CN106903478A - 用于深末梢裂纹修复的系统和方法 - Google Patents

用于深末梢裂纹修复的系统和方法 Download PDF

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CN106903478A
CN106903478A CN201611139188.3A CN201611139188A CN106903478A CN 106903478 A CN106903478 A CN 106903478A CN 201611139188 A CN201611139188 A CN 201611139188A CN 106903478 A CN106903478 A CN 106903478A
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insert
turbo blade
tip cap
blade
scheme
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CN106903478B (zh
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L.J.惠姆斯
J.R.康诺尔
D.J.多里蒂
A.B.克雷施马
P.A.库克
B.L.亨德森
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General Electric Co PLC
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/04—Repairing fractures or cracked metal parts or products, e.g. castings
    • B23P6/045—Repairing fractures or cracked metal parts or products, e.g. castings of turbine components, e.g. moving or stationary blades, rotors, etc.
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
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    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
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    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/19—Soldering, e.g. brazing, or unsoldering taking account of the properties of the materials to be soldered
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
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    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
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    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • 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
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    • 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
    • F01D5/14—Form or construction
    • F01D5/20—Specially-shaped blade tips to seal space between tips and stator
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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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/001—Turbines
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    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
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    • 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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    • F05D2230/00—Manufacture
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    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
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    • F05D2240/00—Components
    • F05D2240/20—Rotors
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Abstract

本申请提供一种修复涡轮叶片(100)的方法。该方法可包括以下步骤：从涡轮叶片(110)完全或部分地移除现有的末梢帽(190)；加工涡轮叶片(100)以形成加工沟槽(220)；将插入物(230)定位在加工沟槽(220)中；将插入物(230)焊接于涡轮叶片(100)；和硬焊涡轮叶片(100)。

Description

用于深末梢裂纹修复的系统和方法
技术领域
本申请和所得的专利大体上涉及燃气涡轮发动机，且更具体而言，涉及用于涡轮翼型件和相关构件中的深末梢裂纹修复的系统和方法。
背景技术
铸造涡轮叶片通常在其远端处包括称为末梢帽(tip cap)的结构。末梢帽是叶片的相对小的延伸部。末梢帽可具有与叶片的截面形状相配的截面形状，且可与叶片的径向外端一体或安装在其上。在使用中的一段时间之后，末梢帽可因热燃烧气体的冲击而被侵蚀、氧化、和/或腐蚀。因为涡轮叶片制造起来可能是昂贵的，所以如果可能，则受损叶片的修复或整修是优选的。涡轮叶片末梢帽的修复可通过将受损材料磨削掉且然后焊接或以其他方式附接替换材料来进行。冷却末梢帽也可延长总有用构件寿命。然而，由于制造约束，提供冷却是困难的。
发明内容
本申请和所得专利因此提供一种修复涡轮叶片的方法。该方法可包括以下步骤：从涡轮叶片完全或部分地移除现有的末梢帽；加工涡轮叶片以形成加工沟槽；将插入物定位在加工沟槽中；将插入物焊接于涡轮叶片；和硬焊涡轮叶片。
本申请和所得的专利还提供一种用于在燃气涡轮发动机中使用的涡轮叶片。涡轮叶片可包括：翼型件；末梢帽，其在翼型件的端部处；插入物，其被在末梢帽附近焊接于翼型件；和可硬焊膏，其被硬焊在插入物附近。
本申请和所得的专利因此提供一种修复涡轮叶片的方法。该方法可包括以下步骤：从涡轮叶片完全或部分地移除现有的末梢帽；加工涡轮叶片中的裂纹以形成加工沟槽；将预烧结预型件插入物定位在加工沟槽中；将预烧结预型件插入物焊接于涡轮叶片；和硬焊涡轮叶片。
技术方案1：一种修复涡轮叶片100的方法，包括：
从所述涡轮叶片100完全或部分地移除现有的末梢帽190；
加工所述涡轮叶片100以形成加工沟槽220；
将插入物230定位在所述加工沟槽220中；
将所述插入物230焊接于所述涡轮叶片100；和
硬焊所述涡轮叶片100。
技术方案2：根据技术方案1所述的方法，其中，移除现有的末梢帽的步骤包括加工所述末梢帽。
技术方案3：根据技术方案1所述的方法，还包括替换所述涡轮叶片100上的所述末梢帽190的步骤。
技术方案4：根据技术方案1所述的方法，还包括形成所述插入物230的步骤。
技术方案5：根据技术方案4所述的方法，其中，形成所述插入物230的步骤包括由预烧结预型件材料240形成所述插入物230。
技术方案6：根据技术方案4所述的方法，其中，形成所述插入物的步骤包括由超级合金材料形成所述插入物。
技术方案7：根据技术方案4所述的方法，其中，形成所述插入物230的步骤包括由基底材料形成所述插入物230。
技术方案8：根据技术方案4所述的方法，其中，形成所述插入物230的步骤包括添加制造过程。
技术方案9：根据技术方案1所述的方法，其中，加工所述涡轮叶片100的步骤包括加工所述涡轮叶片100以移除裂纹210。
技术方案10：根据技术方案1所述的方法，其中，加工所述涡轮叶片100以形成加工沟槽220的步骤包括加工所述加工沟槽220以容纳所述插入物230。
技术方案11：根据技术方案1所述的方法，其中，加工所述涡轮叶片100以形成加工沟槽220的步骤包括加工所述加工沟槽220以容纳所述插入物230和焊接合金250。
技术方案12：根据技术方案1所述的方法，其中，将所述插入物230焊接于所述涡轮叶片100的步骤包括在所述插入物230上的焊接合金250。
技术方案13：根据技术方案1所述的方法，其中，硬焊所述涡轮叶片100的步骤包括在其上硬焊可硬焊膏260。
技术方案14：根据技术方案1所述的方法，其中，所述涡轮叶片100包括第一级动叶。
技术方案15：一种用于在燃气涡轮发动机10中使用的涡轮叶片100，包括：
翼型件110；
末梢帽190，其在所述翼型件110的端部处；
插入物230，其被在所述末梢帽190附近焊接于所述翼型件110；和
可硬焊膏260，其被硬焊在所述插入物230附近。
技术方案16：一种修复涡轮叶片的方法，包括：
从所述涡轮叶片完全或部分地移除现有的末梢帽；
加工所述涡轮叶片中的裂纹以形成加工沟槽；
将预烧结预型件插入物定位在所述加工沟槽中；
将所述预烧结预型件插入物焊接于所述涡轮叶片；和
硬焊所述涡轮叶片。
技术方案17：根据技术方案16所述的方法，其中，移除现有的末梢帽的步骤包括加工所述末梢帽。
技术方案18：根据技术方案16所述的方法，还包括替换所述涡轮叶片上的所述末梢帽的步骤。
技术方案19：根据技术方案16所述的方法，其中，将所述插入物焊接于所述涡轮叶片的步骤包括在所述插入物上的焊接合金。
技术方案20：根据技术方案16所述的方法，其中，硬焊所述涡轮叶片的步骤包括硬焊可硬焊膏。
在阅读结合若干附图和所附权利要求作出的下列详细说明之后，本申请和所得专利的这些和其他特征和改进对本领域技术人员将变得显而易见。
附图说明
图1是燃气涡轮发动机的示意图，其示出压缩机、燃烧器、涡轮、和负载。
图2是涡轮叶片的透视图，其中若干裂纹在其中延伸。
图3是具有加工区域的图2的涡轮叶片的部分透视图。
图4是具有用插入物和焊接合金填充的加工区域的图2的涡轮叶片的部分透视图。
图5是示出可在本文中描述的修复涡轮叶片时的示范步骤的流程图。
部件列表
10 燃气涡轮发动机
15 压缩机
20 空气
25 燃烧器
30 燃料
35 燃烧气体
40 涡轮
45 轴
50 负载
100 涡轮叶片
110 翼型件
120 前缘
130 后缘
140 凹入侧
150 凸出侧
160 柄
170 燕尾件
180 平台
190 末梢帽
200 凹部
210 裂纹
220 加工沟槽
230 插入物
240 PSP
250 焊接合金
260 可硬焊膏。
具体实施方式
现在参考附图(其中贯穿若干视图，类似的标号指类似的元件)，图1示出可在本文中使用的燃气涡轮发动机10的示意图。燃气涡轮发动机10可包括压缩机15。压缩机15压缩进入的空气流20。压缩机15将压缩空气流20输送到燃烧器25。燃烧器25将压缩空气流20与加压燃料流30混合，且点燃该混合物以形成燃烧气体流35。尽管仅示出了单个燃烧器25，但燃气涡轮发动机10可包括以周向阵列等的形式布置的任意数量的燃烧器25。燃烧气体流35又被输送到涡轮40。燃烧气体流35驱动涡轮40，以便产生机械功。在涡轮40中产生的机械功通过轴45来驱动压缩机15和外部负载50(诸如发电机等)。
燃气涡轮发动机10可利用天然气、各种类型的合成气、液态燃料、和/或其他类型的燃料及其掺合物。燃气涡轮发动机10可为由General Electric Company ofSchenectady, New York提供的多种不同的燃气涡轮发动机中的任一种，包括但不限于诸如7系列或9系列重载燃气涡轮发动机等的那些。燃气涡轮发动机10可具有不同的构造，且可使用其他类型的构件。其他类型的燃气涡轮发动机也可用在本文中。多个燃气涡轮发动机、其他类型的涡轮、和其他类型的功率生成设备也可一起用在本文中。
图2是涡轮叶片100的示例的透视图。在该示例中，涡轮叶片100可为第一级动叶，但在本文中可使用任何类型的叶片。一般来说，涡轮叶片100包括翼型件110。翼型件110可从前缘120延伸至后缘130，具有凹入的压力侧外壁140和凸出的吸力侧外壁150。涡轮叶片100还可包括向下延伸的柄160和处于燕尾件170形式的附接件。平台180可在翼型件110和柄160及燕尾件170之间横向地延伸。翼型件110的径向端可包括末梢帽190。末梢帽190可为外侧壁140、150的延伸部。末梢帽190可在其中限定凹陷区域200。本文中描述的涡轮叶片100和末梢帽190仅用于示例目的。许多其他设计和构造可为已知的。
如上所述，末梢帽190可经历高温，且可相对于密封结构(诸如静止护罩)摩擦。结果，裂纹210可由于热感应应力和因氧化引起的材料损耗等而在叶片末梢190中或附近生长。为了修复涡轮叶片100，末梢帽190可被向下加工，以便移除裂纹210或其他类型的磨损、受损、或其他方式有缺陷的部位。末梢帽材料可被以常规方式向下加工。较深的裂纹210可通过焊接等来修复。然而，常规焊接技术仅可修复具有有限深度的裂纹210。具有超过该有限深度的裂纹210的翼型件110可能不能够修补。而且，常规焊接技术一般要求高度熟练的工人且可能是耗时的。
为了修复具有较深裂纹210的翼型件110，图3示出具有在被加工末梢帽190附近的加工沟槽220的翼型件110。具体而言，翼型件110可被精确地加工，以移除裂纹210。加工沟槽220可完全或部分地匹配插入物230的相对大小、形状、和构造。插入物230可由预烧结预型件(PSP)240和/或其他类型的材料形成。预烧结预型件材料240可为可硬焊超级合金等。具体而言，预烧结预型件材料240可为硬焊和超级合金粉末的掺合物。备选地，可使用基底材料、基底合金、它们的组合、和其他材料。插入物230可为实心元件、箔、膏状物、蜂窝构造、它们的组合等。可使用实心元件(诸如板和其他结构)的组合。插入物230可具有任何合适的大小、形状、或构造。插入物230可利用常规方式形成。添加制造过程，即，三维打印，也可用于形成插入物230。可在本文中使用其他构件和其他构造。
一旦插入物230定位在加工沟槽220内，则可通过焊接合金250等将插入物230焊接(基本上定位焊(tack))到合适位置。插入物230可稍微尺寸不足，以便允许焊接合金250延伸到沟槽220表面的空间。一旦固定，则可以以常规方式精整该焊接合金250。焊接合金250可为适合用于焊接的常规材料。一旦插入物230被通过焊接合金250焊接到合适位置，则涡轮叶片55可经历硬焊循环。硬焊循环可以或可以不在加工区域220、插入物230附近，且完全或部分地沿着翼型件110使用额外量的可硬焊膏260或其他类型的可硬焊材料，可使用常规硬焊技术。可硬焊膏260可为适合用于硬焊的常规材料。
因此可通过加工裂纹210、将插入物230焊接到合适位置、且完全或部分地硬焊翼型件110来修复翼型件110中的裂纹210。插入物230可被通过焊接合金250和硬焊过程锁定于合适位置。一旦被修复，则可以以常规方式替换末梢帽190。具体而言，插入物230可作用为平台，可在该平台上重建末梢帽190。多个插入物230可用于修复多个裂纹210。可在本文中使用其他构件和其他构造。
图5示出完全或部分地执行在本文中描述的方法时的示范步骤的流程图。在步骤260处，现有的末梢帽190可被在翼型件110上向下加工。在步骤270处，可通过加工沟槽220来移除裂纹210。在步骤280处，可将插入物230定位在加工沟槽220内。在步骤290处，可通过焊接合金250将插入物230焊接到合适位置。在步骤300处，翼型件110可经历硬焊循环。在步骤310处，可替换末梢帽190。此时，改进的涡轮叶片100可准备用于使用和/或其他类型的处理。在本文中描述的方法步骤不是排他的。可以以任何期望的顺序使用其他或不同的方法步骤以修复涡轮叶片100。
因此本文中描述的系统和方法提供具有深末梢裂纹210的涡轮叶片100的快速和有效率的修复。在本文中描述的系统和方法允许修复具有不能够以常规方式通过简单的焊接或硬焊修复的较深裂纹210的涡轮叶片100。因此本文中描述的系统和方法可以以快速且成本有效的方式延长涡轮叶片100的寿命。本文中描述的系统和方法还可适用于其他类型的热气体路径构件、其他类型的涡轮构件等。
应当明白的是，前述内容仅涉及本申请和所得专利的某些实施例。可由本领域技术人员在本文中作出许多改变和改型，而不偏离如由以下权利要求及其等同物限定的本发明的总体精神和范围。

Claims (10)

1.一种修复涡轮叶片(100)的方法，包括：
从所述涡轮叶片(100)完全或部分地移除现有的末梢帽(190)；
加工所述涡轮叶片(100)以形成加工沟槽(220)；
将插入物(230)定位在所述加工沟槽(220)中；
将所述插入物(230)焊接于所述涡轮叶片(100)；和
硬焊所述涡轮叶片(100)。
2.根据权利要求1所述的方法，其中，移除现有的末梢帽的步骤包括加工所述末梢帽。
3.根据权利要求1所述的方法，还包括替换所述涡轮叶片(100)上的所述末梢帽(190)的步骤。
4.根据权利要求1所述的方法，还包括形成所述插入物(230)的步骤。
5.根据权利要求4所述的方法，其中，形成所述插入物(230)的步骤包括由预烧结预型件材料(240)形成所述插入物(230)。
6.根据权利要求4所述的方法，其中，形成所述插入物的步骤包括由超级合金材料形成所述插入物。
7.根据权利要求4所述的方法，其中，形成所述插入物(230)的步骤包括由基底材料形成所述插入物(230)。
8.根据权利要求4所述的方法，其中，形成所述插入物(230)的步骤包括添加制造过程。
9.根据权利要求1所述的方法，其中，加工所述涡轮叶片(100)的步骤包括加工所述涡轮叶片(100)以移除裂纹(210)。
10.根据权利要求1所述的方法，其中，加工所述涡轮叶片(100)以形成加工沟槽(220)的步骤包括加工所述加工沟槽(220)以容纳所述插入物(230)。
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