EP1398098A1 - Method for fabrication of turbine blades with cooling channels - Google Patents

Method for fabrication of turbine blades with cooling channels Download PDF

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Publication number
EP1398098A1
EP1398098A1 EP03015950A EP03015950A EP1398098A1 EP 1398098 A1 EP1398098 A1 EP 1398098A1 EP 03015950 A EP03015950 A EP 03015950A EP 03015950 A EP03015950 A EP 03015950A EP 1398098 A1 EP1398098 A1 EP 1398098A1
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EP
European Patent Office
Prior art keywords
core
pin
shell
wax
turbine blade
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.)
Granted
Application number
EP03015950A
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German (de)
French (fr)
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EP1398098B1 (en
Inventor
Wilfried Dr. Schneiders
Jörn Dr. Grossmann
Theodor Schmitte
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.)
Doncasters Precision Castings Bochum GmbH
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Doncasters Precision Castings Bochum GmbH
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Publication of EP1398098A1 publication Critical patent/EP1398098A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars

Definitions

  • the invention relates to a method for producing turbine blades cooling channels arranged therein, a ceramic core being produced, which is overmolded with a wax, over which overmolded with wax Core by repeated dipping and sanding a ceramic molded shell is generated, which is burned after removing the wax, the space created by removing the wax to form the turbine blade is poured out with molten metal while doing so Movements of the core in the mold shell by itself starting from the core positioning aids extending into the molded shell are prevented, and after the metal has hardened, the mold shell and the core removed as well as the metallic turbine blade mechanically is processed.
  • the object of the invention is a method of the initially described Specify genus in which movements of the core during the casting can be reliably prevented and impairments of the material properties or surfaces of the turbine blade are excluded.
  • a pin in the positioning aid free face of the core is embedded, which protrudes over the face and is also embedded in the molded shell, and that the protruding end of the Pin is removed during mechanical processing. That leaves them Material properties, the wall thicknesses and the surfaces of all functionally important Areas of the turbine blade from the arrangement of the pin unaffected.
  • the pin can be inserted into the ceramic without additional effort Embed core. Its about that from the so-called crown bottom of the turbine blade protruding end can be easily removed. That under the End of the pin located at the crown bottom does not need to be removed, because it doesn't bother. It is understood that the dimensions of the pin are so be chosen that on the one hand a firm embedding in the core material is possible and that, on the other hand, the pin has sufficient stability when Cast has.
  • the pin should preferably consist of a nickel-based alloy, in particular made of NiCr 82. Such an alloy is essentially resistant to oxidation and has sufficient mechanical strength in the High temperature range above 1,400 ° C. But others can too materials known per se can be used for the pen, e.g. Platinum, Precious metal alloys based on palladium or tungsten, or if necessary, pins made of ceramic materials.
  • a pen is used, its material when firing the molded shell oxidized, then a version is recommended in which the pin with a Abutment for the metal of the turbine blade is provided. It can in the simplest case, it is a circumferential groove.
  • the pen should be like this be embedded in the core that the circumferential groove in the area of later crown bottom.
  • the core shown schematically in Figures 1 and 2 consists of a ceramic material. Its lower section 2 in FIGS. 1 and 2 is set up for connection to a bracket, not shown. from lower section go out two upper sections 3, 4, which are essentially extend parallel to each other. At least the upper section 4 has Profiling 5 on the formation of the cooling channels in the turbine blade serve.
  • the core 1 is manufactured, the upper end faces 6 Pins 7 embedded, which protrude above the upper end faces 6.
  • the pencils consist of a nickel-based alloy in the embodiment shown, namely from NiCr 82.
  • the core prepared in this way is extrusion-coated with a wax layer 8 (FIG. 3).
  • This wax layer 8 defines a space that will later form the Turbine blade is poured out with molten metal.
  • the above the core 1 protruding end 10 of the pin 7 or pins 7 is also over the wax layer 8 and has a in the area of the wax layer 8 Circumferential groove 11.
  • the space released by the wax layer 8 can be melted Metal 12 are poured out, which after cooling and Harden the turbine blade forms.
  • the molten metal 12 also flows into the circumferential groove 11 of the pin or pins 7, so that a positive connection is produced, which is at least necessary if the pen material is burned when the Shaped shell 9 tends to surface oxidation ( Figure 6).
  • the core 1 and the Removed molded shell 9 ( Figure 7) and the resulting turbine blade 13 can be machined.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Casting Devices For Molds (AREA)

Abstract

The method involves making a ceramic core, injecting round it with wax and dipping it and sanding it to produce a ceramic moulding shell. Movement of the core in the shell is prevented by positioning pins (7) embedded in the free end side (6) of the core (1) so as to protrude beyond this end side to bed into the shell. The protruding end of the pin is removed during the mechanical finishing work carried out on the hardened metal blades. The pin is made from a nickel-based alloy, preferably from NiCr 82.

Description

Die Erfindung betrifft ein Verfahren zum Herstellen von Turbinenschaufeln mit darin angeordneten Kühlkanälen, wobei ein keramischer Kern hergestellt wird, der mit einem Wachs umspritzt wird, wobei über dem mit Wachs umspritzten Kern durch wiederholtes Tauchen und Besanden eine keramische Formschale erzeugt wird, die nach dem Entfernen des Wachses gebrannt wird, wobei der durch das Entfernen des Wachses entstandene Raum zur Bildung der Turbinenschaufel mit geschmolzenem Metall ausgegossen wird und dabei Bewegungen des Kerns in der Formschale durch vom Kern ausgehende, sich bis in die Formschale erstreckende Positionierungshilfen verhindert werden, und wobei nach dem Erhärten des Metalls die Formschale und der Kern entfernt werden sowie die metallische Turbinenschaufel mechanisch bearbeitet wird.The invention relates to a method for producing turbine blades cooling channels arranged therein, a ceramic core being produced, which is overmolded with a wax, over which overmolded with wax Core by repeated dipping and sanding a ceramic molded shell is generated, which is burned after removing the wax, the space created by removing the wax to form the turbine blade is poured out with molten metal while doing so Movements of the core in the mold shell by itself starting from the core positioning aids extending into the molded shell are prevented, and after the metal has hardened, the mold shell and the core removed as well as the metallic turbine blade mechanically is processed.

Derartige Verfahren sind in verschiedenen Ausführungen bekannt. In der Regel ist das untere Ende des Kerns beim Abguß fest angeordnet, sein oberes Ende kann aber unter dem Einfluß des einströmenden geschmolzenen Metalls Bewegungen ausführen, die verhindert werden müssen, damit die Wandungen der Turbinenschaufel in allen Bereichen die gewünschte Wandstärke aufweisen.Such methods are known in various versions. In the As a rule, the lower end of the core is fixed when casting upper end can, however, under the influence of the inflowing melted Perform metal movements that must be prevented so that the Walls of the turbine blade in all areas the desired wall thickness exhibit.

Dazu ist es bekannt, in diejenigen Bereiche der den Kern umgebenden Wachsschicht, die später die Wandungen der Turbinenschaufel begrenzen, Stifte einzudrücken, die gegen den Kern stoßen und etwas über die Wachsschicht vorstehen (DE 38 13 287 C2; EP 0 324 229 B1). Die überstehenden Enden der Stifte werden in die Formschale eingebettet und verhindern nach dem Entfernen des Wachses beim Abguß Bewegungen des Kerns. Das ist fertigungstechnisch aufwendig und kann in Abhängigkeit vom Stiftmaterial auch zu lokalen Veränderungen der Materialeigenschaften der Turbinenschaufel sowie zu Problemen bei einer gegebenenfalls nachfolgenden Beschichtung der Turbinenschaufel führen . To do this, it is known in those areas of the core surrounding Wax layer that later delimits the walls of the turbine blade, Push in pins that hit the core and something over the wax layer project (DE 38 13 287 C2; EP 0 324 229 B1). The protruding ones Ends of the pins are embedded in the molded shell and prevent after the removal of the wax during the casting movements of the core. This is production-technically complex and can depend on the pen material also to local changes in the material properties of the turbine blade as well as problems with a subsequent one Lead coating of the turbine blade.

Bei einem anderen bekannten Verfahren (EP 0 585 183 A1) wird der Kern mit Vorsprüngen (Bumper) versehen, die als Abstandshalter dienen. Es ist auch schon vorgeschlagen worden, die Wachsschicht des Kerns bereichsweise zu entfernen, so daß entsprechende Vorsprünge bzw. Abstandshalter von der Formschale gebildet werden (US 6 364 001 B1). Auch das ist fertigungstechnisch aufwendig und garantiert nicht die gewünschte Wandstärke der Turbinenschaufel.In another known method (EP 0 585 183 A1), the core is removed Provide projections (bumpers) that serve as spacers. It is also have already been proposed to increase the wax layer of the core in some areas remove so that appropriate protrusions or spacers from the Shaped shell are formed (US 6 364 001 B1). This is also manufacturing technology complex and does not guarantee the desired wall thickness of the Turbine blade.

Aufgabe der Erfindung ist es, ein Verfahren der eingangs beschriebenen Gattung anzugeben, bei dem Bewegungen des Kerns während des Abgusses zuverlässig verhindert werden und Beeinträchtigungen der Materialeigenschaften oder Oberflächen der Turbinenschaufel ausgeschlossen sind.The object of the invention is a method of the initially described Specify genus in which movements of the core during the casting can be reliably prevented and impairments of the material properties or surfaces of the turbine blade are excluded.

Diese Aufgabe wird dadurch gelöst, daß als Positionierungshilfe ein Stift in die freie Stirnseite des Kerns eingebettet wird, der über die Stirnseite vorsteht und auch in die Formschale eingebettet wird, und daß das vorstehende Ende des Stiftes bei der mechanischen Bearbeitung entfernt wird. Damit bleiben die Materialeigenschaften, die Wandstärken und die Oberflächen aller funktionswichtigen Bereiche der Turbinenschaufel von der Anordnung des Stiftes unberührt. Der Stift läßt sich ohne zusätzlichen Aufwand in den keramischen Kern einbetten. Sein über die vom sogenannten Kronenboden der Turbinenschaufel vorstehendes Ende kann leicht entfernt werden. Das unter dem Kronenboden befindliche Ende des Stiftes braucht nicht entfernt zu werden, denn es stört nicht. Es versteht sich, daß die Abmessungen des Stiftes so gewählt werden, daß einerseits eine feste Einbettung in das Kernmaterial möglich ist und daß andererseits der Stift eine hinreichende Stabilität beim Abguß aufweist.This object is achieved in that a pin in the positioning aid free face of the core is embedded, which protrudes over the face and is also embedded in the molded shell, and that the protruding end of the Pin is removed during mechanical processing. That leaves them Material properties, the wall thicknesses and the surfaces of all functionally important Areas of the turbine blade from the arrangement of the pin unaffected. The pin can be inserted into the ceramic without additional effort Embed core. Its about that from the so-called crown bottom of the turbine blade protruding end can be easily removed. That under the End of the pin located at the crown bottom does not need to be removed, because it doesn't bother. It is understood that the dimensions of the pin are so be chosen that on the one hand a firm embedding in the core material is possible and that, on the other hand, the pin has sufficient stability when Cast has.

Vorzugsweise sollte der Stift aus einer Nickelbasis-Legierung bestehen, insbesondere aus NiCr 82. Eine solche Legierung ist im wesentlichen oxydationsbeständig und weist eine hinreichende mechanische Festigkeit im Hochtemperaturbereich oberhalb 1.400°C auf. Es können aber auch andere an sich bekannte Materialien für den Stift verwendet werden, z.B. Platin, Edelmetall-Legierungen auf Palladiumbasis oder auf Wolframbasis, oder gegebenenfalls auch Stifte aus keramischen Materialien.The pin should preferably consist of a nickel-based alloy, in particular made of NiCr 82. Such an alloy is essentially resistant to oxidation and has sufficient mechanical strength in the High temperature range above 1,400 ° C. But others can too materials known per se can be used for the pen, e.g. Platinum, Precious metal alloys based on palladium or tungsten, or if necessary, pins made of ceramic materials.

Wird ein Stift verwendet, dessen Material beim Brennen der Formschale oxydiert, dann empfiehlt sich eine Ausführung, bei der der Stift mit einem Widerlager für das Metall der Turbinenschaufel versehen wird. Dabei kann es sich im einfachsten Fall um eine Umfangsnut handeln. Der Stift sollte dann so in den Kern eingebettet werden, daß die Umfangsnut sich im Bereich des späteren Kronenbodens befindet.If a pen is used, its material when firing the molded shell oxidized, then a version is recommended in which the pin with a Abutment for the metal of the turbine blade is provided. It can in the simplest case, it is a circumferential groove. The pen should be like this be embedded in the core that the circumferential groove in the area of later crown bottom.

lm folgenden wird ein Ausführungsbeispiel der Erfindung erläutert; es zeigen:

Figur 1
schematisch eine Draufsicht auf eine Breitseite eines Kerns, der für die Herstellung einer Turbinenschaufel mit Kühlkanälen eingesetzt wird,
Figur 2
einen Schnitt in Richtung II-II durch den Gegenstand nach Figur 1,
Figur 3
den Gegenstand nach Figur 2 nach dem Umspritzen mit Wachs,
Figur 4
den Gegenstand nach Figur 3 mit einer keramischen Formschale über der Wachsschicht,
Figur 5
den Gegenstand nach Figur 4 nach dem Ausschmelzen der Wachsschicht,
Figur 6
den Gegenstand nach Figur 5 nach dem Abguß,
Figur 7
den Gegenstand nach Figur 6 nach dem Entfernen des Kerns und der Formschale,
Figur 8
den Gegenstand nach Figur 7 nach dem Entfernen des über den Kronenboden vorstehenden Endes des Stiftes.
An exemplary embodiment of the invention is explained below; show it:
Figure 1
schematically a plan view of a broad side of a core which is used for the production of a turbine blade with cooling channels,
Figure 2
2 shows a section in the direction II-II through the object according to FIG. 1,
Figure 3
the object of Figure 2 after extrusion coating with wax,
Figure 4
3 with a ceramic molded shell over the wax layer,
Figure 5
the object of Figure 4 after melting the wax layer,
Figure 6
5 after the casting,
Figure 7
6 after removal of the core and the molded shell,
Figure 8
the object of Figure 7 after removing the protruding from the crown bottom end of the pin.

Der in den Figuren 1 und 2 schematisch wiedergegebene Kern besteht aus einem keramischen Material. Sein in den Figuren 1 und 2 unterer Abschnitt 2 ist für den Anschluß an eine nicht dargestellte Halterung eingerichtet. Vom unteren Abschnitt gehen zwei obere Abschnitte 3, 4 aus, die sich im wesentlichen parallel zueinander erstrecken. Wenigstens der obere Abschnitt 4 weist Profilierungen 5 auf, die zur Bildung der Kühlkanäle in der Turbinenschaufel dienen. Bei der Herstellung des Kerns 1 werden in die oberen Stirnseiten 6 Stifte 7 eingebettet, die über die oberen Stirnseiten 6 vorstehen. Die Stifte bestehen bei der dargestellten Ausführung aus einer Nickelbasis-Legierung, nämlich aus NiCr 82.The core shown schematically in Figures 1 and 2 consists of a ceramic material. Its lower section 2 in FIGS. 1 and 2 is set up for connection to a bracket, not shown. from lower section go out two upper sections 3, 4, which are essentially extend parallel to each other. At least the upper section 4 has Profiling 5 on the formation of the cooling channels in the turbine blade serve. When the core 1 is manufactured, the upper end faces 6 Pins 7 embedded, which protrude above the upper end faces 6. The pencils consist of a nickel-based alloy in the embodiment shown, namely from NiCr 82.

Der so vorbereitete Kern wird mit einer Wachsschicht 8 umspritzt (Figur 3). Diese Wachsschicht 8 definiert einen Raum, der später zur Bildung der Turbinenschaufel mit geschmolzenem Metall ausgegossen wird. Das über den Kern 1 vorstehende Ende 10 des Stiftes 7 bzw. der Stifte 7 steht auch über die Wachsschicht 8 vor und weist im Bereich der Wachsschicht 8 eine Umfangsnut 11 auf.The core prepared in this way is extrusion-coated with a wax layer 8 (FIG. 3). This wax layer 8 defines a space that will later form the Turbine blade is poured out with molten metal. The above the core 1 protruding end 10 of the pin 7 or pins 7 is also over the wax layer 8 and has a in the area of the wax layer 8 Circumferential groove 11.

In einem weiteren Verfahrensschritt (Figur 4) wird über der Wachsschicht 8 durch mehrfaches Tauchen und Besanden eine keramische Formschale 9 erzeugt. Nach dem Entfernen der Wachsschicht 8 wird die Formschale 9 gebrannt (Figur 5).In a further method step (FIG. 4), 8 by multiple dipping and sanding a ceramic shell 9 generated. After removing the wax layer 8, the molded shell 9 fired (Figure 5).

Nun kann der von der Wachsschicht 8 freigegebene Raum mit geschmolzenem Metall 12 ausgegossen werden, welches nach dem Abkühlen und Erhärten die Turbinenschaufel bildet. Das geschmolzene Metall 12 fließt auch in die Umfangsnut 11 des oder der Stifte 7, so daß ein Formschluß entsteht, der zumindest dann notwendig ist, wenn das Stiftmaterial beim Brennen der Formschale 9 zu Oberflächenoxydation neigt (Figur 6).Now the space released by the wax layer 8 can be melted Metal 12 are poured out, which after cooling and Harden the turbine blade forms. The molten metal 12 also flows into the circumferential groove 11 of the pin or pins 7, so that a positive connection is produced, which is at least necessary if the pen material is burned when the Shaped shell 9 tends to surface oxidation (Figure 6).

Nach dem Abkühlen und Erhärten des Metalls 12 werden der Kern 1 und die Formschale 9 entfernt (Figur 7) und die so entstandene Turbinenschaufel 13 kann mechanisch bearbeitet werden. Im Zuge der mechanischen Bearbeitung wird auch das ursprünglich in die Formschale 9 eingebettete Ende 10 des oder der Stifte 7, welches über den Kronenboden 14 der Turbinenschaufel 13 vorsteht, entfernt. Das sich in das Innere der Turbinenschaufel 13 erstreckende Ende des oder der Stifte 7 wird nicht entfernt, denn es stört nicht.After cooling and hardening of the metal 12, the core 1 and the Removed molded shell 9 (Figure 7) and the resulting turbine blade 13 can be machined. In the course of mechanical processing is also the end 10 of the originally embedded in the molded shell 9 or the pins 7, which over the crown bottom 14 of the turbine blade 13 protrudes, removed. That is in the interior of the turbine blade 13 extending end of the pin or pins 7 is not removed because it bothers Not.

Claims (6)

Verfahren zum Herstellen von Turbinenschaufeln mit darin angeordneten Kühlkanälen, wobei ein keramischer Kern hergestellt wird, der mit einem Wachs umspritzt wird, wobei über dem mit Wachs umspritzten Kern durch wiederholtes Tauchen und Besanden eine keramische Formschale erzeugt wird, die nach dem Entfernen des Wachses gebrannt wird, wobei der durch das Entfernen des Wachses entstandene Raum zur Bildung der Turbinenschaufel mit geschmolzenem Metall ausgegossen wird und dabei Bewegungen des Kerns in der Formschale durch vom Kern ausgehende, sich bis in die Formschale erstreckende Positionierungshilfen verhindert werden, und wobei nach dem Erhärten des Metalls die Formalschale und der Kern entfernt werden sowie die metallische Turbinenschaufel mechanisch bearbeitet wird, dadurch gekennzeichnet, daß als Positionierungshilfe ein Stift (7) in die freie Stirnseite (6) des Kerns (1) eingebettet wird, der über die Stirnseite (6) vorsteht und auch in die Formschale (9) eingebettet wird, und daß das vorstehende Ende (10) des Stiftes (7) bei der mechanischen Bearbeitung entfernt wird.Method for manufacturing turbine blades with cooling channels arranged therein, wherein a ceramic core is produced which is overmolded with a wax, a ceramic molded shell being produced by repeated dipping and sanding over the wax overmolded core, which is fired after the wax has been removed , wherein the space created by the removal of the wax to form the turbine blade is poured out with molten metal and movements of the core in the mold shell are prevented by positioning aids extending from the core and extending into the mold shell, and wherein after the metal has hardened, the Formal shell and the core are removed and the metallic turbine blade is machined, characterized in that as a positioning aid, a pin (7) is embedded in the free end face (6) of the core (1), which protrudes over the end face (6) and also is embedded in the molded shell (9), and that the protruding end (10) of the pin (7) is removed during the mechanical processing. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Stift (7) aus einer Nickelbasis-Legierung besteht.A method according to claim 1, characterized in that the pin (7) consists of a nickel-based alloy. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet , daß der Stift aus NiCr 82 besteht.Method according to claim 1 or 2, characterized in that the pin consists of NiCr 82. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß ein Stift mit einem Widerlager für das Material der Turbinenschaufel (13) eingesetzt wird.Method according to one of claims 1 to 3, characterized in that a pin with an abutment is used for the material of the turbine blade (13). Verfahren nach Anspruch 4, dadurch gekennzeichnet , daß der Stift (7) eine Umfangsnut (11) aufweist.Method according to claim 4, characterized in that the pin (7) has a circumferential groove (11). Verfahren nach einem der Ansprüche 4 oder 5, dadurch gekennzeichnet, daß der Stift (7) so in den Kern (1) eingebettet wird, daß die Umfangsnut (11) im Bereich des späteren Kronenbodens (14) angeordnet ist.Method according to one of claims 4 or 5, characterized in that the pin (7) is embedded in the core (1) in such a way that the circumferential groove (11) is arranged in the region of the subsequent crown base (14).
EP03015950A 2002-08-08 2003-07-14 Method for fabrication of turbine blades with cooling channels Expired - Lifetime EP1398098B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10236339A DE10236339B3 (en) 2002-08-08 2002-08-08 Method for manufacturing turbine blades with cooling ducts involves making ceramic core with positioning pins embedded in free end to protrude into surrounding moulding shell for removal during mechanical finishing of hardened blades
DE10236339 2002-08-08

Publications (2)

Publication Number Publication Date
EP1398098A1 true EP1398098A1 (en) 2004-03-17
EP1398098B1 EP1398098B1 (en) 2006-09-13

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US (1) US6896036B2 (en)
EP (1) EP1398098B1 (en)
JP (1) JP2004076731A (en)
DE (2) DE10236339B3 (en)
ES (1) ES2272858T3 (en)

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US6896036B2 (en) 2005-05-24
DE50305016D1 (en) 2006-10-26
JP2004076731A (en) 2004-03-11
US20040055736A1 (en) 2004-03-25
ES2272858T3 (en) 2007-05-01

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