EP1593445A1 - Process of making a hollow member having an internal coating - Google Patents

Process of making a hollow member having an internal coating Download PDF

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Publication number
EP1593445A1
EP1593445A1 EP04010492A EP04010492A EP1593445A1 EP 1593445 A1 EP1593445 A1 EP 1593445A1 EP 04010492 A EP04010492 A EP 04010492A EP 04010492 A EP04010492 A EP 04010492A EP 1593445 A1 EP1593445 A1 EP 1593445A1
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EP
European Patent Office
Prior art keywords
coating
casting
cast
component
hollow
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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
EP04010492A
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German (de)
French (fr)
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EP1593445B1 (en
Inventor
Knut Halberstadt
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Siemens AG
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Siemens AG
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Publication date
Application filed by Siemens AG filed Critical Siemens AG
Priority to DE502004004360T priority Critical patent/DE502004004360D1/en
Priority to EP04010492A priority patent/EP1593445B1/en
Priority to CNB2005100689161A priority patent/CN1318160C/en
Priority to US11/117,195 priority patent/US20050241797A1/en
Publication of EP1593445A1 publication Critical patent/EP1593445A1/en
Application granted granted Critical
Publication of EP1593445B1 publication Critical patent/EP1593445B1/en
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    • 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
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/165—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents in the manufacture of multilayered shell moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • 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
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • 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
    • B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/002—Removing cores by leaching, washing or dissolving
    • 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
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2230/00—Manufacture
    • F05B2230/90—Coating; Surface treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment

Definitions

  • the present invention relates to a method for Production of a hollow-cast component, in particular a hollow cast turbine blade, with internal coating to the Walls of at least one cavity.
  • Thermally highly stressed components can on their outside be provided with a coating to keep them in thermal stressful environment against corrosion and / or oxidation too protect.
  • MCrAlY coatings suitable. Under an MCrAlY coating is intended in the context of the present Description a coating of a metallic Alloy to understand the chromium (Cr) and aluminum (Al), and in the Y for yttrium or an element of rare earths and M for iron (Fe), cobalt (Co) or nickel (Ni) stand.
  • Turbine blades are high in operation Exposed to temperatures and generally have cavities on, is passed through the cooling fluid. For certain Operating conditions can be in these cavities temperatures occur, providing protection of the interior walls against oxidation and / or require corrosion.
  • Another object of the present invention is therein, an improved hollow-cast turbine component for To make available.
  • the first object is achieved by a method according to claim 1 and the second task by a hollowed out Turbine component solved according to claim 7.
  • the component of a base material cast When casting finds a mold using which at least one casting core for defining the at least one Includes cavity.
  • the inner coating first the inner coating and then cast the component around it.
  • an internal coating especially with a MCrAlY inner coating provided become.
  • the material of the casting core is selected in this case is that it is from the cavity of the finished component remove without the coating material with Will get removed.
  • materials for the casting core are particularly suitable such materials, which are made by chemical processes, which the coating material and the base material of Do not attack the component, remove it from the cavity.
  • materials for the casting core are particularly suitable such materials, which are made by chemical processes, which the coating material and the base material of Do not attack the component, remove it from the cavity.
  • materials for the casting core are suitable therefore especially ceramic materials.
  • the casting temperature is Cast of the component in particular chosen so that they below the melting temperature of the coating material lies to melt the coating material during the casting process, and thus a mixture with the Prevent base material of the component.
  • the application of the coating material on the casting core For example, by means of high-energy spraying such as the high velocity flame tips (High Velocity Oxygen Fuel Spraying, short: HVOF) or Plasma spraying (short: APS) take place.
  • high-energy spraying such as the high velocity flame tips (High Velocity Oxygen Fuel Spraying, short: HVOF) or Plasma spraying (short: APS) take place.
  • a hollow-molded turbine blade according to the invention has at least one cavity and one in the cavity Inner coating, in particular a MCrAlY coating on.
  • Fig. 1 shows a hollow-cast turbine component in one schematic representation.
  • Figures 2-7 show in a highly schematic Depicting various stages of manufacture of the hollow cast turbine blade.
  • FIG 1 is schematically a hollow cast Turbine blade 1 shown in a sectional view.
  • the Turbine blade 1 comprises a blade body 2, in which in the present embodiment, four cavities 3, 5, 7, 9th are formed, the example.
  • the blade body 2 has an outer surface 12 to be used to protect against oxidation and / or corrosion a MCrAlY coating is provided.
  • the Blade body 2 inner surfaces 4, 6, 8, 10 on which the Cavities 3, 5, 7, 9 limit and the inner walls of the Form cavities.
  • the inner surfaces 4, 6, 8, 10 are also provided with a MCrAlY coating 14, 16, 18, 20 to also to protect them against oxidation and / or corrosion.
  • an MCrAlY coating 14 applied to the ceramic cast core 22 This can, for example, a high-energy Spray methods, such as high-speed flame tips (HVOF) or plasma spraying (APS).
  • HVOF high-speed flame tips
  • APS plasma spraying
  • the thickness, with the MCrAlY coating 14 applied to the casting core depends on the thickness, with which the inner walls the turbine blade to be coated.
  • the casting shell 26 becomes knocked off and the blade 1 cleaned (Fig. 6).
  • the casting core 22 is leached, i. of the ceramic casting core 22 is removed by means of an alkali from the solidified turbine blade 1 removed. Because the MCrAlY coating 14 as well as the blade material against the leaches resistant, the MCrAlY coating remains 14 during leaching of the ceramic casting core 22 on the inside of the turbine blade 1 (Fig. 7). in the Below, the turbine blade thus produced in usually mechanically processed and coated outside become.
  • the described method is not only suitable for Internal coating of turbine blades, but basically also for internal coating of other hollow cast components. It is also possible to use the method of applying others Use coatings as MCrAlY coatings. Also
  • the casting core does not necessarily need one ceramic material to be produced. It just has to Be sure that the casting core is removed can, without affecting the inside of the workpiece applied coating is removed with.

Abstract

A hollow cast turbine component is produced by: (i) providing a cast mold comprising a mold insert defining at least one cavity to cast a component; applying a coating material to the portion of the cast mold that defines the cavity; (ii) casting the component from a base material using the cast mold; and (iii) removing the mold insert from the cavity of the component after the casting.

Description

Die vorliegende Erfindung betrifft ein Verfahren zum Herstellen eines hohlgegossenen Bauteils, insbesondere einer hohlgegossenen Turbinenschaufel, mit Innenbeschichtung an den Wänden mindestens eines Hohlraums.The present invention relates to a method for Production of a hollow-cast component, in particular a hollow cast turbine blade, with internal coating to the Walls of at least one cavity.

Thermisch hochbelastete Bauteile können an ihrer Außenseite mit einer Beschichtung versehen werden, um sie im thermisch belastenden Umfeld gegen Korrosion und/oder Oxidation zu schützen. Als Schutz gegen Oxidation und/oder Korrosion sind dabei insbesondere MCrAlY-Beschichtungen geeignet. Unter einer MCrAlY-Beschichtung soll im Rahmen der vorliegenden Beschreibung eine Beschichtung aus einer metallischen Legierung zu verstehen sein, die Chrom (Cr) und Aluminium (Al) umfasst, und in der Y für Yttrium oder ein Element der seltenen Erden und M für Eisen (Fe), Kobalt (Co) oder Nickel (Ni) stehen.Thermally highly stressed components can on their outside be provided with a coating to keep them in thermal stressful environment against corrosion and / or oxidation too protect. As protection against oxidation and / or corrosion in particular MCrAlY coatings suitable. Under an MCrAlY coating is intended in the context of the present Description a coating of a metallic Alloy to understand the chromium (Cr) and aluminum (Al), and in the Y for yttrium or an element of rare earths and M for iron (Fe), cobalt (Co) or nickel (Ni) stand.

Unter bestimmten Betriebsbedingungen sind aber auch die Innenwände im thermisch hochbelastenden Umfeld betriebener hohlgegossener Bauteile Temperaturen ausgesetzt, die einen Schutz der Innenwände gegen Oxidation und/oder Korrosion notwendig machen, damit das Bauteil die vorgesehene Lebensdauer auch tatsächlich erreicht.Under certain operating conditions but are also the Interior walls operated in a thermally highly stressful environment hollow-cast components exposed to temperatures that a Protection of interior walls against oxidation and / or corrosion necessary, so that the component provided Lifespan actually achieved.

Ein Beispiel für derart thermisch hoch belastete hohlgegossene Bauteile sind Turbinenbauteile, insbesondere Turbinenschaufeln. Turbinenschaufeln sind im Betrieb hohen Temperaturen ausgesetzt und weisen in der Regel Hohlräume auf, durch die Kühlfluid geleitet wird. Bei bestimmten Betriebsbedingungen können in diesen Hohlräumen Temperaturen auftreten, die einen Schutz der Innenwände gegen Oxidation und/oder Korrosion erfordern. An example of such a high thermal load Hollow-cast components are turbine components, in particular Turbine blades. Turbine blades are high in operation Exposed to temperatures and generally have cavities on, is passed through the cooling fluid. For certain Operating conditions can be in these cavities temperatures occur, providing protection of the interior walls against oxidation and / or require corrosion.

Bisher wurden die Innenwände hohlgegossener Bauteile durch eine Diffusionsalitierung mehr oder weniger zufriedenstellend geschützt. Mit zunehmenden Betriebstemperaturen erreichen diese Alitierungen jedoch ihre Grenzen, und gegen Korrosion sind sie praktisch wirkungslos.So far, the inner walls of hollow cast components have been through a Diffusalalitierung more or less satisfactory protected. Achieve with increasing operating temperatures however, these alitations have their limitations, and against corrosion they are practically ineffective.

Mit herkömmlichen Methoden ist es nahezu unmöglich, in den zum Teil recht komplizierten Hohlräumen bzw. Innenräumen hohlgegossener Bauteile, etwa in den Hohlräumen von Turbinenschaufeln, insbesondere wirkungsvolle MCrAlY-Beschichtungen aufzubringen. Für das Beschichten der Innenwände hohlgegossener Bauteile lassen sich Spritzprozesse nicht zufriedenstellend einsetzen.With conventional methods, it is almost impossible in the sometimes quite complicated cavities or interiors hollow cast components, such as in the cavities of Turbine blades, especially effective MCrAlY coatings applied. For coating the Inner walls of hollow cast components can be sprayed do not use satisfactorily.

Es ist daher Aufgabe der vorliegenden Erfindung, ein Verfahren zur Verfügung zu stellen, mit dem sich Innenbeschichtungen, insbesondere MCrAlY-Innenbeschichtungen, bei hohlgegossenen Bauteilen auch bei komplexen Hohlräumen realisieren lassen.It is therefore an object of the present invention to provide a To provide method with which Internal coatings, in particular MCrAlY internal coatings, with hollow cast components even with complex cavities let realize.

Eine weitere Aufgabe der vorliegenden Erfindung besteht darin, eine verbessertes hohlgegossenes Turbinenbauteil zur Verfügung zu stellen.Another object of the present invention is therein, an improved hollow-cast turbine component for To make available.

Die erste Aufgabe wird durch ein Verfahren nach Anspruch 1 und die zweite Aufgabe durch ein hohlgegossenes Turbinenbauteil nach Anspruch 7 gelöst.The first object is achieved by a method according to claim 1 and the second task by a hollowed out Turbine component solved according to claim 7.

Im erfindungsgemäßen Verfahren zum Herstellen eines hohlgegossenen Bauteils mit Innenbeschichtung in mindestens einem Hohlraum wird das Bauteil aus einem Basismaterial gegossen. Beim Gießen findet eine Gießform Verwendung, welche mindestens einen Gusskern zum Definieren des mindestens einen Hohlraumes umfasst. Im erfindungsgemäßen Verfahren wird das Beschichtungsmaterial für die Innenbeschichtung des Bauteils vor dem Gießen des Bauteils auf mindestens einen Gusskern aufgebracht. Nach dem Gießen wird der Gusskern dann wieder aus dem Hohlraum entfernt.In the inventive method for producing a hollow cast component with internal coating in at least a cavity, the component of a base material cast. When casting finds a mold using which at least one casting core for defining the at least one Includes cavity. In the method according to the invention is the Coating material for the internal coating of the component before casting the component on at least one casting core applied. After casting, the casting core then becomes again removed from the cavity.

Erfindungsgemäß wird also zuerst die Innenbeschichtung hergestellt, und dann das Bauteil darum herumgegossen. Auf diese Weise können auch äußerst komplexe Hohl- bzw. Innenräume von Bauteilen, etwa von hohlgegossenen Gasturbinenschaufeln, mit einer Innenbeschichtung, insbesondere mit einer MCrAlY-Innenbeschichtung, versehen werden. Das Material des Gusskerns ist dabei derart gewählt ist, dass es sich aus dem Hohlraum des fertigen Bauteils entfernen lässt, ohne dass das Beschichtungsmaterial mit entfernt wird.According to the invention, therefore, first the inner coating and then cast the component around it. On This way, even extremely complex hollow or Interiors of components, such as hollow castings Gas turbine blades, with an internal coating, especially with a MCrAlY inner coating provided become. The material of the casting core is selected in this case is that it is from the cavity of the finished component remove without the coating material with Will get removed.

Als Materialien für den Gusskern eignen sich insbesondere solche Materialien, die sich mittels chemischer Verfahren, welche das Beschichtungsmaterial und das Basismaterial des Bauteils nicht angreifen, aus dem Hohlraum entfernen lassen. Bspw. lassen sich keramische Gusskerne herstellen, die mittels einer geeigneten Lauge, welche eine MCrAlY-Beschichtung sowie das Basismaterial von Turbinenbauteilen nicht angreift, aus Hohlräumen der Turbinenbauteile entfernt werden. Als Materialen für Gusskerne zum Gießen von Turbinenbauteilen, wie etwa Turbinenschaufeln, eignen sich daher insbesondere keramische Werkstoffe.As materials for the casting core are particularly suitable such materials, which are made by chemical processes, which the coating material and the base material of Do not attack the component, remove it from the cavity. For example. can be produced ceramic cores, the by means of a suitable liquor containing an MCrAlY coating and the base material of turbine components not attacks, removed from cavities of the turbine components become. As materials for casting cores for casting Turbine components, such as turbine blades, are suitable therefore especially ceramic materials.

Im erfindungsgemäßen Verfahren wird die Gießtemperatur beim Abguss des Bauteils insbesondere so gewählt, dass sie unterhalb der Schmelztemperatur des Beschichtungsmaterials liegt, um ein Aufschmelzen des Beschichtungsmaterials während des Gießprozesses, und damit eine Vermischung mit dem Basismaterial des Bauteils zu unterbinden.In the method according to the invention, the casting temperature is Cast of the component in particular chosen so that they below the melting temperature of the coating material lies to melt the coating material during the casting process, and thus a mixture with the Prevent base material of the component.

Das Aufbringen des Beschichtungsmaterials auf den Gusskern kann beispielsweise mittels hochenergetischer Spritzverfahren wie etwa dem Hochgeschwindigkeitsflammspitzen (engl. High Velocity Oxygen Fuel Spraying, kurz: HVOF) oder Plasmaspritzen (kurz: APS) erfolgen.The application of the coating material on the casting core For example, by means of high-energy spraying such as the high velocity flame tips (High Velocity Oxygen Fuel Spraying, short: HVOF) or Plasma spraying (short: APS) take place.

Eine erfindungsgemäße hohlgegossene Turbinenschaufel weist mindestens einen Hohlraum und eine im Hohlraum vorhandene Innenbeschichtung, insbesondere eine MCrAlY-Beschichtung auf.A hollow-molded turbine blade according to the invention has at least one cavity and one in the cavity Inner coating, in particular a MCrAlY coating on.

Aufgrund der Innenbeschichtung des hohlgegossenen Turbinenbauteils weist dieses gegenüber hohlgegossenen Turbinenbauteilen nach Stand der Technik eine verbesserte Oxidations- und Korrosionseigenschaft auf. Es kann daher höheren Temperaturen ausgesetzt werden.Due to the inner coating of the hollow cast Turbine component has this hollow-cased Turbine components of the prior art improved Oxidation and corrosion property. It can therefore be exposed to higher temperatures.

Weitere Merkmale, Eigenschaften und Vorteile der vorliegenden Erfindung ergeben sich aus der nachfolgenden Beschreibung eines Ausführungsbeispiels unter Bezugnahme auf die beiliegende Figur.Other features, characteristics and advantages of the present Invention will become apparent from the following description an embodiment with reference to the attached figure.

Fig. 1 zeigt ein hohlgegossenes Turbinenbauteil in einer schematischen Darstellung.Fig. 1 shows a hollow-cast turbine component in one schematic representation.

Figuren 2 - 7 zeigen in einer stark schematisierten Darstellung verschiedene Stadien der Herstellung der hohlgegossenen Turbinenschaufel.Figures 2-7 show in a highly schematic Depicting various stages of manufacture of the hollow cast turbine blade.

In Figur 1 ist schematisch eine hohlgegossene Turbinenschaufel 1 in einer Schnittansicht dargestellt. Die Turbinenschaufel 1 umfasst einen Schaufelkörper 2, in welchem im vorliegenden Ausführungsbeispiel vier Hohlräume 3, 5, 7, 9 ausgebildet sind, die bspw. zum Durchleiten von Kühlluft verwendet werden. Der Schaufelkörper 2 weist eine Außenfläche 12 auf, die zum Schutz gegen Oxidation und/oder Korrosion mit einer MCrAlY-Beschichtung versehen ist. Daneben weist der Schaufelkörper 2 Innenflächen 4, 6, 8, 10 auf, welche die Hohlräume 3, 5, 7, 9 begrenzen und die Innenwände der Hohlräume bilden. Die Innenflächen 4, 6, 8, 10 sind ebenfalls mit einer MCrAlY-Beschichtung 14, 16, 18, 20 versehen, um auch sie gegen Oxidation und/oder Korrosion zu schützen.In Figure 1 is schematically a hollow cast Turbine blade 1 shown in a sectional view. The Turbine blade 1 comprises a blade body 2, in which in the present embodiment, four cavities 3, 5, 7, 9th are formed, the example. For passing cooling air be used. The blade body 2 has an outer surface 12 to be used to protect against oxidation and / or corrosion a MCrAlY coating is provided. In addition, the Blade body 2 inner surfaces 4, 6, 8, 10 on which the Cavities 3, 5, 7, 9 limit and the inner walls of the Form cavities. The inner surfaces 4, 6, 8, 10 are also provided with a MCrAlY coating 14, 16, 18, 20 to also to protect them against oxidation and / or corrosion.

Nachfolgend wird das Verfahren zum Herstellen der mit Bezug auf Figur 1 beschriebenen Turbinenschaufel 1 anhand der Figuren 2 bis 7 erläutert. Das Verfahren kann jedoch auch zum Innenbeschichten anderer hohlgegossener Bauteile Verwendung finden.Hereinafter, the method for producing the reference to Turbine blade 1 described in Figure 1 based on Figures 2 to 7 explained. However, the method can also for Internal coating of other hollow cast components Use Find.

Als erstes wird ein keramischer Gusskern 22 für die Gießform zum Herstellen der Turbinenschaufel geformt und gesintert Fig. 2). Im nächsten Schritt (Fig. 3) wird eine MCrAlY-Beschichtung 14 auf den keramischen Gusskern 22 aufgebracht. Dazu kann beispielsweise ein hochenergetisches Spritzverfahren, etwa Hochgeschwindigkeitsflammspitzen (HVOF) oder Plasmaspritzen (APS), zum Einsatz kommen. Die Dicke, mit der die MCrAlY-Beschichtung 14 auf den Gusskern aufgetragen wird, hängt dabei von der Dicke ab, mit der die Innenwände der Turbinenschaufel beschichtet werden sollen.First, a ceramic casting core 22 for the casting mold shaped and sintered to make the turbine blade Fig. 2). In the next step (Figure 3) becomes an MCrAlY coating 14 applied to the ceramic cast core 22. This can, for example, a high-energy Spray methods, such as high-speed flame tips (HVOF) or plasma spraying (APS). The thickness, with the MCrAlY coating 14 applied to the casting core depends on the thickness, with which the inner walls the turbine blade to be coated.

Nachdem der Gusskern beschichtet worden ist, wird ein Wachsmodell 24 der Turbinenschaufel an den Gusskern 22 angespritzt (Fig. 4). Anschließend wird die äußere Gussschale 26 der Form auf das Wachsmodell 24 aufgebracht. Danach wird das Wachs ausgebrannt und die Gussschale 26 gesintert, um die Gießform 28 fertigzustellen (Fig. 5).After the casting core has been coated, one becomes Wax model 24 of the turbine blade to the casting core 22 molded (Fig. 4). Subsequently, the outer casting shell 26 of the mold applied to the wax model 24. After that will the wax burned out and the casting shell 26 sintered to the To complete the casting mold 28 (FIG. 5).

Nachdem die Gießform 28 fertiggestellt ist, erfolgt das Gießen der Turbinenschaufel 1 im Vakuum. Das Gießen der Turbinenschaufel findet typischerweise bei Abgusstemperaturen von unter 1500 °C statt. Der Schmelzpunkt der MCrAlY-Beschichtung 14 liegt dagegen typischerweise oberhalb von 1600 °C. Ein Aufschmelzen der Beschichtung 14 während des Gießprozesses und damit ein Vermischen des Beschichtungsmaterials mit dem Basismaterial der Turbinenschaufel 1 findet daher nicht statt. Auch bei Verwendung anderer Beschichtungen als der MCrAlY-Beschichtung müssen die Gießtemperaturen unterhalb der Schmelztemperatur des Beschichtungsmaterials liegen, wenn ein Aufschmelzen der Beschichtung und ein Vermischen mit dem Basismaterial vermieden werden soll.After the mold 28 is completed, this is done Pour the turbine blade 1 in a vacuum. The casting of the Turbine blade typically finds at casting temperatures from below 1500 ° C instead. The melting point of the MCrAlY coating By contrast, 14 is typically above 1600 ° C. A melting of the coating 14 during the Casting process and thus a mixing of the Coating material with the base material of Turbine blade 1 therefore does not take place. Also at Use of coatings other than the MCrAlY coating the casting temperatures must be below the melting temperature of the coating material, if a melting of the Coating and mixing with the base material should be avoided.

Nach dem Abschluss des Gießens wird die Gussschale 26 abgeschlagen und die Schaufel 1 gereinigt (Fig. 6). Schließlich wird der Gusskern 22 ausgelaugt, d.h. der keramische Gusskern 22 wird mittels einer Lauge aus der erstarrten Turbinenschaufel 1 entfernt. Da die MCrAlY-Beschichtung 14 genauso wie der Schaufelwerkstoff gegen die verwendeten Laugen resistent ist, verbleibt die MCrAlY-Beschichtung 14 beim Auslaugen des keramischen Gusskerns 22 auf der Innenseite der Turbinenschaufel 1 (Fig. 7). Im Folgenden kann die so hergestellte Turbinenschaufel in üblicher Weise mechanisch bearbeitet und außen beschichtet werden.After the completion of the casting, the casting shell 26 becomes knocked off and the blade 1 cleaned (Fig. 6). Finally, the casting core 22 is leached, i. of the ceramic casting core 22 is removed by means of an alkali from the solidified turbine blade 1 removed. Because the MCrAlY coating 14 as well as the blade material against the leaches resistant, the MCrAlY coating remains 14 during leaching of the ceramic casting core 22 on the inside of the turbine blade 1 (Fig. 7). in the Below, the turbine blade thus produced in usually mechanically processed and coated outside become.

Das beschriebene Verfahren eignet sich nicht nur zum Innenbeschichten von Turbinenschaufeln, sondern grundsätzlich auch zum Innenbeschichten anderer hohlgegossener Bauteile. Ebenso ist es möglich, das Verfahren zum Aufbringen anderer Beschichtungen als MCrAlY-Beschichtungen zu nutzen. Auch braucht der Gusskern nicht notwendigerweise aus einer keramischen Werkstoff hergestellt zu sein. Es muss lediglich sichergestellt sein, dass das der Gusskern entfernt werden kann, ohne dass die auf die Innenseite des Werkstückes aufgebrachte Beschichtung mit entfernt wird.The described method is not only suitable for Internal coating of turbine blades, but basically also for internal coating of other hollow cast components. It is also possible to use the method of applying others Use coatings as MCrAlY coatings. Also The casting core does not necessarily need one ceramic material to be produced. It just has to Be sure that the casting core is removed can, without affecting the inside of the workpiece applied coating is removed with.

Bei den Werkzeugen zur Herstellung der Gusskerne bzw. der Wachsmodelle ist zu beachten, dass diese um die Dicke der Schutzschicht korrigiert werden müssen, um die spezifizierten Wanddicken des hohlgegossenen Bauteils zu gewährleisten.In the tools for the production of the casting cores or the Wax models should be noted that these are around the thickness of the Protective layer must be corrected to the specified To ensure wall thicknesses of the hollow-cast component.

Claims (8)

Verfahren zum Herstellen eines hohlgegossenen Bauteils (1), insbesondere eines hohlgegossenen Turbinenbauteils, mit Innenbeschichtung (14, 16, 18, 20) in mindestens einem Hohlraum (3, 5, 7, 9), bei dem das Bauteil (1) aus einem Basismaterial gegossen wird, beim Gießen eine Gießform, welche mindestens einen Gusskern (22) zum Definieren des mindestens einen Hohlraumes (3, 5, 7, 9) umfasst, Verwendung findet, und der Gusskern (22) nach dem Gießen aus dem Hohlraum (3, 5, 7, 9) entfernt wird dadurch gekennzeichnet, dass das Beschichtungsmaterial für die Innenbeschichtung (14, 16, 18, 20) des Bauteils (1) vor dem Gießen auf mindestens einen Gusskern (22) aufgebracht wird.Method for producing a hollow-cast component (1), in particular a hollow-cast turbine component, with inner coating (14, 16, 18, 20) in at least one cavity (3, 5, 7, 9), in which the component (1) is cast from a base material, when casting a mold, which at least one casting core (22) for defining the at least one cavity (3, 5, 7, 9) is used, and the casting core (22) is removed from the cavity (3, 5, 7, 9) after casting characterized in that the coating material for the inner coating (14, 16, 18, 20) of the component (1) is applied to at least one casting core (22) prior to casting. Verfahren nach Anspruch 1,
dadurch gekennzeichnet, dass als Material für den Gusskern (22) ein Material Verwendung findet, das sich mittels eines chemischen Verfahrens, welches das Beschichtungsmaterial und das Basismaterial des Bauteils (1) nicht angreifet, aus dem Hohlraum (3, 5, 7, 9) entfernen lässt.Method according to claim 1,
characterized in that a material is used as the material for the casting core (22) which is removed from the cavity (3, 5, 7, 9) by means of a chemical process which does not attack the coating material and the base material of the component (1) can be removed. Verfahren nach Anspruch 1 oder 2,
dadurch gekennzeichnet, dass als Material für den Gusskern (22) ein keramischer Werkstoff Verwendung findet. Method according to claim 1 or 2,
characterized in that a ceramic material is used as the material for the cast core (22). Verfahren nach einem der Ansprüche 1 bis 3,
dadurch gekennzeichnet, dass die Gießtemperatur unterhalb der Schmelztemperatur des Beschichtungsmaterials liegt.Method according to one of claims 1 to 3,
characterized in that the casting temperature is below the melting temperature of the coating material. Verfahren nach einem der Ansprüche 1 bis 4,
dadurch gekennzeichnet, dass die Innenbeschichtung (14, 16, 18, 20) eine MCrAlY-Beschichtung ist.Method according to one of claims 1 to 4,
characterized in that the inner coating (14, 16, 18, 20) is an MCrAlY coating. Verfahren nach Anspruch 5,
dadurch gekennzeichnet, dass zum Aufbringen des Beschichtungsmaterials auf den Gusskern (22) ein hochenergetisches Spritzverfahren zum Einsatz kommt.Method according to claim 5,
characterized in that for applying the coating material to the casting core (22), a high-energy spray process is used. Hohlgegossenes Turbinenbauteil (1) mit mindestens einem Hohlraum (3, 5, 7, 9) und einer im Hohlraum (3, 5, 7, 9) vorhandenen Innenbeschichtung (14, 16, 18, 20).Hollow-cast turbine component (1) with at least one Cavity (3, 5, 7, 9) and one in the cavity (3, 5, 7, 9) existing inner coating (14, 16, 18, 20). Hohlgegossene Turbinenbauteil nach Anspruch 7 mit einer MCrAlY-Innenbeschichtung (14, 16, 18, 20).Hollow-cast turbine component according to claim 7 with a MCrAlY inner coating (14, 16, 18, 20).
EP04010492A 2004-05-03 2004-05-03 Process of making a hollow member having an internal coating Not-in-force EP1593445B1 (en)

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DE502004004360T DE502004004360D1 (en) 2004-05-03 2004-05-03 Method for producing a hollow-cast component with internal coating
EP04010492A EP1593445B1 (en) 2004-05-03 2004-05-03 Process of making a hollow member having an internal coating
CNB2005100689161A CN1318160C (en) 2004-05-03 2005-04-27 Process of making a hollow member having an internal coating
US11/117,195 US20050241797A1 (en) 2004-05-03 2005-04-28 Method for producing a hollow cast component having an inner coating

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CN1318160C (en) 2007-05-30
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US20050241797A1 (en) 2005-11-03
CN1693006A (en) 2005-11-09

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