CN112004992A - 具有耐氧化的叶身梢部的涡轮叶片 - Google Patents

具有耐氧化的叶身梢部的涡轮叶片 Download PDF

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CN112004992A
CN112004992A CN201980023175.5A CN201980023175A CN112004992A CN 112004992 A CN112004992 A CN 112004992A CN 201980023175 A CN201980023175 A CN 201980023175A CN 112004992 A CN112004992 A CN 112004992A
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blade
turbine blade
tip
turbine
airfoil
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克里斯蒂安·布伦胡贝尔
贝恩德·布尔鲍姆
罗兰·黑贝尔
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Siemens Energy Global GmbH and Co KG
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Abstract

本发明涉及一种用于燃气轮机的转子的涡轮叶片(1)，所述涡轮叶片包括从叶根(6)沿径向方向延伸的叶身(2)，所述叶身具有包括第一材料的叶身基体(3)和包括第二材料的叶身梢部(4)，其中第二材料是比第一材料更耐氧化的。第二材料的成分至少在子区域中渐变地构成。还提出一种用于制造根据本发明的涡轮叶片的方法。所述方法包括如下步骤：在用于执行增材法的设备的构造平台上提供涡轮叶片的具有第一材料的基体；以特定量施加与第一材料不同的粉末状的第二材料；通过高能射束的作用熔化粉末状的材料；降低构造平台，其中将施加和熔化粉末状的材料以及降低构造平台的步骤以制成叶身尖部所需的次数重复。

Description

具有耐氧化的叶身梢部的涡轮叶片
技术领域
本发明涉及一种涡轮叶片，其叶身具有由第一材料构成的基体和由耐氧化的第二材料构成的叶身梢部，以及一种用于制造所述涡轮叶片的方法。
背景技术
例如用于燃气发电厂和蒸汽发电厂的现代的燃气轮机是持续改进的主题，用于提高其效率。这然而造成在热气路径中的越来越高的温度。用于转子叶片的金属材料，尤其在第一级中，在近几年在其高温下的强度方面(蠕变负荷，热机械疲劳)进行改进。这然而部分地造成氧化特性变差。这特别是在叶片的尖部(叶尖、叶片顶部)处成问题的，因为在叶片顶部的朝向壳体的面(扫掠棱边)上可能在运行中，尤其在第一运行小时内，造成叶片顶部的扫掠。在此，可能造成在叶片的包括镍基超合金的常规的基本材料上沉积的MCrAlY层的磨损，如其例如在文献EP 2 317 078A2中所公开那样，由此基本材料暴露于热的、氧化的燃烧气体。由于在叶身梢部处的材料的氧化造成叶片的更高的间隙耗损和更短的使用寿命。
通常尝试通过间隙的较保守的设计，燃烧温度的降低或通过叶片/叶身梢部的更强的冷却至少限制了该问题。但这些措施造成了更大的冷却空气消耗或造成功率损失。也致力于借助于在环形区段上的足够厚的且有耐磨能力的陶瓷层使叶身梢部的损坏最小。然而这些陶瓷层易碎。在此目的是改进现有技术。
发明内容
所述目的通过具有权利要求1的特征的涡轮叶片实现。本发明的其他有利的实施方式和设计方案从从属权利要求、附图和实施例中得到。本发明的所述实施方式可有利地彼此组合。
本发明的第一方面涉及一种用于燃气轮机的转子的涡轮叶片，包括从叶根沿径向方向延伸的叶身，所述叶身具有包括第一材料的基体和包括第二材料的叶身梢部，其中第二材料是比第一材料更耐氧化的。
叶身梢部的材料由此并不绝对用耐氧化的材料覆层，而是有利地由耐氧化的材料构成。由此可以即使在损坏的情况下也提高叶身梢部相对于在热气中起氧化作用的力的耐抗能力。特别优选地，扫掠棱边的子区域，叶身梢部的沿径向方向指向壳体的部分由这种材料构成。
优选地，构成叶身梢部的第二材料包括MCrAlY合金。MCrAlY合金(M表示Co和/或Ni)有利地优选具有高耐氧化能力的特征。此外，MCrAlY合金可以直接涂覆到第一材料上。对于叶片顶部的构造特别适合的是增材制造法，例如激光堆焊、选择性激光熔化和选择性电子束熔化。
优选地，第二材料具有如下化学成分：
Co：22重量％至26重量％，
Cr：14重量％至18重量％，
Al：9.5重量％至11.5重量％，
Y：0.2重量％至0.7重量％，
Re：0.0重量％至1.8重量％，
Ta：0.0重量％至1.7重量％，
以及剩余物镍和偶然的且不可避免的杂质。所述MCrAlY合金在所述成分中的特征在于特别高的耐温性，这关于叶身梢部切入到相应的涡轮机壳体的可磨损的覆层中起到有利作用，从而有助于防止间隙耗损。在第二材料中的特定的期望的相的构成取决于本领域技术人员的估计和能力。
还优选的是，作为根据本发明的涡轮叶片的第一材料使用合金Alloy247(A247)。A247的使用是有利的，因为上述成分的第二材料形成在A247上的出色的结合。A247是定向凝固或柱形结晶的原料。作为第一材料然而也可以使用其他合金，其中可以存在不同的晶体取向。
在根据本发明的涡轮叶片的一个优选的实施方式中，第二材料的成分至少在子区域中渐变地(gradiert)构成。换言之，第二材料的成分至少在子区域中逐渐从与第一材料的连结面至扫掠棱边地改变。将子区域理解为第二材料的部段，即例如连接于第一和第二材料之间的过渡部或也包括所述过渡部的区域。例如，渐变的成分是有利的，如果在第一和第二材料之间的金属键不够强。在朝向第一材料的区域中，第二材料在其在相应的说明的区域之内的成分的单个元素或所有元素的含量方面优选更类似于第一材料。因此，特别优选的是，第二材料在从第一材料到第二材料的过渡部的区域中渐变为，使得第一材料和第二材料之间的热机械应力被补偿。还特别优选的是，叶身梢部的材料朝扫掠棱边，即叶身梢部的端部方向沿径向方向具有越来越耐氧化的特性。特别是在扫掠棱边的区域中高的耐氧化性是有利的，因为在那特别恶劣的条件会侵蚀叶身梢部的材料。
优选地，根据本发明的涡轮叶片的第二材料具有陶瓷颗粒。陶瓷颗粒有利地提高第二材料的耐磨损性。在第二材料中的陶瓷颗粒的浓度可以是关于叶身梢部的体积均等的，或者替选地朝向扫掠棱边是更高的。特别优选地，立方氮化硼(cBN)或碳化硅(SiC)或这些物质的组合用作为陶瓷添加物，其不视为限制。
优选地，在根据本发明的涡流机叶片的叶身梢部的区域中设置有用于冷却的复杂的结构。换言之，特别在扫掠棱边中装入复杂的冷却结构，例如冷却通道，以便有利地进一步提升叶身梢部的耐氧化性。在此，特别通过上文提到的增材制造法能够实现复杂的结构的提供。
根据本发明的涡轮叶片优选是燃气轮机的转子叶片。燃气轮机优选使用在燃气和蒸汽发电厂中。
本发明的第二方面涉及一种用于制造根据本发明的涡轮叶片的方法，所述方法包括如下步骤：
-在用于执行增材法的设备的构造平台上提供涡轮叶片的具有第一材
料的基体；
-以特定量施加与第一材料不同的粉末状的第二材料；
-通过高能射束的作用熔化粉末状的材料；
-降低构造平台，
其中将施加和熔化粉末状的材料以及降低构造平台的步骤以制成叶身尖部所需的次数重复。
借助于根据本发明的方法可以将第二材料直接涂覆在第一材料上。所述方法包括增材制造法，例如激光堆焊、选择性激光熔化和选择性电子束熔化。
借助于所述方法可以有利地在叶身梢部的区域中，尤其在扫掠棱边中产生复杂的结构，所述复杂的结构有助于叶身梢部的冷却。复杂的结构例如是通道和孔，其适合于流体介质的穿流。因此优选的是，在制造叶身梢部时在叶身梢部中产生复杂的结构。特别优选地，复杂的冷却结构在扫掠棱边中产生。
在根据本发明的方法的一个优选的实施方式中，粉末状的第二材料的成分在涂覆过程中渐变地改变。为此特别是激光堆焊的方法，其中要涂覆的材料通过同时熔化来涂覆到位于其下方的材料的表面上。激光堆焊在此是有利的，因为能够在焊接过程期间在现场改变粉末成分。对此仍优选的是，作为高能射束使用激光束。
优选地，将陶瓷粒混入粉末状的第二材料。第二材料中的陶瓷颗粒的浓度可以遍布叶身梢部体积是均匀的，或者替选地朝向扫掠棱边是更高的，其中朝扫掠棱边方向将与在第一和第二材料的过渡区域中相比更大量的陶瓷粒混入粉末状的第二材料。特别优选地，立方氮化硼(cBN)或碳化硅(SiC)或这些物质的组合用作为陶瓷添加物，而不局限于此。
附图说明
根据附图详细阐述本发明。附图示出：
图1示出根据本发明的涡轮叶片的一个实施方式。
图2示出根据图1的涡轮叶片的叶身梢部的放大视图。
图3示出用于执行根据本发明的方法的设备的示意图。
图4示出根据本发明的方法的一个实施方式的流程图。
具体实施方式
图1示出根据本发明的一个实施方式的用于燃气轮机的转子叶片1。转子叶片1根据示图包括沿径向方向延伸的叶身2，所述叶身具有叶身基体和叶身梢部4。此外，转子叶片1包括叶身平台5和呈圣诞树构成方式的叶根6。
在沿径向方向形成叶身2从而叶身梢部4的终端的端部上，叶身梢部4具有扫掠棱边7。扫掠棱边7沿着环周壁延伸并且在外侧上与环周壁齐平。
叶身基体3具有第一材料。叶身基体的第一材料在本实施例中是合金A247。替选地，第一材料也可以包括其他合金或由其他合金构成。
叶身梢部4从而还有扫掠棱边7具有第二材料，所述第二材料是MCrAlY型的合金。具体来说，第二材料具有如下成分的合金：Co：22重量％至26重量％，Cr：14重量％至18重量％，Al：9.5重量％至11.5重量％，Y：0.2重量％至0.7重量％，Re：0.0重量％至1.8重量％，Ta：0.0重量％至1.7重量％，以及剩余物镍和偶然的且不可避免的杂质。替选地，第二材料也可以包括其他合金或由其他合金构成。MCrAlY材料具有陶瓷颗粒8，其由立方氮化硼(cBN)、碳化硅(SiC)或其组合构成，或者替选地也由其他材料作为添加物构成。
叶身梢部4的材料至少在子区域中渐变地构成。在此，上述合金的合金组成部分的份额渐变地改变，使得其在第一材料和第二材料之间的过渡部9的区域中存在关于热膨胀系数和导热系数的尽可能小的差。为此，在扫掠棱边7的区域中，与在过渡部9的区域中相比，材料的抗氧化性更高。换言之，叶身梢部4的材料的抗氧化性沿径向方向增加。替选地，叶身梢部4的材料也可以不渐变地构成。
上述陶瓷颗粒8的量和浓度也可以渐变地在叶身梢部4的材料中构成。在此，陶瓷颗粒8在扫掠棱边7的区域中的浓度比在第一和第二材料之间的过渡区域9中的浓度更高。
在图2中详细示出具有扫掠棱边7的叶身梢部4的区域。在扫掠棱边7的区域中可见陶瓷颗粒8。扫掠棱边7构成为3D体部。在此，在扫掠棱边7中构成复杂的结构，所述结构特别是呈冷却通道的形式，其进入孔或排出孔10在扫掠棱边7的表面中示出。所述复杂的结构10特别是借助于增材制造法例如激光堆焊或选择性激光熔化来制造。
在用于通过激光堆焊将第二材料涂覆到第一材料上的方法中，在图3中示出的设备20在对于本领域技术人员常用的构造室中提供。构造室包含氮气或稀有气体氛围，以便抵抗在叶片2的材料中的空气夹杂物。所述设备20包括激光装置21，所述激光装置构成为用于产生激光束22或者将激光束从外部激光源转向至要照射的对象。为此，激光装置21具有本领域技术人员已知的构件，例如玻璃纤维线缆和转向镜。
大功率的透镜23，例如F-Theta透镜设计用于将激光束22聚焦。激光束22通过输入装置24传导至叶身梢部4的区域。输入装置24与储存容器25连接，所述储藏容器包含呈粉末形式的应当制造叶身梢部的第二材料。粉末在用于材料传送的装置26上传送至输入装置24。输入装置24优选构成为喷嘴，以便将粉末状的第二材料喷入或喷到叶身梢部4的已经存在的材料的表面上，使得所述第二材料直接在涂覆到材料层上时由激光熔化。
粉末状的第二材料在图3中涂覆到转子叶片的叶身2的基体3上，以便制造叶身4的尖部。
在图4中作为流程图示出用于制造根据图1的根据本发明的叶片1的根据本发明的方法的一个实施方式。在第一步骤S1中在用于执行增材法的设备的构造平台上提供要制造的涡轮叶片1，其具有涡轮叶片2的具有第一材料的基体3。在第二步骤S2中，从储存容器中通过用于至输入装置24的材料传送装置26以特定量传送与第一材料不同的粉末状的第二材料。通过输入装置24将粉末状的材料涂覆到基体3的第一材料上或涂覆到叶身梢部4的已经涂覆的且固化的第二材料上。
在第三步骤S3中，通过激光束22的作用熔化第二材料并且熔化位于其下方的材料。步骤S2和S3可以同时执行，因为激光束22引导穿过输入装置24并且粉末状的材料在施加的时刻已经熔化。
在第四步骤S4中，降低构造平台。将步骤S1至S4以制成叶身梢部所需的次数重复。
对于所描述的激光堆焊替选地，叶身梢部可以通过粉末床工艺如选择性激光熔化或选择性电子束熔化制造。在此情况下，已提供相应的构造室，在所述构造室中可以在形成的材料层上涂覆粉末层并且在所述材料层中将特定区域借助于能量束熔化并且随后固化，并且逐层重复所述工艺，直至制成构件。
本发明的对于本领域技术人员而言近似的变型形式和变化形式属于权利要求的保护范围。

Claims (14)

1.一种用于燃气轮机的转子的涡轮叶片(1)，包括从叶根(6)沿径向方向延伸的叶身(2)，所述叶身具有包括第一材料的叶身基体(3)和包括第二材料的叶身梢部(4)，其中所述第二材料是比第一材料更耐氧化的，其中所述第二材料的成分至少在子区域中渐变地构成。
2.根据权利要求1所述的涡轮叶片(1)，其中所述叶身梢部(4)的材料包括MCrAlY合金。
3.根据权利要求1或2所述的涡轮叶片(1)，其中所述第二材料具有如下化学成分：
Co：22重量％至26重量％，
Cr：14重量％至18重量％，
Al：9.5重量％至11.5重量％，
Y：0.2重量％至0.7重量％，
Re：0.0重量％至1.8重量％，
Ta：0.0重量％至1.7重量％，
以及剩余物镍和偶然的且不可避免的杂质。
4.根据上述权利要求中任一项所述的涡轮叶片(1)，其中作为第一材料使用合金Alloy247。
5.根据上述权利要求中任一项所述的涡轮叶片(1)，其中所述第二材料在从所述第一材料至所述第二材料的过渡部(9)的区域中渐变地构成，使得补偿所述第一材料和所述第二材料之间的热机械应力。
6.根据上述权利要求中任一项所述的涡轮叶片(1)，其中所述叶身梢部(4)的材料朝形成所述叶片的径向端部的扫掠棱边(7)的方向具有增强的耐氧化特性。
7.根据上述权利要求中任一项所述的涡轮叶片(1)，其中所述第二材料具有陶瓷颗粒(8)。
8.根据上述权利要求中任一项所述的涡轮叶片(1)，其中在所述扫掠棱边(7)的区域中构成用于冷却的复杂的结构(10)。
9.根据上述权利要求中任一项所述的涡轮叶片(1)，所述涡轮叶片是燃气轮机的转子叶片。
10.一种用于制造根据上述权利要求中任一项所述的涡轮叶片(1)的方法，包括如下步骤：
-在用于执行增材法的设备的构造平台上提供涡轮叶片的具有第一材料的基体(3)；
-以特定量施加与所述第一材料不同的粉末状的第二材料；
-通过高能射束的作用熔化粉末状的材料；
-降低所述构造平台，
其中将施加和熔化所述粉末状的材料以及降低所述构造平台的步骤以制成所述叶身梢部(4)所需的次数重复。
11.根据权利要求10所述的方法，其中将所述粉末状的第二材料的成分在涂覆过程中渐变地改变。
12.根据权利要求10或11所述的方法，其中将陶瓷粒子(8)混入所述粉末状的第二材料。
13.根据权利要求10至12中任一项所述的方法，其中在所述叶身梢部(4)的扫掠棱边(7)的区域中产生复杂的冷却结构(10)。
14.根据权利要求10至13中任一项所述的方法，其中将激光束(22)用作高能射束。
CN201980023175.5A 2018-03-28 2019-02-13 具有耐氧化的叶身梢部的涡轮叶片 Pending CN112004992A (zh)

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