CN115023306A - 用陶瓷增强件制造复合涡轮发动机整体叶盘的方法 - Google Patents

用陶瓷增强件制造复合涡轮发动机整体叶盘的方法 Download PDF

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CN115023306A
CN115023306A CN202080088703.8A CN202080088703A CN115023306A CN 115023306 A CN115023306 A CN 115023306A CN 202080088703 A CN202080088703 A CN 202080088703A CN 115023306 A CN115023306 A CN 115023306A
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皮埃尔·让·萨洛特
让-米歇尔·帕特里克·莫里斯·弗朗切特
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Abstract

本发明涉及一种制造涡轮发动机金属整体叶轮的方法，所述金属整体叶轮由金属基质复合材料制成的插件增强，该方法包括以下步骤：‑(E1)：将陶瓷纤维缠绕在芯轴周围以形成插件，陶瓷纤维由构成基质的材料环绕；其特征在于，该方法包括以下步骤：‑(E2)：用构成待制造整体叶轮的金属粉末对插件进行火花等离子烧结。

Description

用陶瓷增强件制造复合涡轮发动机整体叶盘的方法
技术领域
本发明涉及制造镍基金属基质复合材料(MMC)的通用领域。
本发明在制造涡轮发动机的整体涡轮叶轮，特别是高压涡轮叶轮，方面特别有意义的应用。
现有技术
已知根据现有技术使用由金属基质复合(MMC)材料制成的插件来增强由金属合金制成的整体涡轮叶轮。这些插件由陶瓷纤维形成，所述陶瓷纤维增强了金属基质。
这种解决方案用于制造一体式叶片环(BLING)。
用MMC插件增强的整体叶轮通常根据以下方法制造：
-将由构成金属基质的材料环绕的陶瓷纤维缠绕在工具上，以形成缠绕的插件；
-将缠绕的插件转移到包括金属合金的模具中，所述金属合金构成待制造的成品部件；
-实施热等静压成型循环，从而通过扩散来压实和焊接模具中存在的所有元件。
然而，已知的解决方案可能遭遇许多困难。
特别地，必须准确地确定热等静压成型步骤的温度和持续时间，从而一方面避免损坏陶瓷纤维，另一方面确保部件的良好压缩。
此外，热等静压成型步骤可导致变形以及对增强件在部件中定位的修改。
最后，在插件缠绕后从模具转移插件的过程中，形成插件的纤维束可能变形。
发明内容
因此，本发明旨在提出一种由MMC插件增强的整体叶轮制造的解决方案，所述解决方案解决了上述的问题。
根据第一方面，本发明提出了一种制造涡轮发动机的整体金属叶轮的方法，所述整体金属叶轮由金属基质复合材料制成的插件增强，该方法包括以下步骤：
-将陶瓷纤维缠绕在芯轴周围以形成所述插件，陶瓷纤维由构成基质的材料环绕；
其特征在于，该方法包括以下步骤：
-用构成待制造整体叶轮的金属粉末对插件进行火花等离子烧结。
火花等离子烧结的使用能够在很短的时间内使MMC插件致密化，从而可以通过在纤维和金属基质之间的交互扩散来限制由于脆化物质的出现而对陶瓷纤维造成损坏的风险，同时确保达到满意的致密化度。
根据一种可能特征，该方法包括以下步骤：
-用构成待制造整体叶轮的第一金属粉末通过火花等离子烧结在芯轴上进行插件的固结；
-将固结的插件放置在模具中，所述模具含有构成待制造整体叶轮的第二金属粉末；
-在模具中用第二金属粉末通过火花等离子烧结使插件致密化。
根据一种可能特征，在固结步骤结束时，所述插件达到介于60％和80％的压实率。
根据一种可能特征，所述第一金属粉末和所述第二金属粉末不同。
根据一种可能特征，所述第一金属粉末和所述第二金属粉末相同。
根据一种可能特征，所述陶瓷纤维覆盖有由构成基质的材料制成的层。
根据一种可能特征，由构成基质的材料制成的纱线股绞在陶瓷纤维周围。
根据一种可能特征，所述整体叶轮由镍基合金制成，陶瓷纤维包括碳，并且覆盖有扩散保护层。
根据一种可能特征，所述整体叶轮由钛基合金制成。
根据一种可能特征，所述陶瓷纤维由碳化硅制成。
根据一种可能特征，所述整体叶轮是一体式叶片环。
附图简要说明
从以下给出的描述，参考附图，本发明的其他特征和优点将变得显而易见，所述附图无任何限制地示出一种示例性实施例。
【图1】图1示意性地表示一种制造涡轮发动机整体叶轮的方法的步骤。
【图2】图2示意性地表示根据一种可能变型，制造涡轮发动机整体叶轮的方法的步骤。
【图3】图3示意性地表示插件在芯轴上固结的剖视图，形成芯轴的纤维缠绕在所述芯轴上。
【图4】图4示意性地表示事先已被致密化的插件的致密化的剖视图。
【图5a】图5a示意性地表示没有扩散保护层的插件的组成的第一变型。
【图5b】图5b示意性地表示具有扩散保护层的插件的组成的第一变型。
【图6a】图6a示意性地表示没有扩散保护层的插件的组成的第二变型。
【图6b】图6b示意性地表示具有扩散保护层的插件的组成的第二变型。
具体实施方式
本发明涉及一种制造涡轮发动机整体叶轮的方法，特别是整体涡轮叶轮。整体叶轮可以是固定轮或被驱动旋转。整体涡轮叶轮是一种定位在涡轮发动机的燃烧室下游的整体叶轮。
整体叶轮可以是高压涡轮的整体叶轮，即直接定位在燃烧室下游的涡轮的整体叶轮，也可以是低压涡轮的整体叶轮，即定位在高压涡轮下游的涡轮的整体叶轮。
涡轮发动机是飞行器涡轮发动机，例如飞机涡轮发动机或直升机涡轮发动机。
如图1和3所示，一种制造涡轮发动机的整体叶轮，特别是涡轮的整体叶轮的方法包括以下步骤：
-E1：通过将由构成基质的材料环绕的陶瓷纤维缠绕在芯轴2周围，制造由金属基质复合材料(MMC)制成的插件1。因此制造的插件1具有环形形状，如图3所示。
-E2：用插件1和构成待制造整体叶轮的金属粉末进行火花等离子烧结。通过压实金属粉末和插件1，并通过施加流经金属粉末和插件1的电流，进行火花等离子烧结。火花等离子烧结具有速度快的优点，火花等离子烧结的持续时间特别地少于15分钟，其限制了不同合金的冶金结构不稳定的风险。因此，与热等静压成型相比，脆化相的形成对陶瓷纤维造成损坏的风险更低。
几种变型可以实施图1所示的方法。特别地，如图2至图4所示，插件1可首先被固结，使得插件1在不存在变形风险的情况下被处理，然后被完全地致密化，以形成待制造的整体叶轮。
因此，如图2所示，根据一种可能变型，该方法包括以下步骤：
-E1：通过将由构成基质的材料所环绕的陶瓷纤维缠绕在芯轴2周围，制造了MMC插件1。
-E20：通过用构成待制造整体叶轮的第一金属粉末P1对插件1进行火花等离子烧结，插件1被固结，同时保持在芯轴2上。在插件1缠绕后，添加第一金属粉末P1。通过缠绕和火花等离子烧结系统S实施步骤E20，所述系统S一方面包括芯轴2，所述芯轴上缠绕有插件1的不同纤维，另一方面包括火花等离子烧结装置3，所述装置被构造成用第一金属粉末P1对直接在芯轴2上的插件1进行火花等离子烧结。火花等离子烧结装置3特别地被构造成将插件1和第一金属粉末P1压紧在芯轴2上，并施加能够烧结粉末的电流。进行固结插件1的步骤E20的火花等离子烧结，以便在不借助夹持工具的情况下保持插件形状的同时可以处理插件1。步骤E20的火花等离子烧结特别地可被构造，使得插件1达到介于60％和80％的压实率。插件1的压实度特别地为火花等离子烧结过程中施加的压力、火花等离子烧结的持续时间、火花等离子烧结过程中施加的电流强度，以及所使用的第一粉末P1的量的函数。这种压实率能够在不存在损坏风险的情况下处理部件，还能够缩短步骤E20的持续时间。压实率与孔隙率成反比，80％的压实率对应于20％的孔隙率。孔隙率在此是指气孔的体积除以部件的总体积。
-E3：将固结的插件1从芯轴2移除，并放置在模具4中。将构成待制造整体叶轮的第二金属粉末P2也放置在模具4中。模具4具有待制造整体叶轮的形状。
-E4：通过在模具4中用第二金属粉末P2对所述插件1进行火花等离子烧结而使插件1致密化，制造整体叶轮。步骤E4的火花等离子烧结能够限制脆化相出现的风险。在致密化步骤E4结束时，插件4具有大于95％的压实率，优选地大于99％。
在致密化步骤E4结束时，获得了一种由嵌入在金属中的MMC纤维插件1所形成的涡轮发动机整体叶轮。
根据一种能够在插件1周围形成多材料的可能变型，第一金属粉末P1和第二金属粉末P2不同。例如，通过使用具有不同色度的两种合金，这两种粉末可以不同。该变型特别地能够适配待制造整体叶轮的机械特性。
根据能够获得更均匀叶轮的另一可能变型，第一金属粉末P1和第二金属粉末P2相同。
如上所述，插件1的陶瓷纤维由构成所述插件1的金属基质的材料制成的层环绕。为此，多种变型是可能的。
根据图5a和5b中所示的第一变型，陶瓷纤维10覆盖有一种由构成基质的材料制成的层11。陶瓷纤维10可以由碳化硅或包括碳的另一陶瓷制成，并且由构成基质的材料制成的层11可以由镍基合金或钛基合金制成。优选地，当由构成基质的材料制成的层11由镍基合金制成并且陶瓷纤维包括碳时，如图5b所示，可在陶瓷纤维10上沉积扩散保护层P，扩散保护层P定位在陶瓷和基质金属之间。扩散保护层P例如可以由钨或氧化铝制成。
根据图6a和6b所示的第二变型，由构成基质的材料制成的纱线12股绞在陶瓷纤维10周围。陶瓷纤维10可以由碳化硅或包括碳的另一陶瓷制成，并且由构成基质的材料制成的层11可以由镍基合金或钛基合金制成。优选地，当由构成基质的材料制成的层11由镍基合金制成并且陶瓷纤维包括碳时，如图6b所示，可在陶瓷纤维10上沉积扩散保护层P，扩散保护层P定位在陶瓷和基质金属之间。扩散保护层P例如可以由钨或氧化铝制成。
通过对插件1进行火花等离子烧结的致密化的使用特别能够降低扩散保护层P的厚度，减少了循环时间。
本发明特别地适用于制造一体式叶片环(BLING)。

Claims (11)

1.一种制造涡轮发动机的金属整体叶轮的方法，所述金属整体叶轮由金属基质复合材料制成的插件(1)增强，所述方法包括以下步骤：
-(E1)：将陶瓷纤维(10)缠绕在芯轴(2)周围以形成插件(1)，陶瓷纤维(10)由构成基质的材料(11、12)环绕；
其特征在于，该方法包括以下步骤：
-(E2)：用构成待制造整体叶轮的金属粉末(P1、P2)对插件(1)进行火花等离子烧结。
2.根据权利要求1所述的方法，其中，所述方法包括以下步骤：
-(E20)：通过构成待制造整体叶轮的第一金属粉末(P1)进行火花等离子烧结，在芯轴(2)上进行插件(1)的固结；
-(E3)：将固结的插件(1)放置在模具(4)中，所述模具(4)含有构成待制造整体叶轮的第二金属粉末(P2)；
-(E4)：在模具(4)中用第二金属粉末(P2)通过火花等离子烧结使插件(1)致密化。
3.根据权利要求2所述的方法，其中，在固结步骤(E20)结束时，所述插件(1)达到介于60％和80％的压实率。
4.根据权利要求2至3任一项所述的方法，其中，所述第一金属粉末(P1)和所述第二金属粉末(P2)不同。
5.根据权利要求2至3任一项所述的方法，其中，所述第一金属粉末(P1)和所述第二金属粉末(P2)相同。
6.根据权利要求1至5任一项所述的方法，其中，所述陶瓷纤维(10)覆盖有由构成所述基质(11)的材料制成的层。
7.根据权利要求1至5任一项所述的方法，其中，由构成基质(12)的材料制成的纱线股绞在陶瓷纤维(10)周围。
8.根据权利要求1至7任一项所述的方法，其中，所述整体叶轮由镍基合金制成，所述陶瓷纤维(10)包括碳并且覆盖有扩散保护层(P)。
9.根据权利要求1至7任一项所述的方法，其中，所述整体叶轮由钛基合金制成。
10.根据权利要求1至9任一项所述的方法，其中，所述陶瓷纤维由碳化硅制成。
11.根据权利要求1至10任一项所述的方法，其中，所述整体叶轮为一体式叶片环。
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