CN113498450A - 用于修理涡轮机转子叶片的方法 - Google Patents
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Abstract
一种用于修理涡轮机转子的叶片(10)的方法,特别是涡轮机风扇,该叶片包括由有机基复合材料制成的扇叶(12)和结合到扇叶的前缘的金属护壳(14),金属护壳(14)具有损伤区域(20),该方法包括:校准扇叶的前缘的步骤,冷却整个扇叶的步骤,接着通过向该损伤区域(20)添加金属材料并使用激光熔化该材料来重新填充损伤区域(20)的步骤,以及通过加工熔化材料来修剪损伤区域(20)的步骤。
Description
技术领域
本发明涉及一种用于修理涡轮机推进器叶片的方法,特别是该涡轮机的风扇。
背景技术
现有技术具体包括文献EP-A1-3045260、DE-A1-102010006384和FR-A1-3046557。
飞机涡轮机包括一个或多个推进器,该推进器可以是涵道式的或非涵道式的。本发明特别适用于风扇的叶片,即涵道式推进器的叶片,但也适用于其他类型的推进器,例如涡轮推进器发动机的非涵道式推进器。
涡轮机推进器在气流的作用下运动,其叶片会受到磨损或撞击的损坏,例如,由鸟撞击叶片引起的飞行物体损坏(FOD)类型。
本发明涉及带有损伤区域的推进器叶片的修理,更具体地,涉及包括由有机基复合材料(OMC)制成的叶片和结合到叶片的前缘的金属护壳的推进器叶片。
以已知的方式,OMC叶片可以包括嵌入在聚合物基体中的编织预制件。预制件是通过三维编织碳纤维获得的。
如在申请FR-A1-3046557中所述,护壳包括分别在叶片的压力侧和吸力侧上延伸的两个侧翼,以及连接两个翼的鼻部。特别是,这两个侧翼和这个鼻部高度暴露在穿过推进器的气流中,特别容易受到磨损、撞击或侵蚀的风险。特别是鼻部,其朝向涡轮机上游侧,并在运行期间形成穿过推进器的气流的前缘,最容易受到损坏的风险。
本发明为修理这种类型的推进器叶片提供了一种简单、有效和经济的解决方案。
发明内容
本发明提出了一种用于修理轮机推进器的叶片方法,涡轮机推进器特别是涡轮机风扇,该叶片包括由有机基复合材料制成的扇叶和接合到扇叶的前缘的金属护壳,金属护壳具有损伤区域,该方法包括:通过向该损伤区域添加金属材料并激光熔化该材料来重新填充该损伤区域的步骤,以及通过加工熔化的材料来修剪该金属区域的步骤。
因此,本发明提出了在原位修理叶片的护壳,即,无需从叶片上取下或移除护壳。这是特别有利的,因为它简化和加速了这种类型的叶片的修理,并且避免了当护壳损坏但仍可修理时报废叶片。
根据本发明,在进行重新填充的步骤和进行修剪步骤之前,该方法包括校准叶片的前缘的步骤和冷却整个扇叶的步骤。
在重新填充损伤区域的步骤的上游增加校准前缘的步骤允许准确地测量损坏前缘的实际轮廓(或几何形状)。实际上,在涡轮机中使用后的叶片可能会变形(所谓的具有真实轮廓的叶片),因此将不再符合刚生产出来的新叶片的尺寸(所谓的具有理论轮廓的叶片)。因此,根据本发明的方法能够根据叶片前缘的实际轮廓(其相对于其理论轮廓可能已经改变)具体地修理叶片的损伤区域。此外,该校准步骤允许准确地识别叶片的前缘上的损伤区域。这允许重新填充步骤沉积严格必要的量的材料,并达到要修理的损伤区域的毫米。
在重新填充步骤之前增加冷却扇叶的步骤允许在胶接处或两种材料(即前缘的金属护壳和由有机基复合材料制成的扇叶)之间的界面附近控制扇叶的前缘的温度。实际上,扇叶的整个体积都被冷却,以便在扇叶损伤区域上沉积和熔化材料的步骤中,将扇叶保持在胶接处可接受的最高温度(可能为120℃)。因此,一般而言,实现材料激光熔化的重新填充参数被优化,同时避免扇叶局部过热和退化。
根据本发明的方法可以包括以下特征和/或步骤中的一个或多个,相互独立地或相互结合地采取:
-校准步骤在冷却步骤之前执行或与冷却步骤同时执行,
-校准步骤借助于可移动的探针执行,
-扇叶被冷却到+20至-20℃之间,优选地0至-20℃之间的温度,
-金属护壳包括分别在扇叶的压力侧和吸力侧上延伸的两个侧翼,以及连接两个侧翼的鼻部,损伤区域位于鼻部上,
-温度阈值是预定的,该温度阈值对应于胶合剂和/或扇叶允许的最高温度,激光熔化借助于机器执行,机器的参数被设置为防止胶合剂和/或扇叶达到该阈值,
-阈值为120℃,
-填充材料与护壳材料相同,
-填充材料是TA6V,
-填充材料是碳化钛TiC,
-至少在重新填充步的骤期间,叶片被保持在框架上,使得该区域向上定向,
-该区域在重新填充的步骤期间被冷却,
-冷却通过传导执行、通过室温下的中性气体执行、通过冷却的中性气体执行、通过喷射液体或固体元素等执行,
-通过低温或珀尔帖效应确保冷却,
-激光熔化借助于移动激光头执行,
-校准和重新填充步骤借助于单个装置执行,该装置包括探针和激光头,并且其中,该装置能够通过枢转使探针在校准步骤期间与扇叶的前缘接触,并且能够使激光头在重新填充步骤期间面对扇叶的前缘,以及
-激光熔化由LMD(激光金属沉积,Laser Metal Deposition,的缩写)或微米激光(μlaser)执行。
附图说明
本发明的进一步特征和优点将从以下具体实施方式中变得明显,为了理解该详细描述,参考附图,其中:
[图1]图1是涡轮机推进器叶片,特别是涡轮机风扇的示意性透视图,
[图2]图2是如图1所示的叶片的护壳的示意性横截面图,
[图3]图3是用于实施根据本发明的方法的设备的局部示意透视图,
[图4]图4是图3的设备的局部示意透视图,并且其中实施了校准步骤,
[图5]图5是图3的设备的局部示意透视图,并且其中实施了重新填充步骤。
具体实施方式
图1示出了推进器的叶片10,推进器特别是飞机涡轮机的风扇。该叶片10包括由有机基复合材料制成的扇叶12和接合到前缘的金属护壳14。
扇叶12进一步包括与前缘相对的后缘16,以及在扇叶的前缘和后缘之间延伸的压力侧和吸力侧。
叶片具有标记为A的延伸轴线。扇叶12的一个纵向端是自由的,并且与其相对的另一纵向端连接到根部18,用于将叶片附接到涡轮机的转子。
如图2中可见,护壳14包括分别在扇叶12的压力侧和吸力侧上延伸的两个侧翼14a,以及将两个翼14a相连接的鼻部14b。
翼14a、14b在它们之间限定出空腔,所述空腔用于接纳扇叶12的前缘以及用于将护壳附接到扇叶的胶合剂。
金属护壳14的组容易损坏,并且因此具有损伤区域20。于是,必须对护壳14进行用于修理的方法。具体地,如图2所示,鼻部14c容易受到损坏。然而,这仅仅是示例,并且本发明可以不加区分地应用于金属护壳14的任何部分。
有利地,包括撞击或磨损的损伤区域20位于从叶片10的顶部(或头部)到叶片总长度的至少三分之二处。叶片10的长度相对于其延伸轴线A测量。更具体地,区域20从叶片10的顶部延伸到叶片10的护壳14的中部。该中部分可以对应于叶片10的前缘的空气动力学轮廓的弯曲部分。
鼻部14c容易受到损坏,于是随后可以对其进行修理方法。
本发明提出了一种用于修理推进器叶片10的护壳14的损伤区域20的方法,该方法包括:
(a)校准扇叶12的前缘的步骤,
(b)冷却整个扇叶12的步骤,
(c)通过向区域20添加金属材料并激光熔化该材料(理想地,基体和填料两者)来重新填充该区域20的步骤,以及
(d)通过加工熔化材料来修剪区域20的步骤。
冷却步骤(b)可以在校准步骤(a)之后或期间执行。
图3示出了用于实施根据本发明的方法的设备22的示例。
该设备22包括用于固定和定位叶片10的框架24。借助于用于保持叶片10的支撑件23,叶片10可以被固定地布置在设备22中。在该示例中,多个支撑件23保持叶片10的根部18、后缘16和顶部。叶片10定位成使其轴线A基本上是水平的。框架24可以被设计成使得叶片10以围绕轴线A可移动的方式安装,并且可以被框架定位成使得护壳14,特别是其受损区域20,如所示的示例中那样面朝上(优选地垂直于激光头26)。
参照图4,系统22包括探针27,其能够通过接触叶片10的前缘来进行检查,并且特别是查找所述区域20。探针27可与护壳14的鼻部14c的边缘或顶部和/或护壳14的翼14a、14b的压力侧和吸入侧表面接触。图3中非限制性地示出了几个待感测的点27'。
设备22包括冷却系统30,优选地通过传导进行冷却。在该示例中并以非限制性的方式,叶片10至少部分地被系统30包围。更具体地,系统30被安装成专门冷却叶片的前缘。
参照图5,设备22还包括激光头26,该激光头适于产生将聚焦在区域20上的激光束。优选地,头26配备有用于向区域20添加重新填充材料的系统28。激光头26和探针27是可移动的。有利地,激光头26和探针27布置在设备22的同一臂25上(在图4中可见)。臂25是能够枢转的可移动装置,并且优选地在90°和180°之间枢转,以使激光头26或探针27相对于叶片10到位。
填充材料优选地与护壳14的材料相同,并且例如是TA6V。有利地,填充材料是碳化钛TiC。
该材料通过激光而被熔化,更具体地,通过LMD或微激光方法熔化。LMD使用连续激光束,而微型激光器应用脉冲光束。在连续激光的情况下,激光连续加热基材和填充材料。结果,热量在同一区域累积并通过基材传播。在脉冲激光的情况下,激光以断续的线的形式“发射”,并且侵入性较小,这使得能够控制热量的扩散区域。
为了确保叶片10的健康,精确地控制护壳14的温度可能很重要,因为护壳越热,越多的热量可以传导到扇叶的胶合剂和材料中并损坏胶合剂和材料。例如,存在胶合剂熔化和护壳从扇叶脱离的风险。
在实践中,优选地温度阈值是预定的,该温度阈值对应于胶合剂和/或扇叶允许的最高温度。激光头26和冷却系统30的参数优选地被调节以防止胶合剂和/或扇叶达到该阈值。例如,该阈值是120℃。
冷却系统30可以设计成通过低温(例如通过喷射液态CO2或干冰或在喷射回路上游冷却的中性气体)冷却扇叶12或叶片10,或通过珀尔帖效应冷却扇叶或叶片。例如,冷却温度在+20至-20℃之间,优选地在0至20℃之间。
本发明有几个优点:
·更快地修理叶片,以便使其尽快再次使用;
·以适配于从工作中返回的叶片的实际空气动力学轮廓的方式进行修理;
·无需拆下护壳来进行清洗以清除胶合剂残留物;
·避免拆卸护壳,以避免配对问题;
·使用双材料(复合材料-金属材料)修理零件,而不使用烤箱、洁净室、真空机等特定装置。
·由于激光焊接和冷却系统中使用的能量低,在不改变复合材料(或实现双材料组件的胶合剂)的情况下重新装载金属护壳;
·限制重新填充引起的护壳变形;
·延长叶片(可能将变形)的使用寿命,以便在涡轮机中进行新的使用;
·限制工作中返回的叶片的报废。
Claims (15)
1.一种用于修理涡轮机推进器的叶片(10)的方法,涡轮机推进器特别是涡轮机风扇,所述叶片包括由有机基复合材料制成的扇叶(12)和接合到所述扇叶的前缘的金属护壳(14),所述金属护壳(14)具有损伤区域(20),所述方法包括:通过向所述损伤区域(20)添加金属材料并激光熔化所述材料来重新填充所述损伤区域(20)的步骤;以及通过加工熔化的材料来修剪所述损伤区域(20)的步骤,其特征在于,在进行重新填充的步骤和修剪的步骤之前,所述方法包括校准所述扇叶(12)的所述前缘的步骤和冷却所述整个扇叶(12)的步骤。
2.根据权利要求1所述的方法,其中,所述校准步骤在所述冷却步骤之前执行或与所述冷却步骤同时执行。
3.根据权利要求1或2所述的方法,其中,所述校准步骤借助于可移动的探针(27)执行。
4.根据前述权利要求中任一项所述的方法,其中,所述扇叶(12)被冷却到+20℃至-20℃之间,优选地0℃至-20℃之间的温度。
5.根据前述权利要求中任一项所述的方法,其中,通过低温或珀尔帖效应确保所述冷却。
6.根据前述权利要求中任一项所述的方法,其中,所述金属护壳(14)包括分别在所述扇叶的压力侧和吸力侧上延伸的两个侧翼(14a、14b),以及连接所述两个侧翼的鼻部(14c),所述损伤区域(20)位于所述鼻部(14c)上。
7.根据权利要求1至6中任一项所述的方法,其中,温度阈值是预定的,所述温度阈值对应于胶合剂和/或所述扇叶允许的最高温度,所述激光熔化借助于机器执行,机器的参数被设置为防止所述胶合剂和/或所述扇叶达到所述阈值。
8.根据权利要求7所述的方法,其中,所述阈值为120℃。
9.根据前述权利要求中任一项所述的方法,其中,所述填充材料与所述护壳的材料相同。
10.根据权利要求9所述的方法,其中,所述填充材料是TA6V。
11.根据权利要求1-8中任一项所述的方法,其中,所述填充材料是碳化钛(TiC)。
12.根据前述权利要求中任一项所述的方法,其中,至少在重新填充的步骤期间,所述叶片(10)被保持在框架(24)上,使得所述区域(20)向上定向。
13.根据权利要求1至12中任一项所述的方法,其中,所述激光熔化借助于可移动的激光头(26)执行。
14.根据权利要求13所述的方法,其中,进行校准的步骤和进行重新填充的步骤借助于单个装置(25)执行,所述装置包括所述探针(27)和所述激光头(26),并且其中,所述装置(25)能够通过枢转使所述探针(27)在进行校准的校准的步骤期间与所述扇叶(12)的所述前缘接触,并且能够使所述激光头(26)在进行重新填充的步骤期间面对所述扇叶(12)的所述前缘。
15.根据前述权利要求中任一项所述的方法,其中,所述激光熔化由LMD或微米激光执行。
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DE102010006384A1 (de) * | 2010-01-29 | 2011-08-04 | Lufthansa Technik AG, 22335 | Reparaturverfahren für ein Verbundbauteil für ein Luftfahrzeug, Verbundbauteil für ein Luftfahrzeug und Einrichtung zur Reparatur eines Verbundbauteiles für ein Luftfahrzeug |
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