CN1180918C - 整体式叶片的转子的翼面制造和修复方法 - Google Patents

整体式叶片的转子的翼面制造和修复方法 Download PDF

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CN1180918C
CN1180918C CNB021080011A CN02108001A CN1180918C CN 1180918 C CN1180918 C CN 1180918C CN B021080011 A CNB021080011 A CN B021080011A CN 02108001 A CN02108001 A CN 02108001A CN 1180918 C CN1180918 C CN 1180918C
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M·P·史密斯
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J·M·斯坦利
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D·S·穆菲
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R·W·鲍姆加藤
T·德麦克
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    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
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    • B23P6/005—Repairing turbine components, e.g. moving or stationary blades, rotors using only replacement pieces of a particular form
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    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/56—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering characterised by the quenching agents
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    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
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    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/49321—Assembling individual fluid flow interacting members, e.g., blades, vanes, buckets, on rotary support member
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T29/49323—Assembling fluid flow directing devices, e.g., stators, diaphragms, nozzles
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y10T29/49325—Shaping integrally bladed rotor

Abstract

本发明涉及一种制造整体式叶片转子的方法，包括提供一最好由钛基合金制成的毂部分并将同样最好由钛基合金制成的翼面焊接在该毂部分上。该方法还包括在焊接前部分时效和冷却该毂部分，并在焊接后时效该翼面和在该翼面和该毂部分之间的焊接接点。该焊后时效步骤最好采用一新型封装的局部翼面加热装置实施，该装置具有多个编织在由高温织物材料制成的外套中的加热元件。本发明的方法还用于修复整体式叶片转子。

Description

整体式叶片的转子的翼面制造和修复方法
技术领域
本发明涉及一种用于制造/修复整体式叶片的转子的方法和一种用于上述方法的新型封装的局部翼面加热装置。
背景技术
出于改进性能和效率的需要，在大型高性能气体涡轮发动机越来越多地使用整体式叶片的转子构件。在传统的转子中，旋转翼面通过圆盘边缘拉削制成的鸠尾槽保持。在整体式叶片的转子中，该翼面和圆盘形成一连续的金属件。由整体式叶片的转子提供的质量和燃料节约来自其以与传统设计的转子相比用更少的圆盘质量来保持旋转翼面的能力。此外，该整体式叶片转子圆盘的降低的圆盘质量允许作用或从该转子得到反应的其他部件重量降低，即，轴、毂和轴承。
已往，与在大型气体涡轮发动机中使用整体式叶片的转子相关联的主要缺点是缺少可靠的用于修复已经损坏且超出弯曲极限的整体式叶片的转子翼面的方法。由于该翼面与圆盘成一整体，超过弯曲极限的翼面损坏需要以相当高的成本在检修时除去整个转子并用新的整体式叶片的转子替换。
与整体式叶片的转子相关联的其它问题涉及用于生产它们的制造方法。它们可在一单件大的锻件上机加工而成；然而，这种方法不是所希望的。大的锻件例如大的钢坯，具有较低的性能，并且取决其材料而相当昂贵的相当大的初始材料被加工掉。同样，由于在生产中不可避免的加工误差该零件有成为废品的危险。用于生产整体式叶片的转子的另外的方法是通过一粘接工艺将单独锻制的翼面连接到一转子上。
基本上由6.0％重量比的铝、2.0％重量比的锡、4.0％重量比的锆、6.0％重量比的钼和基本与之平衡的钛组成的钛合金由于其高韧性、拉伸和疲劳强度和良好的可焊接性是用于整体式叶片的转子所需的合金。然而，由于该焊接区域是正交马氏体的显微结构，它是一种在焊接后处理困难的合金。首先，OEM摩擦焊接必须焊后热处理以便稳定该显微结构并释放应力。其次，由于外部部件损坏该整体式叶片的转子能够经受随后的在使用中的焊接修复。虽然焊接性能可采用全溶液时效焊后热处理被恢复，由于可能的翼面扭曲和表面污染特别对于非0EM焊接，实施这种操作是不切实际的。当前1100°F和2-6小时焊后热处理导致与母体金属相比有低的冲击强度和不充分的疲劳裂纹扩散能力的非常硬的焊接区域。该焊后热处理可加热至1300°F平均温度最多2小时以便恢复可接受的焊接区域冲击和韧性；然而，此种处理导致在基线状态下4-6％的拉伸强度损失。这种损失对于许多高强度零件是不可接受的。
发明内容
因此，本发明的目的在于提供一种改进的用于制造和/或修复整体式叶片的转子的方法。
本发明的另一目的在于提供一种允许使用能保持高拉伸和疲劳强度的高温焊后热处理的方法。
本发明的又一目的在于提供一种新型封装的局部翼面加热装置以便执行所述高温焊后热处理。
按照本发明的第一方面，一种用于产生整体式叶片的转子的方法广泛地包括提供一最好由钛基焊接制成的毂部分，并将一同样最好由钛基焊接制成的翼面焊接到该毂部分上。在焊接之前，该毂部分和翼面可用溶液处理、油淬火、部分时效和先于焊接冷却。该方法还包括在焊接后对于在该毂部分和该翼面之间的焊接接点施加一高温焊接平均热处理。
使用一种新型封装的局部翼面加热装置进行该焊后平均热处理。该装置广泛地包括编织在由高温织物材料制成的外套中的多个加热元件。该加热装置放置在该翼面和焊接接点的上方以便实施该焊后热处理。
一种按照本发明的用于修复整体式叶片转子的方法广泛地包括，加工掉整体式叶片转子翼面的损坏部分并将未损坏的翼面部分焊接到该整体式叶片转子翼面的剩余部分上。其后在该未损坏的翼面和焊接接点的上方放置该封装的局部翼面加热装置并进行焊后热处理以便释放残余应力并恢复该焊接接点和连接金属的显微结构和机械性能。
该制造/修复方法和该封装的局部翼面加热装置的其他细节以及其他目的和伴随的优点将在下面描述和附图中阐明，其中相同的参考标号代表相同的元件。
附图说明
图1是具有焊接在毂部分的翼面的整体式叶片转子的示意图；
图2是按照本发明的封装的局部翼面加热装置的示意图；
图3是定位在翼面和焊接接点上方的图2的加热装置的示意图；以及
图4和5是说明使用本发明的制造/修复方法所得到的改进的图表。
具体实施方式
现参考附图，图1表示一具有毂部分12和翼面14的整体式叶片转子10，翼面14沿一焊接接点16焊接在该毂部分上并且翼面部分15沿焊接线16′焊接在未损坏的翼面部分11上。图1还表示出某种具有需要修复的损坏尖部19的翼面11。毂部分12、翼面14、和翼面部分15可采用适合的现有方法形成。毂部分12、翼面11、14和17中的每个和翼面部分15由钛基焊接制成。适合的钛基合金包括一由6.0％重量比的铝、2.0％重量比的锡、4.0％重量比的锆、6.0％重量比的钼和基本与之平衡的钛(TI-6246)组成的钛基合金；一由6.0％重量比的铝、2.0％重量比的锡、4.0％重量比的锆、2.0％重量比的钼和基本与之平衡的钛(TI-6242)组成的钛基合金；和一由6.0％重量比的铝、4.0％重量比的钒、和基本与之平衡的钛(TI-64)组成的钛基合金。在钛合金优选的同时，上述方法可采用由镍基合金例如Inco 718制成的毂部分、翼面和翼面部分。毂部分12、翼面11、14和17、和/或翼面部分15可由同样合金或不同合金制成。
焊接接点16可采用任何现有技术已知的方法形成。例如，采用一例如OEM摩擦焊接的摩擦焊接方法，将每个翼面14可焊接在毂部分12上。
在焊接之前，毂部分12和每个翼面14可经过溶液处理和油淬火。例如，如果毂部分和/或翼面14由TI 6246合金制成，则进行溶液处理并且油淬火。该溶液处理和油淬火通过将毂部分12和翼面14加热到约1620°F和约1655°F之间的范围内的温度下并在约1到4小时之间的范围内的第一加热实现。该溶液处理和油淬火可在具有空气或氩气的电炉中进行。毂部分12和/或翼面14可位于适合的架子夹具中以最小延迟的实时方式传送到油箱(未示出)。作为选择，一具有油淬火能力的真空炉可用于进行该溶液处理。在该油淬火步骤完成后，毂部分12和翼面14在约1075°F和约1125°F之间的范围内的温度下并在约2到约8小时之间的范围内时效处理。该局部时效处理可采用具有任何气体的现有技术已知的炉子进行。在局部时效后，毂部分12和翼面14以每分钟40°F到每分钟100°F的速率冷却。
如上所述，为制造整体式叶片转子，每个翼面14都焊接在毂部分12上。在焊接完成后，毂部分12和在翼面14和毂部分之间的焊接接点16进行过时效焊后热处理，其间焊接接点16在惰性气体中加热到1275°F和1325°F之间的范围内的温度下并在约1到4小时之间的范围内。在该焊后热处理后，翼面14和焊接接点16以每分钟40°F到每分钟100°F的速率冷却。
按照本发明，该焊后热处理最好采用新型封装的局部翼面加热装置20进行，如图2所示。加热装置20包括一由例如高温铝硅酸盐纤维的陶瓷绝缘材料制成的外套或滤袋22。外套或滤袋22有双重作用。首先，它集中由装置20在翼面表面产生的热量，并使得焊接接点16和周围热作用区达到并稳定在该预期的焊后热处理温度。其次，外套22阻止相邻翼面的无意加热。
装置20有多个编织在外套22的纤维中的辐射电阻加热元件24。加热元件24最好包括高功率密度加热丝。加热元件24用于将热直接辐射到翼面表面。加热元件24可布置在单独控制的加热元件区域内。例如，装置20可有4个单独控制的加热元件区域。
箔型钛吸气片26同样编织在外套22的纤维内以便阻止大气污染并使局部加热装置20进一步具有温度控制能力。
装置20还包括多个编织在外套22的纤维内的非接触热电偶丝28。热电偶丝28用于在焊后热处理期间对温度进行精确控制。在每个加热区域中，可变变压器30连接在加热元件24上并为该加热元件供电。在每个加热区域中作为由热电偶丝28检测到的温度功能，变压器30用于改变供给加热元件24的电流。
通过在翼面14和焊接接点16的上方放置装置20，如图3所示使用装置20。电能供应到辐射加热元件24上使得在所述焊后热处理的温度下热能施加到焊接接点16上。电能在所述焊后热处理的时间范围内继续保持一段时间。
用于制造整体式叶片转子的同样基本的方法可用于修复损坏的整体式叶片转子。为修复整体式叶片转子，首先采用任何适合的现有技术已知的加工方法将转子翼面的损坏的部分19加工掉。此后，将未损坏的部分15焊接到整体式叶片转子的剩余翼面部分11上。任何适合的现有技术已知的焊接方法例如摩擦焊接方法可用于将翼面部分15焊接到部分11上。未损坏翼面部分15可由任何上述的钛基合金或镍基合金制成。
于是，加热装置20放置在未损坏的翼面15和焊接接点16’的上方并通电进行上述焊后热处理，其间在惰性气体的环境下加热到1275°F和1325°F之间的范围内的温度下并在约1到4小时之间的范围内。在该焊后热处理后，未损坏的翼面15和焊接接点16’以每分钟40°F到每分钟100°F的速率冷却。
在该焊后热处理后，加工未损坏的翼面部分15以便获得所需的几何形状。
本发明的加热装置20其优点在于提供集中的、局部的加热，使得相邻的整体式叶片转子的翼面和圆盘毂的温度正好保持在导致强度不足和/或尺寸变形的温度下。同时，加热装置20提供所需的用于释放超合金翼面材料的焊后应力的温度和持续时间。
现参考图4和5，图中表示出本发明的方法怎样消除母体金属(P/M)强度不足并使合金韧性与基线相配。如图4所示，与进行溶液处理、空气冷却、1100°F下时效(合金2)和进行溶液处理、空气冷却、1300°F下时效(合金3)的同样合金相比，一种形成整体式叶片转子并进行溶液处理、油淬火、1100°F下的局部时效和1300°F下的过时效处理的Ti-6Al-2Sn-4Zr-6Mo合金的最终拉伸强度，屈服强度和延长性能更好。图5表示出本发明的方法对于用于整体式叶片转子圆盘部分的Ti-6Al-2Sn-4Zr-6Mo合金的夏氏冲击强度的影响。
在处理由钛基材料制成的整体式叶片转子的文章中描述了加热装置20的同时，它可用于处理其他材料例如镍基超合金制成的整体式叶片转子。
显然按照本发明提供一种用于修复单晶镍基超合金部件的方法，该方法能完全满足上面提出的目的、措施和优点。在文中具体实施例中描述本发明的同时，对于阅读上述描述的本领域技术人员其他的选型、改型和变型将变得显而易见。因此，认为这些选型、改型和变型落入所附权利要求的广义的范围内。

Claims (11)

1.一种制造整体式叶片转子的方法，包括以下步骤：
提供一由金属合金制成的毂部分；
将一由金属合金制成的翼面焊接在所述毂部分上；以及
将该毂部分在1620°F和1655°F之间的范围内的温度下并在1到4小时之间的范围时间内进行溶液处理，并且在所述焊接步骤前将该溶液处理后的毂部分油淬火。
2.如权利要求1所述的方法，还包括在所述焊接步骤前将该溶液处理和油淬火后的毂部分在1075°F和1125°F之间的范围内的温度下并在2到8小时之间的范围内进行局部时效。
3.如权利要求2所述的方法，还包括以每分钟40°F到每分钟100°F的速率冷却该局部时效后的毂部分。
4.如权利要求1所述的方法，还包括在所述焊接步骤后将所述翼面和一所述翼面和所述毂部分之间的焊接接点在1275°F和1325°F之间的范围内的温度下并在1到4小时之间的范围内进行时效，并以每分钟40°F到每分钟100°F的速率冷却该时效后的翼面。
5.如权利要求4所述的方法，其特征在于，所述时效步骤包括将一封装的局部翼面加热装置放置在所述焊接接点的上方并直接把热量辐射至所述翼面的一个表面，并且所述封装的局部翼面加热装置具有多个电阻加热元件，所述时效步骤包括改变施加在所述加热元件上的电功率以便在所述温度范围内的一个温度下加热所述翼面和所述焊接接点。
6.如权利要求1所述的方法，其特征在于，所述毂部分和所述翼面每个均由钛合金制成。
7.如权利要求1所述的方法，其特征在于，所述毂部分和所述翼面均由钛基合金制成，该合金基本上由6.0％重量比的铝、2.0％重量比的锡、4.0％重量比的锆、6.0％重量比的钼和基本与之平衡的钛组成。
8.一种用于制造整体式叶片转子的方法，包括：
提供一由金属合金制成的毂部分；
将一由金属合金制成的翼面焊接在所述毂部分上；
在所述焊接步骤前将所述毂部分和所述翼面至少之一在1075°F和1125°F之间的范围内的温度下并在2到8小时之间的范围内进行局部时效；以及
在所述焊接步骤后所将所述翼面和一在所述翼面和所述毂部分之间的焊接接点在1275°F和1325°F之间的范围内的温度下并在1到4小时之间的范围内进行时效。
9.如权利要求8所述的方法，其特征在于，所述时效步骤包括将一封装的局部翼面加热装置放置在所述焊接接点的上方并对所述翼面的一个表面上直接辐射热能，所述封装的局部翼面加热装置具有多个电阻加热元件，并且所述时效步骤包括改变施加在所述加热元件的电功率以便在所述温度范围内的一温度下加热所述翼面和所述焊接接点。
10.如权利要求8所述的方法，其特征在于，所述毂部分和所述翼面之一由基本上由6.0％重量比的铝、2.0％重量比的锡、4.0％重量比的锆、6.0％重量比的钼和基本与之平衡的钛组成的钛基合金制成，所述毂部分和所述翼面之另一由基本上由6.0％重量比的铝、4.0％重量比的钒、和基本与之平衡的钛组成的钛基合金制成。
11.如权利要求8所述的方法，其特征在于，所述毂部分和所述翼面之一由基本上由6.0％重量比的铝、2.0％重量比的锡、4.0％重量比的锆、6.0％重量比的钼和基本与之平衡的钛组成的钛基合金制成，所述毂部分和所述翼面之另一由基本上由6.0％重量比的铝、2.0％重量比的锡、4.0％重量比的锆、2.0％重量比的钼和基本与之平衡的钛组成的钛基合金制成。
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US20020195176A1 (en) 2002-12-26
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US20030000602A1 (en) 2003-01-02
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