CN113530607A - 一种具有u型叶片对的涡轮叶盘 - Google Patents

一种具有u型叶片对的涡轮叶盘 Download PDF

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CN113530607A
CN113530607A CN202110373573.9A CN202110373573A CN113530607A CN 113530607 A CN113530607 A CN 113530607A CN 202110373573 A CN202110373573 A CN 202110373573A CN 113530607 A CN113530607 A CN 113530607A
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blade
shaped
turbine blade
engines
pairs
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CN113530607B (zh
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刘持栋
刘小冲
栗尼娜
成来飞
张毅
陈超
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Northwestern Polytechnical University
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Abstract

本发明涉及一种具有U型叶片对的涡轮叶盘，采用耐高温的非金属材料的U型叶片对和叶间镶嵌件，辅以金属材质的插销、端盖等附件，通过组合装配为涡轮叶盘构件。本发明克服了现有技术中心金属涡轮叶盘耐高温性能不足、重量大，用于高温环境时涡轮叶盘必须依赖于冷却设施等缺点，克服了陶瓷基复合材料整体涡轮叶盘难以制备大尺度构件、制备周期长、性能一致性差等缺点，可显著提升涡轮叶盘的耐温性、降低重量，进而提高发动机工作效率和推重比等综合指标。本发明的具有U型叶片对的涡轮叶盘，能够用于燃气涡轮发动机的高压或低压涡轮叶盘，可以是固体发动机、液体发动机、冲压发动机、核能发动机或其组合功能发动机的涡轮叶盘。

Description

一种具有U型叶片对的涡轮叶盘
技术领域
本发明属于发动机涡轮叶盘，涉及一种具有U型叶片对的涡轮叶盘，尤其指一种含有连续纤维增强陶瓷基复合材料叶片的涡轮叶盘结构。
背景技术
随着高性能航空、航天、新能源等技术的发展，对其动力系统的发动机效率、涡轮工作温度、重量、使用寿命和可靠性等提出了更高的需求。涡轮转子是发动机内将燃料内能转化为动能的核心部件，对动力系统性能具有深刻的、根本性影响。常规高温合金涡轮叶盘在耐温性能、高温强度、疲劳寿命等方面逐渐逼近其应用极限，而且在合金成分、涡轮结构优化等方面的空间逐步缩小，性能提升难度和复杂度巨大，严重制约了先进动力技术的发展。
文献1(罗潇等，涡轮发动机用陶瓷基复合材料涡轮转子研究进展，推进技术，2021，42(1)：230-240)研究认为，由于陶瓷基复合材料具有低密度、耐高温、抗冲击、长寿命特点，发展陶瓷基复合材料涡轮转动构件已经成为高性能发动机的必然趋势。
公告号为CN109650924A(一种基于SiC纤维陶瓷基复合材料整体涡轮叶盘制备方法)、CN112266256A(基于连续碳/碳化硅纤维混杂增强陶瓷基复合材料整体涡轮叶盘的制备方法)、CN106966747B(一种制备航空发动机用复合材料整体涡轮叶盘及其制备方法与应用)和CN106968716B(陶瓷基复合材料整体涡轮叶盘)的中国发明专利中，分别公开了几种连续纤维增强的陶瓷基复合材料整体涡轮叶盘制备方法。上述发明均是通过整体编织技术制备涡轮叶盘预制体，再利用化学气相渗透法或树脂浸渍裂解法制备界面层和陶瓷基体，随后采用机械加工的方法加工出叶片。以上技术方案均只适合于尺寸较小的涡轮叶盘构件，当构件尺度较大时，容易在构件内部产生预制体和陶瓷基体的非均匀性，且制备成品率低、成本高、维修性差。
现有技术中，金属材料一般耐温性为1050摄氏度，用于高温环境时涡轮叶盘必须依赖于冷却设施。而耐高温非金属材料耐温性很好，尤其是陶瓷基复合材料耐温性可达1350摄氏度，但是现有的涡轮叶盘的结构设计，使得采用陶瓷基复合材料受到尺寸的限制，无法实现燃气涡轮发动机的高压或低压涡轮叶盘，可以是固体发动机、液体发动机、冲压发动机、核能发动机或其组合功能发动机的涡轮叶盘的需求。
发明内容
要解决的技术问题
为了避免现有技术的不足之处，本发明提出一种具有U型叶片对的涡轮叶盘，可大幅降低陶瓷基复合材料涡轮叶盘的制备成本，可实现大尺度涡轮叶盘的高效率、批量化制备，可提高构件的性能一致性，可使得陶瓷基复合材料涡轮叶盘具有良好的维修性。
技术方案
一种具有U型叶片对的涡轮叶盘，其特征在于包括两个端盖104、齿轮件106、叶片对101、镶嵌件102和插销105；所述叶片对101的根部为U型结构，U型结构延展为叶片型面成为两个叶片的叶片对101；两个端盖104之间设有齿轮件106和与齿轮件106的轮齿数目相等的叶片对101，插销105穿过叶片对101的U型弯后置于齿轮件106的轮齿内，镶嵌件嵌入叶片对与U型弯连接的叶片型面过渡区302，且与叶片型面过渡区302结构尺寸吻合；多个连接件103的螺钉穿过两个端盖104以及镶嵌件上的通孔与螺母连接，将两个端盖104、齿轮件106和叶片对101固连为涡轮叶盘；在耐高温非金属材料的结构件与高温合金结构件之间设有垫片；所述叶片对101 和镶嵌件采用耐高温非金属材料，其他结构件采用金属材料；所述插销105采用耐高温非金属材料或金属材料。
所述齿轮件与一侧的端盖为一个整体结构。
所述耐高温非金属材料采用连续纤维增强陶瓷基复合材料。
所述连续纤维增强陶瓷基复合材料的制备是：通过化学气相渗透技术在纤维预制体上制备热解碳或氮化硼界面层，再通过化学气相渗透法或熔体渗透法或树脂浸渍裂解法中的一种或几种的组合在制备了界面层预制体内部制备陶瓷基体。
所述叶片对的纤维预制体是含连续纤维的单向无纬布，或含连续纤维的二维编织布叠层包括平纹、斜纹、缎纹；或上述纤维布中的一种或几种的组合；纤维预制体中纤维体积百分比可在20～70％范围内调整。
所述叶间镶嵌件和插销的纤维预制体是含连续纤维的二维编织布叠层或三维针刺织物包括平纹、斜纹或缎纹，纤维预制体中纤维体积百分比可在20～50％范围内调整。
所述纤维包括碳纤维、碳化硅纤维和氮化硅纤维中的一种或多种的组合
所述陶瓷包括碳化硅、碳化硼或氮化硅中的一种或几种的组合。
所述插销采用镍基高温合金、钴基高温合金、钛合金或铁基合高温合金。
所述齿轮件采用钛合金、铝合金、铁基合高温合金、钴基高温合金或镍基高温合金。
所述端盖选用钴基高温合金或镍基高温合金。
所述垫片采用铁合金、镍基高温合金、钴基高温合金、钛合金、铜合金、铝合金中的一种或几种，其厚度可在0.1mm至0.8mm之间。
所述连接件用铁基合高温合金、钴基高温合金或镍基高温合金。
陶瓷基复合材料零件制备方法的具体步骤为：
(1)对于叶片对零件，将纤维布的径向平行于按照图3所示的纤维走向方向铺设，叠层至额定厚度后进行缝合定型，定型后的预制体厚度需超过成品尺寸1～2mm；对于叶间镶嵌件和插销，将纤维布或预制体的径向平行于涡轮轴向铺设，叠层至额定厚度后进行缝合定型，定型后的预制体厚度需超过成品尺寸2～5mm。
(2)利用化学气相渗透法在上述预制体的纤维表面制备热解碳或氮化硼界面层。当采用热解碳作为界面层时，热解碳在纤维表面的厚度为100～400nm；当采用氮化硼作为界面层时，氮化硼在纤维表面的厚度为200～700nm。
(3)利用化学气相渗透法、熔体渗透法和树脂浸渍裂解法中的一种或几种的组合工艺，在制备了界面层的预制体内部制备陶瓷基体。陶瓷基体可以是碳化硅、碳化硼和氮化硅中的一种或几种的组合。制备陶瓷基体工序可能需执行多次，从而使零件的密度逐渐增加至最终密度。采用碳纤维预制体时，陶瓷基体制备完毕后材料的最终密度为1.9～2.3g/cm3；当采用碳化硅纤维预制体时，陶瓷基体制备完毕后材料的最终密度为2.4～2.8g/cm3；当采用氮化硅纤维预制体时，陶瓷基体制备完毕后材料的最终密度为1.9～2.6g/cm3。
(4)采用立方氮化硼或者金刚石刀具对制备完陶瓷基体的零件按照加工至合格尺寸。必要时，加工步骤可分为粗加工、半精加工和精加工等子工序；必要时，加工步骤可以与陶瓷基体制备工序穿插进行。
(5)对加工完毕的叶片对零件的叶片主体部分制备环境屏障涂层。完成陶瓷基复合材料零件制备。
具有U型叶片对的涡轮叶盘的装配步骤为：
步骤1：按照设计要求，分别制备相应数量的陶瓷基复合材料叶片对、叶间镶嵌件和插销(采用陶瓷基复合材料材质的插销时)。
步骤2：按照设计要求，分别采用机械加工或铸造的方式制备相应数量的插销(采用金属材质的插销时)、齿轮件、端盖、垫片和连接件。
步骤3：将一侧的金属端盖通过常规的过盈配合工艺装配到涡轮轴上，保证金属端盖在涡轮轴上的轴向位置精度。优选地，在装配前提前做好端盖的动平衡调节。
步骤4：将齿轮件通过常规的过盈配合工艺装配到涡轮轴上，保证金属齿轮件与端盖内侧贴合到位。优选地，在装配前提前做好齿轮件的动平衡调节。
步骤5：将叶片对的U型连接区的底部与齿轮件的各个凹槽贴合，并随之插入相应的插销。插销的弧型面与叶片U型连接区内侧贴合，对侧面与端盖翻边内缘贴合。
步骤6：将叶片对内部和相邻叶片对之间的叶间镶嵌件逐个插入到对应位置，并随之插入相应的螺栓(或螺柱)，以避免零件发生大幅度移动。
步骤7：将另一侧的金属端盖通过常规的过盈配合工艺装配到涡轮轴上，保证端盖内侧与金属齿轮件贴合到位。优选地，在装配前提前做好端盖的动平衡调节。
步骤8：通过螺母连接两侧端盖和叶间镶嵌件，完成装配。优选地，两侧端盖通过连接件连接完毕后，对螺纹连接处进行防松锁固处理。
步骤9：对装配完毕的涡轮叶盘进行动平衡调节，动平衡调节时的材料去除或增加均在金属端盖上实施。
有益效果
本发明提出的一种具有U型叶片对的涡轮叶盘，采用耐高温的非金属材料的U型叶片对和叶间镶嵌件，辅以金属材质的插销、端盖等附件，通过组合装配为涡轮叶盘构件。本发明克服了现有技术中心金属涡轮叶盘耐高温性能不足、重量大，用于高温环境时涡轮叶盘必须依赖于冷却设施等缺点，克服了陶瓷基复合材料整体涡轮叶盘难以制备大尺度构件、制备周期长、性能一致性差等缺点，可显著提升涡轮叶盘的耐温性、降低重量，进而提高发动机工作效率和推重比等综合指标。
本发明的具有U型叶片对的涡轮叶盘，能够用于燃气涡轮发动机的高压或低压涡轮叶盘，可以是固体发动机、液体发动机、冲压发动机、核能发动机或其组合功能发动机的涡轮叶盘。
本发明的优点是：根据涡轮叶盘的使用环境条件，仅在高温区采用连续纤维增强的陶瓷基复合材料叶片和叶间镶嵌件，通过合理的结构形式保证陶瓷基复合材料零件的纤维连续性和工艺可达性；在非高温区采用金属零件，不仅可有效分担陶瓷基复合材料零件的离心载荷，又降低了金属零件自身在工作时的应力水平。相比于陶瓷基复合材料整体涡轮叶盘，本发明减少了昂贵的陶瓷基复合材料的使用量，大幅降低了涡轮叶盘的制造成本；有利于涡轮叶盘的批量化制造和质量控制；使得涡轮叶盘具有良好的维修性。
附图说明
图1为本发明涡轮叶盘的结构示意图；
图2为本发明陶瓷基复合材料零件可采用的预制体形式示意图；
图3为本发明叶片对零件的结构示意图。
图4为本发明齿轮件106的结构示意图；
图5为本发明叶片对101的结构示意图；
图6为本发明插销105的结构示意图；
图7为本发明叶间镶嵌件的结构示意图；
图8为本发明涡轮叶盘的部分剖视结构示意图；
图9为本发明涡轮叶盘的爆炸图；
图10为本发明采用的预制体结构示意图
图11为本发明叶片对101的三维结构示意图。
图中标记：100-涡轮叶盘，101-叶片对，102-叶间镶嵌件，103-连接件，104-端盖，105-插销，106-齿轮件；201-单向无纬布，202-二维平纹布，203-二维斜纹布，204-二维缎纹布，205-三维针刺预制体；301-叶片主体，302-叶片型面过渡区，303-叶片U 型区，304-预制体纤维径向示意线。
具体实施方式
现结合实施例、附图对本发明作进一步描述：
附图所示的涡轮叶盘100，由15个叶片对101、30个叶间镶嵌件102、30组连接件103(每组包括1个螺栓和1个螺母)、2个端盖、15个插销、1个齿轮件组成。其中，15个叶片对101和30个叶间镶嵌件102采用碳化硅纤维增强碳化硅陶瓷基复合材料；连接件103采用镍基高温合金GH4169；端盖104采用镍基高温合金GH3128；插销105和齿轮件106采用钛合金TA15。上述涡轮叶盘的结构装配图可参见附图。
实施例中，叶片对101的纤维预制体采用连续碳化硅纤维单向无纬布201和二维平纹布202的组合，二维平纹布202位于叶片表层0.3mm处；叶间镶嵌件102的纤维预制体采用连续碳化硅纤维二维平纹布202叠层后的缝合织物。叶片对101和叶间镶嵌件102均采用化学气相渗透技术制备氮化硼界面层，界面层厚度为300～450nm。叶片对101采用化学气相渗透技术制备碳化硅陶瓷基体，最终密度为2.5～2.8g/cm3，叶片对101零件本体材料的径向拉伸强度为370～480MPa，弹性极限应力为180～240MPa。叶间镶嵌件102采用化学气相渗透技术制备碳化硅和碳化硼复合陶瓷基体，最终密度为2.4～2.6g/cm3。
本涡轮叶盘100的制作方法，包括以下步骤：
(1)对于叶片对101零件，以连续碳化硅纤维单向无纬布201和二维平纹布202 为原材料，先后在定型模具上铺设单向无纬布201和二维平纹布202，其纤维径向与预制体纤维径向示意线304走向平行，二维平纹布202位于叶片表层0.3mm厚度区域。对于叶间镶嵌件102零件，以连续碳化硅纤维二维平纹布202为原材料，将二维平纹布202叠层缝合为块状预制体板，预制体厚度需超过成品尺寸2～5mm。分别以镍基高温合金GH4169、镍基高温合金GH3128和钛合金TA15为原材料，通过机械加工的方式将连接件、端盖、插销和齿轮件加工至合格尺寸。
(2)对于叶片对101和叶间镶嵌件102零件，采用化学气相渗透技术制备厚度为300～450nm的氮化硼界面层，制备时以氨气作为氮源，氯化硼作为硼源，氢气作为稀释气体，制备温度为700℃，沉积时间80h。
(3)对于叶片对101零件，采用化学气相渗透技术制备碳化硅陶瓷基体，制备过程穿插粗加工和精加工工序，最终密度为2.5～2.8g/cm3；随后采用等离子喷涂技术在叶片对的叶片主体301表面制备环境屏障涂层，涂层厚度约为0.2～0.4mm。对于镶嵌件零件，采用化学气相渗透技术交替制备碳化硅和碳化硼陶瓷基体，制备过程穿插粗加工和精加工工序，最终密度为2.4～2.6g/cm3。
(4)将一侧的端盖104通过过盈配合工艺装配到涡轮轴上，保证端盖104在涡轮轴上的轴向位置精度。
(5)将齿轮件106通过过盈配合工艺装配到涡轮轴上，保证齿轮件106与端盖 104内侧贴合到位。
(6)将叶片U型区303的底部与齿轮件106的各个凹槽贴合，并随之插入相应位置的插销105。插销105的弧型面与叶片U型区303内侧贴合，对侧面与端盖104 翻边内缘台阶贴合。
(7)将叶片对101内部和相邻叶片对101之间的叶间镶嵌件102逐个插入到对应位置，并随之插入相应的连接件103(螺栓或螺柱)，以避免零件发生大幅度移动。
(8)将另一侧的端盖104通过过盈配合工艺装配到涡轮轴上，保证端盖104内侧与齿轮件106贴合到位。
(9)通过连接件103(螺母)连接两侧端盖104和叶间镶嵌件102，采用锁紧丝对一周的连接件103进行防松锁固处理。
(10)采用在两侧端盖104去除材料的手段对装配完毕的涡轮叶盘100实施动平衡调节。

Claims (11)

1.一种具有U型叶片对的涡轮叶盘，其特征在于包括两个端盖(104)、齿轮件(106)、叶片对(101)、镶嵌件(102)和插销(105)；所述叶片对(101)的根部为U型结构，U型结构延展为叶片型面成为两个叶片的叶片对(101)；两个端盖(104)之间设有齿轮件(106)和与齿轮件(106)的轮齿数目相等的叶片对(101)，插销(105)穿过叶片对(101)的U型弯后置于齿轮件(106)的轮齿内，镶嵌件嵌入叶片对与U型弯连接的叶片型面过渡区(302)，且与叶片型面过渡区(302)结构尺寸吻合；多个连接件(103)的螺钉穿过两个端盖(104)以及镶嵌件上的通孔与螺母连接，将两个端盖(104)、齿轮件(106)和叶片对(101)固连为涡轮叶盘；在耐高温非金属材料的结构件与高温合金结构件之间设有垫片；所述叶片对(101)和镶嵌件采用耐高温非金属材料，其他结构件采用金属材料；所述插销(105)采用耐高温非金属材料或金属材料。
2.根据权利要求1所述具有U型叶片对的涡轮叶盘，其特征在于：所述齿轮件与一侧的端盖为一个整体结构。
3.根据权利要求1所述具有U型叶片对的涡轮叶盘，其特征在于：所述耐高温非金属材料采用连续纤维增强陶瓷基复合材料。
4.根据权利要求3所述具有U型叶片对的涡轮叶盘，其特征在于：所述连续纤维增强陶瓷基复合材料的制备是：通过化学气相渗透技术在纤维预制体上制备热解碳或氮化硼界面层，再通过化学气相渗透法或熔体渗透法或树脂浸渍裂解法中的一种或几种的组合在制备了界面层预制体内部制备陶瓷基体。
5.根据权利要求4所述具有U型叶片对的涡轮叶盘，其特征在于：所述叶片对的纤维预制体是含连续纤维的单向无纬布，或含连续纤维的二维编织布叠层包括平纹、斜纹、缎纹；或上述纤维布中的一种或几种的组合；纤维预制体中纤维体积百分比可在20～70％范围内调整。
6.根据权利要求4所述具有U型叶片对的涡轮叶盘，其特征在于：所述叶间镶嵌件和插销的纤维预制体是含连续纤维的二维编织布叠层或三维针刺织物包括平纹、斜纹或缎纹，纤维预制体中纤维体积百分比可在20～50％范围内调整。
7.根据权利要求5或6所述具有U型叶片对的涡轮叶盘，其特征在于：所述纤维包括碳纤维、碳化硅纤维和氮化硅纤维中的一种或多种的组合。
8.根据权利要求4所述具有U型叶片对的涡轮叶盘，其特征在于：所述陶瓷包括碳化硅、碳化硼或氮化硅中的一种或几种的组合。
9.根据权利要求1所述具有U型叶片对的涡轮叶盘，其特征在于：所述插销采用镍基高温合金、钴基高温合金、钛合金或铁基合高温合金。
10.根据权利要求1所述具有U型叶片对的涡轮叶盘，其特征在于：所述齿轮件采用钛合金、铝合金、铁基合高温合金、钴基高温合金或镍基高温合金。
11.根据权利要求1所述具有U型叶片对的涡轮叶盘，其特征在于：所述端盖选用钴基高温合金或镍基高温合金。
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