CN108603511B - 用于制造旋转机械的部件的方法 - Google Patents

用于制造旋转机械的部件的方法 Download PDF

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CN108603511B
CN108603511B CN201680071014.XA CN201680071014A CN108603511B CN 108603511 B CN108603511 B CN 108603511B CN 201680071014 A CN201680071014 A CN 201680071014A CN 108603511 B CN108603511 B CN 108603511B
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component
inner portion
structural inner
protective outer
structural
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CN108603511A (zh
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L.托尼纳雷利
M.贾诺齐
I.焦瓦内蒂
P.托齐
A.迪马蒂奥
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Nuovo Pignone Technologie SRL
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    • B22—CASTING; POWDER METALLURGY
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    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • B22F3/15—Hot isostatic pressing
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    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • 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
    • 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
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    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/286—Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion
    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/18—Rotors
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/20—Refractory metals
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • 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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    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
    • F05D2220/32—Application in turbines in gas turbines
    • 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
    • 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
    • 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
    • F05D2230/30—Manufacture with deposition of material
    • 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
    • F05D2230/40—Heat treatment
    • F05D2230/42—Heat treatment by hot isostatic pressing
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    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Abstract

本公开提供一种用于制造旋转机械的部件(1)的方法，所述方法包括以下步骤：通过使用第一材料进行增材制造来形成结构性内部部分(2)；用由第二材料制成的保护性外部部分(7)覆盖所述结构性内部部分(2)；其中所述第一材料的熔点高于第二材料。

Description

用于制造旋转机械的部件的方法
技术领域
本公开涉及一种用于制造旋转机械的部件的方法。确切地说，本公开涉及制造燃气涡轮叶片。因此，所述具体应用将在本公开中多次提及，但是并不旨在丧失一般性。
背景技术
早期涡轮机的一个关键限制因素是可用于高温部分(燃烧器和涡轮)的材料的性能。对更好材料的需求激发了合金和制造技术领域内的大量研究，所述研究得出了使现代燃气涡轮成为可能的一长串新材料和新方法。最早的所述新材料之一是用于BritishWhittle发动机中的Nimonic(尼蒙克镍基合金)。
20世纪40年代超合金和20世纪50年代中新加工方法例如真空感应熔炼(vacuuminduction melting)的开发极大地提高了涡轮叶片的耐温能力。其他加工方法例如热等静压(hot isostatic pressing)改进了用于涡轮叶片的合金，并且提高了涡轮叶片的性能。现代涡轮叶片通常使用含铬、钴和铼的镍基超合金(superalloy)。
除了合金改进之外，一个重大突破是定向凝固(directional solidification，DS)和单晶(single crystal，SC)生产方法的开发。这些方法通过沿一个方向(DS)对准晶界或通过整体消除晶界(SC)来帮助大大提高抗疲劳和蠕变强度。
涡轮叶片材料技术的另一个重大改进是热障涂层(TBC)的开发。DS和SC的开发改善了抗蠕变性和抗疲劳性，TBC改善了抗腐蚀性和抗氧化性，这两者均会在温度升高时变得更加突出。20世纪70年代应用的首个TBC是铝化物涂层。20世纪80年代开始出现改进的陶瓷涂层。这些涂层将涡轮叶片的耐温能力提高了大约200°F(90℃)。所述涂层还可以延长叶片寿命，在某些情况下几乎可以使涡轮叶片的寿命加倍。
大多数涡轮叶片通过熔模铸造(investment casting)(或失蜡铸造(lost-waxprocessing))来制造。此工艺涉及制造叶片形状的精确阴模，所述阴模将填充蜡以形成叶片形状。如果叶片是中空的(即，它具有内部冷却通道)，则将通道形状的陶瓷芯插入到中间。对所述蜡叶片涂覆耐热材料以制造壳体，然后向所述壳体填充叶片合金。DS或SC材料的此步骤可能会更复杂，但过程相似。如果叶片中间有陶瓷芯，则所述陶瓷芯会溶解在溶液中，留下中空的叶片。所述叶片将涂覆TBC，然后根据需要对冷却孔进行机加工，进而形成完整的涡轮叶片。
上述涡轮叶片和工艺存在操作温度方面的限制，并且如所属技术领域中已知的那样，涡轮处的温度较高可增加此机械的效率。因此，如上所述，现有技术的已知解决方案在叶片上采用各种类型的冷却。不利的是，冷却本身降低了所述机械的效率并且增加了涡轮级的结构复杂性。
发明内容
因此，本发明的第一实施例涉及一种用于制造旋转机械的部件的方法。所述方法包括以下步骤：通过使用第一材料进行增材制造来形成结构性内部部分。之后，向所述结构性内部部分覆盖有由第二材料制成的保护性外部部分。
本发明的第二实施例涉及一种用于旋转机械的部件。所述部件包括结构性内部部分，所述结构性内部部分通过增材制造制成并且由第一材料制成。此外，所述部件包括保护性外部部分，所述保护性外部部分覆盖所述结构性内部部分并且由第二材料制成。
在这两个实施例中，所述第一材料的熔点高于所述第二材料。
有利的是，由于所述内部部分的承载能力，部件1的热结构抗性得以增加，而所述内部部分转而通过所述外部部分免于遭受腐蚀。这使得能够提高燃气涡轮的效率，或者替代性地，使得能够减少或消除在当前温度下对冷却系统的需求。部件的寿命得以延长。
有利的是，生产所述部件的成本也显著降低。
附图说明
进一步的详情和具体的实施例将参考附图来提供，其中：
图1是根据本发明第一实施例的用于旋转机械的部件的示意图；
图2是根据本发明第二实施例的用于旋转机械的部件的详细图；以及
图3是根据本发明第三实施例的用于旋转机械的部件的示意图。
具体实施方式
以下示例性实施例说明中将参照附图。不同附图中的相同的附图标记是指相同或类似的元件。以下详细说明并非限制本发明。相反，本发明的范围由所附权利要求书限定。
整个说明书中提及的“一个实施例”或“实施例”意味着结合实施例所描述的特定特征、结构或者特性包括在所公开主题的至少一个实施例中。因此，在整个说明书的不同地方出现的短语“在一个实施例中”或“在实施例中”并不一定是指同一实施例。另外，特定特征、结构或者特性可以以任何适当方式组合在一个或多个实施例中。
参考附图，其中1表示用于旋转机械的部件。如上所述，部件1可以是燃气涡轮叶片。
部件1设计成在高温下操作，因此预期在这些温度下既能经受结构性载荷，又能经受腐蚀。根据本公开的含义，高于1000℃的温度视作是高温。
在部件1是旋转机械的叶片的应用中，结构性载荷的主要来源是旋转组件的惯性力以及由工作流体产生的流体动力。主要腐蚀剂是氧。因此，旨在用于解释本发明实施例的这些环境特性不应解释成限制本申请的范围。
部件1包括结构性内部部分2，所述结构性内部部分是总承载能力的主要提供者。因此，内部部分2由具有适当机械性质的第一材料制成。
针对内部部分2所需的主要性质是抗拉强度和抗蠕变性。抗拉强度是指在失效或断裂之前，材料能够在拉伸或者拉动状态下经受的最大应力。抗蠕变性是指受载状态下蠕变的减少。在材料科学中，蠕变(有时称为冷流)是固体材料在机械应力影响下缓慢移动或永久变形的趋势。蠕变的发生可能是长期暴露于仍然低于材料屈服强度的高应力级下的结果。蠕变在长期受热的材料中更为严重，并且通常在材料接近其熔点时增加。
所需的性质可以通过采用相应选择的第一材料来获得。实际上，所述第一材料包括重量占支配地位的耐高温金属(refractory metal)或共晶金属(eutectic metal)。所述耐高温金属包括钨或钨合金或者钼合金或硅化物。
所述共晶金属包括镍合金或钴合金。第一材料的示例可以是基于硅化物的复合材料，所述材料包括：
-Mo、B、W、Nb、Ta、Ti、Cr、Co、Y的硅化物，或者它们的组合，
-Si3N4，以及
-选自由氧化钇、氧化铈及其组合构成的群组的至少一种氧化物。
对于示例性应用，最终抗拉强度的最小值在1100℃下是450MPa，并且在1300℃下是300MPa。
在结构上，内部部分2可以具有晶格、分支结构或者任何其他种类的复杂形状。在图2中作为示例示出的晶格结构由多个节点4限定，所述多个节点4以逐层方式布置，或者布置在预定的三维重复结构上。相邻节点4由梁5接合在一起。这些梁5趋于主要对抗轴向载荷，而抗弯曲载荷性能和抗横向载荷性能由梁5的几何形状来确保。由节点4和梁5构成的预定义重复集合限定晶格结构的单元6。对于示例性应用，所述单元6可以是六角形的。
分支结构是与晶格结构类似、但缺少单元6的结构，因此梁5布置成针对预期载荷优化部件1的承载能力。
复杂形状是无法轻易定义成规则或半规则几何形叠加的形状。
如图1中所示，部件1包括保护性外部部分7，所述保护性外部部分至少部分覆盖内部部分2。所述外部部分7由第二材料制成。
根据本发明的实施例，所述第一材料的熔点高于所述第二材料。换言之，尽管所述第一材料是根据其结构特性选择的，但是所述第二材料的选择是使用不同引导参数，特别是抗腐蚀性做出的。实际上，所述第二材料选择成使其在高温下的抗腐蚀性和抗氧化性高于第一材料。换言之，所述第一材料在高温下可能快速腐蚀和氧化，确切地说，所述第一材料在高温下比所述第二材料更快腐蚀和氧化。因此，由于外部部分7在内部部分2上的分层，所述第二材料可以保护第一材料免受腐蚀。例如，所述第二材料可以包括镍铝合金，例如Ni3Al、R108、CM247、NiAl、NiAlSi、NiCoCrAlY。
更详细地说，所述内部部分2的至少两个机械性质高于外部部分7。如上所述，所述机械性质是抗拉强度和抗蠕变性。
在特别有利的实施例中，内部部分2也成形为形成容器8以用于接收第二材料的粉末。所述容器配置成对抗在热等静压加压(hot isostatic pressuring)期间达到的压力。
所述保护性外部部分的厚度不小于1mm，优选地不小于2mm。所述保护性外部部分不是涂层，而是具有不同机械性质的厚层。用于制造部件1的方法也是本发明的实施例。所述方法包括以下步骤：通过使用第一材料进行增材制造来形成结构性内部部分2。所述增材制造工艺可以是直接金属激光熔化(DMLM)、直接金属激光烧结(DMLS)、选择性激光熔化(SLM)、电子束熔化(EBM)、粘合剂射流、注射模塑或任何其他适当工艺。
之后，利用保护性外部部分7覆盖所述结构性内部部分2。所述外部部分7由以上指定的第二材料制成。更详细地说，覆盖内部部分2的步骤包括将第二材料热等静压在内部部分2上的子步骤。替代地，覆盖内部部分2的步骤可以包括将第二材料熔模铸造在内部部分2上的子步骤。
应注意，覆盖内部部分2的步骤至少部分地在大体上没有氧的空气中进行。优选地，工作气氛由氩组成。
在一个实施例中，保护性外部部分可以直接粘附到结构性内部部分。
所述保护性外层可以具有内表面，所述内表面与结构性内部结构的外表面互补。
确切地说，所述保护性外层和结构性内层可以成形为彼此机械地配合。例如，结构性内层可以包括表面空腔，所述表面空腔成形为当所述保护性外层覆盖所述结构性内部部分时，通过保护性外层中进入所述空腔内的部分来实现机械连接。
在进一步实施例中，所述保护性外部部分覆盖结构性内部部分但不粘附在结构性内部部分上。在此情况下，可以提供中间材料层(未示出)。例如，可以通过熔模铸造将中间层沉积在结构性内部部分上，并且随后通过热等静压使用保护性外部部分覆盖所述中间层。所述中间层的材料可以与保护性外层相同或与其不同。

Claims (11)

1.一种用于旋转机械的部件（1），所述部件包括：
- 结构性内部部分（2），所述结构性内部部分通过增材制造制成并且由第一材料制成，所述结构性内部部分（2）由包括多个单元的晶格结构限定，每个单元由重复的节点（4）和梁（5）的集合形成，其中相邻的节点（4）由所述梁（5）接合；
- 保护性外部部分（7），所述保护性外部部分覆盖所述结构性内部部分（2）并且由第二材料制成；
其中所述第一材料的熔点高于所述第二材料，并且其中所述保护性外部部分（7）通过热等静压制成，并且其中所述部件是燃气涡轮的叶片。
2.根据权利要求1所述的部件（1），其中所述结构性内部部分（2）的至少两个机械性质高于所述保护性外部部分。
3.根据权利要求2所述的部件（1），其中所述机械性质是抗拉强度和抗蠕变性。
4.根据权利要求1到3中的任一权利要求所述的部件（1），其中所述第二材料在高温下的抗腐蚀性和抗氧化性高于所述第一材料。
5.根据权利要求4所述的部件（1），其中所述高温高于1000℃。
6.根据权利要求1到3中的任一权利要求所述的部件（1），其中所述结构性内部部分（2）具有分支结构或复杂形状，其中复杂形状是无法轻易定义成规则或半规则几何形叠加的形状。
7.根据权利要求1到3中的任一权利要求所述的部件（1），其中所述第二材料包括镍铝合金。
8.根据权利要求1到3中的任一权利要求所述的部件（1），其中所述第一材料包括重量占支配地位的耐高温金属或共晶金属。
9.根据权利要求8所述的部件（1），其中所述耐高温金属包括钨或钨合金或者钼合金。
10.根据权利要求1到3中的任一权利要求所述的部件（1），其中所述结构性内部部分也成形为形成容器以用于接收所述第二材料的粉末；所述容器配置成对抗在所述热等静压加压期间达到的压力。
11.根据权利要求1到3中的任一权利要求所述的部件（1），其中所述保护性外部部分（7）完全覆盖所述结构性内部部分（2）。
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