DE10331599A1 - Component for a gas turbine and method for producing the same - Google Patents

Abstract

The invention relates to a component, namely a vane or vane segment, for a gas turbine, in particular for an aircraft engine. DOLLAR A A vane (10) comprises at least one airfoil (11) and at least one shroud (12). DOLLAR A According to the invention, the mass and cross-section of the or each shroud (12) are optimized with respect to manufacture of the vane by powder metallurgy injection molding, wherein the vane or vane segment is made by powder metallurgy injection molding (Figure 1).

Description

The The invention relates to a component, namely a vane or a vane segment, for a Gas turbine according to the preamble of claim 1. Furthermore The invention relates to a method for producing such Component according to the preamble of claim 10.

modern Gas turbines, in particular aircraft engines, must meet the highest standards with regard to on reliability, Weight, performance, economy and durability meet. In recent decades, especially in the civil sector Aircraft engines developed that fully meet the above requirements be fair and high level achieved technical perfection. In the development of aircraft engines plays Among other things, the selection of materials, the search for new, suitable Materials as well as the search for new manufacturing processes one decisive role.

The most importantly, nowadays for Aircraft engines or other gas turbines used materials are titanium alloys, nickel alloys (also superalloys called) and high-strength steels. The high-strength steels be for Shaft parts, gear parts, compressor housing and turbine housing used. Titanium alloys are typical materials for compressor parts. nickel alloys are for the hot ones Parts of the aircraft engine suitable.

Out The prior art has numerous methods for the production of Blades or blade segments, in particular vanes or vane segments, for Aircraft engines known. As known from the prior art Procedure for the manufacture of blades, in particular guide vanes, are here forging and investment casting called. Guide vanes in the compressor area are common Forged parts while the vanes of the turbine are usually precision castings. Also It is already known from the prior art to use shovels of the ECM process, a so-called electrochemical machining.

The vanes or vane segments form vane rings and are integral components of gas turbines. The vanes include an outer shroud, an airfoil, and an inner shroud wherein the shrouds extend substantially about the longitudinal axis of the gas turbine, and wherein the airfoils are disposed substantially radially. Such blades are for example from the DE 199 41 133 C1 known.

Of these, Based on the present invention, the problem underlying a novel component, namely a novel vane or a novel vane segment, for one Gas turbine and a method for producing the same propose.

This Problem is solved by that the aforementioned component by the features of the characterizing Part of claim 1 is further developed.

According to the invention Mass and cross-section of the or each shroud in terms of a manufacture of the vane or the vane segment optimized by powder metallurgical injection molding, wherein the vane or the vane segment produced by powder metallurgy injection molding are. It is therefore within the meaning of the present invention the guide vanes, in particular the guide vanes of a compressor an aircraft engine, by powder metallurgical injection molding, ie in MIM technology, manufacture, and the design of the vanes in terms of to optimize production by powder metallurgical injection molding.

To an advantageous embodiment of the invention, the or each Shroud a masseminimierte and stiffness-maximized structure. For this purpose, preferably in an outwardly directed surface of the or each shroud, preferably at least the outer shroud, for mass minimization recesses are introduced, with limitations the recesses optimize the stiffness of the or each shroud. The recesses are as pockets and those between the recesses arranged boundaries are formed as webs, wherein the Bags and webs form a ribbing of any geometry, and the pockets preferably round and / or rectangular and / or triangular and / or hexagonal are formed.

To a first advantageous embodiment of the invention are the Recesses as in the longitudinal direction of the shroud extending pockets and the limits as between the pockets arranged, also extending in the longitudinal direction of the shroud Webs formed.

According to a second alternative advantageous embodiment of the invention, the recesses are as approximately rectangular pockets and the boundaries as between the pockets, in the longitudinal direction of the shroud and in the transverse direction formed of the shroud extending webs.

To a further, alternative advantageous embodiment of the invention The recesses are considered to be approximately triangular pockets and the boundaries as between the pockets, running in the diagonal direction of the shroud Webs formed.

The inventive method is independent Claim 10 defined.

preferred Further developments of the invention will become apparent from the dependent claims and the following description.

embodiments The invention will be described, but not limited to, with reference to the drawing explained in more detail. In the drawing shows:

1 FIG. 2: a detail from a guide vane according to a first exemplary embodiment of the invention in a schematized, perspective view from above onto an outer cover band of the guide vane;

2 a section of a guide vane according to the invention according to a second embodiment of the invention in a view analogous to 1 ;

3 FIG. 2: a section from a guide vane according to the invention according to a third exemplary embodiment of the invention in a view analogous to FIG 1 and 2 ;

4 a schematic side view of a guide vane according to the invention;

5 a guide vane according to the invention according to a further embodiment of the invention in a view analogous to 1 and 2 ;

6 a guide vane segment according to the invention in a view analogous to 5 ; and

7 : a block diagram to illustrate the individual process steps in powder metallurgy injection molding.

Hereinafter, the invention with reference to 1 to 7 explained in more detail. 1 to 6 show schematic views of inventive guide vanes. 7 illustrates the individual process steps for the production of the guide vanes according to the invention.

1 shows a guide vane according to the invention in the neck, wherein in 1 an airfoil 11 and an outer cover tape 12 the vane 10 are shown. In addition to the outer cover tape shown 12 can still be an inner cover tape available.

According to the invention, the design of the outer cover tape 12 , So the mass and the cross section of the same, with regard to a production of the guide vane 10 optimized by powder metallurgical injection molding. For this purpose, the mass or mass distribution and the cross section or the cross-sectional distribution of the outer shroud 12 to the appropriate sizes of the airfoil 11 customized. A uniform cross-sectional distribution and mass distribution throughout the component to be produced, ie in the entire guide vane 10 , is particularly advantageous in powder metallurgy injection molding. A different mass distribution and cross-sectional distribution, for example, different wall thicknesses, namely in powder metallurgy injection molding, in particular during sintering and cooling of a component during powder metallurgy injection molding, lead to a delay or cracking of the component to be produced. This is avoided by the present invention. The uniform cross-sectional distribution and mass distribution in the entire component to be produced can be achieved in the simplest case, that the thickness or thickness of the or each shroud corresponds approximately to the thickness or thickness of the airfoil.

In the embodiment of 1 are in a middle section 13 of the outer cover tape 12 for minimizing the mass of the outer cover tape 12 recesses 14 in an outward-facing surface 15 of the outer cover tape 12 brought in. The recesses 14 are as in the longitudinal direction of the outer shroud 12 extending pockets or notches or grooves formed. By introducing the recesses 14 in the surface 15 of the outer cover tape 12 can the mass of the outer cover tape 12 be minimized. Between which in the longitudinal direction of the outer cover tape 12 extending recesses 14 are limits 16 arranged. The limits 16 are formed as also extending in the longitudinal direction of the shroud webs. The limits 16 or the webs form a ribbing and optimize or maximize the strength structure of the outer shroud 12 , Although in 1 not shown, the recesses and the limitations 16 in addition to the middle section 13 also in the two lateral sections 17 . 18 of the outer cover tape 12 extend. Features the vane 10 in addition to the outer cover tape 12 also over an inner cover tape, this can be analogous to the outer cover tape 12 be educated.

2 shows a second, inventive embodiment, namely a vane 19 in a view analogous to 1 , The vane 19 according to 2 again has an airfoil 20 and an outer cover tape 21 , In a middle section 22 of the outer cover tape 21 are also in the embodiment of 2 recesses 23 in an outward-facing surface 24 of the outer cover tape 21 brought in. The recesses 23 in turn serve the mass reduction. Between the recesses 23 pass boundaries 25 that serve to increase stiffness. In the embodiment of 2 are the recesses 23 designed as triangular recesses or pockets. The limits 25 which the recesses 23 limit each other are in the embodiment of 2 as in the diagonal direction of the outer cover band 21 formed extending webs. In addition to the diagonal direction of the outer shroud 21 extending webs or boundaries 25 are lateral webs or boundaries 26 present, extending in the longitudinal direction of the outer shroud 21 extend and two of the recesses 23 on a longitudinal edge of the outer cover band 21 limit. Also in the embodiment of 2 can the recesses 23 and the footbridges 25 not just in the middle section 22 extend the outer shroud, but also in the region of the lateral sections 27 . 28 , Similarly, in the case where the vane 19 an inner cover tape comprises, the same in analogy to the outer cover tape 21 be educated.

3 shows a further, inventive embodiment of a guide vane 29 , Also the vane according to 3 includes an airfoil 30 and an outer cover tape 31 , In a middle section 32 of the outer cover tape 31 are recesses 33 introduced, wherein the recesses 33 in an outward-facing surface 34 of the outer cover tape 31 are introduced. As 3 can be taken, are the recesses 33 in the embodiment according to 3 not just in the middle section 32 of the outer cover tape 31 introduced into the same, but also in the lateral sections 35 and 36 thereof. In the embodiment according to 3 are the recesses 33 as formed in approximately rectangular pockets or notches, on the one hand by extending in the longitudinal direction of the shroud boundaries 37 and on the other hand by boundaries extending in the transverse direction of the shroud 38 are limited. The limits 37 and 38 form a grid-shaped ribbing and in turn serve to maximize the strength of the outer shroud. In the embodiment of 3 form the recesses formed as rectangular notches 33 on the outward facing surface 34 of the outer cover tape 31 a bag structure that extends both over the middle section 32 as well as the lateral sections 35 and 36 of the outer cover tape 31 extends. Features the vane 29 Over an inner cover tape, so may be designed in analogy to the outer cover tape.

All embodiments according to 1 to 3 is therefore common that the outer shroud of the vanes has a masseminimierte and stiffness-maximized structure. To minimize the mass of the outer cover band recesses or pockets are introduced into the outer shroud. The stiffness is maximized by extending between the recesses or pockets boundaries, which are formed as webs.

4 shows a further embodiment of a guide vane according to the invention 39 , The vane 39 according to 4 again has an airfoil 40 , an outer cover tape 41 as well as an inner cover band 42 , Outer shroud 41 as well as inner cover tape 42 have within the meaning of the invention a masseminimierte and stiffness-maximized structure. So are in 4 in the area of the inner cover tape 42 recesses 43 indicated. These can according to one of the embodiments according to 1 to 3 be educated. To avoid repetition, reference is made to the above statements.

5 shows a further embodiment of a guide vane according to the invention 52 , The vane 52 according to 5 again has an airfoil 53 , an outer cover tape 54 as well as an inner cover band 55 , Outer shroud 54 as well as inner cover tape 54 have within the meaning of the invention a masseminimierte and stiffness-maximized structure. This structure of the embodiment according to 5 corresponds substantially to the structure of the embodiment according to 2 , To avoid repetition, therefore, the same reference numerals are used for the same elements. In a middle section 22 of the outer cover tape 54 are recesses 23 in an outward-facing surface 24 of the outer cover tape 54 introduced, which in turn are designed as triangular recesses or pockets. In the embodiment of 5 is in contrast to the embodiment of 2 but only one in the diagonal direction of the outer cover tape 54 extending limit 25 present, which are the two recesses 23 limited from each other. In addition to the diagonal direction of the outer shroud 21 extending web or the boundary 25 are lateral webs or boundaries 26 present, extending in the longitudinal direction of the outer shroud 54 extend and the two recesses 23 on a longitudinal edge of the outer cover band 54 limit. In the embodiment of 5 extends one of both recesses 23 not just in the middle section 22 the outer shroud, but rather also in the region of the adjacent, lateral section 27 , The inner cover tape 55 can be analogous to the outer cover tape 21 be educated.

At this point it should be noted that vane segments, the more such vanes 10 . 19 . 29 . 39 respectively. 52 include, are constructed according to the same inventive principle. Multiple vanes or vane segments form a closed vane ring. So shows 6 a vane segment 56 with four vanes 52 that in the sense of 5 are formed.

It is still within the meaning of the present invention, the trained according to the above principle guide vanes 10 . 19 . 29 . 39 respectively. 52 or the vane segment 56 produced by powder metallurgy injection molding. Powder metallurgy injection molding is also referred to as metal injection molding (MIM). The vanes 10 . 19 . 29 . 39 such as 52 are in the range of or each shroud within the meaning of the invention so masseminimiert or stiffness-maximized that a particularly advantageous manufacturability is given by powder metallurgy injection molding. Namely, the cross section and the mass of the or each shroud are adapted to the mass and cross section of the or each blade. During sintering and cooling during powder metallurgical injection molding, this ensures that the entire guide blade is subjected to uniform stress during cooling and sintering. Metallurgical defects such as geometric deformations or cracks on the vane are avoided.

The following will be with reference to 7 the individual process steps of powder metallurgy injection molding for the production of the guide vanes 10 . 19 . 29 . 39 such as 52 explained. In a first step 44 For example, a metal powder, hard metal powder or ceramic powder is provided. In a second step 45 a binder and optionally a plasticizer are provided. The in process step 44 provided metal powder and that in the process step 45 provided binders and plasticizers are in the process step 46 mixed and homogenized, so that forms a homogeneous mass. The volume fraction of the metal powder in the homogeneous mass is preferably between 50% and 70%. The proportion of binder and plasticizer in the homogeneous mass thus varies approximately between 30% and 50%.

This homogeneous mass of metal powder, binder and plasticizer is further processed by injection molding in the sense of step 47. In injection molding moldings are made. These shaped bodies already have all the typical features of the guide vanes to be produced 10 . 19 . 29 . 39 as well as 52 on. In particular, the shaped bodies have the geometric shape of the guide blade to be produced 10 . 19 . 29 . 39 and 52. So you already have the mass-minimized and stiffness-maximized structure in the area of the or each shroud. However, they have a volume increased by the binder content and plasticizer content.

In the subsequent step 48 the binder and the plasticizer are expelled from the moldings. The process step 48 can also be called the final binding process. The expulsion of binder and plasticizer can be done in different ways. This is usually done by fractional, thermal decomposition or evaporation. Another possibility consists of sucking out the thermally liquefied binding and plasticizing agents by capillary forces, by sublimation or by solvents.

Following the delivery process in the sense of the step 48 become the moldings in the sense of the step 49 sintered. During the sintering, the moldings become the components, namely the guide vanes 10 . 19 . 29 . 39 such as 52 , condensed with the final, geometric properties. Accordingly, during the sintering, the moldings shrink, whereby the dimensions of the moldings must uniformly decrease in all three spatial directions. The linear shrinkage is dependent on the binder content and plasticizer content between 10 and 20%. The sintering can be carried out under different protective gases or under vacuum. After sintering lies the finished vane 10 . 19 . 29 . 39 such as 52 before, what in 1 through the step 50 is shown. If necessary, after sintering (step 49 ) the component still a refining process in the sense of the step 51 be subjected. However, the refining process is optional. It can also immediately after sintering a ready-to-install vane 10 . 19 . 29 . 39 such as 52 available.

In the above manner also Leitschaufelsegmente comprising a plurality of vanes, can be produced. So in this case in step 47 be made by injection molding moldings for a multi-vanes segment comprising Leitschaufelsegment.

As already mentioned, it is therefore a finding of the present invention, guide vanes for aircraft engines, in particular vanes for compressors of an aircraft engine, on the one hand by powder metallurgical injection molding forth on the other hand, to adapt the structure of the guide vane, namely the structure of the or each shroud thereof, to powder metallurgical injection molding or to optimize it with regard to powder metallurgical injection molding. In the area of the or each shroud mass and cross-section reduction takes place while optimizing the rigidity or strength. The homogenization of the mass and the cross section in the region of the entire guide blade leads to an improved MIM manufacturability. Since the cost of the component to be produced depends directly on the weight of the component during manufacture by powder metallurgical injection molding, there is also a cost reduction.

10

vane

11

airfoil

12

Outer shroud

13

section

14

recess

15

surface

16

limit

17

section

18

section

19

vane

20

airfoil

21

Outer shroud

22

section

23

recess

24

surface

25

limit

26

limit

27

section

28

section

29

vane

30

airfoil

31

Outer shroud

32

section

33

recess

34

surface

35

section

36

section

37

limit

38

limit

39

vane

40

airfoil

41

Outer shroud

42

Inner shroud

43

recess

44

step

45

step

46

step

47

step

48

step

49

step

50

step

51

step

52

vane

53

airfoil

54

Outer shroud

55

Inner shroud

56

vane segment

Claims (17)

Component, vane or vane segment, for a gas turbine, in particular for an aircraft engine, with at least one airfoil (US Pat. 11 . 20 . 30 . 40 . 53 ) and at least one shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ), characterized in that the mass and cross-section of the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) are optimized for manufacturing the vane or the vane segment by powder metallurgy injection molding, and that the vane or vane segment is made by powder metallurgy injection molding. Component according to claim 1, characterized in that the mass and the cross-section of the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) to the mass and cross section of the or each blade ( 11 . 20 . 30 . 40 . 53 ) are adjusted. Component according to claim 1 or 2, characterized in that the mass distribution and the cross-sectional distribution of the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) to the mass distribution and cross-sectional distribution of the or each airfoil ( 11 . 20 . 30 . 40 . 53 ) are adjusted. Component according to one or more of claims 1 to 3, characterized in that the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) has a masseminimized and stiffness-maximized structure. Component according to one or more of claims 1 to 4, characterized in that the thickness or strength of the or each shroud is approximately the thickness of the airfoil. Component according to one or more of claims 1 to 4, characterized in that in an outwardly directed surface ( 15 . 24 . 34 ) of the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) for mass minimization recesses ( 14 . 23 . 33 ), where boundaries ( 16 . 25 . 26 . 37 . 38 ) of the recesses the rigidity of the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) optimize. Component according to claim 6, characterized in that the recesses ( 14 . 23 . 33 ) as pockets and between the recesses ( 14 . 23 . 33 ) ( 16 . 25 . 26 . 37 . 38 ) are formed as webs, wherein the pockets and webs form a ribbing of any geometry, wherein the pockets are in particular round and / or rectangular and / or triangular and / or hexagonal. Component according to claim 6 or 7, characterized in that the recesses ( 14 ) as in the longitudinal direction of the shroud ( 12 ) running pockets and the boundaries ( 16 ) arranged between the pockets, also in the longitudinal direction of the shroud ( 12 ) extending webs are formed. Component according to claim 6 or 7, characterized in that the recesses ( 33 ) as roughly rectangular pockets and the boundaries ( 35 . 36 ) arranged between the pockets, in the longitudinal direction of the shroud ( 31 ) and in the transverse direction of the shroud ( 31 ) extending webs are formed. Component according to claim 6 or 7, characterized in that the recesses ( 23 ) as approximately triangular pockets and the boundaries ( 25 ) arranged between the pockets, in the diagonal direction of the shroud ( 21 ) extending webs are formed. Method for producing a component, namely a guide vane or a vane segment, for a gas turbine, in particular for an aircraft engine, with at least one airfoil ( 11 . 20 . 30 . 40 . 53 ) and at least one shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ), the mass and the cross-section of the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) are optimized by powder metallurgy injection molding. Method according to claim 11, characterized in that the mass of the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) and stiffness is maximized. Method according to claim 11 or 12, characterized in that in an outwardly directed surface ( 15 . 24 . 34 ) of the or each shroud ( 12 . 21 . 31 . 41 . 42 . 54 . 55 ) for mass minimization recesses ( 14 . 23 . 33 ), where boundaries ( 16 . 25 . 26 . 37 . 38 ) of the recesses ( 14 . 23 . 33 ) the stiffness of the or each shroud ( 12 . 21 . 31 . 41 . 42 ) optimize. Method according to claim 13, characterized in that the recesses ( 14 . 23 . 33 ) as pockets and between the recesses ( 14 . 23 . 33 ) ( 16 . 25 . 26 . 37 . 38 ) are introduced as webs in the surface of the or each shroud, wherein the pockets and webs form a ribbing of any geometry, wherein the pockets are in particular round and / or rectangular and / or triangular and / or hexagonal. Method according to claim 13 or 14, characterized in that the recesses ( 14 ) than in the longitudinal direction of the shroud ( 12 ) extending notches and the boundaries ( 16 ) arranged between the notches, also extending in the longitudinal direction of the shroud webs in the surface ( 15 ) of the or each shroud. Method according to claim 13 or 14, characterized in that the recesses ( 33 ) as roughly rectangular notches and the boundaries ( 37 . 38 ) arranged between the notches, in the longitudinal direction of the shroud ( 31 ) and in the transverse direction of the shroud ( 31 ) running webs in the surface ( 34 ) of the or each shroud ( 31 ) are introduced. Method according to claim 13 or 14, characterized in that the recesses ( 23 ) as approximately triangular notches and the boundaries ( 25 ) arranged between the notches, in the diagonal direction of the shroud ( 21 ) running webs in the surface ( 24 ) of the or each shroud ( 21 ) are introduced.