CN108779030A - Cmc堆叠体的激光接合 - Google Patents

Cmc堆叠体的激光接合 Download PDF

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CN108779030A
CN108779030A CN201780017688.6A CN201780017688A CN108779030A CN 108779030 A CN108779030 A CN 108779030A CN 201780017688 A CN201780017688 A CN 201780017688A CN 108779030 A CN108779030 A CN 108779030A
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ceramic
cmc layers
cmc
deposits
layers
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阿林达姆·达斯古普塔
阿南德·A·库尔卡尼
艾哈迈德·卡迈勒
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Siemens Energy Inc
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Abstract

一种制造燃气涡轮发动机部件(10)的方法和如此形成的部件。所述方法包括：沿着金属芯(30)堆叠复数个CMC层(16)以形成不连接的CMC层的堆叠体，其中所述层的相邻边缘面(46)限定了表面(44)；将陶瓷材料(14)附加地沉积至表面(44)的仅选择部分以将所述层的至少一些在它们的相应边缘面处结合在一起；以及选择用于沉积陶瓷材料的位置以实现所得部件的预定机械特性。

Description

CMC堆叠体的激光接合
技术领域
本发明涉及通过接合CMC层的堆叠体形成的燃气轮机部件，并且更具体地，涉及一种用附加地沉积在所述堆叠体上的陶瓷沉积物接合这样的CMC层的方法。
背景技术
经济和环境的需求正在推动联合循环发电厂与燃气轮机发动机顶部循环的效率越来越高。为了实现这种效率，燃气轮机循环需要在高达1600摄氏度至1800摄氏度的涡轮入口温度下操作。在这些温度下，达到材料操作极限和/或冷却流要求增加太多以至于较高入口温度的优势被抵消。已经用于解决这种挑战的一种技术是将陶瓷基复合(CMC)材料用于热气体路径表面，例如涡轮叶片(vane)或叶轮(blade)等。合适的材料种类的一个实例是氧化物-氧化物复合材料。这种材料的整体结构是有问题的，并且已经提出使用堆叠的CMC层来完成部件。Burke等的美国专利号7,247,003公开了这样的结构。然而，这种结构的一个挑战是CMC层没有结合而是它们螺栓连接在金属背衬上。压力侧和吸力侧二者上的非常高的热负荷可以导致该配置中的金属背衬的结构损坏。除了结构要求之外，CMC堆叠体可能成为覆盖涂层粘附的问题，其中覆盖涂层可以是例如陶瓷热障涂层(TBC)。因此，技术上仍存在改进的空间。
附图说明
在下面的描述中参照附图解释本发明，附图示出：
图1是由CMC堆叠体和其上的陶瓷沉积物形成的燃气轮机部件的一个示例性实施方案的透视图。
图2是添加覆盖涂层之后图1的陶瓷沉积物沿所示的线2-2的截面图。
图3是燃气轮机部件的一个替代示例性实施方案的透视图。
图4是相邻的CMC层之间的界面的示意图。
图5示意性说明了形成图1的陶瓷沉积物的方法。
具体实施方式
本发明人设计了一种创新的CMC层合结构，所述结构提供了改善的结构完整性、改善的层间密封以及改善的任意施加的覆盖层的粘附。所提出的结构包括附加地形成在CMC堆叠体上的陶瓷沉积物。可以施加陶瓷沉积物使其将至少两个相邻的CMC层彼此结合。也可以沉积陶瓷沉积物使其形成将提高覆盖层的粘附的凸起结构(rasied structure)。陶瓷沉积物可以是CMC层结合在一起的唯一方式，并且陶瓷沉积物可以形成气密密封使得燃烧气体不会在CMC层之间穿过。替代地，也可以使用常规方式，例如用粘结剂将CMC层结合在一起并密封，使得相邻的CMC层之间的界面可以使用一种或更多种陶瓷沉积物和粘结剂的组合来结合和密封。发明人还设计了一种用于通过增材制造工艺使用激光束加热和熔化陶瓷粉末以形成陶瓷沉积物来施加陶瓷沉积物的方法。
已知熔化单个CMC层的边缘，如Marini等的美国公开号2007/0075455中公开的。然而，Marini仅公开了对单层的自由边缘进行密封以改善耐磨性或硬度，并且这导致光滑的涂层/沉积物。本文公开的方法用陶瓷沉积物将复数个CMC层沿着它们接合的边缘结合在一起，所述陶瓷沉积物可以更粗糙，因此比Mariana的光滑涂层更适用于覆盖层粘附。如本文所使用的，每个CMC层在任何结合操作之前是独立结构。也就是说，尽管每个CMC层可以包含树脂材料作为其组成的一部分，但是邻接的CMC层没有通过可能存在于任何单独的CMC层内的基体材料结合在一起。因此，尽管CMC层本身可以是层合体，因为其可以包括通过树脂材料结合在一起的纤维层，但是在本文中每个CMC层被认为是单个独立的CMC层。
图1是由CMC堆叠体12和其上的陶瓷沉积物14形成的燃气轮机部件10的一个示例性实施方案的示图。CMC堆叠体12包括复数个CMC层16，例如氧化物-氧化物复合材料。在这个示例性实施方案中，每个CMC层16呈部件10的翼型部20的层18的形式，其中部件10可以是燃气涡轮发动机叶轮或叶片。还包括金属芯30。在这个示例性实施方案中，金属芯30为部分中空的，具有可用作冷却通道的腔。在该配置中，CMC堆叠体12的CMC层16保护金属芯30免受燃烧气体的影响同时金属芯30为部件10提供强度。然而，本公开内容并不意味着限于这样特定的结构并且如本领域普通技术人员将理解的可以更宽泛地应用本教导。
陶瓷沉积物14呈将相邻的CMC层32结合在一起的焊道(bead)形状，类似于边缘焊缝(weld bead)。相邻的CMC层32限定了其间具有周边36的界面34(例如，由搭接表面(faying surface)限定的区域)。陶瓷沉积物14可以沿着周边36的一部分延伸或者其可以沿着整个周边36延伸。CMC堆叠体12的各种实施方案可以包括沿着周边36的一部分延伸的陶瓷沉积物14、沿着整个周边36延伸的陶瓷沉积物14或者二者的组合。选择陶瓷沉积物14的全部或部分延伸和/或使用相邻的CMC层32之间的粘结剂可以基于部件10在完成时的期望/预定的机械特性。例如，与陶瓷沉积物14的部分边缘结合允许结构内的一些柔性，而单独的粘结剂或粘结剂和边缘结合可以提供更强/更不柔韧的结构。边缘结合、粘结剂和/或螺栓连接的任意组合可用于在部件10中实现期望的机械特性。
此外，可以通过控制沉积过程将陶瓷沉积物14的孔隙率控制为约百分之四十至百分之九十以实现期望的机械特性，包括例如渗透性和刚性。当形成为不可渗透(气密)的陶瓷沉积物时，并且当形成在相邻的CMC层32之间时，陶瓷沉积物14密封相邻的CMC层32使得燃烧气体不能在其间穿过到达金属芯30。陶瓷沉积物14的孔隙率还控制陶瓷沉积物14的弹性模量(刚性)。陶瓷沉积物14的应变耐受性(strain tolerance)与弹性模量有关。因此，控制孔隙率可以控制陶瓷沉积物14的刚性以及应变耐受性。因此，如果相邻的CMC层之间的顺应结合(固定)是期望的，则陶瓷沉积物14可以制成更多孔的。替代地，如果优选刚性结合，则陶瓷沉积物14可以制成较少孔的。可以控制机械特性使得其在整个陶瓷沉积物14中是均匀的，或者使得其从一个陶瓷沉积物14局部地变化到另一个或者根据需要在给定的陶瓷沉积物14内变化。
图2是已经添加了覆盖层38的图1的陶瓷沉积物14沿着线2-2的截面图。陶瓷沉积物14形成接合相邻的CMC层32的角部40的焊道，从而在其间形成防止燃烧气体穿过界面34的密封部42。陶瓷沉积物14相对于部件10的由相应CMC层16的边缘面46形成的表面44凸起。因此，在一个示例性实施方案中，陶瓷沉积物不覆盖整个边缘面46。如果陶瓷沉积物14形成在一个边缘面46的两个角部，则可能仍然存在边缘面46的(以及因此表面44的)未被陶瓷沉积物14覆盖的其余部分48。陶瓷沉积物14相对于表面44的提高性质提供了更大的表面积，其提高了对覆盖层38的粘附。陶瓷沉积物14还可以成形为包括可以更好地接合覆盖层38的特征部，例如槽、悬凸部等。这些又改善了覆盖层38的设计寿命和抗剥落性(spallationresistance)。
图3是其中陶瓷沉积物14’在部件的表面44上形成图案的一个替代示例性实施方案的示图。陶瓷沉积物14’结合至至少两个相邻的CMC层32的相应边缘面46，并且由于其跨越相应界面34，因此陶瓷沉积物14’将相邻的CMC层32彼此固定。如上，可以在图案内根据需要控制机械特性以产生预定的机械特性。例如，朝向后缘(trailing edge)50，陶瓷沉积物14’可以沉积得更致密，因此更具刚性以获得结构完整性。朝向前缘52，陶瓷沉积物14’可以更多孔且更柔韧，从而提高其吸收冲击的能力，从而减少外来物损伤(foreign objectdamage，FOD)。在另一个实例中，陶瓷沉积物14’可以形成为气密的，但是足够多孔以允许CMC堆叠体12靠近金属芯30的微小变形，这提供了存在时的最终结构稳定性。
虽然示出了交叉形图案，但是如本领域普通技术人员将理解的可以使用任何图案。例如，图案的焊道可以间隔得更近，其中寻求更大的覆盖层粘附。同样，也可以局部地控制陶瓷沉积物14、14’的高度、宽度、纵横比(例如，就高度/厚度与宽度而言，3:1至5:1)、截面形状和表面粗糙度以实现所寻求的覆盖层粘附、柔性和结构完整性的平衡。
图4是相邻的CMC层32和相邻的CMC层32之间的界面34的示意图。界面34由相邻的CMC层32之间的区域(类似于搭接区域)限定。CMC层16中的开口60接收金属芯30(未示出)并且界面34位于CMC堆叠体12外部的燃烧气体和开口60之间。因此，界面34可以被密封以防止燃烧气体侵入CMC层16之间，使得燃烧气体不会到达其中的金属芯30和开口60。可以通过在界面34的整个周边36周围形成陶瓷沉积物14来实现密封。替代地，可以以在周边36周围提供连续的密封部的方式通过将一个或更多个陶瓷沉积物14与粘结剂62组合来实现密封。
粘结剂62可以在施加的相邻的CMC层32之间允许很小的相对运动。陶瓷沉积物14固定相邻的CMC层32的边缘40，但是不延伸至界面34中，因此可以允许相邻的CMC层32之间的更多相对运动。因此，界面34可以被定制以根据设计要求局部地控制每个界面34内的相对运动。
图5示意性说明了形成陶瓷沉积物14、14’并且特别地图1的陶瓷沉积物14的方法的一个示例性实施方案。在这个示例性实施方案中，通过使从能量束源72(例如，激光器)发射的能量束70横过以熔化陶瓷材料来形成陶瓷沉积物。然后，熔化的陶瓷材料冷却以形成陶瓷沉积物14。能量束源72可以为具有512纳米波长的绿色激光系统并且可以产生光斑尺寸大约为50微米的激光束。
该方法可以是自体的(autogenous)，使得熔化的陶瓷是来自CMC层16的陶瓷。替代地或另外地，陶瓷粉末74可以用作填料并且预先放置在其中待形成陶瓷沉积物14的表面44上。陶瓷粉末74可以包括一(1)微米及以上的颗粒。替代地或另外地，陶瓷粉末74可以通过从陶瓷粉末源80经由输送管82输送的陶瓷粉末流78被供给至处理位置76。另一些实施方案可以使用糊料、带或带状物来为陶瓷沉积物提供陶瓷填料材料。待熔化的陶瓷(无论是CMC层16的一部分还是单独的填料材料)对于所选择的能量束70可以是半透明或不透明的，以便捕获热能。填料材料可以提供有或不具有粘合剂材料。
用于形成陶瓷沉积物14的过程可以是反复的。在这样一个示例性实施方案中，陶瓷沉积物14可以分层构建，其中每个层通过以上述公开的方式熔化陶瓷来产生。每个层可以为十(10)微米厚至二(2)毫米厚。部件10可以定位在陶瓷粉末床(未示出)、所形成的相应层、所减少的部件、和形成在在先形成的层上的下一层中。这样的方法将允许一维(1D)印刷(陶瓷沉积物14)、二维(2D)印刷(陶瓷沉积物14’)和三维(3D)陶瓷沉积物，这意味着：在图2的截面图中，陶瓷沉积物14的截面形状可以根据需要设计以更好地例如用悬凸部或底切(undercut)将覆盖层38粘附至CMC堆叠体12。
本文提出的创新部件和方法能够制造具有改善的结构完整性和覆盖层粘附的燃气轮机部件。这些改善可以在相邻的CMC层之间局部地定制以及局部地在跨越复数个CMC层的部件的区域中定制，从而提高设计灵活性。因此，这代表了本领域的显著改进。
尽管在本文中已经示出并描述了本发明的多个实施方案，但是显而易见的是这样的实施方案仅以示例的方式被提供。本文中在不背离本发明的情况下可以进行大量的变型、修改和替代。因此，旨在本发明仅受所附权利要求的精神和范围限制。

Claims (10)

1.一种制造燃气涡轮发动机部件(10)的方法，所述方法包括：
沿着金属芯(30)堆叠复数个CMC层(16)以形成不连接的CMC层的堆叠体，其中所述复数个CMC层的相邻边缘面(46)限定了表面(44)；
将陶瓷材料附加地沉积至所述表面的仅选择部分以将所述复数个CMC层的至少一些在它们的相应边缘面处结合在一起；以及
选择用于沉积所述陶瓷材料(14)的位置以实现所得部件的预定机械特性。
2.根据权利要求1所述的方法，还包括：
在所述复数个CMC层的至少一些之间施加粘结剂；以及
选择用于施加所述粘结剂和用于附加地沉积所述陶瓷材料的位置以密封防止气体侵入相邻的CMC层之间。
3.根据权利要求1所述的方法，还包括：
附加地沉积所述陶瓷材料以形成在所述表面上方延伸的陶瓷沉积物；以及
将覆盖层沉积至所述表面，覆于所述陶瓷沉积物之上。
4.根据权利要求1所述的方法，还包括沿着所述复数个CMC层中的两个的相邻边缘面之间的界面附加地沉积所述陶瓷材料以在其间形成密封部。
5.根据权利要求1所述的方法，还包括控制附加地沉积陶瓷材料的步骤以实现有效促进所述预定机械特性的所述陶瓷材料的预定孔隙率。
6.一种通过权利要求1所述的方法形成的燃气涡轮发动机叶片，其中所述陶瓷材料靠近所述叶片的后缘沉积。
7.一种燃气涡轮发动机部件，包括：
包括至少两个CMC层的堆叠体，其中相邻的CMC层限定了其间不含基体材料的界面；
结合至所述至少两个CMC层的边缘的陶瓷沉积物，其中所述陶瓷沉积物将所述至少两个CMC层彼此固定。
8.根据权利要求7所述的燃气涡轮发动机部件，其中所述边缘限定了表面，并且其中所述陶瓷沉积物相对于所述表面的其余部分凸起。
9.根据权利要求7所述的燃气涡轮发动机部件，其中所述界面限定了周边，其中所述陶瓷沉积物在所述周边处形成密封所述界面的焊道。
10.根据权利要求7所述的燃气涡轮发动机部件，其中所述边缘限定了表面，其中所述陶瓷沉积物限定了结合至所述表面的图案，其中所述图案将邻接的CMC层彼此固定。
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Application publication date: 20181109