EP1131176B2 - Single crystal vane segment and method of manufacture - Google Patents

Single crystal vane segment and method of manufacture Download PDF

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Publication number
EP1131176B2
EP1131176B2 EP99969597A EP99969597A EP1131176B2 EP 1131176 B2 EP1131176 B2 EP 1131176B2 EP 99969597 A EP99969597 A EP 99969597A EP 99969597 A EP99969597 A EP 99969597A EP 1131176 B2 EP1131176 B2 EP 1131176B2
Authority
EP
European Patent Office
Prior art keywords
directionally solidified
alloy
single crystal
vane segment
substantially parallel
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.)
Expired - Lifetime
Application number
EP99969597A
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German (de)
English (en)
French (fr)
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EP1131176B1 (en
EP1131176A4 (en
EP1131176A1 (en
Inventor
Donald J. Frasier
Philip S. Burkholder
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Rolls Royce Corp
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Rolls Royce Corp
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Publication date
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Application filed by Rolls Royce Corp filed Critical Rolls Royce Corp
Priority to DE69933132T priority Critical patent/DE69933132T3/de
Publication of EP1131176A1 publication Critical patent/EP1131176A1/en
Publication of EP1131176A4 publication Critical patent/EP1131176A4/en
Publication of EP1131176B1 publication Critical patent/EP1131176B1/en
Application granted granted Critical
Publication of EP1131176B2 publication Critical patent/EP1131176B2/en
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    • 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

Definitions

  • the present invention relates generally to cast gas turbine engine components and their method of manufacture. More particularly, in one embodiment of the present invention, a multi-airfoil vane segment is produced as a single crystal casting from a Rhenium containing directionally solidified (DS) chemistry alloy.
  • DS directionally solidified
  • the performance of a gas turbine engine generally increases with an increase in the operating temperature of a high temperature working fluid flowing from a combustion chamber.
  • One factor recognized by gas turbine engine designers as limiting the allowable temperature of the working fluid is the capability of the engine components to not degrade when exposed to the high temperature working fluid.
  • the airfoils, such as blades and vanes, within the engine are among the components exposed to significant thermal and kinetic loading during engine operation.
  • Many gas turbine engines utilize cast components formed of a nickel or cobalt alloy.
  • the components can be cast as a polycrystalline, directionally solidified, or single crystal structure.
  • the most desirable material properties are associated with the single crystal structure.
  • the geometry of some components, such as the multi-airfoil vane segment causes difficulty during the casting process largely association with grain or crystal defects.
  • Single crystal alloys are not tolerant to these types of defects and therefore castings, which exhibit these defects, are generally not suitable for engine use. Thus, the casting yields are lower and consequently the cost to manufacture the component increases.
  • a directionally solidified component has material properties between single crystal and polycrystalline and are easier to produce than single crystal components.
  • Directionally solidified components are generally defined as multi-crystal structure with columnar grains and are generally cast from a directionally solidified alloy containing grain boundary strengtheners.
  • the directionally solidified component is best suited for designs where the stress field is oriented along the columnar grains and the stress filed transverse to the columnar grain is minimized.
  • the stress fields are elevated along the airfoils and in a transverse direction associated the inner and outer shrouds which tie the airfoils together.
  • a vane segment component comprising a single cast single crystal structure formed of a directional solidified alloy type material, said single crystal structure has a plurality of airfoils integrally connected between a first endwall member and a second endwall member, said single crystal structure has its ⁇ 001> crystal direction substantially parallel with a tangent to one of said endwall members and its ⁇ 010> crystal direction substantially parallel with an average airfoil stacking axis.
  • a gas turbine engine component comprising an integrally cast single crystal vane segment including a plurality of vanes, each of said plurality of vanes including a leading edge and a trailing edge and a first end and a second end, said vane segment has a first endwall member integrally connected with each of said first ends and a second endwall member integrally connected with each of said second ends, said vane segment formed of a directionally solidified alloy type material and having its ⁇ 001> crystal direction substantially parallel with a tangent to one of said endwall members and its ⁇ 010> crystal direction substantially parallel with an average airfoil stacking axis.
  • a method for producing a single crystal vane segment comprising:
  • a gas turbine engine 20 which includes a fan section 21, a compressor section 22, a combustor section 23, and a turbine section 24 that are integrated together to produce an aircraft flight propulsion engine.
  • This type of gas turbine engine is generally referred to as a turbo-fan.
  • One alternate form of a gas turbine engine includes a compressor, a combustor, and a turbine that have been integrated together to produce an aircraft flight propulsion engine without the fan section.
  • aircraft is generic and includes helicopters, airplanes, missiles, unmanned space devices and any other substantially similar devices. It is important to realize that there are a multitude of ways in which the gas turbine engine components can be linked together. Additional compressors and turbines could be added with intercoolers connecting between the compressors and reheat combustion chambers could be added between the turbines.
  • a gas turbine engine is equally suited to be used for an industrial application.
  • industrial gas turbine engines such as pumping sets for gas and oil transmission lines, electricity generation, and naval propulsion.
  • the compressor section 22 includes a rotor 25 having a plurality of compressor blades 26 coupled thereto.
  • the rotor 25 is affixed to a shaft 27 that is rotatable within the gas turbine engine 20.
  • a plurality of compressor vanes 28 are positioned within the compressor section 22 to direct the fluid flow relative to blades 26.
  • Turbine section 24 includes a plurality of turbine blades 30 that are coupled to a rotor disk 31.
  • the rotor disk 31 is affixed to the shaft 27, which is rotatable within the gas turbine engine 20.
  • Energy extracted in the turbine section 24 from the hot gas exiting the combustor section 23 is transmitted through shaft 27 to drive the compressor section 22.
  • a plurality of turbine vanes 32 are positioned within the turbine section 24 to direct the hot gaseous flow stream exiting the combustor section 23.
  • the turbine section 24 provides power to a fan shaft 33, which drives the fan section 21.
  • the fan section 21 includes a fan 34 having a plurality of fan blades 35. Air enters the gas turbine engine 20 in the direction of arrows A and passes through the fan section 21 into the compressor section 22 and a bypass duct 36. Further details related to the principles and components of a conventional gas turbine engine will not be described herein as they are believed known to one of ordinary skill in the art.
  • a vane segment 50 which forms a portion of a turbine nozzle.
  • a plurality of vane segments 50 are conventionally joined together to collectively form the complete 360° turbine nozzle.
  • Each of the vane segments 50 include a plurality of vanes 32 that are coupled to end wall members 51 and 52.
  • the embodiment of vane segment 50, illustrated in FIG. 2 has four vanes coupled thereto, however it is contemplated herein that a vane segment may have one or more vanes per vane segment and is not limited to a vane segment having four vanes.
  • the turbine nozzle includes eleven vane segments having four vanes each. However, a turbine nozzle formed from other quantities of vane segments, and vane segments having other numbers of vanes are contemplated herein.
  • Vane 32 has a leading edge 32a and a trailing edge 32b and an outer surface extending therebetween.
  • the term spanwise will be used herein to indicate an orientation between the first end wall member 51 and the second end wall member 52. Further, the term streamwise will be used herein to indicate an orientation between the leading edge 32a and the trailing edge 32b.
  • Each vane 50 defines an airfoil with the outer surface 53 extending between the leading edge 32a and the trailing edge 32b. The leading and trailing edges of the vane extend between a first end 32c and a second opposite other end 32d.
  • the outer surface 53 of the vane 50 includes a convex suction side (not illustrated) and a concave pressure side 55.
  • the gas turbine engine vane 32 is a hollow single-cast single crystal structure produced by single crystal casting techniques utilizing a directionally solidified alloy composition.
  • the gas turbine engine vane is a solid single-cast single crystal structure produced by single crystal casting techniques utilizing a directionally solidified alloy composition.
  • the present invention contemplates gas turbine engine vanes having internal cooling passageways and apertures for the passage of a cooling media. Cast single crystal casting techniques are believed known to those of ordinary skill in the art. One process for producing a cast single crystal structure is set forth in United States Patent No. 5,295,530 to O'Connor, which is incorporated herein by reference.
  • the material utilized to produce the cast single crystal structure is a directionally solidified alloy, which often is referred to as a DS alloy. More preferably, the alloy is a second-generation directionally solidified superalloy. Second-generation directionally solidified superalloys have creep rupture strengths similar to first generation single crystal superalloys, such as CMSX-2 ® and CMSX-3® at up to 1000 degrees centigrade. For example in Fig. 3 , there is illustrated a Larson-Miller Plot showing the strength of CM 186 LC in comparison to CMSX 2/3 and CM247LC.
  • Examples of the second-generation superalloys include, but are not intended to be limited herein to: PWA 1426 (a Pratt & Whitney product); René 142 (a General Electric product); and, CM186 LC (a Cannon -Muskegon product).
  • PWA 1426 a Pratt & Whitney product
  • René 142 a General Electric product
  • CM186 LC a Cannon -Muskegon product
  • Other directionally solidified alloys are contemplated herein for use in producing a cast single crystal structure.
  • Each of the directionally solidified alloys include grain boundary strengtheners that are designed to increase grain boundary strength.
  • the alloys PWA 1426, Rene 142 and CM186 LC each include boron, carbon, hafnium, and zirconium as their grain boundary strengtheners.
  • Other directionally solidified alloys containing grain boundary strengtheners are contemplated herein.
  • a grain boundary is generally defined as a region in the cast component of non-oriented structure having a width of only a few atomic diameters which serves to accommodate the crystallographic orientation difference or mismatch between adjacent grains. It will be appreciated by those skilled in the art that neither low angle grain boundaries nor high angle grain boundaries will be present in a theoretical "single crystal". However, it will be further appreciated that although there may be one or more grain boundaries present in commercial single crystal structures, they are still characterized as a single crystal structure. Further, manufacturing processes more tolerant of these crystal anomalies are inherently less expensive.
  • Rhenium containing alloys PWA 1426, Rene 142 and CM186 LC are disclosed in Table I. TABLE I. NOMINAL COMPOSITION, WEIGHT % Alloy Cr Co Mo W Ta Re Al Ti Hf C B Zr Ni Density (kg/dm) PWA 1426 6.5 12 2 6 4 3 6.0 - 1.5 .10 .015 .03 BAL 8.6 René 142 6.8 12 2 5 6 3 6.2 - 1.5 .12 .015 .02 BAL 8.6 CM 186 LC 6.0 9 .5 8 3 3 5.7 .7 1.4 .07 .015 .005 BAL 8.70
  • FIG. 4 there is illustrated a casting mold 200 with a molten metal receiving cavity for receiving molten metal therein and forming the multi-airfoil vane segment.
  • FIG. 5 there is illustrated the multi-airfoil vane segment 50 and metallic starter seed 62 with the walls of a casting mold 200 removed to aid the reader. A portion of the metallic starter seed 62 extends into the molten metal receiving cavity of the mold. The molten directionally solidified alloy contacts the starter seed 62 and causes the partial melt back thereof.
  • the starter seed 62 is not in contact with a chill 65. More preferably an insulator 90 is disposed between the starter seed 62 and the chill 65. The insulator 90 functions to thermally insulate the starter seed 62 from the cooling chill 65 and thus promote melting of a portion of the starter seed.
  • the directionally solidified alloy is solidified by a thermal gradient moving vertically through the casting mold. More particularly, the directionally solidified alloy is solidified epitaxially from the unmelted portion of the starter seed 62 to form the single crystal product.
  • the thermal gradient for solidifying the directionally solidified alloy is produced by a combination of mold heating and mold cooling.
  • One system for effectuating the thermal gradient in the mold comprises a mold heater, a mold cooling cone, a chill and the withdrawal of the structure being cast. Further details related to the growing of single crystal alloy structures are believed known to those of ordinary skill in the art and therefore have not been provided.
  • the cast single crystal alloy product has been described in terms of a vane segment, however other cast single crystal product configurations formed of a directionally solidified alloy, such as blades seals, shrouds, blade tracks, nozzle liners and other components subjected to high temperature and stress are contemplated herein.
  • the starter seed 62 is formed and/or oriented such that the seeds ⁇ 001> (primary orientation) crystal direction is substantially parallel with a tangent A, and the seeds ⁇ 010> (secondary orientation) crystal direction is substantially parallel with the average airfoil stacking axis B.
  • the average airfoil stacking axis B is generally defined by the average of each airfoil stacking axis B 1 , B 2 , B 3 , and B 4 .
  • the illustration of FIG. 5 is not intended herein to limit the solidification direction to that shown in the drawings. In an alternative embodiment the solidification direction is substantially parallel to the average airfoil stacking axis B. Further, other solidification directions are contemplated herein.
  • the present invention is not limited to the use of a starter seed to impart the crystallographic structure to the crystal being grown.
  • Single crystals can be grown by techniques generally known to one of ordinary skill in the art, such as utilizing thermal nucleation and the selection of a grain for continued growth with a pigtail sorting structure.
  • the cast single crystal vane segment can be used without the long homogenization heat treat cycles commonly used to maximize properties of cast single crystal articles.
  • the article can be used in a fully heat treated condition.
  • the fully heat treated article maximizes stress rupture and minimizes the formation of deleterious topologically close packed (TCP) phases such as sigma upon the long term exposure of the article to high temperature and stress.
  • TCP topologically close packed

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
EP99969597A 1998-11-05 1999-11-04 Single crystal vane segment and method of manufacture Expired - Lifetime EP1131176B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE69933132T DE69933132T3 (de) 1998-11-05 1999-11-04 Einkristall-leitschaufel und verfahren zu deren herstellung

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US10714198P 1998-11-05 1998-11-05
US107141P 1998-11-05
US25166099A 1999-02-17 1999-02-17
US251660 1999-02-17
PCT/US1999/025976 WO2000025959A1 (en) 1998-11-05 1999-11-04 Single crystal vane segment and method of manufacture

Publications (4)

Publication Number Publication Date
EP1131176A1 EP1131176A1 (en) 2001-09-12
EP1131176A4 EP1131176A4 (en) 2003-06-11
EP1131176B1 EP1131176B1 (en) 2006-09-06
EP1131176B2 true EP1131176B2 (en) 2012-03-14

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ID=26804439

Family Applications (1)

Application Number Title Priority Date Filing Date
EP99969597A Expired - Lifetime EP1131176B2 (en) 1998-11-05 1999-11-04 Single crystal vane segment and method of manufacture

Country Status (5)

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EP (1) EP1131176B2 (ja)
JP (1) JP2004538358A (ja)
CA (1) CA2349412C (ja)
DE (1) DE69933132T3 (ja)
WO (1) WO2000025959A1 (ja)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2927270B1 (fr) * 2008-02-08 2010-10-22 Snecma Procede de fabrication d'aubes a solidification dirigee
JP5232492B2 (ja) * 2008-02-13 2013-07-10 株式会社日本製鋼所 偏析性に優れたＮｉ基超合金
PL2615243T3 (pl) 2012-01-11 2017-12-29 MTU Aero Engines AG Segment wieńca łopatkowego do maszyny przepływowej i sposób jego wytwarzania
DE102016221470A1 (de) 2016-11-02 2018-05-03 Siemens Aktiengesellschaft Superlegierung ohne Titan, Pulver, Verfahren und Bauteil
KR102206061B1 (ko) * 2020-06-12 2021-01-21 터보파워텍(주) 터빈용 실링 세그먼트의 제조방법 및 제조장치

Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3494709A (en) † 1965-05-27 1970-02-10 United Aircraft Corp Single crystal metallic part
US4180119A (en) † 1978-09-18 1979-12-25 Howmet Turbine Components Corporation Mold for directionally solidified single crystal castings and method for preparing same
GB2071695A (en) † 1980-03-13 1981-09-23 Rolls Royce An alloy suitable for making single-crystal castings and a casting made thereof
EP0100150A2 (en) † 1982-07-28 1984-02-08 Trw Inc. Single crystal metal airfoil
EP0208645A2 (en) † 1985-06-10 1987-01-14 United Technologies Corporation Advanced high strength single crystal superalloy compositions
US4637448A (en) † 1984-08-27 1987-01-20 Westinghouse Electric Corp. Method for production of combustion turbine blade having a single crystal portion
US4637449A (en) † 1981-07-03 1987-01-20 Rolls-Royce Limited Component casting
US4707192A (en) † 1984-02-23 1987-11-17 National Research Institute For Metals Nickel-base single crystal superalloy and process for production thereof
US4813470A (en) † 1987-11-05 1989-03-21 Allied-Signal Inc. Casting turbine components with integral airfoils
US4908183A (en) † 1985-11-01 1990-03-13 United Technologies Corporation High strength single crystal superalloys
EP0413439A1 (en) † 1989-08-14 1991-02-20 Cannon-Muskegon Corporation Low carbon directional solidification alloy
US5068084A (en) † 1986-01-02 1991-11-26 United Technologies Corporation Columnar grain superalloy articles
US5399313A (en) † 1981-10-02 1995-03-21 General Electric Company Nickel-based superalloys for producing single crystal articles having improved tolerance to low angle grain boundaries
US5584662A (en) † 1995-03-06 1996-12-17 General Electric Company Laser shock peening for gas turbine engine vane repair
JPH09157777A (ja) † 1995-12-12 1997-06-17 Mitsubishi Materials Corp 耐熱疲労特性、高温クリープおよび高温耐食性に優れたＮｉ基合金
EP0789087A1 (en) † 1996-02-09 1997-08-13 Hitachi, Ltd. High strength Ni-base superalloy for directionally solidified castings
US5706881A (en) † 1994-05-12 1998-01-13 Howmet Research Corporation Heat treatment of superalloy casting with partial mold removal
WO1999067435A1 (en) † 1998-06-23 1999-12-29 Siemens Aktiengesellschaft Directionally solidified casting with improved transverse stress rupture strength

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4169742A (en) * 1976-12-16 1979-10-02 General Electric Company Cast nickel-base alloy article
FR2724857B1 (fr) * 1980-12-30 1997-01-03 Snecma Procede de fabrication d'aubes cristallines
US4804311A (en) * 1981-12-14 1989-02-14 United Technologies Corporation Transverse directional solidification of metal single crystal articles
EP0637476B1 (en) * 1993-08-06 2000-02-23 Hitachi, Ltd. Blade for gas turbine, manufacturing method of the same, and gas turbine including the blade
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

Patent Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3494709A (en) † 1965-05-27 1970-02-10 United Aircraft Corp Single crystal metallic part
US4180119A (en) † 1978-09-18 1979-12-25 Howmet Turbine Components Corporation Mold for directionally solidified single crystal castings and method for preparing same
GB2071695A (en) † 1980-03-13 1981-09-23 Rolls Royce An alloy suitable for making single-crystal castings and a casting made thereof
US4637449A (en) † 1981-07-03 1987-01-20 Rolls-Royce Limited Component casting
US5399313A (en) † 1981-10-02 1995-03-21 General Electric Company Nickel-based superalloys for producing single crystal articles having improved tolerance to low angle grain boundaries
EP0100150A2 (en) † 1982-07-28 1984-02-08 Trw Inc. Single crystal metal airfoil
US4707192A (en) † 1984-02-23 1987-11-17 National Research Institute For Metals Nickel-base single crystal superalloy and process for production thereof
US4637448A (en) † 1984-08-27 1987-01-20 Westinghouse Electric Corp. Method for production of combustion turbine blade having a single crystal portion
EP0208645A2 (en) † 1985-06-10 1987-01-14 United Technologies Corporation Advanced high strength single crystal superalloy compositions
US4908183A (en) † 1985-11-01 1990-03-13 United Technologies Corporation High strength single crystal superalloys
US5068084A (en) † 1986-01-02 1991-11-26 United Technologies Corporation Columnar grain superalloy articles
US4813470A (en) † 1987-11-05 1989-03-21 Allied-Signal Inc. Casting turbine components with integral airfoils
EP0413439A1 (en) † 1989-08-14 1991-02-20 Cannon-Muskegon Corporation Low carbon directional solidification alloy
US5706881A (en) † 1994-05-12 1998-01-13 Howmet Research Corporation Heat treatment of superalloy casting with partial mold removal
US5584662A (en) † 1995-03-06 1996-12-17 General Electric Company Laser shock peening for gas turbine engine vane repair
JPH09157777A (ja) † 1995-12-12 1997-06-17 Mitsubishi Materials Corp 耐熱疲労特性、高温クリープおよび高温耐食性に優れたＮｉ基合金
EP0789087A1 (en) † 1996-02-09 1997-08-13 Hitachi, Ltd. High strength Ni-base superalloy for directionally solidified castings
WO1999067435A1 (en) † 1998-06-23 1999-12-29 Siemens Aktiengesellschaft Directionally solidified casting with improved transverse stress rupture strength

Also Published As

Publication number Publication date
DE69933132T3 (de) 2012-09-06
CA2349412C (en) 2009-09-01
EP1131176B1 (en) 2006-09-06
CA2349412A1 (en) 2000-05-11
JP2004538358A (ja) 2004-12-24
WO2000025959A1 (en) 2000-05-11
EP1131176A4 (en) 2003-06-11
EP1131176A1 (en) 2001-09-12
DE69933132D1 (de) 2006-10-19
DE69933132T2 (de) 2007-08-09

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