CN109937103A - 用于制造涡轮机叶片的方法 - Google Patents

用于制造涡轮机叶片的方法 Download PDF

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CN109937103A
CN109937103A CN201780069635.9A CN201780069635A CN109937103A CN 109937103 A CN109937103 A CN 109937103A CN 201780069635 A CN201780069635 A CN 201780069635A CN 109937103 A CN109937103 A CN 109937103A
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blade
alloy
increasing material
method described
material manufacturing
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CN109937103B (zh
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雅恩·丹尼斯
丹尼斯·丹尼尔·吉恩·博斯雷奥
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Safran Helicopter Engines SAS
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    • 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
    • F01D17/00—Regulating or controlling by varying flow
    • F01D17/10—Final actuators
    • F01D17/12—Final actuators arranged in stator parts
    • F01D17/14—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits
    • F01D17/16—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes
    • F01D17/162—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes for axial flow, i.e. the vanes turning around axes which are essentially perpendicular to the rotor centre line
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
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    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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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
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    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
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    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
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    • 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
    • B33Y70/00—Materials specially adapted for 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C9/00—Alloys based on copper
    • C22C9/06—Alloys based on copper with nickel or cobalt as the next major constituent
    • 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
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/186—Film cooling
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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
    • F01D5/28—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
    • F01D9/00—Stators
    • F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • F01D9/04—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector
    • F01D9/041—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector using blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
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    • 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
    • B22F10/60—Treatment of workpieces or articles after build-up
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/18—Dissimilar materials
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    • 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
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/187—Convection cooling
    • 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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    • F05D2230/31—Layer deposition
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    • 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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    • F05D2240/00—Components
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Abstract

本发明涉及一种用于制造具有至少一个3D腔(7)的涡轮机叶片(P)的方法，其特征在于，所述叶片是由基于铜和镍的合金的金属增材制造粉末的层的连续沉积和选择性固结而生产的，所述合金包括2％至7％的镍。本发明还涉及一种涡轮机叶片，其特征在于，所述涡轮机叶片是通过金属增材制造使用所述方法来制造的。

Description

用于制造涡轮机叶片的方法
技术领域
本发明涉及涡轮机叶片的制造，更具体地涉及具有复杂内部形状的叶片的制造，并且更具体地涉及当这些叶片也具有复杂的外部形状时叶片的制造。
这在包括内部腔的类型的变螺距压缩机叶片的情况下是特别有利的应用。
背景技术
许多涡轮机叶片，特别是压缩机分配器的一些变螺距叶片(称为进口导向叶片“Inlet Guide Vane，IGV”)，可以具有复杂的3D形状，从而防止这些叶片被制造成一体件。
这在其中内部腔设置成用于空气循环的IGV叶片的情况下尤其如此。
用于制造这种叶片的传统技术在于通过锻造制造旨在构成完整形状的各种部件(主叶片本体、盖子和在叶片尾部的盖)、加工支撑表面并且通过感应钎焊组装它们。
这种实施方式很复杂，并且在与复杂的外部形状结合的情况下变得更加不可能。
然而，进一步地，这几乎不符合工业操作，特别是在公差和成本方面。
同样很复杂的铸造方法不构成可能的解决方案，特别是考虑到叶片的飞边厚度。
金属注射成形(或者MIM)技术就其自身而言将涉及多个部件的注射以及在烧结期间的钎焊。该金属注射成形技术的使用甚至比锻造解决方案的使用更复杂。
另外，目前在许多领域中常规使用增材制造技术。
然而，迄今为止，由增材制造机器制造商提出的解决方案不符合涡轮机叶片所期望的机械特性和热特性。
发明内容
本发明的目的在于提出一种具有复杂内部形状的涡轮机叶片的制造方法。
本发明的另一目的在于提出一种制造方法，该制造方法实施起来简单并且符合在工业操作中所期望的成本和公差水平。
本发明的又一目的在于提出一种方法，该方法允许制造具有良好导热性和良好耐磨性的叶片。
特别地，本发明提出了一种用于制造具有至少一个3D腔的类型的涡轮机叶片的方法，其特征在于，所述叶片是由基于铜和镍的合金的金属增材制造粉末的层的连续沉积和选择性固结而生产的，所述合金包含2％至7％的镍，优选地包含2％至5％的镍，甚至更优选地包含约3％的镍。
本发明还涉及一种以这种方式制造的涡轮机叶片，所述叶片由铜和镍合金基材料制成，所述合金包含2％至7％的镍(优选地包含2％至5％的镍，甚至更优选地包含约3％的镍)，这使得该叶片具有期望的机械性能和热性能。
本发明有利地适用于涡轮机压缩机分配器的变螺距叶片，该变螺距叶片包括至少一个空气循环腔。
附图说明
本发明的其它特征和优点通过以下的说明将变得更加清晰，该说明是纯说明性的而非限制性的，并且应当参考单个附图来阅读该说明，在该单个附图中示意性地示出了涡轮机压缩机叶片。
具体实施方式
图1的叶片P是涡轮机压缩机分配器的变螺距叶片。
该叶片从根部1延伸并且具有前缘2、后缘3，该后缘3与拱背4和拱腹5连接。在该叶片的与根部1相对的端部处，叶片P终止于圆柱形板6，该圆柱形板6用于将叶片P铰接附连到压缩机壳体上。
腔7在叶片内部沿着该叶片的长度延伸。该腔7旨在允许空气循环。
为此，根部1具有一个或多个用作空气进口的孔口8。
后缘3就其自身而言具有多个形成空气出口的开口8。这些开口8具有优化其航空性能的形状(这有助于使部件的形状复杂化)。
这种叶片具有例如10cm的长度和约4cm的腹板宽度。
该叶片构成的部件通过金属粉末床的增材制造在单个步骤中被制造。
为此，使用了采用电子束熔化(Electron Beam Melting，EBM)技术的增材制造机器或者使用了通过选择性激光熔化(Selective Laser Melting，SLM)技术进行的增材制造。
金属增材制造的其他技术也是可能的(例如，结合两种技术的机器)。
制造粉末基于铜和镍的合金，该合金包含2％至7％的镍，优选地包含2％至5％的镍，尤其更优选地包含约3％的镍。
含有2％至7％的镍的铜合金族是具有高导热性与良好抗侵蚀性之间的最佳折中的铜合金族。对于IGV叶片(其中内部腔设置成用于空气循环)的应用，需要良好的导热性，例如以允许有效的除霜，以及需要良好的抗侵蚀性，因为该叶片位于发动机进口处并因此可能经受例如沙子的侵蚀。
粉末层连续地沉积并且固结，以便逐层构建叶片。
在通过激光熔化进行增材制造的情况下，下面给出了优选的制造参数：
-激光功率：介于100W至500W之间，更优选地介于300W至400W之间；
-激光束在粉末层上的扫描速度：介于300mm/s至2000mm/s之间，更优选地介于700mm/s至1000mm/s之间；
-激光束移动所沿的线路之间的间隙：介于0.005mm至0.02mm之间，更优选地介于0.007mm至0.015mm之间；
-粉末层的厚度：介于20μm至40μm之间；
-粉末的粒度D50：约35μm。
在制造之后，将由此生产出来的叶片与机器的支撑板脱离。
在抽吸剩余的粉末之后，可以对叶片进行精加工处理(抛光、或者甚至是对某些表面进行再加工)。
还可以对叶片进行补充热处理(例如在介于350℃至620℃之间的温度下进行老化处理)。
应当注意，所获得的叶片由铜和镍合金基材料制成，所述合金包含2％至7％的镍，该所获得的叶片在热性能和机械性能方面特别令人满意：该合金高度导热并且具有高的耐磨性。
因此，所提出的方法特别适于具有空气循环腔的叶片的情况。
在没有钎焊的情况下，该方法简单并且成本低。该方法进一步使得公差能够符合航空工业所期望的公差。

Claims (10)

1.一种用于制造具有至少一个3D腔的类型的涡轮机叶片的方法，其特征在于，所述叶片是通过基于铜和镍的合金的金属增材制造粉末的层的连续沉积和选择性固结而生产的，所述合金包含2％至7％的镍。
2.根据权利要求1所述的方法，其特征在于，实施通过EBM技术进行的增材制造。
3.根据权利要求1或2所述的方法，其特征在于，实施通过激光熔化进行的增材制造。
4.根据权利要求3所述的方法，其特征在于，激光功率介于100W至500W之间。
5.根据权利要求3所述的方法，其特征在于，激光束在粉末层上的扫描速度介于300mm/s至2000mm/s之间。
6.根据权利要求3所述的方法，其特征在于，激光束移动所沿的线路之间的间隙介于0.005mm至0.02mm之间。
7.根据权利要求3所述的方法，其特征在于，粉末层的厚度介于20μm至40μm之间。
8.根据权利要求3所述的方法，其特征在于，粉末的粒度D50为约35μm。
9.一种涡轮机叶片，其特征在于，所述涡轮机叶片是通过实施根据前述权利要求中任一项所述的方法通过金属增材制造来制造的，所述叶片由铜和镍合金基材料制成，所述合金包含2％至7％的镍。
10.一种涡轮机压缩机分配器的变螺距叶片，所述变螺距叶片包括至少一个空气循环腔，其特征在于，所述变螺距叶片是通过实施根据前述权利要求中任一项所述的方法通过金属增材制造来制造的，所述叶片由铜和镍合金基材料制成，所述合金包含2％至7％的镍。
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FR3121061B1 (fr) 2021-03-26 2023-08-04 Safran Aircraft Engines Procede de fabrication d’une piece en alliage metallique pour une turbomachine

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CN105458272A (zh) * 2014-09-25 2016-04-06 通用电气公司 制品以及用于在制品中制备成形的冷却孔的的方法
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GB183809A (en) * 1921-07-28 1923-03-22 Mitsu Bishi Zosen Kabushiki Ka Improvements in alloy for turbine blades
EP0166940B1 (de) * 1984-07-05 1989-03-29 Mtu Motoren- Und Turbinen-Union MàœNchen Gmbh Einlaufbelag einer Strömungsmaschine
US9175568B2 (en) * 2010-06-22 2015-11-03 Honeywell International Inc. Methods for manufacturing turbine components
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