CN104903546B - 纤维强化后的涡轮零部件 - Google Patents

纤维强化后的涡轮零部件 Download PDF

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CN104903546B
CN104903546B CN201380069552.1A CN201380069552A CN104903546B CN 104903546 B CN104903546 B CN 104903546B CN 201380069552 A CN201380069552 A CN 201380069552A CN 104903546 B CN104903546 B CN 104903546B
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reinforcing fiber
fiber
blade part
width
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CN104903546A (zh
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河西谦
中村武志
渡边文章
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Abstract

本发明提供涡轮零部件，具备：沿长边方向延伸的叶片部；与上述叶片部的一端连续且在与上述长边方向交叉的宽度方向上比上述叶片部膨出的燕尾部；从上述叶片部至上述燕尾部连续地行进的多个第一强化纤维；在上述叶片部至少局部地沿上述宽度方向行进的第二强化纤维；以及结合上述多个第一强化纤维和上述第二强化纤维的整体的基体，在上述叶片部，上述第二强化纤维织入上述多个第一强化纤维之间而构成三维织物，在上述燕尾部，上述多个第一强化纤维不会被织入的其它纤维而在上述宽度方向上汇集，而在上述宽度方向上展开。

Description

纤维强化后的涡轮零部件
技术领域
本发明涉及纤维强化后的涡轮零部件，尤其涉及由包含强化纤维的陶瓷基复合材料构成的涡轮动叶片。
背景技术
如图8A中举例表示那样，航空器用涡轮风扇发动机具备用于从燃烧气体取出能量的多级涡轮，各级的涡轮由在涡轮盘的周围排列的多个涡轮动叶片构成。如图8B中举例表示那样，各涡轮动叶片100大致由叶片部102、包围外侧的围带部104、包围内侧的平板部108、以及用于与涡轮盘结合的燕尾部106构成。在由围带部104和平板部108包围的空间流动燃烧气体，叶片部102承受该流动的燃烧气体并将其能量变换为旋转能量，向涡轮盘传递。随着旋转，各涡轮动叶片100受到离心力CF。
由于涡轮动叶片暴露于燃烧气体的高温下，所以选择在高温时具有足够的强度的材料，在以往例如是Ni基合金。近几年，根据航空器的燃料效率提高的要求，研究了利用能够更加耐高温的温度且更加轻型的陶瓷基复合材料(CMC)。CMC是通过将由陶瓷构成的强化纤维埋入相同种类的或者不同种类的陶瓷的基体而成的。由CMC构成的部件的制造例如通过编织强化纤维而成为织物、并利用浸渍法或气相法在该纤维间填充基体而成。专利文献1、2公开相关的技术。
现有技术文献
专利文献
专利文献1：美国专利第7510379号公报
专利文献2：美国专利申请公开2009/0165924号公报
发明内容
发明所要解决的课题
由于织物较薄，所以制造较薄的板状的CMC部件容易。具有某程度的厚度的CMC部件能够通过使强化纤维织物重叠来制造。然而，强化纤维织物重叠后的面间不通过强化纤维连接。由于CMC的高强度较多依赖于强化纤维，所以这样的部位显著强度较差，且针对剥离或剪切的破坏较脆弱。
在如涡轮动叶片那样不是单纯的板状的复杂形状的部件中，对于上述的问题需要特别注意。例如叶片部是接近单纯的板状的形状，因而能够通过使纤维朝向长边方向并在与其正交的宽度方向上重叠强化纤维织物来形成。由于朝向长边方向的纤维沿着离心力的方向，所以提供对抗离心力的足够的强度。另一个方面，燕尾部需要比叶片部沿宽度方向膨出而与涡轮盘卡合。膨出的构造能够通过在该部位追加地重叠强化纤维织物来形成。但是，这样的构造中，由于离心力以剪切重叠的面的方式作用于燕尾部，所以有引起剪切破坏的担忧。
如上所述，本发明人发现问题的根源在于使强化纤维织物重叠，想到解决该问题的构造，从而完成本发明。
用于解决课题的方案
根据本发明的一个方面，涡轮零部件具备：叶片部，其沿长边方向延伸；燕尾部，其与上述叶片部的一端连续，且在与上述长边方向交叉的宽度方向上比上述叶片部膨出；多个第一强化纤维，它们从上述叶片部至上述燕尾部连续地行进；第二强化纤维，其在上述叶片部处至少局部地沿上述宽度方向行进；以及基体，其结合上述多个第一强化纤维和上述第二强化纤维的整体，其中，在上述叶片部，上述第二强化纤维织入上述多个第一强化纤维之间而构成三维织物，在上述燕尾部，上述多个第一强化纤维不会被织入的其它纤维而在上述宽度方向上汇集，而在上述宽度方向上展开。
发明的效果如下。
由陶瓷基复合材料构成的涡轮零部件在燕尾部也能够确保足够的强度。
附图说明
图1是本发明的一个实施方式的涡轮动叶片和涡轮盘的立体图。
图2是示意的涡轮动叶片的剖视图，举例表示了叶片部的内侧端以及燕尾部的强化纤维织物的行进。
图3是其它例子的示意的涡轮动叶片的剖视图。
图4是另一其它例子的示意的涡轮动叶片的剖视图。
图5是用于本实施方式的由强化纤维构成的三维织物的示意立体图。
图6A是涡轮动叶片的示意立体图，举例表示了包含追加的强化纤维织物的涡轮动叶片。
图6B是沿图6A的VIB-VIB线取得的涡轮动叶片的示意剖视图。
图7A是与图6A不同的例子的涡轮动叶片的示意立体图。
图7B是沿图7A的VIIB-VIIB线取得的涡轮动叶片的示意剖视图。
图8A是局部切断来观察内部构造的航空器用涡轮风扇发动机的立体图。
图8B是一般的涡轮动叶片的立体图。
具体实施方式
以下，参照附图对本发明的几个举例表示的实施方式进行说明。
本实施方式能够用于如涡轮动叶片那样复杂形状的涡轮零部件，但也能够用于需要高温强度的其它多种机械部件。以下，以图1中举例表示的涡轮动叶片1为例对本实施方式进行说明。
本说明书以及权利要求书中，涡轮的径向与涡轮动叶片的长边方向一致，将其称作长边方向。同样将涡轮的轴向称作进深方向，将涡轮的旋转的切线方向称作宽度方向。附图以及以下的说明中，将长边方向、进深方向、以及宽度方向分别表示为X、Y、Z。各图的例子中这些方向相互正交，但在本实施方式中不是必须是正交，它们也可以相互斜向地交叉。
参照图1，涡轮动叶片1具备：沿长边方向X延伸的叶片部2；从叶片部2的外侧端沿宽度方向Z伸出的围带部4；从叶片部2的内侧端沿宽度方向Z伸出的平板部8；以及比平板部8还向内周方向突出的燕尾部6。燕尾部6与叶片部2的下端连续，沿宽度方向Z比叶片部2膨出，并与具有与燕尾部6的形状互补的形状的涡轮盘9卡合。多个涡轮动叶片1受到燃烧气流，与涡轮盘9一体地进行旋转运动R。因旋转运动R而对涡轮动叶片1作用离心力CF。
涡轮动叶片1局部或者整体由陶瓷基复合材料(CMC)构成。其整体也可以是一体，至少叶片部2以及燕尾部6由CMC一体形成。
该强化纤维至少局部地三维编织而如图5中举例表示那样构成三维织物。沿长边方向X行进的多个第一强化纤维10在进深方向Y以及宽度方向Z上隔开间隔地平行并列，一个以上的第二强化纤维织入其间，从而构成三维织物。第二强化纤维至少局部地沿宽度方向Z行进，还在进深方向Y上也行进，从而包含这样的三维织物的CMC在所有方向上具有足够的强度。
第一强化纤维10以及第二强化纤维例如是碳化硅纤维、碳纤维、氮化硅纤维、氧化铝纤维、氮化硼纤维中任一个，但也可以是其它适当的陶瓷，还可以是它们中两个以上的混合物。并且，第一强化纤维10和第二强化纤维也可以是相同的材料，也可以是不同的材料。
第一强化纤维10以及第二强化纤维通过基体相互结合。基体也能够使用任意的陶瓷，例如能够使用与第一、第二强化纤维相同种类的陶瓷。组合的一个例子是氮化硅纤维的强化纤维和由氮化硅构成的基体的组合，这在高温强度以及轻型性的方面优异。
参照图2，第一强化纤维10从叶片部2至燕尾部6连续行进。在叶片部2，第二强化纤维织入第一强化纤维10之间而构成三维织物。由于第一强化纤维10被第二强化纤维汇集，所以在宽度方向Z上比较薄。
如上所述，第一强化纤维10连续地到达燕尾部6，在此处不构成三维织物。即，在燕尾部6，第一强化纤维10不会被在其之间织入的其它纤维在宽度方向Z上汇集，而在宽度方向Z上展开。本说明书以及权利要求书中，“展开”这个词是指解开、扩开纤维间的间隔、在横向上扩大、分散的意思。由此，燕尾部6比叶片部2沿宽度方向Z膨出。
此外，在燕尾部6，第一强化纤维10也可以相互独立，或者也可以构成多个二维织物。即，在燕尾部6，第一强化纤维10形成多个层，各层中在第一强化纤维10间织入沿进深方向Y行进的其它强化纤维，由此也可以构成各层在进深方向Y上捆束的二维织物。构成二维织物使第一强化纤维10的处理变得容易。
第一强化纤维10也可以在叶片部2和燕尾部6双方中，从其中心C至表面沿宽度方向Z是等间隔。例如图2中与辅助线La相交的交点Pa1、Pa2、…Pan是等间隔，在辅助线Lb上交点Pb1、Pb2、…Pbn也是等间隔。第一强化纤维10在中心C与长边方向X大致平行地行进，并随着接近燕尾部6的表面而沿向表面渐近的方向行进。
根据上述的例子，除最表面的之外，任一个第一强化纤维10都不与表面平行，但也可以在表面附近与表面平行地行进。图3所示的例子中，第一强化纤维10’在燕尾部6的表面附近P(从第k个至第n个)与表面平行地行进，但在接近中心C的部位E(从第1个至第k－1个)不与表面平行。必然第一强化纤维10’是不等间隔。例如，在与辅助线Lc相交的交点Pc1、Pc2、…Pcn中，交点Pck、…Pcn相互是等间隔，交点Pc1、Pc2、…也相互是等间隔，但交点Pc1、Pc2、…的间隔与交点Pck、…Pcn的间隔不相等。图示的例子中，Pck、…Pcn的间隔的更窄，但也可以更宽。同样，与辅助线Ld相交的交点Pd1、Pd2、…Pdn也是不等间隔。
燕尾部6的表面附近暴露于与表面平行的朝向的、比较大的应力下。并且，第一强化纤维与表面平行地行进、以及第一强化纤维在表面附近是窄间隔这对于强度的提高有利。即，这些实施方式中，与表面平行的第一强化纤维(表面层)的比例大这从强度的观点看有利。但是，若这样的比例过大，则对于维持燕尾部6的构造不利。因此，相对于全层数量(n×2－1)，表面层的数量((n－k+1)×2)的比((n－k+1)×2)/(n×2－1)优选为20～50％。
上述的例子中，在接近中心C的部位，强化纤维是等间隔，但在这样的部位中也可以是不等间隔。图4所示的例子中，与图3的例子相同，第一强化纤维10”在燕尾部6的表面附近P(从第k个至第n个)与表面平行地行进，与辅助线Le、Lf相交的交点Pek、…Pen以及Pfk、…Pfn分别是等间隔。另一方面，第一强化纤维10”在离中心C较近的部位(从第1个至第k－1个)不与表面平行，离中心C越近间隔变得越窄。即，与辅助线Le、Lf相交的交点Pe1、Pe2、…以及Pf1、Pf2、…分别是不等间隔。并且即使在表面附近，第一强化纤维10”也可以是不等间隔。由于中心C附近暴露于比较大的压缩应力下，所以强化纤维的间隔较窄对于抵抗该压缩应力有利。
参照图6A、图6B，在燕尾部6，也可以在第一强化纤维10的各层之间夹设多个第三强化纤维20。第三强化纤维20可以是与第一、第二强化纤维相同的材料，也可以如图示那样是平板状的织物或者无纺纤维束。这样的织物或者无纺纤维束朝向沿进深方向Y延伸的方向，被夹持在第一强化纤维10的各层之间，由此对维持沿宽度方向Z膨出的构造有作用。并且，这样的织物或者无纺纤维束的沿长边方向X的长度也可以不同。例如如图示那样，在部位61使长度不同的织物或者无纺纤维束并列而能够形成阶梯状的构造。这对于在该部位61维持朝向下方渐渐加宽的构造有利。同样，在下端附近的部位62也可以形成阶梯状的构造。
参照图7A、图7B，在第一强化纤维10的各层之间夹设的第三强化纤维也可以不是织物或者无纺纤维束而是独立的多个纤维30。多个纤维30例如朝向进深方向Y，被夹持在第一强化纤维10的各层之间。并且，多个第三强化纤维30与宽度方向Z平行地并列。沿宽度方向Z并列的第三强化纤维30的数量不固定，在燕尾部6的上部61和下端62也可以不同。
第三强化纤维30相对于第一强化纤维10的比越大，对于维持膨出的燕尾部6的形状越有利，但若过大则在强度方面不利。因此，第一强化纤维10与第三强化纤维的体积比优选为1：2至3：1，更加优选为1：1至2：1。另外，在燕尾部6的下端62(在长边方向X上，燕尾部6的长度的10％的部分)，第一强化纤维10与第三强化纤维的体积比优选为1：5至1：0。
燕尾部6也可以还包含不织入于第一强化纤维10的追加的强化纤维。例如，以在制造工序中使第一强化纤维10的处理变得容易为目的、或者防止第三强化纤维30的脱落为目的，对它们进行捆束的强化纤维也可以在宽度方向Z上行进，这也可以在埋入于基体之后残留。
本实施方式的涡轮动叶片1能够大致如下制造。
由强化纤维构成的三维织物能够通过公知的方法编织。例如，使分别由聚碳硅烷所构成的经纱以及纬纱构成的多个层重叠，并以贯通该叠层的方式织入由聚碳硅烷构成的斜纱。在这样的三维织物的一端，在一定的长度不织入斜纱，而使经纱展开。构成三维织物的部分是成为叶片部2的部分，不织入偏纱的部分是成为燕尾部6的部分。也可以将织物的一部分分支，而形成成为围带部4以及平板部8的部分。
通过对这样的一端展开的三维织物进行烧制，从而聚碳硅烷变化为氮化硅，而能得到强化纤维三维织物。或者也可以将预先成为陶瓷纤维的纤维编织为三维织物。也可以在得到的强化纤维三维织物夹设第三强化纤维。
使它们一体地嵌入与涡轮动叶片1的形状对应的模具，加压并成形。另外，通过将糊状的基体前驱体填充于模具，来使前驱体浸渍于强化纤维。优选将它们封入模具，保持该状态地进行加热从而对前驱体进行烧结。通过烧结来由前驱体生成陶瓷，这成为结合强化纤维的基体。
上述是浸渍法的制造，但也可以代替它而应用气相法或其它的方法。
根据本实施方式，得到如下涡轮零部件，即，从叶片部至燕尾部，由沿长边方向连续地行进的纤维强化。由于在叶片部与燕尾部之间纤维不中断，所以涡轮零部件相对于沿长边方向施加的离心力具有足够的强度。并且，由于燕尾部不具有相对于剥离或剪切的破坏而脆弱的面，所以即使与涡轮盘卡合而受到离心力，也能够发挥足够的强度。并且，即便在燕尾部因剥离或剪切的破坏产生龟裂，在叶片部处强化纤维也沿宽度方向行进，从而该强化纤维抵抗龟裂向叶片部发展。因此，本实施方式的涡轮零部件难以引起致命的破损。
通过优选的实施方式对本发明进行了说明，但本发明不限定于上述实施方式。基于上述公开内容，具有该技术领域的通常技术的人能够通过实施方式的修正或变形来实施本发明。
工业上的可利用性
本发明提供在燕尾部也能够确保足够的强度的由陶瓷基复合材料构成的涡轮零部件。

Claims (5)

1.一种涡轮零部件，其具备：
叶片部，其沿长边方向延伸；
燕尾部，其与上述叶片部的一端连续、且在与上述长边方向交叉的宽度方向上比上述叶片部膨出；
多个第一强化纤维，它们从上述叶片部至上述燕尾部连续地行进；
第二强化纤维，其在上述叶片部至少局部地沿上述宽度方向行进；以及
基体，其结合上述多个第一强化纤维和上述第二强化纤维的整体，
上述涡轮零部件的特征在于，
在上述叶片部，上述第二强化纤维织入上述多个第一强化纤维之间而构成三维织物，
在上述燕尾部，上述多个第一强化纤维不会被织入的其它纤维在上述宽度方向上汇集，而在上述宽度方向上展开。
2.根据权利要求1所述的涡轮零部件，其特征在于，
上述多个第一强化纤维从由碳化硅纤维、碳纤维、氮化硅纤维、氧化铝纤维、氮化硼纤维构成的组中选择的一个以上的纤维构成。
3.根据权利要求1所述的涡轮零部件，其特征在于，
上述基体由与上述第一强化纤维或上述第二强化纤维相同种类的陶瓷构成。
4.根据权利要求1所述的涡轮零部件，其特征在于，
包含多个第三强化纤维，该多个第三强化纤维在上述燕尾部沿与上述长边方向和上述宽度方向双方交叉的进深方向在上述多个第一强化纤维之间行进。
5.根据权利要求4所述的涡轮零部件，其特征在于，
上述多个第三强化纤维构成织物或者无纺纤维束。
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