DE102017214259A1 - Turbine component, manufacturing method thereto - Google Patents

Abstract

The invention relates to a turbine component, in particular a high-temperature suitable turbine component such as a gas turbine component. In particular, the invention relates to a turbine component of hybrid material. In addition, the invention relates to a method for producing a turbine component in hybrid technology of CMC material and metal. It is proposed the transmission of the forces acting on the metallic support structure while shading them by a laminate layer stack of ceramic fiber composite material. Thus, the possibility of using the hybrid technology for rotating turbine components is created. The transmission of the load by centrifugal forces is essentially created by a toothed structure of the metallic carrier structure with the laminate layer stack and by a final metal layer.

Description

The invention relates to a turbine component, in particular a high-temperature suitable turbine component such as a gas turbine component. In particular, the invention relates to a turbine component of hybrid material. In addition, the invention relates to a method for producing a turbine component in hybrid technology of CMC material and metal.

The increase in efficiency of gas turbines takes place in the field of tension between the material of the turbine components and hot gas. Thus, high-temperature stable, mechanically highly resilient, oxidation-insensitive as possible materials for the production of turbine components, such as the blades and vanes of gas turbines, used, which are equipped with cooling systems, so that the components produced therefrom are sufficiently cooled during operation.

Substantial improvement in the thermal efficiency of power plant gas turbine systems is achieved by increasing the operating temperature of the hot gas and / or a cooling strategy for the rotor and / or vanes, which requires the least possible amount of cooling air.

To date, nickel superalloys have been used with additional protective coatings for the hot gas-loaded components of gas turbines.

The requirements for material for these components are extremely high, especially with regard to creep resistance, creep rupture resistance, breakage resistance and damage tolerance.

A new material concept for gas turbine components envisages the use of so-called hybrid structures, in which ceramic laminates of ceramic fiber composite material CMC (Ceramic Matrix Composite) are built on metallic support structures.

From the PCT / US2015 / 023017 For example, a turbine component having a metallic support structure on which a stack of laminated layers of a ceramic fiber composite material is constructed is known. The present development is based on this basic work and the disclosure of this earlier application is therefore also part of the present description.

The CMC materials can generally withstand temperatures up to 1500 ° C, in particular up to 1200 ° C. There is a need for CMC materials that are stable even at higher temperatures.

CMC materials have a ceramic matrix in which ceramic reinforcing fibers, especially long or continuous fibers, are embedded. In particular, to use the reinforcing effect of the reinforcing fibers, it is advantageous to use the CMC material in the form of individual layers, within which a certain preferred direction of the fiber reinforcement, as a laminate.

To improve the mechanical strength of the laminate layers are applied, for example, to metallic support structures. For a design optimization is possible from the PCT / US2015 / 023017 It is known to produce these metallic carrier structures by means of additive manufacturing methods, in particular by means of selective laser sintering, selective laser melting, multi-jet fusion, electron beam melting and / or laser metal deposition before or after or during the construction of the CMC laminate layer stacks.

However, a disadvantage of the turbine components constructed from a metallic support structure and CMC laminates is that the mechanical strength of these turbine components, also because of the ceramic properties of the CMC laminates, such as grain size and / or grain growth, has hitherto been limited to non-rotating turbine components , Therefore, so far, the above-mentioned hybrid material concepts for turbine components are used essentially only with respect to stationary turbine components.

It is therefore an object of the present invention to provide a concept as to how the use of these CMC-metal hybrid concepts can also be realized for rotating turbine components such as turbine blade and / or guide blade or blade.

This object is solved by the subject matter of the present invention as disclosed in the specification, figures and claims.

General knowledge of the invention is that the greatest burden on turbine components such as vanes or blades in hybrid structure in addition to the high temperature, the centrifugal forces acting, so the tensile stress in the radial direction, so that an effective connection between the metallic support structure and a top metallic Laminate layer, this centrifugal forces on the metallic support structure directs and thus relieves the CMC material components. This could be the disadvantages of the PCT / US2015 / 023017 known prior art overcome.

Accordingly, the subject matter of the invention is a turbine component comprising on a platform at least one metallic support structure surrounded by a laminate ply stack of CMC laminates, the metallic support structure overhanging the laminate ply stack and forming the top end of the laminate ply stack.

• - Stapeln einer Vielzahl von Laminatlagen aus keramischem Faserverbundmaterial CMC auf einer Plattform und aufeinander zur Ausbildung eines Laminatlagen-Stapels, wobei der Laminatlagen-Stapel zumindest eine Öffnung definiert,
• - Aufbau einer metallischen Trägerstruktur innerhalb der durch die Laminatlagen gebildeten Öffnung durch Schmelzen und Wiedererstarren aufeinanderfolgender Schichten metallischen Precursormaterials vor, während oder nach dem Stapeln der Laminatlagen und
• - Aufbau einer metallischen Lage als äußerste oder oberste Abschluss-Lage des CMC-Laminatlagen-Stapels durch Schmelzen und Wiedererstarren metallischen Precursormaterials.

In particular, such a turbine component is obtainable by

• Stacking a plurality of laminate layers of ceramic fiber composite material CMC on a platform and on each other to form a laminate layer stack, wherein the laminate layer stack defines at least one opening,
• - Forming a metallic support structure within the opening formed by the laminate layers by melting and Wiedererstarren successive layers of metallic precursor material before, during or after stacking the laminate layers and
• - Construction of a metallic layer as the outermost or uppermost termination layer of the CMC laminate layer stack by melting and re-solidification of metallic precursor material.

• - Stapeln einer Anzahl von Laminatlagen aus keramischem Faserverbundmaterial CMC auf einer Plattform und aufeinander zur Ausbildung eines Laminatlagen-Stapels, wobei jede der Laminatlagen zumindest eine Öffnung definiert und die Laminatlagen zum Stapel so aufeinander gelegt werden, dass eine Öffnung, deren Umfang ungefähr die metallische Trägerstruktur umgibt, gebildet wird,
• - Aufbau einer metallischen Trägerstruktur zumindest innerhalb der zumindest einen durch den Laminatlagen-Stapel definierten Öffnung durch Schmelzen und Wiedererstarren aufeinanderfolgender Schichten metallischen Precursormaterials vor, während oder nach dem Stapeln der Laminatlagen und
• - Aufbau einer metallischen Schicht als äußerste oder oberste Abschluss-Lage des CMC-Laminatlagen-Stapels durch Schmelzen und Wiedererstarren metallischen Precursormaterials im Verbund mit der metallischen Trägerstruktur.

In addition, the subject of the present invention is a method for producing a turbine component, comprising the following method steps:

• Stacking a number of laminate layers of ceramic fiber composite material CMC on a platform and on each other to form a laminate ply stack, wherein each of the laminate ply defines at least one opening and the laminate layers are stacked against each other such that an opening whose perimeter is approximately the metallic support structure surrounds, is formed,
• - Construction of a metallic support structure at least within the at least one opening defined by the laminate layer stack by melting and re-solidifying successive layers of metallic precursor material before, during or after stacking the laminate layers and
• - Construction of a metallic layer as the outermost or topmost layer of the CMC laminate layer stack by melting and re-solidification of metallic precursor material in conjunction with the metallic support structure.

In the present case, a "laminate" is a layer or a two-dimensional composite of two layers of ceramic composite material, for example CMC, arranged one above the other.

In the present case, a "stack of laminates" is referred to as a stack of several laminates arranged one above the other, wherein the arrangement does not have to coincide with one another, but may be congruent.

In the present case, a "metallic support structure" is understood as meaning a metallic structure constructed on a platform, such as a blade root, via a generative manufacturing process in the 3D process, around which, for example, a laminate layer stack is arranged or which carries a laminate layer stack.

In a laminate ply stack also several metallic support structures can be incorporated.

In accordance with the invention, the metallic carrier extends beyond the opening defined by the laminate ply stack and widened there to form the upper or outer laminate ply termination. Thus, the load is transmitted to the metallic support structure by radially acting pulling forces of a rotating turbine component and does not lie on the laminate layer stack of CMC material.

• - ersten Verfahrensschritt eine unterste Laminatlage abgelegt wird, die zumindest eine Öffnung hat, in einem
• - zweiten Verfahrensschritt über ein additives Fertigungsverfahren die metallische Trägerstruktur teilweise oder ganz die Öffnung füllend und gegebenenfalls noch die angrenzende Laminatlage bedeckend aufgebaut wird
• - diese beiden ersten Verfahrensschritte zumindest zweimal ausgeführt werden und in einem
• - abschließenden Verfahrensschritt über ein additives Fertigungsverfahren die metallische Trägerstruktur fertiggestellt wird.

According to an advantageous embodiment of the invention, the method is performed so that on the platform in a

• - First step, a lowermost laminate layer is deposited, which has at least one opening, in one
• - Second process step via an additive manufacturing process, the metallic support structure partially or completely filling the opening and optionally still the adjacent laminate layer is constructed covering
• - These two first steps are performed at least twice and in one
• - Final process step via an additive manufacturing process, the metallic support structure is completed.

According to an advantageous embodiment of the invention, the metallic support structure extends as fully as possible over the uppermost laminate layer.

During the formation of the turbine component in a hybrid structure, it may be provided that at times the metallic carrier structure projects beyond the stack of laminate layers or vice versa.

By manufacturing the metallic support structure before, during and after the deposition of the laminate layers to form the stack can various designs are realized, which enable special cooling structures.

For example, the metallic support structure at least partially overlaps the one or the other laminate layer, wherein, for example, the formation of toothed structures, ie a toothing of the metallic support beyond the edge of the laminate layer stack at the opening before the next laminate layer is deposited.

In this way, the hybrid structure can be optimized because, on the one hand, force or stress is transferred from the ceramic layer to the metallic carrier structure and, on the other hand, heat is transferred from the metallic carrier structure to the ceramic layer.

Finally, the formation of cooling structures can be achieved by a toothed overlap of the metallic carrier structure with the ceramic layer.

Above all, the advantages of the hybrid structure can also be seen in the fact that the ceramic component makes it possible to build up an excellent heat shield for the metallic carrier structure and conversely that the metallic carrier structure decreases the mechanical loads on the ceramic component. In addition, the cooling structure for guiding the cooling air can be provided within the ceramic, within the metallic and / or finally in the boundary region, ie in the interface between the ceramic layer and the metallic support structure. The generative production methods can be used to realize arbitrarily complex structures.

The metallic support structure is used in high temperature resistant metals such as all refractory metals, tungsten, molybdenum, nickel alloys known for hot gas applications, such as nickel and / or cobalt superalloys. By "super alloys" are meant high-oxidation, corrosion and temperature-resistant alloys known for hot gas turbine components. These are used as corresponding metallic precursors by known 3D methods for producing metallic components.

The ceramic composites, also referred to as CMCs, may be, for example, oxide-based CMCs and / or metal-carbide-based CMCs. Oxide-based CMCs include, for example, a bedding matrix of a metal oxide such as alumina, mullite and / or silica. For example, metal carbide based CMCs include a bedding matrix of a silicon carbide or a nitrogen and / or boron enriched metal carbide. Silicon carbide is in the present case also encompassed by the generic term "metal carbide".

The reinforcing fiber in the CMC may be of the same or different material as the bedding matrix.

In the case of material which is the same according to chemical analysis, the reinforcing fiber may differ from the material of the bedding matrix, for example by the degree of crystallinity, by one or more dopants, by the modification and / or by the particle size of the bedding matrix.

The fiber reinforcement can be in the form of fiber, continuous fiber, fiber bundle, fiber fabric and / or three-dimensional fiber composite. The fiber, which form a fiber bundle, a fiber fabric and / or a three-dimensional fiber composite, may be the same or different.

In particular, in the bedding ceramic matrix, a ceramic fiber selected from the group consisting of the following fibers: alumina, mullite, silica, yttrium-aluminum oxide, for example, with zirconium oxide added, are present.

According to an advantageous embodiment, the ceramic fiber reinforcement may be wholly or partially supplemented or replaced by a metallic fiber reinforcement. In this case, preference is given to metallic fibers which have heat-insulating properties.

• 1a und 1b zeigen den Stand der Technik, wie er aus der PCT/US2015/023017 bekannt ist,
• 2a und 2b zeigen eine Ausführungsform der Erfindung mit einer metallischen Abschlusslage des Laminatlagenstapels und
• 3a und 3b zeigen Ausführungsformen, wie ein Laminatlagenstapel im Inneren aufgebaut sein kann.

In the following the invention will be explained in more detail with reference to figures which each show embodiments of the invention:

• 1a and 1b show the state of the art, as he from the PCT / US2015 / 023017 is known
• 2a and 2 B show an embodiment of the invention with a metallic end layer of the laminate layer stack and
• 3a and 3b show embodiments how a laminate layer stack can be constructed inside.

1 shows a platform 1 For example, a blade root of a guide or blade of a gas turbine. On the platform in the example shown here is a conventional blade, but only half. According to 1a is located on the blade hull 2 a location 3 from CMC, the two openings 4 having. In these openings is a generative manufacturing process, a metallic support structure 5 built up.

In 1b one recognizes the constructed metallic carrier structure 5 in both openings 4 to the topmost location 3 of the laminate layer stack 6 is constructed. The metallic support structure has at least one cooling air channel 7 on. The laminate ply stack includes the CMC plies 3 ,

2a shows the same view as 1b , wherein the construction of a metallic end layer 8th through the arrow 9 is indicated.

In 2 B one recognizes the position of the metallic end position 8th on the laminate sheet pile 6 ,

The metallic final position 8th on the laminate sheet pile 6 is preferred with the metallic support structure 5 In order for the centrifugal force, which acts on the blade tip with rotating turbine components during operation, from the support structure 5 is recorded.

In the embodiment shown here covers the final position 8th the laminate layer stack 6 completely. Alternatively, the metallic end layer 8th even partially over the surface of the laminate ply stack 6 extend.

Finally, it is also included within the scope of the invention that the uppermost metallic end layer is partially laterally along the laminate ply stack 6 extends.

In the 3a and 3b are examples of the toothed structure of CMC laminate layer 3 and metallic support structure 5 shown.

In 3a you can see the CMC laminate layer 3 with the opening 4 in which the metallic support structure 5 is constructed. However, the metallic support structure does not as a whole form the circumference of the opening 4 After, but in the edge region leaves the metallic support structure free spaces that as cooling structures and / or cooling air ducts 7 are usable. The metal of the metallic support structure overlaps in small areas 10 with the CMC location at the same level as out of the PCT / US2015 / 023017 as "interlocking structure with clamping fingers" is known.

Besides these from the PCT / US2015 / 023017 In the present case, known overlapping interlocking structure regions can also be provided in that so-called "mixed regions" are present in which the metallic carrier structure, possibly in the form of a fiber, for example also of an endless fiber, continues into the laminate layer of ceramic fiber composite material and interweaves with it is. In the so-called mixed areas there is no layer structure of CMC layer and metallic layer with defined interface, but the two materials merge into one another, so that in the laminate islands, fibers, fabrics and / or composites are identifiable, consisting of the material of metallic support structure are.

Preferably, these islands, fibers, fabrics and / or composites are connected to the metallic support structure, but may also be present separately.

3b shows a similar embodiment with the overlap in small areas 10 the metallic support structure 5 and a ceramic layer 3 in at least one plane of the laminate ply stack 6 , Here, however, the cooling channels are not between the laminate layer 3 and the metallic support structure 5 , as in 3a shown formed, but completely within the metallic support by cooling structures 7 All made of metallic material 5 are enclosed.

Preferably, the cooling air passages pass through 7 the entire pile 6 and each have a cooling air inlet and a cooling air outlet, but not shown in the figures shown here.

The Hybrid Concept for Rotating Turbine Components, firstly disclosed herein, discloses a technique that can provide an optimum combination of a CMC with a superalloy to produce a turbine component. It is proposed the transmission of the forces acting on the metallic support structure while shading them by a laminate layer stack of ceramic fiber composite material. Thus, the possibility of using the hybrid technology for rotating turbine components is created. The transmission of the load by centrifugal forces is essentially created by a toothed structure of the metallic carrier structure with the laminate layer stack and by a final metal layer.

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

• US 2015023017 PCT [0007, 0010, 0014, 0038, 0047, 0048]

Claims (15)

Turbine component, on a platform at least one metallic support structure, which is surrounded by a laminate layer stack of CMC laminates comprising, wherein the metallic support structure projects beyond the laminate layer stack and forms the upper end of the laminate layer stack. Turbine component after Claim 1 obtainable by - stacking a plurality of laminate layers of ceramic fiber composite material CMC on a platform and subsequently on each other to form a laminate ply stack, the laminate ply stack defining at least one internal opening, - forming a metallic support structure within the opening formed by the laminate layers Melting and re-solidifying successive layers of metallic precursor material before, during or after stacking the laminate layers; and - forming a metallic layer as the outermost or topmost layer of the CMC laminate layer stack by melting and re-solidifying metallic precursor material. Turbine component according to one of the preceding claims, wherein at least one cooling air channel is provided within the metallic support structure. Turbine component according to one of the preceding claims, wherein at least one cooling air channel is provided within the laminate layer stack. Turbine component according to one of the preceding claims, wherein at least one cooling air channel is provided within the opening formed by the laminate layer stack. Turbine component according to one of the preceding claims, wherein at least one laminate layer is provided which is connected to the metallic support structure via overlapping and / or mixed regions. Turbine component according to one of the preceding claims, wherein at least one cooling air passage extends along the boundary surface between the metallic support structure and the ceramic laminate layer. Turbine component according to one of the preceding claims, wherein the metallic end layer partially covers the uppermost ceramic laminate layer. Turbine component according to one of the preceding claims, wherein the uppermost metallic end layer also extends at least partially laterally along the laminate layer stack. Turbine component according to one of the preceding claims, wherein in the uppermost metallic end layer, an inlet and / or an outlet opening for cooling air is provided. Turbine component according to one of the preceding claims, wherein the ceramic fiber composite material is present as an oxide-based and / or as a carbide-based ceramic fiber composite material. Turbine component according to one of the preceding claims, wherein the fiber reinforcement in the ceramic fiber composite material in the form of fibers, continuous fibers, fiber bundles, fiber fabrics and / or three-dimensional fiber composites is present. Turbine component according to one of the preceding claims, wherein the metallic support structure of a nickel and / or cobalt-based superalloy. Method for producing a turbine component, comprising the following method steps: Stacking a number of laminate layers of ceramic fiber composite material CMC on a platform and on each other to form a laminate ply stack, wherein each of the laminate ply defines at least one opening and the laminate layers are stacked against each other such that an opening whose perimeter is approximately the metallic support structure surrounds, is formed, - Construction of a metallic support structure at least within the at least one opening defined by the laminate layer stack by melting and re-solidifying successive layers of metallic precursor material before, during or after stacking the laminate layers and - Construction of a metallic layer as the outermost or topmost layer of the CMC laminate layer stack by melting and re-solidification of metallic precursor material in conjunction with the metallic support structure. Method according to Claim 14 , wherein on the platform in a - first process step, a lowermost laminate layer is deposited, which has at least one opening, in a - second process step via an additive manufacturing process, the metallic support structure partially or completely filling the opening and possibly still the adjacent laminate layer in subregions covered covering becomes - these two first method steps are carried out at least twice and in a - final process step via an additive manufacturing process, the metallic support structure is completed after completion of the laminate layer stack.

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