DE102019201422A1 - Method for producing a component of a turbomachine provided with a measuring device - Google Patents

Abstract

The invention relates to a method for producing a component of a turbomachine which is provided with a measuring device and which is made of a ceramic fiber composite material and a coating (30) to protect at least one surface (11) of the component (1) from wear and / or from oxidation and / or has corrosion during operation of the turbomachine. In a first step, a semi-finished product (10) of the component (1) is provided, and then the at least one surface (11) of the semi-finished product (10) to be provided with a coating (30) is structured. This is provided with a structure (21, 22) which is provided for arranging a measuring device (25).

Description

The invention relates to a method for producing a component of a turbomachine which is provided with a measuring device and which is produced from a ceramic fiber composite material and a coating for protecting at least one surface of the component from wear and / or oxidation and / or corrosion during the operation of the turbomachine having.

Measuring devices on components are used, for example, to monitor the load or the behavior of, in particular, highly stressed components, for example in order to draw conclusions about their load during operation and / or to receive information about existing or impending wear of the component. In addition, it is difficult to detect loads in the area of the surface of components, in particular loads that act on or in the area of coatings to protect at least one surface of the component against wear and / or against oxidation and / or corrosion, in particular on the Interfaces of such coatings, such as so-called EBC (Environmental Barrier Coatings) coatings.

Reliable mounting of measuring devices such as strain gauges (DMS) or temperature sensors directly on or in the area of the surfaces of components that are made of ceramic fiber composite materials (CMC components) is difficult because the thermal expansion coefficients of ceramic fiber composite materials and the usual materials of measuring devices, metals, in particular, differ from one another and in particular fail quickly on highly stressed engine components and on the vibration stresses frequently occurring there under temperature.

From the French patent specification FR 2 891 896 B1 For example, a method for producing a component of a turbomachine provided with a measuring device is known, in which sensor elements are arranged in blind bores in the semi-finished product. A disadvantage of the described method is the additional effort for the production of blind bores and the insertion and wiring of the sensor elements on the component, as well as the low durability resulting from inadequate fastening of the measuring device on the component at high loads on the component.

Proceeding from this, it is an object of the present invention to propose an improved method for producing a component of a turbomachine provided with a measuring device and a corresponding component which is made of a ceramic fiber composite material and a coating for protecting at least one surface of the component from wear and tear / or before oxidation and / or corrosion during operation of the turbomachine. This is achieved according to the invention by the teaching of the independent claims. Advantageous embodiments of the invention are the subject of the dependent claims.

1. a) Bereitstellen eines Halbzeugs des Bauteils;
2. b) Strukturieren der wenigstens einen mit einer Beschichtung zu versehenen Oberfläche des Halbzeugs; und
3. c) Beschichten der wenigstens einen strukturierten Oberfläche des Halbzeugs.

Dabei wird vorgeschlagen, dass wenigstens eine mit einer Beschichtung zu versehene Oberfläche beim Schritt b) mit einer Struktur versehen wird, welche zum Anordnen einer Messeinrichtung in einem folgenden Schritt b1) vorgesehen ist, wobei die Messeinrichtung im Schritt b1) und damit vor dem Beschichten im Schritt c), wenigstens teilweise in situ mittels eines additiven Fertigungsverfahrens hergestellt und angeordnet wird.To achieve the object, a method for producing a component of a turbomachine which is provided with a measuring device and which is made of a ceramic fiber composite material and a coating for protecting at least one surface of the component against wear and / or against oxidation and / or corrosion, in particular, is proposed before wear due to oxidation and / or corrosion during operation of the turbomachine. The process has the following steps:

1. a) providing a semi-finished product of the component;
2. b) structuring the at least one surface of the semifinished product to be provided with a coating; and
3. c) coating the at least one structured surface of the semi-finished product.

It is proposed that at least one surface to be provided with a coating is provided in step b) with a structure which is provided for arranging a measuring device in a subsequent step b1), the measuring device in step b1) and thus before coating in Step c) is produced and arranged at least partially in situ by means of an additive manufacturing process.

The semi-finished product of the component produced using the proposed method is made of a ceramic fiber composite material. Such materials are particularly characterized by a high temperature resistance and a low specific weight. An example of a ceramic fiber composite material used for components of turbomachines is a fiber-reinforced silicon carbide composite ceramic. Since such components are exposed to wear during operation of the turbomachine, in particular due to the air flow flowing through the turbomachine, they are usually provided with a coating which protects in particular from abrasive and / or oxidative wear.

In a first step, a semi-finished product of the component is made available. At least one surface of the semi-finished product is provided to be provided with a coating. In one on it In the following step, this at least one surface, which can also be one or more areas of the surface of the semifinished product, is structured in order to prepare it for applying the coating. The structuring takes place in particular mechanically, chemically and / or optically and brings the surface into a structure which is suitable for establishing a good connection with the coating. It is proposed here to produce the surface during structuring in such a way that the arrangement of a measuring device on this surface is made possible or simplified, for example by providing suitable surface properties, in particular with regard to the surface roughness and geometry or topology, in particular taking into account those for arranging the measuring device designated areas. When structuring, for example, recesses arranged on the surface can also be produced, in which at least parts of the measuring device can be arranged. It is proposed to produce such properties of the structure of the surface together with the step for structuring the surface already used in the prior art, in particular with a suitable mechanical, chemical and / or optical processing method. In this way, no additional step and in particular no additional method for structuring the surface (s) of the semi-finished product is required to prepare the surface both for applying a coating and for arranging a measuring device, so that the additional preparation of the surface for arranging a measuring device takes time - And can be done inexpensively.

After structuring the surface, the measuring device is arranged on the surface prepared for this purpose. It is proposed to manufacture the measuring device at least partially in situ, that is to say on site, by means of an additive manufacturing process on the prepared surface. In this way, a measuring device can be produced which is suitably firmly connected to the surface of the semi-finished product. Suitable additive manufacturing processes for manufacturing the measuring device are, for example, 3D powder printing processes, metal printing, laser deposition welding or lithography-based processes.

Furthermore, the measuring device, which can be designed individually on the component for the intended purpose, can be designed, in particular, taking into account the loads to be expected on the component, as a result of which an extended service life is made possible, in particular under normal component loads. By means of a measuring device produced at least partially in situ directly on the semi-finished product, measured values such as component behavior under load or temperatures can be recorded directly on the component and forwarded to an evaluation device. Accordingly, it is also possible to at least partially produce electrical connecting lines of the measuring device to an evaluation device, to which the acquired measured values are fed, directly in situ on the component by means of an additive manufacturing method, for example to improve the durability and routing of the connecting lines.

After the measuring device has been arranged, it is coated together with the at least one surface of the semifinished product prepared for coating, in order to provide protection in particular from thermal and / or erosive loads caused by the gas stream flowing through the turbomachine. So-called EBC (Environmental Barrier Coatings) coatings are usually provided on components of turbomachines, for example using a thermal spray process such as a high-speed flame spray process (High Velocity Oxygen Fuel, HVOF) or using a chemical vapor deposition process (Chemical Vapor Deposition, CVD) be deposited on the surface of the semi-finished product.

In the proposed method, structures are used to prepare the surface of the semi-finished product for the application of measuring devices, which structures are used anyway for a protective layer application. The method enables measuring points to be manufactured in situ, which means that a further manufacturing step and thus costly reworking of the semi-finished product can be omitted. With the proposed use of innovative process technologies, damage-free application of durable measuring devices to highly stressed components is also achieved. In addition, the proposed method also enables the detection of loads which act on or in the area of coatings in order to protect at least one surface of the component from wear or oxidation and / or corrosion. Thus, information about the interfaces between the component surface and a coating can also be determined by measuring devices produced with the proposed method.

In one embodiment of the method for producing a component, the structure provided for arranging a measuring device has at least one channel sunk into the surface of the semi-finished product. Measuring devices can be produced and arranged in such recesses without these influencing the subsequent surface of the component, in particular due to their structural height. Furthermore, the surface of a channel can be formed in a suitable manner, for example with regard to the roughness of the surface on which the measuring device is manufactured and arranged. Furthermore, the at least one channel can also be provided for arranging additively manufactured or prepared electrical connecting lines of the measuring device, which are also arranged in a protected manner in a channel.

In one embodiment of the method, the structure provided for arranging a measuring device is generated by means of an optical method, in particular by means of a laser beam. The production of the structure provided for the arrangement of a measuring device by means of an optical method such as a laser or electron beam is particularly advantageous if the structuring of the at least one surface provided for the arrangement of a coating for preparing the coating is also already produced with this processing method. In this way, the preparation of the at least one surface and the structure for arranging the measuring device can be carried out in one work step or with one manufacturing method, in particular in one work step. The structuring of the surface by means of a laser beam can take place, for example, by means of a dry laser or also by means of a laser guided in a water jet, which avoids thermal damage to the surface of the semi-finished product, such as, in particular, distortion or deposits.

In one embodiment of the method, the measuring device produced by means of the additive manufacturing method is applied directly to the structured surface of the semi-finished product. The surface, in particular due to the previous structuring, has a surface suitable for applying a measuring device by means of an additive manufacturing process, so that it is directly suitable as a substrate for arranging and assembling the measuring device. For example, the surface is structured in a manner that enables a firm connection to be formed between the semifinished product and the measuring device built additively thereon, so that the connection produced in this way can withstand particularly high mechanical loads.

In one embodiment of the method, the material for producing the measuring device is applied to the structured surface of the semifinished product and / or to an already produced area of the measuring device by means of the additive manufacturing process by means of a doctor blade or by means of a nozzle. In this way, a uniform and error-free application of the material used to manufacture the measuring device is possible in order to produce a robust measuring device.

In one embodiment of the method, the measuring device has functional elements which can be applied directly to the structured surface of the semifinished product and / or to an area of the measuring device which has already been produced in an additive manner and can be connected thereto. This is particularly necessary if a measuring device has functional elements that cannot be produced by an additive manufacturing process. In this way, such functional elements can be added to the measuring device in the additive manufacturing process and integrated into it.

In one embodiment of the method, in step c) and thus when coating the at least one structured surface of the semi-finished product, the structured surface with the measuring device arranged thereon is coated directly with a cover layer. This procedure is suitable, for example, when, in particular, the material and the surface of the semi-finished product are suitable for establishing a firm connection with the cover layer deposited thereon. With a measuring device produced in this way, information relating to the loads at the interfaces between the component and a coating arranged thereon can be obtained.

In one embodiment of the method, in step c) and thus when coating the at least one structured surface of the semifinished product, the structured surface with the measuring device arranged thereon is first coated with an adhesive layer and then with a cover layer. This procedure is suitable, for example, when, in particular, the material and the surface of the semi-finished product are not suitable for establishing a firm connection with the cover layer deposited thereon. In this case, an adhesive layer is first applied to the surface of the semi-finished product, which forms a firm connection with it. The surface of a suitable adhesive layer is structured in such a way that a cover layer applied or deposited thereon forms a firm connection with it, and the cover layer thus has a firm connection with the surface of the semi-finished product, in particular via the adhesive layer.

In a second aspect, a component for a turbomachine is proposed to achieve the object, which component is manufactured in particular according to one or more aspects of the previously described method for producing a component of a turbomachine. In this case, the component has a structure on a surface arranged under a coating, on which a measuring device produced at least partially in situ by means of an additive manufacturing method is arranged.

The component is produced using a method for producing a component of a turbomachine provided with a measuring device, which component at least partially corresponds to the method described above and optionally has method steps described for this and one or more of the properties and features described above. The component thus also has one or more of the features and properties of a component produced using the manufacturing method mentioned in the preceding description.

• 1 zeigt eine schematische Schnittdarstellung eines Ausschnitts von einem im Schritt a) bereit gestellten beispielhaften Halbzeug;
• 2 eine schematische Schnittdarstellung sowie eine Draufsicht auf einen Ausschnitt des beispielhaften Halbzeugs aus 1, auf dessen strukturierter Oberfläche im Schritt b1) eine Messanordnung hergestellt und angeordnet wird; und
• 3 eine schematische Schnittdarstellung sowie eine Draufsicht auf das beispielhafte Halbzeug aus den 1 und 2, auf dessen strukturierter Oberfläche im Schritt b1) eine Messanordnung hergestellt und angeordnet wird; und
• 4 eine schematische Schnittdarstellung des hergestellten und im Schritt c) beschichteten beispielhaften Bauteils.

Further features, advantages and possible uses of the invention result from the following description in connection with the figures. It shows

• 1 shows a schematic sectional illustration of a section of an exemplary semi-finished product provided in step a);
• 2nd is a schematic sectional view and a plan view of a section of the exemplary semi-finished product from 1 , on the structured surface of which a measuring arrangement is produced and arranged in step b1); and
• 3rd is a schematic sectional view and a plan view of the exemplary semi-finished product from the 1 and 2nd , on the structured surface of which a measuring arrangement is produced and arranged in step b1); and
• 4th is a schematic sectional view of the manufactured and coated in step c) exemplary component.

1 shows a schematic sectional view of an exemplary semi-finished product provided in step a) 10th which is a surface 11 has to be protected with a coating to protect against thermal and / or erosive loads, in particular against wear, oxidation and / or corrosion by the gas stream flowing through the turbomachine. The semi-finished product 10th is made of a ceramic fiber composite (CMC), in the exemplary embodiment a silicon carbide material that is reinforced with silicon carbide fibers (SiC / SiC material). The fiber layers 12th of the exemplary semi-finished product 10th are in 1 shown schematically.

2nd shows a schematic sectional view and a plan view of a section of the exemplary semi-finished product 10th with its surface structured in step b) 11 . The structuring of the surface 11 takes place in the exemplary embodiment by means of a laser 20 whose laser beam hits the surface 11 structured so that a favorable surface structure for applying a coating is created. Thereby using the laser 20 further structures in the form of channels 21 on the surface 11 formed, which are provided for arranging a measuring device. In the exemplary embodiment, the structure has a larger, approximately circular recess 22 on, which is provided in particular for arranging sensors and channels leading thereon or away therefrom 21 , which are provided for arranging connecting lines for current or signal routing, in particular to an evaluation device. The cut information in the lower illustration shows the position of the cut through the semi-finished product 11 , which in the above sectional view in 2nd is shown.

3rd shows a schematic sectional illustration and a top view of a section of the exemplary semi-finished product 10, on its structured surface 11 in step b1) a measuring arrangement 25th is manufactured and arranged. In the exemplary embodiment, the measuring arrangement 25th by means of an additive 3D printing process in the channels formed in the previous step b) 21 as well as in the recess 22 on the surface 11 of the semi-finished product 10th manufactured. The first layer of the material applied with the additive 3D printing process is placed directly on the bottom of the channels eleven or the recess 22 arranged so that there is a firm connection between the semi-finished product 10th and the measuring arrangement produced 25th trains.

In the representation in 3rd above is an exemplary printhead 24th shown with which the 3D printing process is carried out. The measurement arrangement 25th the exemplary embodiment has a data collection node 26 for example in the form of a strain gauge, which is also directly on the structured surface of the semi-finished product by means of the 3D printing process 10th in the area of the recess 22 will be produced. On this data collection node 26 connecting lines leading to or away from these 27 are also directly on the structured surface of the semi-finished product by means of the 3D printing process 10th in the area of the channels 21 manufactured.

4th shows a schematic sectional view of the manufactured and coated in step c) exemplary component 1 . To make a firm connection between the one on the surface 11 of the semi-finished product 10th of the component 1 arranged top layer 30th in the form of an EBC coating and the surface 11 of the semi-finished product 10th In the first step, an adhesive layer is produced 31 on the structured surface 11 of the semi-finished product 10th upset. This adhesive layer 31 also surrounds the textured surface 11 of the semi-finished product 10th arranged measuring device 25th . By cutting off the top layer 30th on the one with a coating 30th to be provided surface 11 of the component 1 finally lies with a measuring device 25th provided component 1 for a turbomachine in which loads, in particular in the area of the surface and / or a coating of the surface, can be detected.

Reference list

1

Component

10th

Workpiece

11

surface

12th

Fiber layers

20

laser

21

channel

22

Recess

24th

Printhead

25th

Measuring device

26

Data acquisition node

27

Connecting lines

30th

Top layer, coating

31

Adhesive layer

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included 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.

Patent literature cited

• FR 2891896 B1 [0004]

Claims (9)

Method for producing a component of a turbomachine which is provided with a measuring device and which is made of a ceramic fiber composite material, and a coating (30) for protecting at least one surface (11) of the component (1) against wear and / or against oxidation and / or corrosion comprises during the operation of the turbomachine, with the following steps: a) providing a semi-finished product (10) of the component (1); b) structuring the at least one surface (11) of the semifinished product (10) to be provided with a coating (30); c) coating the at least one structured surface (11) of the semi-finished product (10); characterized in that at least one surface (11) to be provided with a coating (30) is provided in step b) with a structure (21, 22) which is provided for arranging a measuring device (25) in a subsequent step b1), wherein the measuring device (25) in step b1) and thus before coating in step c) is at least partially manufactured and arranged in situ by means of an additive manufacturing method. Method of manufacturing a component according to Claim 1 characterized in that the structure (21, 22) provided for arranging a measuring device (25) has at least one channel (21) sunk into the surface (11) of the semifinished product (10). Method for producing a component according to at least one of the preceding claims, characterized in that the structure (21, 22) provided for arranging a measuring device (25) is produced by means of an optical method, in particular by means of a laser beam (20). Method for producing a component according to at least one of the preceding claims, characterized in that the measuring device (25) produced by means of the additive manufacturing method is applied directly to the structured surface (11) of the semifinished product (10). Method for manufacturing a component according to at least one of the preceding claims, characterized in that the material for manufacturing the measuring device (25) by the additive manufacturing method by means of a doctor blade or a nozzle onto the structured surface (11) of the semi-finished product (10) and / or can be applied to an already produced area of the measuring device (25). Method for producing a component according to at least one of the preceding claims, characterized in that the measuring device (25) has functional elements which directly on the structured surface (11) of the semifinished product (10) and / or on an area of the measuring device which has already been produced in an additive manner (25) can be applied and connected to it. Method for producing a component according to at least one of the preceding claims, characterized in that in step c) the structured surface (11) with the measuring device (25) arranged thereon is coated with a cover layer (30). Method for producing a component according to at least one of the Claims 1 to 6 , characterized in that in step c) the structured surface (11) with the measuring device (25) arranged thereon is first coated with an adhesive layer (31) and then with a cover layer (30). Component for a turbomachine, which is produced in particular according to a method for producing a component of a turbomachine according to one of the preceding claims, characterized in that the component (1) has a structure (21) on a surface (11) arranged under a coating (30) , 22), on which a measuring device (25) produced at least partially in situ by means of an additive manufacturing method is arranged.

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