CN105298547A - 排气涡轮增压器的涡轮以及相关生产方法 - Google Patents

排气涡轮增压器的涡轮以及相关生产方法 Download PDF

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CN105298547A
CN105298547A CN201510341238.5A CN201510341238A CN105298547A CN 105298547 A CN105298547 A CN 105298547A CN 201510341238 A CN201510341238 A CN 201510341238A CN 105298547 A CN105298547 A CN 105298547A
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turbine
diameter
blade
present
supercharger
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托马斯·施特里德尔迈尔
约亨·施拉耶
安东·安格卢什
安德烈亚斯·施特伦佩尔
京特·温克勒
谢诺尔·瑟于特
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BMTS Technology GmbH and Co KG
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Bosch Mahle Turbo Systems GmbH and Co KG
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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
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F01D5/04—Blade-carrying members, e.g. rotors for radial-flow machines or engines
    • F01D5/043—Blade-carrying members, e.g. rotors for radial-flow machines or engines of the axial inlet- radial outlet, or vice versa, type
    • F01D5/048—Form or construction
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • 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
    • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
    • B23K15/00—Electron-beam welding or cutting
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    • B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
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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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring 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
    • 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
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B37/00—Engines characterised by provision of pumps driven at least for part of the time by exhaust
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C6/00—Plural gas-turbine plants; Combinations of gas-turbine plants with other apparatus; Adaptations of gas-turbine plants for special use
    • F02C6/04—Gas-turbine plants providing heated or pressurised working fluid for other apparatus, e.g. without mechanical power output
    • F02C6/10—Gas-turbine plants providing heated or pressurised working fluid for other apparatus, e.g. without mechanical power output supplying working fluid to a user, e.g. a chemical process, which returns working fluid to a turbine of the plant
    • F02C6/12—Turbochargers, i.e. plants for augmenting mechanical power output of internal-combustion piston engines by increase of charge pressure
    • 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
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • 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
    • F05D2220/40—Application in turbochargers
    • 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
    • F05D2230/21—Manufacture essentially without removing material by casting
    • F05D2230/211—Manufacture essentially without removing material by casting by precision casting, e.g. microfusing or investment casting
    • 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
    • F05D2230/22—Manufacture essentially without removing material by sintering
    • 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
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • 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
    • F05D2230/60—Assembly methods
    • 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
    • F05D2240/24—Rotors for turbines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
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    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/17—Alloys
    • F05D2300/174—Titanium alloys, e.g. TiAl
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Abstract

本发明涉及一种排气涡轮增压器(2)的涡轮(1)，其依靠金属注射成型(MIM)、选择性激光熔炼(SLM)或者电子束熔炼(EBM)由TiAl合金生产，并且在该情形下，涡轮出口叶片末端处的直径dS与涡轮出口叶片根部处的直径dN之商Q大于3.85。

Description

排气涡轮增压器的涡轮以及相关生产方法
技术领域
本发明涉及一种排气涡轮增压器的涡轮。此外本发明涉及一种具有这种涡轮的排气涡轮增压器以及用于生产这种涡轮的方法。
背景技术
除了已经证明的由镍基合金制成的涡轮之外，近年来已经逐渐考虑重量优化的涡轮，这种涡轮尤其利用轻金属合金和陶瓷材料。在该情况下重量优化的涡轮的优势是，降低质量惯性矩，因为装备有这种重量优化的涡轮，所以改善了排气涡轮增压器的瞬态特性。为了该目的，使用钛铝合金(γ-TiAl)，因为钛铝合金比通常使用的镍基合金密度约低50％。
现在，这些Ti-Al涡轮主要是通过铸造处理生产的。当铸造镍基合金和TiAl时，现在涡轮初始从前面即从涡轮突出部开始浇铸，其中，铸造处理受到一些限制。铸造处理期间的一个挑战尤其还在于，浇铸点处的涡轮突出部或者径向最窄截面的直径。在铸造处理的过程期间，最小涡轮毂直径或者涡轮突出部直径存在限制，这种限制直接影响了铸造处理期间的流动速度或者铸造期间的凝固行为。该最小可实现毂直径反过来对涡轮总体直径产生了限制。
发明内容
本发明因此解决的问题是，提供用于排气涡轮增压器或者一般增压设备的涡轮的改进或者至少可替换的实施例，这不仅确保了高的生产质量而且还额外地增加了涡轮的效率。
根据本发明，该问题通过独立权利要求的主题解决。有利实施例是从属权利要求的主题。
本发明是基于这样的总体构思：依靠特定生产方法利用TiAl合金来生产排气涡轮增压器的涡轮或者径向涡轮，同时能够降低涡轮出口叶片根部处(即在毂的区域中)的直径。根据本发明，这通过金属注射成型(MIM)、选择性激光熔炼(SLM)或者电子束熔炼(EBM)而实现的，此外，涡轮出口叶片末端处的直径与涡轮出口叶片根部处的直径之商大于3.85。该值是从测试得来的，并且被证明是特别有效的，使得在当前情形下，术语限制值已经能够最广义的使用。在金属注射成型期间，TiAl合金与粘合剂混合，作为粉末被注射到注射模具中，其中，随后涡轮从工具脱模。这之后是分离，最后是烧结。在该情况下MIM方法不同于铸造方法，在MIM方法中，涡轮形式是依靠蜡/陶瓷生产的。在由钛铝合金依靠MIM方法生产涡轮期间，涡轮从后面即从轮背侧/帽状件(calotte)被“注射成型”，而不是像在铸造期间那样从前面成型。这使得能够保持涡轮突出部或者毂的直径比铸造处理期间的直径小，因为不存在这样的铸造功能，由此使得在铸造期间通常需要考虑的一些参数(诸如，铸造处理期间的流动速度，以及铸造处理期间的凝固行为)不再起任何作用。在电子束熔炼(EBM)期间，钛铝合金同样呈现为粉末，同时自由可控制的电子束用作能量源以选择性地熔炼粉末。所生成的部件因而是以层的方式在真空或者在惰性气体气氛下生产的。在该处理中，粉末逐层沉积在粉末床中，并且限定了暴露的区域。在该情况下，选择性激光熔炼类似于EBM方法起作用，但是，同时激光用于选择性地构建层。与纯激光烧结相比，在SLM方法期间材料完全熔炼。使用EBM/SLM方法，涡轮突出部或者涡轮毂不具有铸造功能，基于该原因能够降低其直径。
因而本发明的核心是通过依靠提到的方法生产钛铝合金涡轮使涡轮出口上的突出部/毂变细，即依靠金属注射成型(MIM)、电子束熔炼(EBM)或者选择性激光熔炼(SLM)，因而其重量可降低。
在涡轮突出部的"变细"方面，明显地需要考虑一些关于磨光期间涡轮处理的限制，例如涡轮在涡轮突出部上仍必须是可抓握的；关于可能的平衡性方面，仍需存在足够材料以用于在涡轮突出部平面的区域中移除。根据本发明所采用及描述的生产方法额外地允许生产具有较大几何精度的涡轮，结果是，失衡本身趋向于更低，由于此，为了能够抵消此失衡在涡轮突出部上要求平衡质量较小。
通过将涡轮突出部或者涡轮毂变细，在设计涡轮的流量以及实现更小、更轻、惯性优化的涡轮方面通常能够获得主要的自由度。通过在叶片根部的区域中降低涡轮出口处涡轮的直径，涡轮的叶片本身能够设计得较长，结果是，能够对流量产生积极影响。相反，即使当叶片具有与先前涡轮相同的长度时也甚至能够实现相同流量，但是因为涡轮毂直径降低，所以已经开始进一步向内，由此能够降低该涡轮的总直径。通过降低涡轮毂的区域中的直径，能够明显节约材料，结果是，能够积极地影响尤其涡轮的质量惯性，从而间接影响排气涡轮增压器的响应行为。
一般来说，根据本发明的涡轮能够获得以下基本优势：
-降低重量和/或降低尺寸，
-降低材料费用，降低成本并且改善生态平衡，
-降低质量惯性矩，
-设计流量具有新的自由度，
-因为较低的质量，改善了转子(涡轮-轴组合)的重力中心。
在该情况下，根据本发明的涡轮的优势能够适用于径向涡轮，还能够适用于斜流式涡轮。
此外，本发明基于这样的总体构思：排气涡轮增压器装备有前面段落描述的根据本发明的涡轮。这种改进型排气涡轮增压器具有明显改进的响应行为，因为涡轮具有明显降低的质量，因而也具有明显降低的质量惯性矩。此处，在尺寸上，涡轮能够在涡轮出口的叶片根部处具有降低的直径(dN)，从而用该涡轮实现更高的排气流量，而无需在涡轮叶片上采用特殊措施。相反，这还使得能够使用具有降低涡轮外径的涡轮，该涡轮的尺寸更紧凑，因为在相同排气流量的情况下，能够在涡轮入口、还在涡轮出口处降低涡轮的尺寸。
此外，本发明是基于这样的总体构思：提供了用于生产排气涡轮增压器的涡轮的改进方法，使用这种方法，依靠金属注射成型、选择性激光熔炼或者电子束熔炼由钛铝合金生产涡轮。同时，涡轮出口叶片末端处的直径与涡轮出口叶片根部处的直径之商确定为最小商3.85，使得依靠根据本发明的方法生产的涡轮具有的商大于3.85。在该情况下提到的方法可明显增加生产精度，尤其还相对于复杂叶片结构也是如此，结果是，能够降低布置在毂的区域中的用于抵消失衡的质量。
借助附图，本发明的进一步重要的特征及优势能够从属权利要求、附图以及相关附图的说明获得。
应该理解的是，上文提到的以及下文仍将解释的特征不仅能够使用在相应的组合状态中，而且能够以其他组合或者本身单独使用，这并未脱离本发明的范围。
附图说明
附图示出了本发明的优选示范实施例，以下说明书更详细地解释了本发明的优选示范实施例。
单独的图1示出了根据本发明的涡轮。
具体实施方式
在图1的情况下，根据本发明的涡轮1在排气涡轮增压器2中能够设计为涡轮，具有商： Q = d s d N > 3,85 .
此外，根据本发明的涡轮1是依靠金属注射成型(MIM)，选择性激光熔炼(SLM)或者电子束熔炼(EBM)由钛铝合金生产的。在该情况下，涡轮1连接至轴3(例如焊接至轴3)并且在处理中形成排气涡轮增压器2的转子。
通过根据本发明依靠提到的生产方法以及依靠钛铝合金来生产涡轮1，相比于基于镍基合金的常规涡轮能够实现明显降低的重量，同时这种低重量还导致质量惯性矩降低，质量惯性矩降低对排气涡轮增压器2的响应行为具有积极效应。在叶片根部区域，涡轮出口处的涡轮直径降低是由于这样的事实：因为依靠提到的生产方法改善了生产精度，所以存在较低的失衡，以及由此使得用于抵消这种失衡的抵消质量也降低了。由于提到的生产方法，在毂的区域中不再需要保留铸造突出部，这些方法甚至允许从其背侧形成涡轮1。通过降低涡轮出口叶片根部处的直径dN，能够额外地实现相同外径以使得在径向方向设计较长的各叶片4，结果是，涡轮1完全能够具有更高生产量。
如果不改变生产量，以这种方式降低涡轮出口叶片根部处的直径dN可使得叶片4一起径向朝向内部移动，由此可降低涡轮1的整个外径，这对涡轮要求的安装空间具有有利效果，因而还间接地对排气涡轮增压器2要求的安装空间具有有效效果。由于此，在设计涡轮1的流量方面获得了迄今为止还未知的自由度。
通过在毂的区域降低涡轮1的质量，总的来说能够节约材料，结果是，不仅能够节约资源以及节省材料成本，而且能够额外地改善环境兼容性。

Claims (3)

1.一种排气涡轮增压器(2)的涡轮(1)，其依靠金属注射成型(MIM)、选择性激光熔炼(SLM)或者电子束熔炼(EBM)由TiAl合金生产，在此期间，涡轮出口叶片末端处的直径dS与涡轮出口叶片根部处的直径dN之商Q大于3.85，即：
Q = d s d N > 3,85 .
2.一种排气涡轮增压器(2)，具有根据权利要求1或2所述的涡轮(1)。
3.一种用于生产涡轮(1)的方法，涡轮出口叶片末端处的直径dS与涡轮出口叶片根部处的直径dN之商Q大于3.85，
Q = d s d N > 3.85
以及其中，所述涡轮(1)依靠金属注射成型(MIM)、选择性激光熔炼(SLM)或者电子束熔炼(EBM)由TiAl合金生产。
CN201510341238.5A 2014-07-09 2015-06-18 排气涡轮增压器的涡轮以及相关生产方法 Pending CN105298547A (zh)

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