DE102010051534A1 - Forming an adapter for connecting blade to rotor base body of turbomachine, comprises applying material layer on connecting surface of blade to form first adapter portion and applying second material on first adapter portion - Google Patents

Abstract

Forming an adapter (4) for connecting a blade (2) to a rotor base body of a turbomachine, where the blade is made of a first material and the rotor base body is made of a second material, comprises: applying at least one material layer acting as a diffusion barrier on a connecting surface of the blade to form a first adapter portion (14); and applying the second material surface on the first adapter portion for forming a second adapter portion (16). An independent claim is also included for an integrally bladed rotor of a turbomachine, preferably an aircraft engine, comprising many blade-adapter arrangements (1), which are produced by the above mentioned method.

Description

The invention relates to a method for forming an adapter for connecting a blade to a rotor main body of a turbomachine and an integrally bladed rotor.

An adapter for connecting a blade to a rotor base body for producing an integrally bladed rotor in disk construction (Blisk) or ring construction (Bling) of a gas turbine is, for example, in the European application EP 2 198 128 A1 shown by the applicant. The adapter is made in one piece and, like the rotor body, consists of a melt-weldable nickel wrought alloy. The blade is made of a different material, namely a non-fusion weldable nickel casting alloy. The adapter is first tethered to the blade by a fusion-free welding process such as pressure welding, friction welding or diffusion bonding to the blade. Thereafter, the rotor body-side connection of the blade-adapter assembly is made to the rotor body by means of a known fusion welding process.

From the German patent DE 10 2008 039 113 B3 The Applicant is also a one-piece adapter for connecting a blade made of a first material to a rotor base body of a different second material known. First, the adapter is tethered from the rotor body material to the blade by means of rotary friction welding. Then, the blade-adapter assembly is connected by linear friction welding to the rotor body.

From the German patent application DE 10 2008 052 247 A1 The applicant is a method for connecting a blade made of a first material such as a titanium alloy to a rotor base made of a different second material such as a nickel-nickel alloy by using a multi-part adapter known. The adapter has a first portion of the blade material and a second portion of the rotor body material, which are separated by an intermediate layer acting as a third section. The intermediate layer serves as a diffusion barrier for brittle-phase-forming elements such as aluminum.

The preparation of this three-part adapter is done for example by sintering. The connection of the adapter to the blade and to the rotor takes place simultaneously by linear friction welding. The adapter is positioned between the blade and the rotor body and moved back and forth in translational motion. This known method is suitable for the connection of blades made of a first material to rotor bodies of a different kind of material, between which in particular there is a certain incompatibility. However, the manufacture of the three-piece adapter and the simultaneous connection of the adapter to the blade and to the rotor body are relatively expensive.

The object of the invention is to provide a method which eliminates the aforementioned disadvantages and enables a simplified design of an adapter for connecting a blade to a rotor base made of a different material or a different material group, and to provide an integrally bladed rotor with a plurality of such blades ,

This object is achieved by a method having the features of patent claim 1 and by an integrally bladed rotor having the features of patent claim 13.

In a method according to the invention for forming an adapter for connecting a blade made of a first material to a rotor base body made of a different second material, at least one material layer acting as a diffusion barrier is applied to a contact surface of the blade to form a first adapter section. Subsequently, by applying the second material or the rotor base body material, a second adapter section is formed flat on the first adapter section. Among other things, it is advantageous in the method according to the invention that, when the adapter is formed, a blade-adapter arrangement which can be connected to a rotor main body is automatically formed. In addition, due to the direct connection of the diffusion barrier, the adapter no longer consists of three sections, but only two sections, whereby the adapter itself is stabilized.

In a preferred method, the blade material used is a titanium alloy and the rotor base material is a nickel-wrought alloy. Examples of nickel wrought alloys are IN718, Waspaloy and Udimet720LI. As a result, there is a certain incompatibility between the blade material and the rotor base body material, which is quasi eliminated by the acting as a diffusion barrier first portion.

In an alternative method, a nickel casting alloy is selected as the blade material and a nickel-wrought alloy as the rotor base material. Examples of nickel wrought alloys are also IN718, Waspaloy and Udimet720LI.

In a preferred embodiment, the at least one layer of material of the first Applied adapter section by friction surfacing. The friction surfacing is a fusion-free welding process and thus allows the connection of dissimilar materials. In addition, it causes a very good connection of the material layer to the blade or its connection surface. The height of the material layer produced by friction surfacing ranges from a few tenths of a millimeter to a few millimeters. In general, one layer of material is sufficient.

In one embodiment, the first adapter portion has a graduated construction of a plurality of material layers of different composition. Preferably, the material layers are applied by the use of welding rods with different material compositions by friction surfacing.

In an alternative embodiment, the at least one layer of material is applied as a film by a diffusion process, for example diffusion bonding or diffusion soldering. The diffusion process also allows a very good connection of the material layer or diffusion barrier to the blade.

For the alternative embodiment of a graduated diffusion barrier, an exemplary embodiment provides for forming a multiplicity of material layers of different compositions for forming the first adapter section, which are applied in layers by using films having different materials or material compositions by a diffusion method.

In one exemplary embodiment, the second adapter section is applied in layers to the diffusion barrier. In this case, the layer-wise application is preferably carried out by means of friction surfacing, diffusion welding, diffusion soldering and comparative melt-free application methods. Alternatively, however, the second adapter section or its material layers can also be connected to the diffusion barrier by a fusion welding process. Examples are laser or electron beam melts.

In another embodiment, the second adapter portion is applied as a one-piece body to the first adapter portion or the diffusion barrier. As a result, the second adapter portion can be formed at the same time for the application of the diffusion barrier to the component, whereby the manufacturing time of the component adapter assembly is shortened. The connection of the second adapter section to the diffusion barrier can be effected, for example, by linear friction welding, rotational friction welding, diffusion welding, diffusion soldering and the like. Alternatively, however, the second adapter section can also be connected to the diffusion barrier by a fusion welding process, such as laser or electron beam melting.

To improve the properties of a blade adapter assembly produced according to the invention and in particular to improve the properties of the adapter, it can be compacted, for example, by hot isostatic pressing.

An integrally bladed rotor according to the invention, such as an integrally bladed rotor disk or an integrally bladed rotor ring of a turbomachine, has a plurality of blade-adapter assemblies made by the method of the present invention. Such a rotor is characterized inter alia by an optimized connection of the blades on the rotor body.

Other advantageous embodiments of the invention are the subject of further subclaims.

In the following, preferred embodiments of the invention will be explained in more detail with reference to highly simplified schematic illustrations. Show it:

1 a perspective view of a first embodiment of an adapter according to the invention,

2 a preferred application of an in 1 shown diffusion barrier as the first adapter section, and

3 a perspective view of a second embodiment of an adapter according to the invention.

1 shows a perspective view of a blade-adapter assembly 1 for cohesive connection of a blade 2 from a first material by means of an adapter 4 to a rotor base body, not shown, made of a second material for producing an integrally bladed rotor disk or an integrally bladed rotor ring of an aircraft engine. The rotor base body, not shown, consists of a material of a highly heat-resistant nickel wrought alloy such as IN718 and is thus melt-weldable.

The shovel 2 consists of a non-fusion weldable titanium alloy from the group of titanium-based alloys and TiAl alloys. Thus, there is some incompatibility between the blade material and the rotor body material. She has a shovel foot 6 for connection to the adapter 4 , an airfoil 8th as well as two platforms facing away from each other 10a . 10b of which one in and the other opposite to the flow direction of one between the blade root 6 and the blade 8th integrally arranged body portion 12 extends.

The adapter according to the invention 4 has a first section 14 , by means of which he attached to the blade foot 6 Tied, and a second section 16 for connection to the rotor body.

The first adapter section 14 serves as a diffusion barrier for brittle-phase-forming elements such as aluminum and thus enables a cohesive connection of the blade 2 on the rotor body despite the existing incompatibility between the blade material and the rotor body material. The adapter section 14 has a graduated construction with several layers of material 18a . 18b . 18c whose material composition is in each case selected such that the material composition of the first adapter section 14 continuously changes from the blade material to the rotor body material or almost changes.

The material layers 18a . 18b . 18c are preferably composed of a matrix alloy with metal particles uniformly distributed therein. The matrix alloy consists of a material alloy that corresponds to the blade material, for example, a titanium alloy, or of a material alloy, the rotor body material or the second adapter portion 16 as IN718 corresponds. The metal particles are preferably formed from alloys and refractory metals and / or platinum metals.

The second adapter section 16 has one of the scoop 2 remote connection surface 20 for connecting the blade-adapter assembly 1 to the rotor body. In the first embodiment, the second section 16 a layer-like structure of a variety of material layers 22a to 22h on, each consisting of the rotor body material, ie in the embodiment shown from IN718 exist.

The material layers 18a to 18c as well as the material layers 22a to 22h are preferably applied by friction surfacing. It will, as in 2 for example, based on the application of the first material layer 18a on a connection surface 24 of the blade foot 6 shown a rotating welding pin 26 frontally in parallel tracks or tracks 28a . 28b under pressure over the connection surface 24 emotional. Preferably, the adjacent tracks 28a . 28b each an overlap area 30 on. The material composition or the material of the welding pin 26 corresponds to the material of the material layer to be produced 18a , During the coating, the applied material layer reaches 18a a temperature near the melting point and at the same time undergoes plastic deformation. This process is repeated until the connection surface 24 with the material layer 18a is covered. Subsequently, the second material layer 18b on the first material layer 18a applied. For this purpose, the welding pin 26 by a welding pin with a material composition corresponding to the second material layer to be produced 18b replaced and this rotating under pressure over the first layer of material 18a guided. These steps are repeated until all material layers 18a . 18b . 18c are formed.

After forming the first adapter section 14 and thus the diffusion barrier becomes the second adapter section 16 by layer-wise application of the material layers 22a to 22h educated. For this purpose, welding pins from the rotor main body material or here IN718 under pressure and rotation like a web over the respective previous material layer 18c or material situation 20a to 20g emotional.

After making the blade-adapter assembly 1 this is compressed to improve the material properties, for example, by a hot isostatic pressing method. After that, the blade-adapter assembly 1 with the from the outermost layer of material 22h of the second adapter section 16 educated and in 1 numbered interface 20 positioned on an opposite bonding surface of the rotor body and joined by a fusion welding process such as laser beam welding or electron beam welding.

3 shows a perspective view of a blade-adapter assembly 1 with a second adapter according to the invention 4 for material connection to a rotor main body of an aircraft engine, not shown. The scoop adapter assembly 1 is similar to the one in the 1 and 2 described first embodiment executed. She has a shovel 2 from a first material, for example a titanium alloy, and a two-part adapter 4 with a diffusion barrier as the first section 14 and with a second section 16 from a nickel wrought alloy corresponding to the rotor main body material such as IN718.

In contrast to the aforementioned first embodiment, the second adapter section 16 however, as a one piece solid body 32 executed and as such to the first adapter section 14 For example, by linear friction welding, rotary friction welding, diffusion welding, diffusion soldering and the like connected. The formation of the first adapter section 14 takes place as described in 2 by friction surfacing.

In an alternative method, the first adapter section 14 or the diffusion barrier as a foil on the blade root 6 For example, applied by diffusion welding or diffusion soldering. In the case of a graduated diffusion barrier, the films of different compositions become with the blade root 6 diffusion welded or soldered to a composite. The second adapter section 16 becomes then also foil-wise or as a one-piece body 32 by diffusion welding or brazing, friction surfacing, linear friction welding, laser or electron beam welding to the first adapter section 14 applied.

Disclosed is a method for forming a two-part adapter on a blade made of a first material for connecting the blade to a rotor base made of a different second material, wherein the two adapter sections by applying a diffusion barrier to the blade and a subsequent application of the rotor base material to the diffusion barrier and a turbine blisk with a variety of such blade adapter assemblies.

LIST OF REFERENCE NUMBERS

1

Blade adapter assembly

2

shovel

4

adapter

6

blade

8th

airfoil

10a, b

platform

12

body part

14

first section

16

second part

18a, b, c

material layer

20

interface

22a to 22h

single layer

24

surface

26

welding pin

28a, b

track

30

overlap area

32

one-piece body

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 2198128 A1 [0002]
• DE 102008039113 B3 [0003]
• DE 102008052247 A1 [0004]

Claims (13)

Method for forming an adapter ( 4 ) for connecting a blade ( 2 ) to a rotor body of a turbomachine, wherein the blade ( 2 ) is made of a first material and the rotor base body is made of a second material, comprising the steps of: - applying at least one material layer acting as a diffusion barrier ( 18a . 18b . 18c ) on a connection surface ( 24 ) of the blade ( 2 ) for forming a first adapter section ( 14 ), and - application of the second material surface ( 20a to 20g ; 32 ) on the first adapter section ( 14 ) for forming a second adapter section ( 16 ). The method of claim 1, wherein a titanium alloy is selected as the first material and a nickel wrought alloys as the second material. A method according to claim 1, wherein a nickel casting alloy is selected as the first material and a nickel wrought alloy as the second material. Method according to claim 1, 2 or 3, wherein the at least one material layer ( 18a . 18b . 18c ) is applied by friction surfacing. Method according to claim 4, wherein the first adapter section ( 14 ) of a plurality of material layers ( 18a . 18b . 18c ), which is layered by use of welding rods ( 26 ) are applied with different material compositions. Method according to claim 1, 2 or 3, wherein the at least one material layer ( 18a . 18b . 18c ) is applied as a film by a diffusion process. Method according to claim 6, wherein the first adapter section ( 14 ) of a plurality of material layers ( 18a . 18b . 18c ), which are applied in layers by using films with different material compositions. Method according to one of the preceding claims, wherein the material of the second adapter section ( 16 ) in material layers ( 20a to 20h ) on the first adapter section ( 14 ) is applied. Method according to one of claims 1 to 7, wherein the second adapter section ( 16 ) as a one-piece body ( 32 ) on the first adapter section ( 14 ) is applied. Method according to one of the preceding claims, wherein the second adapter section ( 16 ) by a fusion-free welding process on the first adapter section ( 14 ) is applied. Method according to one of claims 1 to 9, wherein the second adapter section ( 16 ) by a fusion welding process on the first adapter section ( 14 ). Method according to one of the preceding claims, wherein the with the adapter ( 4 ) provided blade ( 2 ) is compressed by hot isostatic pressing. Integrally bladed rotor of a turbomachine, in particular an aircraft engine, with a plurality of blade adapter arrangements ( 1 ) produced by a method according to any one of the preceding claims.

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