CN1469792A - 在具有隔热涂层的金属工件上钻孔的方法 - Google Patents

在具有隔热涂层的金属工件上钻孔的方法 Download PDF

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CN1469792A
CN1469792A CNA018174817A CN01817481A CN1469792A CN 1469792 A CN1469792 A CN 1469792A CN A018174817 A CNA018174817 A CN A018174817A CN 01817481 A CN01817481 A CN 01817481A CN 1469792 A CN1469792 A CN 1469792A
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G·罗林格尔
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Abstract

本发明提供一种在具有陶瓷外涂层(2)的隔热涂层(3)的金属工件(1)上钻孔的方法，通过激光钻成一个沉孔，直到延伸通过陶瓷外涂层但是基本上不进入金属工件的深度，并且随后激光穿过工件钻一个和沉孔对齐的孔，沉孔的直径比该孔大。

Description

在具有隔热涂层的金属工件上钻孔的方法
发明背景
用于航空应用或者陆基涡轮机应用的燃烧室内衬具有一系列的激光钻孔，它们成某一角度，用来在操作过程中产生冷却作用。激光钻成的冷却孔称作喷射孔。一个典型的部件将具有几千个喷射孔，以利于合适的冷却方式。喷射孔一般相对于部件表面以非常陡的角度(例如17°-25°)钻成(见附图)。这些喷射孔可以通过三个不同的方法由激光钻成：环钻孔；冲击钻孔；或者飞击式激光(Laser-on-the-Fly)。激光钻孔的环钻方式用聚焦光束穿透材料，然后围绕孔来回移动从而生成孔，它是最费时间的方式。根据材料厚度和进入角度，每个环钻激光钻孔要花费8到12秒。激光钻孔的冲击钻方式使用散焦的激光光束用来生成孔，它采用一系列的脉冲激光射入金属，直到孔完全生成。根据材料厚度和进入角度，冲击式激光钻孔每个孔要花费1到5秒。激光钻孔的飞击式激光法使用散焦的激光光束，当旋转装置和激光脉冲的速度同步时，一次一个脉冲地在旋转周期内钻成大量的孔(见美国专利US6130405)。根据材料厚度和进入角度，飞击式激光法制成的每个孔花费0.3到2秒。
用来制成燃烧室内衬的典型材料是具有熔点约为2400°F的高温不锈钢合金。为了提高这些部件的期望寿命，设计工程师给部件增加了一层具有陶瓷外涂层的隔热涂层(TBC)。如图所示，TBC一般包括粘合层3，用来将陶瓷外涂层2粘合到金属底层1。粘合层可以是MCrAlY粘合层，其中M是Ni、Co或者Fe或者Co和Ni的组合；铝化物粘合层；或者铂铝化物粘合层。陶瓷基外涂层可以是，例如由氧化钇稳定的氧化锆。MCrAlY粘合层可以通过不同的方法涂布，包括等离子喷涂、电子束物理气相沉积或者溅射，且陶瓷外涂层可以通过不同的方法涂布，包括等离子喷涂、电子束物理气相沉积、溅射和化学气相沉积。陶瓷外涂层具有很高的熔点，例如4500°F。
这个隔热涂层的增加，虽然提高了部件寿命和发动机的性能，但造成了激光钻孔操作的问题。如图4所示当激光钻通陶瓷涂层进入到基体金属时，在底层基体金属和隔热涂层相交部位产生大面积的重铸区域4。这个重铸区域测量出为0.024英寸厚。一些原始设备制造商(OEM)的燃烧室内衬的设计规格定为最大允许重铸厚度为0.004英寸。高于容许极限的重铸层对部件的寿命有害，因为应力裂纹可能最终从重铸层生成。重铸区域凹窝是在TBC接触基体金属处激光作用的直接结果。由于基体金属的熔点为2400°F，远低于陶瓷外涂层的4500°F，熔化材料具有在结合点产生小凹窝的趋势(见图3)。当采用冲击或者飞击式激光钻孔法，在第一和第二脉冲之间产生凹窝。在随后的完全形成孔所必需的激光脉冲中，熔化的材料被向外排出。当材料被向外排出时，熔化材料的一部分重新沉积在产生的凹窝中。在凹窝中的这些材料的凝固形成了重铸区域4的“气孔”(见图4)。
许多不同的参数设定和气体辅助组合用来减少重铸“气泡”。所有组合的结果都是相近的，检测到重铸“气泡”是明显存在的。当使用环钻方式激光钻孔时，因为激光束环绕圆周穿透，重铸“气泡”得到消除。然而，由于环钻方式生产所述部件需要很长的循环时间，所以这不是一个可以接受的解决方案。
附图说明
本发明将通过参照附图的实施例更加具体地讲述：
图1是钻有沉孔的工件的示意图；
图2是具有如本发明所述钻出的孔的工件的示意图；
图3是沿图2中孔6的中心线7向下看到的辅助视图。
图4是具有依照现有技术钻成的孔的工件的示意图。
图5是沿图4中孔6的中心线7向下看到的辅助视图。
发明内容
本发明提供一种在具有陶瓷外涂层的隔热涂层的金属工件上钻孔的方法，通过激光钻成一个沉孔，直到延伸通过陶瓷外涂层但是基本上不进入金属工件的深度，并且随后激光穿过工件钻一个和沉孔对齐的孔，沉孔的直径比该孔大。
发明详述
目前覆盖有隔热涂层(TBC)的航空部件的激光钻孔(采用冲击和飞击式激光(LOF)方法)会造成激光重铸凹窝，它可以达到0.024英寸的厚度。本发明的方法通过使用激光束在钻喷射冷却孔之前在隔热层中形成沉孔，从而明显减少或者消除激光重铸凹窝。
这种方法可以在具有陶瓷外除层的隔热涂层的金属工件上钻通孔。虽然只提供了具有不锈钢合金(例如GTD222，Haynesl88或者AMS5878)的燃气涡轮机内衬的具体示例，其他的燃气涡轮机部件也可以通过这种方法钻孔，包括例如涡轮机叶片以及气体排放喷嘴。包括其他合金的工件也可以从本方法获益，包括镍或者钴基超合金。如图所示，工件上的隔热涂层一般包括粘合层3以便将陶瓷外涂层2粘合到金属底层1上，以及可包括粘合层和陶瓷外涂层的组合物，它们通过已知技术方法涂布。一般燃烧室内衬的TBC厚度，对于粘合层而言约0.003到0.010英寸，对于陶瓷外涂层而言约0.009到0.020英寸。
当钻孔时，首先用激光钻出沉孔5(见图1)。钻成的沉孔5的直径大于主孔6，但是同心或者互相对齐。如图1所示，通过激光钻孔制成的沉孔5显示出一个弯曲的或者圆角式的表面。沉孔5的直径大于要钻成的孔6，用来避免在钻孔6的过程中重铸“气泡”的形成。沉孔5延伸或者穿透陶瓷外涂层2，但是基本上不进入到金属底层1。一般沉孔5将延伸进入粘合层3，在沉孔的钻孔过程中粘合层充当缓冲层阻止对金属底层1的破坏。沉孔直径一般比主孔直径大50％到150％，最好大75％到125％。一般对于燃烧室内衬的冷却孔6，孔的直径从大约0.019到0.024英寸，而沉孔直径从大约0.040到0.050英寸。
钻制完沉孔5后，与沉孔对齐对孔6进行激光钻孔(见图2)。由于沉孔大于主孔，在TBC和底层结合部位重铸气泡的形成也得到明显的减少或者避免。
实施例
圆柱形高温不锈钢合金(AMS 5878)燃烧室内衬覆盖了一层隔热涂层(TBC)，涂层包括0.003到0.008英寸的NiCrAlY(Mectco Amdry 964)粘合层和通过等离子喷涂施加的0.009到0.014英寸的氧化钇稳定的氧化锆(Mectco 204NS)陶瓷外涂层。需要一系列喷射冷却孔的燃烧室内衬固定到旋转装置上。旋转装置是通过CNC控制装置控制并且和脉冲ND:YAC激光器相结合的激光加工中心的一部分。根据孔形设计，激光钻孔的方式既可以是冲击钻孔也可以是飞击式激光钻孔。部件具有TBC的一侧是喷射孔的入口侧。
激光头设为喷射孔需要的入口角度(20°)。将激光头散焦到确定的量，从而生产用于直径0.020英寸的喷射孔的直径0.040英寸的沉孔。Lumonics JK-704ND:YAG激光器和200mm集焦透镜一起使用，并且设定到LD1操作模式。最初的沉孔操作使用压缩空气作为辅助气体。通过两个激光脉冲散焦约0.500英寸形成所需的直径(0.040英寸)和深度(0.010到0.015英寸)沉孔，该沉孔穿透陶瓷外涂层并且进入粘合层，但是不进入底层。制成如图1所示的沉孔5。进行激光钻孔仅仅去除陶瓷外涂层，直到比喷射孔大的直径。当整排沉孔完成后，激光头然后散射到所确定的位置，形成所需要的直径为0.020英寸的喷射冷却孔。喷射冷却孔钻孔操作的辅助气体是氧气。然后和沉孔时齐，通过冲击或者飞击式激光钻孔方式钻喷射孔。制成的喷射冷却孔具有约0.001到0.002英寸厚的减小的重铸层。
相应的没有制造沉孔的钻孔操作所制成的喷射冷却孔产生了大约0.010到0.020英寸厚和大约0.050英寸长的重铸层气泡。

Claims (12)

1.一种在具有陶瓷外涂层的隔热涂层的金属工件上钻孔的方法，包括：
激光钻成一个沉孔，直到延伸通过陶瓷外涂层但是基本上不直接进入金属工件的深度；
随后激光穿过工件钻一个和沉孔相对齐的孔，沉孔的直径比该孔大。
2.如权利要求1所述的方法，其特征在于，金属工件为燃气涡轮机燃烧室内衬以及所述孔为冷却孔。
3.如权利要求2所述的方法，其特征在于，沉孔和孔通过冲击钻孔方式钻成。
4.如权利要求2所述的方法，其特征在于，沉孔和孔通过飞击式激光钻孔方式钻成。
5.如权利要求1所述的方法，其特征在于，隔热涂层还包括用来将陶瓷外涂层粘合到金属工件上的粘合层。
6.如权利要求2所述的方法，其特征在于，金属工件包括不锈钢合金。
7.如权利要求2所述的方法，其特征在于，沉孔和冷却孔以相对于工件表面17到25度的角度钻成。
8.如权利要求5所述的方法，其特征在于，沉孔直径比所述孔直径大50％到150％。
9.如权利要求8所述的方法，其特征在于，沉孔延伸入粘合层。
10.如权利要求9所述的方法，其特征在于，沉孔具有弯曲的表面。
11.如权利要求10所述的方法，其特征在于，陶瓷外涂层为氧化钇稳定的氧化锆。
12.如权利要求11所述的方法，其特征在于，粘合层是从由McrAlY组成的组中选择的，其中M是Ni、Co、Fe或者Ni和Co的组合，铂铝化物和铝化物。
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