属部件(30)的方法(200)，其特征在于，在所述热等静压压制步骤(240)之前，所述方法包括在所述成形工具(420)上置放的第一金属盘卷上堆积至少一个第二金属盘卷的步骤。
7.根据权利要求6所述的制作金属部件(30)的方法(200)，其特征在于，在所述堆积步骤期间按顺序堆放的两个金属盘卷上的切割节距彼此偏离。
8.根据权利要求1到3其中一项权利要求所述的制作金属部件(30)的方法(200)，其特征在于，所述金属部件(30)是涡轮机叶片前缘或后缘的金属加强件或螺旋桨的金属加强件。
9.根据权利要求1到3其中一项权利要求所述的制作金属部件(30)的方法(200)，其特征在于，所述成形工具是成形模板或等静压压制工具(400)的凸模(420)或所述等静压压制工具(400)的凹模(410)。
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