DE102011111011A1 - Adjustable shovel element of a gas turbine of an aircraft engine, comprises adjusting device for changing shape of adjustable shovel element, which is constructed by a generative manufacturing process - Google Patents

Abstract

Adjustable shovel element (1), preferably an adjustable shovel element of a gas turbine of an aircraft engine, comprises at least one adjusting device (17) for changing the shape of the adjustable shovel element. The adjustable shovel element together with the adjusting device is constructed by a generative manufacturing process. An independent claim is also included for constructing the adjustable shovel element, preferably the adjustable shovel element of the gas turbine of the aircraft engine, comprising constructing the adjustable shovel element having the adjusting device by the generative manufacturing process.

Description

The present invention relates to an adjusting blade element and a method for forming, repairing and / or replacing such a Verstellschaufelelementes, in particular a Verstellschaufelelementes a turbine, for. As a gas turbine of an aircraft engine, or a compressor, by means of a generative manufacturing process.

In general, adjusting vane elements are made mechanically adjustable. However, this has the disadvantage that the mechanism for this is expensive and expensive to manufacture and assemble. In particular, the construction of the mechanical adjustment is expensive. In addition, the mechanical adjustment leads to a weight gain and increased wear. In addition, an increased control effort is necessary to perform the adjustment speed or load-dependent.

Furthermore, for example, from the DE 961 742 Blades are known, which are formed from a spar connected to a blade carrier and a subsequent flow in the direction of this hollow part. The blades are here made of metal, wherein the spar and a suction-side wall of the respective blade are made in one piece, while a pressure-side wall of the blade forms a special, firmly clamped to the remaining parts component. The spar, with the suction-side wall and the pressure-side wall growing out of it, are made of different metals which expand to different extents when the temperature increases.

However, these blades have the disadvantage that they are expensive to manufacture and assembly. In particular, the pressure-side wall must be additionally fastened correspondingly to the spar with the suction-side wall.

Against this background, the invention is based on the object of providing an improved adjusting blade element.

According to the invention, an adjusting vane element, in particular an adjusting vane element of a gas turbine of an aircraft engine, is provided, which has at least one adjusting device for changing the shape of the adjusting vane element, wherein the adjusting vane element together with its at least one adjusting device z. B. is constructed by a generative manufacturing process.

The adjusting vane element has the advantage that the adjusting device automatically changes the shape of the adjusting vane element. Due to the automatically occurring adaptation of the adjusting vane element therefore eliminates an additional separate tax expense. In addition, no axes and other elements needed for the controlled movement are necessary in the Verstellschaufelelement, as the blade deforms itself. In addition, the adjusting blade element can be produced together with its adjusting device by the generative manufacturing method, without the adjusting device having to be attached separately to the adjusting blade element later. This allows the Verstellschaufelelement be produced inexpensively and a complex assembly of the adjustment omitted.

The knowledge / idea on which the present invention is based is to provide a self-adjusting adjusting vane element, the adjusting vane element being designed to be common with an adjusting device for this purpose, for example. B. by a generative manufacturing process.

Advantageous embodiments and modifications of the invention will become apparent from the dependent claims and the description with reference to the drawings.

In one embodiment according to the invention, at least one setting device is designed as an inner structure which is formed within the at least partially hollow adjusting blade element. In this case, the internal structure can have, for example, a varying mass or a varying cross section, such that upon rotation of the adjusting vane element, this adjusting vane element deforms due to the centrifugal forces generated by the internal structure.

In a further embodiment according to the invention, the inner structure is formed as an inner wall which extends in the longitudinal direction and / or transverse direction of the adjusting vane element. The cross section or the mass can be suitably adapted so that the adjusting blade element deforms to a predetermined extent by the centrifugal forces generated by means of the adjusting device.

According to a further embodiment of the invention, the adjusting blade element has at least two regions made of a different material or a different material combination, wherein the regions form the adjusting device. The materials or material combinations may have a different coefficient of thermal expansion, so that when the adjusting blade element heats up, one region expands more strongly than the other region, thereby changing the shape of the adjusting blade element.

In another embodiment according to the invention, the at least one adjusting device is a piezoelectric element. The piezoelectric element can be controlled or regulated by applying a suitable voltage to change the shape of the Verstellschaufelelements.

The above embodiments and developments can, if appropriate, combine with each other as desired. Further possible refinements, developments and implementations of the invention also include combinations, not explicitly mentioned, of features of the invention described above or below with regard to the exemplary embodiments. In particular, the person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the present invention.

The invention will be explained in more detail with reference to the exemplary embodiments specified in the schematic figures of the drawings. Show it:

1 a sectional view of a Verstellschaufelelementes according to a first embodiment of the invention;

2 a sectional view of a Verstellschaufelelementes according to a second embodiment of the invention;

3 a sectional view of a Verstellschaufelelementes according to a third embodiment of the invention; and

4 a flow diagram for producing a Verstellschaufelelements according to the invention.

In the figures of the drawing are the same, functionally identical and same-acting elements, features and components - unless otherwise stated, each provided with the same reference numerals.

In 1 is a schematic and highly simplified sectional view of a Verstellschaufelelementes 1 shown according to a first embodiment of the invention.

According to the invention, an adjusting vane element 1 built by a generative manufacturing process and in particular manufactured, replaced or repaired. In generative manufacturing processes, a workpiece is generally built up layer by layer. Generative manufacturing processes include, for example, so-called rapid manufacturing and so-called rapid prototyping, etc. In the case of the corresponding generative processes, for example laser sintering, selective laser sintering (SLS), electron beam sintering, electron beam melting (EBM), laser cutting, selective Laser Melting (SLM) or 3D printing are known, the added or to be applied material in powder form. According to the invention, for example, a powder of at least one metal, a metal alloy, a plastic and / or ceramic can be used. However, the invention is not limited to the aforementioned generative manufacturing method, as well as the material or the material combination of the powder.

In so-called selective laser melting (SLM), as an example of a generative manufacturing process, the material to be processed is applied in powder form in layers to a support or a construction platform. The pulverulent material of the respective layer or powder layer is then completely locally remelted by means of laser radiation in a component region of the component to be produced and forms a solid material layer after solidification. To apply the next powder layer, for example, the construction platform is lowered by one layer thickness and the new powder layer is applied, and then the component area of the powder layer is solidified by laser radiation. This cycle is repeated until all layers have been remelted or the finished component is made from the solidified component regions of the powder layers. Subsequently, the finished component is cleaned of the excess powder and can either be processed as needed or used immediately.

As in the embodiment of a Verstellschaufelelements 1 in 1 is shown has the Verstellschaufelelement 1 for example, an outer wall 2 on. The outer wall 2 forms the contour or outer contour of the adjusting blade element 1 , which by an adjustment 17 the adjusting vane element 1 is automatically changeable or customizable. Inside is the adjusting blade element 1 z. B. partially or completely hollow and has as adjustment 17 for automatically adjusting or adjusting the shape of the adjusting vane element 1 an interior structure 3 on, for example, an inner wall 4 , In this case, the inner wall 4 circumferential or only in one or more sections with the outer wall 2 the adjusting vane element 1 be connected, in particular be integrally connected.

The inner wall 4 extends as an internal structure 3 for example, in the longitudinal direction of the adjusting blade element 1 from a first end 5 to a second end 6 the adjusting vane element 1 , In this case, the inner wall 4 for example, with a varying cross section 7 and be designed with a varying mass. As in the embodiment in 1 is shown is the cross section 7 in a section, e.g. B. a middle section 8th the inner wall 4 z. B. larger than in the two outer sections 9 educated. The cross section of the middle section 8th the inner wall 4 can be formed so larger or the middle section 8th have a greater mass that the centrifugal force F passing through the inner wall 4 the adjusting vane element 1 is generated, the adjusting blade element 1 z. B. more curved, such as an arrow X and a dashed line in 1 is indicated.

The outer wall 2 and the internal structure 3 , here an inner wall 4 with a varying cross section 7 , the adjusting blade element 1 are made in one piece and made of the same material or the same material combination. By the cross section 7 in at least one section 8th increases and thereby the mass in this section 8th is increased, the centrifugal force in this section 8th be increased, for example, a curving or bending of the Verstellschaufelelements 1 and thus achieve a different configuration or fluidic configuration, as with a dashed line in 1 is indicated.

By means of a corresponding generative manufacturing process, such as one of the aforementioned generative manufacturing methods, it becomes possible to use an adjusting blade element 1 , For example, a blade or a vane, with an inner structure 3 as an example of an adjustment 17 for automatically adjusting or adjusting the shape of the adjusting vane element 1 to provide. This interior structure 3 can be designed so that the adjusting blade element 1 depending on z. B. from one speed, another geometry forms or has. This change in shape is caused by the greater effect of centrifugal forces by larger masses. As a result, z. B. distances between several Verstellschaufelelementen 1 a device, such as a turbine or a compressor, regulates and all other advantages of Verstellschaufelelemente 1 be used. Advantage of this principle is also the elimination of a controller, since the speed of the blade 1 automatically adjusted by the acting forces. Ie. by the automatically occurring adaptation of the adjusting blade element 1 there is no tax expense. In addition, there are no axes and other elements required for controlled movement in the Verstellschaufelelement 1 necessary, as the shovel 1 self-deformed.

In 2 is a schematic and highly simplified sectional view of a Verstellschaufelelementes 1 according to a second embodiment of the invention.

A similar effect, ie a change in the geometry or shape of the Verstellschaufelelements 1 can be achieved according to the second embodiment of the invention, by the attachment of a further material or a further combination of materials to the Verstellschaufelelement 1 to an adjustment 17 for automatically adjusting or adjusting the shape of the adjusting vane element 1 provide. The further material or the further material combination can in this case another thermal behavior, eg. Example, a different coefficient of thermal expansion, as the base material or the base material combination, so that z. B. an adjusting blade element 1 in the form of a bi-metal, which deforms when heated. The heating of the adjusting blade element 1 It increases with an increase in the speed of a device with such a Verstellschaufelelement, such as. As a turbine or a compressor.

Instead of or in addition to the bi-metal may also be at least one piezoelectric element 10 (For example, a controlled piezoelectric element) as adjusting 17 be used as in the embodiment in 2 is indicated by a dashed line. This variant has the additional advantage that the adjustment takes place without loss of time. The adjusting blade element 1 For example, in at least one section, e.g. B. on its outside 11 or its inside 12 , with a piezo element 10 be provided. For this we use the adjusting blade element 1 formed with at least one or more layers of a piezoelectric crystal, a piezoelectric ceramic and / or a polycrystalline material. To change the shape of the Verstellschaufelelements 1 gets to the piezo element 10 z. B. applied a suitable electrical voltage. By applying an electrical voltage, the piezoelectric element 10 controlled and / or regulated accordingly and thus the shape of the adjusting blade element 1 to be changed.

As in the embodiment in 2 is shown has the Verstellschaufelelement 1 For example, at least two areas, ie a first and a second area 13 on, which are made of a different material or a different combination of materials and as adjusting 17 for automatically adjusting or adjusting the shape of the adjusting vane element 1 act. The first area 13 forms, as in the embodiment in 2 is illustrated, a first page, z. B. outside 11 , the adjusting blade element 1 and the second area 14 forms a second page, z. B. the inside 12 , the adjusting blade element 1 ,

Here, for example, the first area 13 or the outside 11 the adjusting vane element 1 made of a first material or a first material combination and the second area 14 or the inside 12 the adjusting vane element 1 from another second material or another second material combination. The materials and material combinations are chosen, for example, such that they z. B. have a different thermal behavior. The adjusting blade element 1 as it is in the embodiment in 2 is shown, for. B. solid. Since the materials or material combinations differ, for example, in terms of their thermal expansion coefficient, deforms the Verstellschaufelelement 1 when heated. As described above, the heating of the adjusting vane element decreases 1 For example, with an increase in the rotational speed of a device, such an adjusting blade element 1 has, such as a turbine or a compressor to.

In 3 is a sectional view of a Verstellschaufelelementes 1 shown according to a third embodiment of the invention. The third embodiment of the invention essentially represents a combination of the first and second embodiments of the invention.

According to the third embodiment of the invention, the adjusting vane element 1 be at least partially or completely hollow. In this case, the adjusting blade element 1 comparable to the adjusting blade element 1 as it is in the embodiment in 1 shown is an outer wall 2 exhibit. One half 15 the outer wall 2 , z. B. half 15 which the outside 11 the adjusting vane element 1 forms, may be made of a first material or a first combination of materials and the other half 16 the outer wall 2 the adjusting vane element 1 which z. B. the inside 12 the adjusting vane element 1 forms, may be made of another second material or another second combination of materials. Both halves 12 . 13 serve as adjustment 17 for automatically adjusting or adjusting the shape of the adjusting vane element 1 As in 3 is shown, may optionally additionally at least one additional internal structure 3 as adjusting device 17 in the at least partially or completely hollow adjusting blade element 1 be provided, for example, an inner wall 4 which z. B. in the longitudinal direction, as in the embodiment in 3 is shown, and / or in the transverse direction of the Verstellschaufelelements 1 extends as in the embodiment in 3 indicated by a dotted line.

This interior structure 3 can, like the inner wall 4 in the embodiment in 1 be made of a material or a combination of materials or according to the second embodiment of the invention have at least two areas with different materials or material combinations. In this case, the cross section of the internal structure 3 , here z. B. the inner wall 4 be constant or vary.

In 4 FIG. 3 is a flowchart of one embodiment of a method of manufacturing, repairing and / or replacing an advance vane element having an interior structure according to the invention.

In this case, in a step S1, a powder layer to be solidified selectively by energy radiation, for example a metal powder layer, is applied to a building platform. In a next step S2, the powder layer is selectively solidified. For this purpose, the powder layer by means of energy radiation, such. As a laser beam and / or an electron beam, an energy source in a component region for forming a Verstellschaufelelements with its outer wall and its at least one inner structure solidified as adjusting. Subsequently, step S1 is repeated and the next layer of powder to be selectively solidified is applied to the last powder layer and the component area of the powder layer is solidified. The steps S1 and S2 are repeated until the adjusting vane element with its outer wall and its at least one inner structure is completely constructed from its component regions and in particular is completely manufactured, repaired or replaced. In a step S3, the powder after the Verstellschaufelelement 1 is completely removed and the Verstellschaufelelement can be used directly or further processed.

To produce the Verstellschaufelelement with at least two areas of a different material or material combination, which serve as adjusting, such as in the 2 and 3 For example, instead of a powder, at least two powders of a different material or a different material combination are used to form the respective powder layer to be selectively solidified. The powder layer to be selectively solidified accordingly has a region with the first powder for solidifying a first portion of the component region. The first subregion corresponds to the first region of the adjusting vane element. Furthermore, the respectively selectively to be solidified powder layer on a second area with the second powder, for solidifying a second portion of the Component region. The second subregion corresponds to the second region of the adjusting vane element. The two different powders for forming the respective powder layer can be applied, for example, via corresponding powder feed nozzles, which are arranged in a grid over the build platform, on which the powder layers are formed and selectively solidified. Likewise, the Pulverzuführdüsen can also be provided along the construction platform in one, two or all three directions movable in space to form the respective powder layer with areas with powders of a different material or material combination. However, the invention is not limited to powder feed nozzles, which are designed to be movable and / or arranged in a latching manner. Other apparatuses and / or methods suitable for forming a powder layer with regions of different powders may also be used to produce an adjusting vane element according to the invention.

Although the present invention has been described above with reference to the preferred embodiments, it is not limited thereto, but modified in many ways. In particular, the embodiments described above can be combined with one another, in particular individual features thereof.

In particular, the invention is not limited to an inner wall in the longitudinal direction of the Verstellschaufelelements as an internal structure. The internal structure can have any shape and arrangement suitable for changing the shape of the adjusting vane element.

LIST OF REFERENCE NUMBERS

1

Verstellschaufelelement

2

outer wall

3

internal structure

4

inner wall

5

first end

5

second end

7

cross-section

8th

middle section

9

outer section

10

piezo element

11

outside

12

inside

13

first area

14

second area

15

first half

16

second half

17

adjustment

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

• DE 961742 [0003]

Claims (11)

Adjusting blade element ( 1 ), in particular a Verstellschaufelelement a gas turbine of an aircraft engine, which at least one adjustment ( 17 ) for changing the shape of the adjusting blade element ( 1 ), wherein the adjusting blade element ( 1 ) together with its at least one adjustment device ( 17 ) is constructed by a generative manufacturing process. An adjusting vane element according to claim 1, characterized in that the at least one adjusting device ( 17 ) as an internal structure ( 3 ) is formed, which within the at least partially hollow Verstellschaufelelements ( 1 ) is trained. An adjusting vane element according to claim 2, characterized in that the internal structure ( 3 ) as an inner wall ( 4 ) is formed, which in the longitudinal direction and / or transverse direction of the Verstellschaufelelements ( 1 ) and whose cross section ( 7 ) or mass preferably varies. An adjusting vane element according to at least one of the preceding claims, characterized in that the adjusting vane element ( 1 ) at least two areas ( 13 . 14 ; 15 . 16 ) of a different material or a different material combination, which the adjusting device ( 17 ) form. An adjusting vane element according to claim 4, characterized in that the materials or material combinations of the regions ( 13 . 14 ; 15 . 16 ) have a different thermal expansion coefficient. An adjusting vane element according to at least one of claims 4 or 5, characterized in that the one area ( 13 ; 15 ) an outside ( 11 ) of the adjusting blade element ( 1 ) and the other area ( 14 ; 16 ) an inside ( 12 ) forms the Verstellschaufelelements. An adjusting vane element according to at least one of the preceding claims, characterized in that the at least one adjusting device ( 17 ) as a piezo element ( 10 ) is trained. Method for constructing an adjusting blade element ( 1 ), in particular an adjusting blade element ( 1 ) of a gas turbine of an aircraft engine, the method comprising the following step: constructing the adjusting blade element ( 1 ) with at least one adjusting device ( 17 ) for changing the shape of the adjusting blade element ( 1 ) by a generative manufacturing process. Method according to claim 8, characterized in that the step of building up the adjusting vane element ( 1 ) with at least one adjusting device ( 17 ) additionally comprises the step of: forming the at least one adjusting device ( 17 ) of a different material or material combination than the base material or the base material combination of the adjusting blade element. Method according to claim 8 or 9, characterized in that the step of building up the adjusting vane element ( 1 ) with at least one adjusting device ( 17 ) additionally comprises the step of: forming the at least one adjusting device ( 17 ) of at least one layer ( 10 ) of a piezocrystal, a piezoelectric ceramic and / or a polycrystalline material. A method according to claim 8, 9 or 10, characterized in that the step of building up the adjusting vane element ( 1 ) with at least one adjusting device ( 17 ) additionally comprises the step of: forming the at least one adjusting device ( 17 ) as an internal structure ( 3 . 4 ) of the adjusting blade element ( 1 ) having a preferably varying cross section ( 7 ) or a preferably varying mass.

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