CN106393388B - 层片、制造层片的方法以及利用层片制造制品的方法 - Google Patents

层片、制造层片的方法以及利用层片制造制品的方法 Download PDF

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CN106393388B
CN106393388B CN201610602318.6A CN201610602318A CN106393388B CN 106393388 B CN106393388 B CN 106393388B CN 201610602318 A CN201610602318 A CN 201610602318A CN 106393388 B CN106393388 B CN 106393388B
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J.J.基特尔森
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General Electric Co PLC
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Abstract

本发明涉及层片、制造层片的方法以及利用层片制造制品的方法，具体而言公开了一种用于制造层片(100)的方法。方法包括打印层片，层片包括近净形状(102)和陶瓷基复合物非纺织材料(104)。公开了层片其中近净形状是制品的预设的层(108)。还公开了用于制造制品的方法。方法包括打印第一层片(200)和第二层片(206)。第一层片(200)包括第一近净形状(202)和第一陶瓷基复合物非纺织材料(204)，以及第二层片(206)包括第二近净形状(208)和第二陶瓷基复合物非纺织材料(208)。方法还包括将第二层片(206)施加到第一层片(200)上以及巩固第一层片(200)和第二层片(206)。

Description

层片、制造层片的方法以及利用层片制造制品的方法
技术领域
本发明涉及层片(plies)、用于制造层片的方法以及用于由层片制造制品的方法。更特别地本发明涉及层片、用于制造层片的方法以及用于由包括近净形状(near netshape，有时称为近终形状)和陶瓷基复合物(ceramic matrix composite，有时称为陶瓷基(质)复合材料)非纺织(nonwoven，有时称为非织造)材料的层片制造制品的方法。
背景技术
燃气轮机持续地被修改以提供提高的效率和性能。这些修改包括在更高的温度下和在更恶劣的条件下运行的能力，其经常需要材料修改和/或覆层以保护部件免于遭受这样的温度和条件。当引入更多的修改时，实现了额外的挑战。
一种用于提高性能和效率的修改涉及由陶瓷基复合物(CMC)形成燃气轮机部件，例如但不限于护罩、涡轮机支柱、喷嘴/导叶、燃烧衬套、轮叶/叶片，护罩环、排气管道、扩大衬套以及喷气排气喷嘴。CMC燃气轮机部件可由CMC材料的层片形成。然而CMC材料是昂贵的，并且削减CMC材料片至所需的用于层片的形状导致产生大量的CMC废料。另外削减过程可将缺陷引入到层片中，并且可需要多个削减步骤以达到足够精确的构形。
发明内容
在一种示例性的实施例中，用于制造层片的方法包括打印层片，层片包括近净形状和陶瓷基复合物非纺织材料。
在另一示例性的实施例中，用于制造制品的方法包括打印第一层片和第二层片。第一层片包括第一近净形状和第一陶瓷基复合物非纺织材料，并且第二层片包括第二近净形状和第二陶瓷基复合物非纺织材料。该方法此外包括将第二层片施加到第一层片上，并且巩固第一层片和第二层片。
在另一示例性的实施例中，层片包括近净形状和陶瓷基复合物非纺织材料，其中近净形状是制品的预设的层。
技术方案1. 一种用于制造层片(100)的方法，所述方法包含打印层片(100)，所述层片(100)包括近净形状(102)和陶瓷基复合物非纺织材料(104)。
技术方案2. 根据技术方案1所述的方法，其特征在于，打印包括通过连续丝制作过程挤出施覆有覆层的预浸渍丝束(300)。
技术方案3. 根据技术方案2所述的方法，其特征在于，打印包括使用三维连续纤维布局打印机(302)。
技术方案4. 根据技术方案1所述的方法，其特征在于，非纺织材料(104)是单向带(106)。
技术方案5. 根据技术方案4所述的方法，其特征在于，所述近净形状(102)是涡轮机部件(400)的预设的层(108)。
技术方案6. 根据技术方案5所述的方法，其特征在于，所述涡轮机部件(400)是翼形件(402)。
技术方案7. 根据技术方案6所述的方法，其特征在于，所述涡轮机部件(400)是喷嘴(404)。
技术方案8. 一种用于制造制品的方法，所述方法包含：
打印第一层片(200)，所述第一层片(200)包括第一近净形状(202)和第一陶瓷基复合物非纺织材料(204)；
打印第二层片(206)，所述第二层片(206)包括第二近净形状(208)和第二陶瓷基复合物非纺织材料(210)；
将所述第二层片(206)施加到所述第一层片(200)上；并且
巩固所述第一层片(200)和所述第二层片(206)。
技术方案9. 根据技术方案9所述的方法，其特征在于，打印第一层片(200)此外包括将施覆有覆层的预浸渍丝束(300)直接地挤出到衬底上。
技术方案10. 根据技术方案11所述的方法，其特征在于，通过将施覆有覆层的预浸渍丝束(300)直接地挤出到所述第一层片(200)上使得打印所述第二层片(206)和将所述第二层片(206)施加到所述第一层片(200)上同时地发生。
技术方案11. 根据技术方案8所述的方法，其特征在于，所述第一近净形状(202)和所述第二近净形状(208)是制品的邻近的预设的层(108)。
技术方案12. 根据技术方案15所述的方法，其特征在于，所述制品是涡轮机部件(400)。
技术方案13. 根据技术方案16所述的方法，其特征在于，所述涡轮机部件(400)是翼形件(402)。
技术方案14. 根据技术方案17所述的方法，其特征在于，所述涡轮机部件(400)是喷嘴(404)。
技术方案15. 根据技术方案8所述的方法，其特征在于，巩固所述第一层片(200)和所述第二层片(206)包括从包括在高压釜中处理、烧尽、局部热处理、感应加热及其组合的组群中所选择的技术。
本发明的其它特征和优点将可从下文结合借助于示例阐明了本发明的原理的附图对优选的实施例所进行的更详细的描述中看出。
附图说明
图1是根据本发明公开内容的一种实施例的层片的透视图。
图2是根据本发明公开内容的一种实施例的第一层片和第二层片的透视图。
图3是根据本发明公开内容的一种实施例的第一层片和第二层片的透视图，其中第二层片在正直接地形成到第一层片上的过程中。
图4是根据本发明公开内容的一种实施例的正被施加以形成涡轮机喷嘴的层片的透视图。
图5是根据本发明公开内容的一种实施例的正被施加以形成涡轮机喷嘴的层片的透视图。
只要有可能，将贯穿所有附图使用相同的参考标号以代表相同的零件。
具体实施方式
提供了示例性的层片、用于制造层片的方法以及用于由层片制造制品的方法。与未利用一个或多个在此所公开的特征的方法和产品相比，本发明公开内容的实施例提供了成本效率和时间效率更高的用于制造层片和由层片所形成的制品的方法并且提供了用于非纺织纤维的定向(directionalization)能力以在任何点处跟随在层片内部中的预设的纤维路径选择线路。
参考图1，层片100包括近净形状102和陶瓷基复合物(CMC)非纺织材料104。近净形状102是制品的预设的层108。预设的层108可为任何合适的拓扑构造(topologicalconstruct)，包括但不限于制品的横截面层，制品的曲形层、制品的成角度的层或其组合，其中预设的层108适合于构成更大的制品的一部分。
陶瓷基复合物非纺织材料104可为任何合适的材料，包括但不限于单向带106、包括了随机地排列的纤维的带、包括了非连续纤维的带、包括了圆形的纤维的带或其组合。在一个实施例中，非连续纤维包括任何合适的纤维长度，包括但不限于，小于约0.15英寸、备选地小于约0.1英寸、备选地小于约0.05英寸、备选地约0.01英寸到约0.15英寸，备选地约0.02英寸到约0.12英寸、备选地约0.05英寸到约0.1英寸的纤维长度。在另一实施例中，在单向带106中纤维相对彼此的定向可改变。在另一实施例中，在单向带106中纤维相对彼此的定向改变了约90°。CMCs的示例包括但不限于SiC、SiN、氧化铝、基于氧化物的复合陶瓷以及其组合。
用于制造层片的方法100包括打印层片100。在一个实施例中，层片100如打印的那样且在没有进一步修改的情况下包括近净形状102。打印层片100可包括通过连续丝(continuous filament，有时称为长丝)制作过程挤出施覆有覆层的预浸渍丝束(tow)300(在图3中示出)。在另一实施例中，连续纤维包括任何合适的纤维长度，包括但不限于至少约0.05英寸、备选地至少约0.1英寸、备选地至少约0.15英寸、备选地约0.05英寸到约0.5英寸、备选地约0.1英寸到约0.3英寸、备选地约0.15英寸到约0.25英寸的纤维长度。
打印层片100可此外包括使用三维连续纤维布局打印机302(在图3中示出)以通过连续丝制作过程挤出施覆有覆层的预浸渍丝束300。在一个实施例中，当层片100被挤出时，加热预浸渍丝束300，部分地固化层片100。在另一实施例中，加热器元件包含在挤出机或打印机302的印床中。
在一个实施例中，施覆有覆层的预浸渍丝束300包括施覆有覆层的CMC纤维、CMC粒子以及碳微粒。施覆有覆层的预浸渍丝束300可此外包括溶剂、树脂、酒精或其混合物。CMC粒子可为亚微米大小的粒子。在另一实施例中，CMC粒子包括不超过约1微米、备选地不超过约10微米、备选地不超过约20微米的最大尺寸。碳微粒可包括但不限于元素碳、碳氢化合物、任何包含碳的有机材料或其组合。元素碳可呈现为一种或多种形式。
参考图2，在一个实施例中，用于制造制品的方法包括打印第一层片200和第二层片206。第一层片200包括第一近净形状202和第一CMC非纺织材料204。第一层片200可通过将施覆有覆层的预浸渍丝束300直接挤出到衬底上或通过无衬底地打印层片来打印。第一层片200可机械地或手动地转移到衬底上以用于进一步加工。衬底可为任何合适的物体，包括但不限于制品表面、中间物表面、工具作业(tooling)表面，涡轮机部件表面或其组合。第二层片206包括第二近净形状208和第二CMC非纺织材料210，其中第一近净形状202和第二近净形状208是制品的邻近的预设的层108。该方法此外包括将第二层片206施加到第一层片200上并且巩固第一层片200和第二层片206。通过这种方法可施加任何数量的层片100。巩固第一层片200和第二层片206(以及任何额外的层片100)可包括任何合适的技术，包括但不限于在高压釜中处理、烧尽(burn out，有时称为烧除)、局部热处理、感应加热或其组合。
在一个实施例中，用于制造的方法还包括致密化第一层片200和第二层片206。致密化可包括任何合适的技术，包括但不限于熔体渗入或汽相沉积。汽相沉积可包括纯硅、任何合适的氧化物(包括但不限于氧化硅)或其组合的沉积。熔体渗入可包括但不限于将硅熔化进入到第一层片200和第二层片206中并且使硅与碳微粒反应以形成碳化硅，从而巩固了第一层片200和第二层片206。
第二层片206可通过将施覆有覆层的预浸渍丝束300直接地挤出到衬底上或通过无衬底地打印层片来打印。在一个实施例中，第二层片206手动地或机械地转移到衬底上以用于进一步加工。在另一实施例中，第二层片206手动地或机械地转移到第一层片200上，该第一层片200位于衬底上以用于进一步加工。
参考图3，在另一实施例中，通过将施覆有覆层的预浸渍丝束300直接地挤出到第一层片200上而使得打印第二层片206和将第二层片206施加到第一层片200上同时地发生。同时的挤出可包括打印第一层片200的一部分，并且然后在形成第二层片206的同等的部分并且同时地施加第二层片206的同等的部分之前将施覆有覆层的预浸渍丝束300直接地挤出到第一层片200的这一部分上。在另一实施例中，将施覆有覆层的预浸渍丝束直接地挤出到第一层片200上包括使用三维连续纤维布局打印机302。
参考图4和5，近净形状102是涡轮机部件400的预设的层108。涡轮机部件可为任何适合适的部件，包括但不限于护罩、涡轮机支柱、翼形件402、喷嘴404(导叶)、燃烧衬套、轮叶(叶片)、护罩环、排气管道、扩大衬套、喷气排气喷嘴或其组合。在一个实施例中(图4)层片100是具有横截面拓扑的预设的层108，并且在另一实施例中(图5)层片100是具有曲形拓扑的预设的层108。
虽然已经参考优选实施例描述了本发明，但是本领域技术人员将理解的是，在不脱离本发明的范围的情况下可做出各种改变并且可用等同物代替其元件。此外可做出一些修改以使得特定情况或材料适合于本发明的教导而不脱离本发明的本质范围。因此，意图本发明不受限于作为预期用于执行本发明的最佳模式而公开的特定实施例，而是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 (15)

1.一种用于制造层片(100)的方法，所述方法包含打印层片(100)，所述层片(100)包括近净形状(102)和陶瓷基复合物非纺织材料(104)，其中打印层片包括：
通过连续丝制作过程将施覆有覆层的预浸渍丝束挤出到印刷机的印床上，所述施覆有覆层的预浸渍丝束包括：
陶瓷基复合物纤维；
陶瓷基复合物纤维粒子；
碳微粒；以及
选自下者组成的组的材料：溶剂、树脂、酒精或其混合物；且
在挤出所述施覆有覆层的预浸渍丝束的同时通过加热所述施覆有覆层的预浸渍丝束挤出到其上的所述印床加热所述施覆有覆层的预浸渍丝束，加热所述施覆有覆层的预浸渍丝束部分地固化所述施覆有覆层的预浸渍丝束。
2.根据权利要求1所述的方法，其特征在于，打印包括通过连续丝制作过程挤出施覆有覆层的预浸渍丝束(300)。
3.根据权利要求2所述的方法，其特征在于，打印包括使用三维连续纤维布局打印机(302)。
4.根据权利要求1所述的方法，其特征在于，陶瓷基复合物非纺织材料(104)是单向带(106)。
5.根据权利要求4所述的方法，其特征在于，所述近净形状(102)是涡轮机部件(400)的预设的层(108)。
6.根据权利要求5所述的方法，其特征在于，所述涡轮机部件(400)是翼形件(402)。
7.根据权利要求6所述的方法，其特征在于，所述涡轮机部件(400)是喷嘴(404)。
8.一种用于制造制品的方法，所述方法包含：
打印第一层片(200)，所述第一层片(200)包括第一近净形状(202)和第一陶瓷基复合物非纺织材料(204)；
打印第二层片(206)，所述第二层片(206)包括第二近净形状(208)和第二陶瓷基复合物非纺织材料(210)；
将所述第二层片(206)施加到所述第一层片(200)上；并且
巩固所述第一层片(200)和所述第二层片(206)，
其中打印所述第一层片和打印所述第二层片包括：
通过连续丝制作过程将施覆有覆层的预浸渍丝束挤出到印刷机的印床上，所述施覆有覆层的预浸渍丝束包括：
陶瓷基复合物纤维；
陶瓷基复合物纤维粒子；
碳微粒；以及
选自下者组成的组的材料：溶剂、树脂、酒精或其混合物；且
在挤出所述施覆有覆层的预浸渍丝束的同时通过加热所述施覆有覆层的预浸渍丝束挤出到其上的所述印床加热所述施覆有覆层的预浸渍丝束，加热所述施覆有覆层的预浸渍丝束部分地固化所述施覆有覆层的预浸渍丝束。
9.根据权利要求8所述的方法，其特征在于，打印第一层片(200)此外包括将施覆有覆层的预浸渍丝束(300)直接地挤出到衬底上。
10.根据权利要求8所述的方法，其特征在于，通过将施覆有覆层的预浸渍丝束(300)直接地挤出到所述第一层片(200)上使得打印所述第二层片(206)和将所述第二层片(206)施加到所述第一层片(200)上同时地发生。
11.根据权利要求8所述的方法，其特征在于，所述第一近净形状(202)和所述第二近净形状(208)是制品的邻近的预设的层(108)。
12.根据权利要求8所述的方法，其特征在于，所述制品是涡轮机部件(400)。
13.根据权利要求12所述的方法，其特征在于，所述涡轮机部件(400)是翼形件(402)。
14.根据权利要求12所述的方法，其特征在于，所述涡轮机部件(400)是喷嘴(404)。
15.根据权利要求8所述的方法，其特征在于，巩固所述第一层片(200)和所述第二层片(206)包括选自下者组成的组的技术：在高压釜中处理、烧尽、局部热处理、感应加热或其组合。
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JP6976044B2 (ja) 2021-12-01
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