CN107138726B - 一种具有点阵冷却结构的导向叶片制备方法 - Google Patents

一种具有点阵冷却结构的导向叶片制备方法 Download PDF

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CN107138726B
CN107138726B CN201710334204.2A CN201710334204A CN107138726B CN 107138726 B CN107138726 B CN 107138726B CN 201710334204 A CN201710334204 A CN 201710334204A CN 107138726 B CN107138726 B CN 107138726B
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CN107138726A (zh
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孙兵兵
刘伟
秦仁耀
唐思熠
郭绍庆
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AECC Beijing Institute of Aeronautical Materials
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Abstract

本发明属于导向叶片制备技术领域，特别涉及一种具有点阵冷却结构的导向叶片制备方法。本发明采用激光选区熔化快速成型技术制备具有点阵结构的导向叶片，点阵结构由点阵单元组成，每个点阵单元由杆件组成，点阵单元呈四面体或金字塔或kagome构型，点阵结构充满导向叶片叶身内腔，本发明以激光为能量源，利用粉末床选区快速成型设备，通过设置合适的导向叶片成形方向和工艺参数，直接由CAD模型一步完成带有点阵结构的导向器叶片的制备，无需模具，合金材料利用率高，得到的导向器叶片散热性能优异，成形精度良好，可大幅度改善导向叶片的散热性能，提高冷却效率。

Description

一种具有点阵冷却结构的导向叶片制备方法
技术领域
本发明属于导向叶片制备技术领域，特别涉及一种具有点阵冷却结构的导向叶片制备方法。
背景技术
燃气涡轮发动机的效率随着涡轮入口温度的提高而增加，目前的燃气温度已经远高于叶片材料的温度极限，必须对涡轮叶片进行有效的冷却才能保证燃气涡轮的正常工作。燃气轮机中的高温部件，如燃烧室、涡轮、尾喷管等的工作环境非常恶劣，由此造成高温部件的可靠性差、寿命短。据美国权威部门的统计，燃气轮机中的故障有60％以上出现在高温部件，并有不断上升的趋势。我国的一些燃气轮机高温部件的寿命只有几百小时，高温部件的材料费及加工费高昂，由此带来的经济损失十分严重。
目前，燃气轮机最常采用冷却结构是内部冷却结合气膜冷却，即在叶片表面制备出数量多而密的气膜孔，从叶片内腔向外喷出小股冷气在叶片外表面形成气膜，隔离热源并带走热量，同时叶片内腔通过冷却气流冷却，以降低叶片实际的工作温度。为达到优良的冷却效果，先进燃气轮机的叶片冷却结构已经非常复杂，但冷却效果仍显不足，由于冷效不足，易造成导孔处热障涂层剥落，导孔、缘板、叶身等处出现裂纹等缺陷，继续保持原有散热结构的前提下，提高构件的冷却能力已十分困难。
点阵结构具有较高的表面积，且能通过金属杆单元和内部连通结构的流体对流传热，具有十分良好的主动传热特性，因此，采用点阵结构这种新型的、高效的冷却方式，有望进一步提高燃气轮机导向叶片的冷却效率，提高构件使用寿命，延长翻修周期。
涡轮导向叶片传统制造技术为精密铸造。由于受到蜡模、型芯制备、浇铸等工艺技术限制，精密铸造在制造超复杂结构时浇铸成形困难，细微结构难以充填成形，工艺出现微小波动，就会导致成批报废。而对于带有点阵结构的导向叶片，采用铸造工艺制造更加困难，几乎无法制造。
发明内容
为克服上述困难，本发明提供了一种利用激光选区熔化成形技术制备带有点阵结构的导向叶片制备方法。
本发明技术方案的具体内容是：
采用激光选区熔化快速成型技术制备具有点阵结构的导向叶片，点阵结构由点阵单元组成，每个点阵单元呈四面体或金字塔或kagome构型，点阵结构充满导向叶片叶身内腔，制备过程包括以下步骤：
(1)建立具有点阵结构的导向叶片的三维CAD模型；
(2)根据点阵单元中的杆件的方向设计点阵结构导向叶片激光选区熔化成形方向，确保点阵结构中所有杆件与成形面的夹角≥45°，所有杆件均不添加成形辅助支撑；
(3)根据步骤(2)中所确定具有点阵结构的的导向叶片成形方向以及导向叶片的结构特点，对导向叶片中不能满足自支撑的部位，添加成形辅助支撑；
(4)在成形方向上对具有点阵结构的导向叶片进行分层切片处理，分割成厚度均匀的切片，切片包括导向叶片的横截面轮廓和加工路径，并将切片信息文件导入激光选区熔化快速成形设备中；
(5)在激光选区熔化快速成形设备的粉末桶内装入合金粉末，并将成形基板置于激光选区熔化成形设备的成形腔内的可升降平台上；
(6)对激光选区熔化成形设备的成形腔中充入高纯氩气；
(7)使用激光选区熔化快速成形设备中的刮粉装置，在成形基板上均匀铺设一层合金粉末；
(8)激光按步骤(4)所设计的加工路径，熔化指定区域的合金粉末，激光扫描到的地方，合金粉末熔化形成熔池，激光离开，熔池迅速凝固得到一层沉积层。制备过程中始终保持激光选区熔化设备中的风扇处于开启状态；
(9)完成步骤(8)后，成形基板下降一个层厚的距离，刮粉装置在步骤(8)中形成的沉积层上，再均匀铺设一层合金粉末；
(10)重复上述步骤(8)和(9)，直到新型冷却结构导向叶片制备完成，待导向叶片温度降至室温后取出；
(11)若添加了成形辅助支撑，去除成形辅助支撑。
步骤(3)中所述的添加成形辅助支撑，是指对导向叶片结构中与成形面夹角＜45°的部位添加成形辅助支撑。
步骤(4)中所述的切片厚度为：0.02～0.05mm。
步骤(5)中所选用的合金粉末呈球形或近球形，直径≤53μm。
步骤(5)中所选用的成形基板为45号钢。
步骤(6)中所述氧含量为：≤20ppm。
步骤(7)中所述的粉末层厚度为：0.02～0.05mm。
步骤(8)中所述激光功率为：100～500W，扫描间距为：0.12mm，光斑直径为：0.1～0.5mm。
步骤(9)中所述成形基板下降高度为：0.02～0.05mm，步骤(9)中所述的粉末层厚度为：0.02～0.05mm。
步骤(11)中所述的支撑去除为手工去除。
本发明具有的优点和有益效果
本发明首先利用计算机得到带有点阵结构导向叶片的CAD数值模型，然后在确保点阵结构能顺利成形的条件下，确定导向叶片的成形方向，再利用分层软件在导向叶片的成形方向上进行分层切片，并生成扫描路径，最后激光根据设定的扫描路径，逐点熔化沉积合金粉末，并逐层堆积，形成带有新型冷却结构的导向叶片。本制备方法经济、快速，特别适合用于复杂点阵结构的制备。
附图说明
图1是本发明中向叶片点阵填充位置示意图，其中，1叶身内腔示意图；2缘板外壁示意图；
图2是本发明点阵单元中一种典型结构示意图。
具体实施方式
以下结合实例对本发明做进一步阐述，但本发明并不局限于具体实施例。
采用激光选区熔化技术制备带有点阵结构的导向叶片，该方法的步骤是：
利用三维绘图软件(solidworks等)建立带有点阵结构的导向叶片的三维CAD模型；
根据叶片中点阵单元的方向，调整具有新型冷却结构的导向叶片的成形方向，保证所有点阵单元中杆件与成形面夹角≥45°。
根据步骤(2)中所确定的导向叶片成形方向，以及导向叶片的结构特点，对导向叶片中与成形面夹角＜45°的悬空部位添加成形辅助支撑；
(1)在成形方向上对导向叶片进行分层切片处理，均匀分割成厚度约为0.02～0.05μm的切片，切片包括导向器叶片的横截面轮廓信息和加工路径，并将切片文件导入激光选区熔化快速成形设备中；
(2)在激光选区熔化快速成形设备的粉末桶内装入直径≤53μm，球形或近球形的合金粉末，并将厚度约为50mm厚的45号钢成形基板置于激光选区熔化成形设备的成形腔内的可升价平台上；
(3)对激光选区熔化成形设备的成形腔中充入高纯氩气，直至成形腔内气体氧含量≤20ppm。
(4)使用激光选区熔化快速成形设备中的刮粉装置，在成形基板上均匀铺设厚度为0.02～0.05mm厚的一层合金粉末；
(5)激光按步骤(4)所预设的加工路径，熔化指定区域的合金粉末，激光扫描到的地方，合金粉末熔化形成熔池，激光离开，熔池迅速凝固得到一层沉积层。激光扫描速度：5m·s～1，激光功率为：100～500W，扫描间距为：0.12mm，光斑直径为：0.1～0.5mm。制备过程中始终保持激光选区熔化设备中的风扇处于开启状态；
(6)完成步骤(8)后，成形基板下降0.02～0.05mm，刮粉装置在步骤(8)中形成的沉积层上，再均匀铺设厚度为0.02～0.05mm的合金粉末；
(7)重复上述步骤(8)和(9)，直到具有新型冷却结构的导向叶片制备完成，待导向叶片温度降至室温后取出；
(8)采用手工去除方式，将成形辅助支撑去除。
实施例
利用激光选区熔化制备叶腔内带有点阵结构的K640导向叶片：
(1)利用三维绘图软件(solidworks等)建立带有点阵结构的导向叶片的三维CAD模型；
(2)根据具有新型冷却结构的导向叶片中点阵的结构特点，调整导向叶片成形方向，保证导向叶片中所有点阵单元均能在不添加支撑的条件下顺利成形；
(3)根据步骤(2)中所确定的导向叶片成形方向，以及导向叶片的结构特点，对导向叶片中与成形面夹角＜45°的悬空部位添加成形辅助支撑；
(4)在成形方向上对导向叶片进行分层切片处理，均匀分割成厚度约为0.02～0.05μm的切片，切片包括导向器叶片的横截面轮廓信息和加工路径，并将切片文件导入激光选区熔化快速成形设备中；
(5)在激光选区熔化快速成形设备的粉末桶内装入直径≤53μm，球形或近球形的K640合金粉末，并将厚度约为50mm厚的45号钢成形基板置于激光选区熔化成形设备的成形腔内的可升价平台上；
(6)对激光选区熔化成形设备的成形腔中充入高纯氩气，直至成形腔内气体氧含量≤20ppm；
(7)使用激光选区熔化快速成形设备中的刮粉装置，在成形基板上均匀铺设厚度为0.03mm厚的一层合金粉末；
(8)激光按步骤(4)所预设的加工路径，熔化指定区域的合金粉末，激光扫描到的地方，合金粉末熔化形成熔池，激光离开，熔池迅速凝固得到一层沉积层。激光扫描速度：5m·s～1，激光功率为：300W，扫描间距为：0.12mm，光斑直径为：0.2mm。制备过程中始终保持激光选区熔化设备中的风扇处于开启状态；
(9)完成步骤(8)后，成形基板下降0.03mm，刮粉装置在步骤(8)中形成的沉积层上，再均匀铺设厚度为0.03mm的K640合金粉末；
(10)重复上述步骤(8)和(9)，直到新型冷却结构导向叶片制备完成，待导向叶片温度降至室温后取出；
(11)采用手工去除方式，去除成形辅助支撑。
以上所述仅为本发明的优选实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书内容所做的等效结构或等效流程变换，或直接或间接运用在其他相关技术领域，均同理包括在本发明的专利保护范围内。

Claims (9)

1.一种具有点阵冷却结构的导向叶片制备方法，其特征在于：采用激光选区熔化快速成型技术制备具有点阵结构的导向叶片，点阵结构由点阵单元组成，每个点阵单元由杆件组成，点阵单元呈四面体或金字塔或kagome构型，点阵结构充满导向叶片叶身内腔，制备过程包括以下步骤：
(1)建立具有点阵结构的导向叶片的三维CAD模型；
(2)根据点阵单元中的杆件的方向设计点阵结构导向叶片激光选区熔化成形方向，确保点阵结构中所有杆件与成形面的夹角≥45°，所有杆件均不添加成形辅助支撑；
(3)根据步骤(2)中所确定具有点阵结构的导向叶片成形方向以及导向叶片的结构特点，对导向叶片中不能满足自支撑的部位，添加成形辅助支撑；所述添加成形辅助支撑是指对导向叶片结构中与成形面夹角＜45°的部位添加成形辅助支撑；
(4)在成形方向上对具有点阵结构的导向叶片进行分层切片处理，分割成厚度均匀的切片，切片包括导向叶片的横截面轮廓和加工路径，并将切片信息文件导入激光选区熔化快速成形设备中；
(5)在激光选区熔化快速成形设备的粉末桶内装入合金粉末，并将成形基板置于激光选区熔化成形设备的成形腔内的可升降平台上；
(6)对激光选区熔化成形设备的成形腔中充入高纯氩气；
(7)使用激光选区熔化快速成形设备中的刮粉装置，在成形基板上均匀铺设一层合金粉末；
(8)激光按步骤(4)所设计的加工路径，熔化指定区域的合金粉末，激光扫描到的地方，合金粉末熔化形成熔池，激光离开，熔池迅速凝固得到一层沉积层；制备过程中始终保持激光选区熔化设备中的风扇处于开启状态；
(9)完成步骤(8)后，成形基板下降一个层厚的距离，刮粉装置在步骤(8)中形成的沉积层上，再均匀铺设一层合金粉末；
(10)重复上述步骤(8)和(9)，直到冷却结构导向叶片制备完成，待导向叶片温度降至室温后取出；
(11)若添加了成形辅助支撑，去除成形辅助支撑。
2.根据权利要求1所述的具有点阵冷却结构的导向叶片制备方法，其特征在于：步骤(4)中所述的切片厚度为：0.02～0.05mm。
3.根据权利要求1所述的具有点阵冷却结构的导向叶片制备方法，其特征在于：步骤(5)中所选用的合金粉末呈球形或近球形，直径≤53μm。
4.根据权利要求1所述的具有点阵冷却结构的导向叶片制备方法，其特征在于：步骤(5)中所选用的成形基板为45号钢。
5.根据权利要求1所述的具有点阵冷却结构的导向叶片制备方法，其特征在于：步骤(6)中成形腔中氧含量为：≤20ppm。
6.根据权利要求1所述的具有点阵冷却结构的导向叶片制备方法，其特征在于：步骤(7)中粉末层厚度为：0.02～0.05mm。
7.根据权利要求1所述的具有点阵冷却结构的导向叶片制备方法，其特征在于：步骤(8)中所述激光功率为：100～500W，扫描间距为：0.12mm，光斑直径为：0.1～0.5mm。
8.根据权利要求1所述的具有点阵冷却结构的导向叶片制备方法，其特征在于：步骤(9)中所述成形基板下降高度为：0.02～0.05mm，步骤(9)中粉末层厚度为：0.02～0.05mm。
9.根据权利要求1所述的具有点阵冷却结构的导向叶片制备方法，其特征在于：步骤(11)中所述的支撑去除为手工去除。
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