EP0493685A1 - Verfahren und Vorrichtung zur Reparatur von Triebwerksschaufeln - Google Patents

Verfahren und Vorrichtung zur Reparatur von Triebwerksschaufeln Download PDF

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Publication number
EP0493685A1
EP0493685A1 EP91120539A EP91120539A EP0493685A1 EP 0493685 A1 EP0493685 A1 EP 0493685A1 EP 91120539 A EP91120539 A EP 91120539A EP 91120539 A EP91120539 A EP 91120539A EP 0493685 A1 EP0493685 A1 EP 0493685A1
Authority
EP
European Patent Office
Prior art keywords
blade
heat conduction
conduction block
casting mold
remnant
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP91120539A
Other languages
German (de)
English (en)
French (fr)
Inventor
Jürgen Dr. Wortmann
Fritz Staub
Bruno Dr. Walser
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sulzer MTU Casting Tech GmbH
Original Assignee
Sulzer MTU Casting Tech GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sulzer MTU Casting Tech GmbH filed Critical Sulzer MTU Casting Tech GmbH
Publication of EP0493685A1 publication Critical patent/EP0493685A1/de
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/005—Repairing methods or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/10—Repairing defective or damaged objects by metal casting procedures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045—Directionally solidified castings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49318—Repairing or disassembling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49718—Repairing
    • Y10T29/49721—Repairing with disassembling
    • Y10T29/49723—Repairing with disassembling including reconditioning of part
    • Y10T29/49725—Repairing with disassembling including reconditioning of part by shaping
    • Y10T29/49726—Removing material
    • Y10T29/49728—Removing material and by a metallurgical operation, e.g., welding, diffusion bonding, casting
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49718—Repairing
    • Y10T29/49746—Repairing by applying fluent material, e.g., coating, casting

Definitions

  • the invention relates to a method and device for repairing engine blades.
  • DE 28 25 283 discloses a method for cladding metals to "repair typical gas turbine engine parts made of alloys based on Fe, Co or Ni using a compatible cored wire". Such repair methods have the disadvantage that, when used for single-crystal engine blades, they form a polycrystalline region which reduces the strength properties of single-crystal blades.
  • this method and device has the disadvantage that the seed crystal surface is exposed to an aggressive atmosphere through the evaporation of volatile constituents from the casting mold during the entire cleaning and heating up period of the casting mold, which increases the risk of poly growth, dislocation formation and high crystal defect concentration at least in the initial phase of crystal growth increased.
  • the object of the invention is to ensure a repair of single-crystal engine blades by specifying a method and a device so that the repaired blade consists entirely of single-crystal material, a decrease in the strength properties is avoided and an inexpensive replication of defective blade sections is made possible.
  • This method has the advantage that the preparation of a low-defect single-crystalline blade remnant guarantees an undisturbed epitaxial growth of the melt on the core material of the blade remnant and thus on a strongly structured blade cross-sectional area, since the blade remnant in the area of the separation is advantageously only a few seconds without covering the melted melt Mold is exposed.
  • a preferred implementation of the method is to keep the blade remainder in a heat conduction block adapted to the contour.
  • a cutout close to the contour is worked into the heat conduction block by preferably electrochemical eroding.
  • the remainder of the blade serves as a tool before removing its polycrystalline, high-tension and defect-rich surface.
  • the complicated blade contour is advantageously worked into the heat conduction block by means of electrochemical eroding.
  • the heat conduction block has parting lines parallel to the longitudinal axis of the remainder of the blade.
  • the blade remnant can then be removed by stripping polycrystalline, high-voltage and defect-rich layers in the area of the intended melting down to a defect-free core material.
  • the stripping of polycrystalline layers can be achieved by plasma etching, electrochemical eroding or mechanical removal.
  • the accumulation of crystalline defects in near-surface areas of the blade remainder introduced during coating, operation or stripping of the blades is reduced by etching off the disturbed areas to a defect density of at most three visually recognizable defects per cm2 and with a defect area of 0.1 mm2.
  • Such a low defect density of the remaining core material has not been a problem for a single-crystal one Crystal growth proved.
  • the blade remnant is freed of surface-rich areas and strained layers in the area of the separation, which have formed, for example, during storage or during stripping.
  • the casting mold before the blade residue, casting mold and metal melt are brought together, the casting mold is spatially separated from the blade residue and from the melted material and is cleaned to high-temperature vacuum during heating and heated to the casting temperature. This extreme cleanliness of the single-crystal surface of the blade remnant in the area of the separation has so far only been achieved with this method.
  • a device for carrying out the repair of an engine blade has locally separated stations, of which a first station is equipped with a crucible, a heating device for melting the melting material and a device for pouring off the melt.
  • a second station is equipped with a holder for the casting mold and a heating device for separate high-temperature vacuum cleaning and heating of the casting mold.
  • a third station is equipped with a heat conduction block and a coolable holder with high-temperature-resistant coupling elements for the melt-tight connection of the casting mold and the heat conduction block.
  • the spatially separated stations have the advantage that they can be coordinated in time and spatially separated for the implementation of the method, so that mutual contamination in the preparation phase is excluded. Furthermore, they can be equipped differently depending on the purity requirements.
  • the equipment specified above is an advantageous minimum equipment of each station, whereby the high temperature vacuum cleaning the casting mold by means of a vacuum and heating device is of central importance for the success of the repair.
  • this unit in the form of a first station from the other stations during the melting phase, with the aim of being able to be cast or high-temperature vacuum-cleaned and preheated state, to couple stations one and two to the third station, which holds the endangered, high-purity and low-defect surface of the blade core material.
  • the heat of crystallization is dissipated for the coolable holding of the heat conduction block during crystal growth.
  • the cooling of the holder is only activated if the temperature control requires it.
  • the core material of the blade remnant protrudes from the heat conduction block, preferably by a height that corresponds at least to the greatest wall thickness of the core material.
  • a preferred arrangement has an outer flange in the bottom region of the casting mold, which has a positive fit with a flange on the heat conduction block corresponds, so that a stepless transition between the blade remainder and the area to be repaired is advantageously achieved, since a fitting of the downwardly open casting mold onto the blade remainder cross-section is ensured by the corresponding flanges.
  • the flanges of the casting mold and heat conduction block form a bayonet lock with inner conical sealing surfaces, so that advantageously after the casting mold is placed on the rest of the blade with its core material cross section, the inner conical sealing surfaces secure a melt-tight connection and with a rapid rotary movement on the bayonet ring of the bayonet lock, a positive connection between the casting mold and the heat conduction block can be produced at high temperatures.
  • the heat conduction block has at least two separating joints in the longitudinal direction of the blade remainder, which ensure removal of the block after the blade has been repaired.
  • the corresponding flanges preferably have mutually fitting annular grooves, which ensure that the casting mold is placed centrally on the holder and the heat conduction block.
  • the quick-release fastener can be equipped with at least two clips that can be attached externally, which quickly and positively connect the heat conduction block and casting mold in hot state after the casting mold has been put on.
  • the hot casting mold is preferably transported to the third station and then the casting mold and holder from the third station to the first station by means of a travel device for quickly bringing together the hot casting mold, heat conduction block with core material and crucible with metal melt.
  • the pouring station is not moved with the hot melt, as a result of which the temperature of the melt is set very precisely until it is poured can.
  • travel devices are provided for the hot mold from the second station and for the crucible with melt from the first station to the third station.
  • the device preferably has a travel device for holding the third station to the second station and the first station is arranged above the second station and has a tilting device for the crucible
  • the three stations can be arranged one above the other in a container.
  • the container has slides between the stations.
  • a lifting device is arranged as a moving device. After the different preparations of the three stations in the three evacuable rooms for casting and opening the slide, the lifting device can advantageously bring together the three units for casting in the shortest possible time.
  • the device has several individual heat conduction blocks assigned to the blades, which can be cooled by a common holder and, if necessary, moved.
  • the second station then has a plurality of casting molds which are connected, for example, via a common flange to the common mounting of the heat conduction blocks before the melt is poured off.
  • the blade area 1, including the damaged area is separated at the leading edge 2.
  • the separating cut is made approximately orthogonal to the longitudinal axis of the blade, so that the usable blade remainder 5 ends with an easily editable cross section of the blade.
  • This cross section can then be used without high material loss in order to work out, with the help of the blade remnant 5, from a heat conduction block 4, as shown in FIG. 2, a continuous recess which is adapted to the blade contour.
  • a single-crystalline core material 3 from the single-crystal blade residue 5 which is defect-rich in the area of the separating cut and is usually covered with a polycrystalline protective layer.
  • the blade cross section becomes thinner as a function of the layer thickness of a polycrystalline protective layer and the depth of penetration of the stress-rich and defect-rich layers, as shown in FIG. 2 with position 3.
  • FIG. 2 shows a downwardly open casting mold 6 which is adapted to a blade remainder 5 and which consists of a heat-insulating material and was modeled on the separated blade part 30 by the known lost wax method.
  • the casting mold 6 widens toward the blade remainder 5 towards a flange 31 which corresponds to a flange 32 of the heat conduction block 4.
  • Both flanges 31 and 32 are fixed with brackets 9.
  • An annular groove 33 is machined in the flange 31 in order to ensure a precise placement of the casting mold 6 on the heat conduction block 4.
  • an additional annular groove 34 in the flange 32 of the heat conduction block is filled with sealing material in order to complete the casting mold 6.
  • the blade remainder 5 is fitted with the core material 3 at its tip in the recess 35 of the heat conduction block 5. Then the heat conduction block is inserted into the holder 7, which has a cooling 8. After vacuum heating and placing the downwardly open casting mold 6 on the heat conduction block 4, the clamps 9 are pushed over the flanges 31 and 32 in the hot state and the melted material which has melted in the meantime can be poured onto the scoop rest 5 via the funnel-shaped sprue 36 of the casting mold.
  • the high-purity surface of the core material 3 is not contaminated until the melt is poured off.
  • the core material 3 is melted until the cooling 8 of the holder 7 dissipates so much heat via the heat conduction block 4 that a single-crystal epitaxial growth on the melted blade cross-section used and a repaired single-crystalline blade forms with increasing crystallization speed.
  • FIG. 3 shows a device for repairing a turbine blade, which has three locally separate stations 26, 27 and 28.
  • the first station 26 is equipped with a crucible 20 and a heating device 22 for melting the melting material and a tilting device 37 for pouring off the melt.
  • a second station 27 is equipped with a receptacle 38 for a downwardly open casting mold 6 with an opening 39 adapted to the seed crystal cross section and a heating device 23 for separate high-temperature vacuum cleaning and heating of the casting mold 6.
  • a third station 28 has at least one heat conduction block 4, which has a recess 35 adapted to the blade cross section for receiving the residual blade 5, and a coolable holder 7 with high-temperature-resistant coupling elements for the melt-tight connection of mold 6 and heat conduction block 4.
  • the three statins 26, 27 and 28 are arranged in a container 25 one above the other in FIG. 3 and separated by two vacuum slides 17 and 18.
  • a third vacuum slide 19 in the lid 40 of the container 25 enables the melting material to be introduced into the crucible 20.
  • the vacuum slides 17 and 18 are closed when the melting material in the crucible 20 is melted and during the high-temperature vacuum cleaning and heating of the casting mold 6 and preheating of the blade remnant 5.
  • the slides 17 and 18 are opened as soon as a pressure equalization by introducing inert gas via the feed lines 14, 15 and 16 or by equalizing the vacuums by means of the vacuum lines 11, 12 and 13 is made.
  • the heat conduction block 4 can then be connected to the casting mold in a few seconds and both can be lifted into the casting area of the crucible 20. After casting the molten metal a single-crystal solidification of the melt can take place in a middle or deep position or in a further station (not shown).
  • the casting mold 6 is separated from the repaired single-crystal blade by known means. Appropriate parting lines in the casting mold 6 can be used several times.
EP91120539A 1990-12-13 1991-11-29 Verfahren und Vorrichtung zur Reparatur von Triebwerksschaufeln Ceased EP0493685A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE4039807A DE4039807C1 (zh) 1990-12-13 1990-12-13
DE4039807 1990-12-13

Publications (1)

Publication Number Publication Date
EP0493685A1 true EP0493685A1 (de) 1992-07-08

Family

ID=6420232

Family Applications (1)

Application Number Title Priority Date Filing Date
EP91120539A Ceased EP0493685A1 (de) 1990-12-13 1991-11-29 Verfahren und Vorrichtung zur Reparatur von Triebwerksschaufeln

Country Status (3)

Country Link
US (1) US5193272A (zh)
EP (1) EP0493685A1 (zh)
DE (1) DE4039807C1 (zh)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0581547A1 (en) * 1992-07-30 1994-02-02 General Electric Company Method for providing an extension on an end of an article and extended article
EP0581548A1 (en) * 1992-07-30 1994-02-02 General Electric Company Method for providing an extension on an end of an article having internal passageways
WO2004097179A1 (de) * 2003-04-27 2004-11-11 Mtu Aero Engines Gmbh Verfahren zur wartung von gasturbinen

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US5900170A (en) * 1995-05-01 1999-05-04 United Technologies Corporation Containerless method of producing crack free metallic articles by energy beam deposition with reduced power density
US5914059A (en) * 1995-05-01 1999-06-22 United Technologies Corporation Method of repairing metallic articles by energy beam deposition with reduced power density
US5778960A (en) * 1995-10-02 1998-07-14 General Electric Company Method for providing an extension on an end of an article
US5904201A (en) * 1996-01-18 1999-05-18 General Electric Company Solidification of an article extension from a melt using a ceramic mold
US5743322A (en) * 1996-06-27 1998-04-28 General Electric Company Method for forming an article extension by casting using a ceramic mold
US5673745A (en) * 1996-06-27 1997-10-07 General Electric Company Method for forming an article extension by melting of an alloy preform in a ceramic mold
US5676191A (en) * 1996-06-27 1997-10-14 General Electric Company Solidification of an article extension from a melt using an integral mandrel and ceramic mold
US5673744A (en) * 1996-06-27 1997-10-07 General Electric Company Method for forming an article extension by melting of a mandrel in a ceramic mold
EP1340567A1 (en) * 2002-02-27 2003-09-03 ALSTOM (Switzerland) Ltd Method of removing casting defects
EP1437426A1 (de) * 2003-01-10 2004-07-14 Siemens Aktiengesellschaft Verfahren zum Herstellen von einkristallinen Strukturen
DE10319019B4 (de) * 2003-04-27 2006-03-30 Mtu Aero Engines Gmbh Verfahren zur Wartung, insbesondere Reparatur, von Gasturbinen
US7047612B2 (en) * 2003-05-02 2006-05-23 Caterpillar Inc. Method for repairing a casting
DE102006026704A1 (de) * 2006-06-08 2007-12-13 Mtu Aero Engines Gmbh Verfahren zur Herstellung oder Reparatur von Turbinen- oder Triebwerksbauteilen, sowie Bauteil, nämlich Turbinen- oder Triebwerksbauteil
US9415438B2 (en) * 2013-04-19 2016-08-16 United Technologies Corporation Method for forming single crystal parts using additive manufacturing and remelt
KR102116503B1 (ko) * 2018-12-03 2020-05-28 두산중공업 주식회사 날개요소 수리방법 및 블레이드 수리방법

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GB2071778A (en) * 1980-03-19 1981-09-23 Gen Electric Method and replacement member for repairing a gas turbine engine blade
EP0276404A1 (de) * 1986-12-12 1988-08-03 BBC Brown Boveri AG Verfahren zur Verlängerung des Schaufelblattes von Strömungsmaschinenschaufeln
EP0401187A2 (en) * 1989-06-01 1990-12-05 Abb Stal Ab Method for reconstruction of blades and vanes in steam turbines at existing erosion damages

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GB2071778A (en) * 1980-03-19 1981-09-23 Gen Electric Method and replacement member for repairing a gas turbine engine blade
EP0276404A1 (de) * 1986-12-12 1988-08-03 BBC Brown Boveri AG Verfahren zur Verlängerung des Schaufelblattes von Strömungsmaschinenschaufeln
EP0401187A2 (en) * 1989-06-01 1990-12-05 Abb Stal Ab Method for reconstruction of blades and vanes in steam turbines at existing erosion damages

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0581547A1 (en) * 1992-07-30 1994-02-02 General Electric Company Method for providing an extension on an end of an article and extended article
EP0581548A1 (en) * 1992-07-30 1994-02-02 General Electric Company Method for providing an extension on an end of an article having internal passageways
WO2004097179A1 (de) * 2003-04-27 2004-11-11 Mtu Aero Engines Gmbh Verfahren zur wartung von gasturbinen
US7827686B2 (en) 2003-04-27 2010-11-09 Mtu Aero Engines Gmbh Method for the maintenance of gas turbines

Also Published As

Publication number Publication date
DE4039807C1 (zh) 1991-10-02
US5193272A (en) 1993-03-16

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