EP1645347A1 - Procédé de fabrication d'une pièce moulée à charge thermique élevée - Google Patents

Procédé de fabrication d'une pièce moulée à charge thermique élevée Download PDF

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Publication number
EP1645347A1
EP1645347A1 EP05111586A EP05111586A EP1645347A1 EP 1645347 A1 EP1645347 A1 EP 1645347A1 EP 05111586 A EP05111586 A EP 05111586A EP 05111586 A EP05111586 A EP 05111586A EP 1645347 A1 EP1645347 A1 EP 1645347A1
Authority
EP
European Patent Office
Prior art keywords
casting
ceramic
mold
cooling
polymer foam
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
EP05111586A
Other languages
German (de)
English (en)
Other versions
EP1645347B1 (fr
Inventor
Alexander Dr. Beeck
Peter Dr. Ernst
Reinhard Fried
Hans-Joachim Prof. Dr. Rösler
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.)
General Electric Technology GmbH
Original Assignee
Alstom Technology AG
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 Alstom Technology AG filed Critical Alstom Technology AG
Publication of EP1645347A1 publication Critical patent/EP1645347A1/fr
Application granted granted Critical
Publication of EP1645347B1 publication Critical patent/EP1645347B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • B22C7/023—Patterns made from expanded plastic materials
    • 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
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/043—Removing the consumable pattern
    • 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
    • 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
    • F01D5/182—Transpiration cooling
    • F01D5/183—Blade walls being porous
    • 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
    • F01D5/186—Film cooling
    • 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
    • F01D5/187—Convection cooling
    • 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
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/21—Manufacture essentially without removing material by casting
    • F05D2230/211—Manufacture essentially without removing material by casting by precision casting, e.g. microfusing or investment casting
    • 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
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/606—Directionally-solidified crystalline structures
    • 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
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/611—Coating
    • 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
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/612—Foam

Definitions

  • the invention relates to a method for producing a thermally loaded casting of a thermal turbomachine, in particular a blade of a gas turbine, according to the preamble of the independent claim.
  • thermal turbomachines charged with hot gas for example turbine blades of gas turbines
  • cooling air bores or with cooling structures in order to be able to increase the temperature of the hot gas on the one hand and to extend the service life of the affected parts on the other hand.
  • the inside or a double-walled cooling system for example a turbine blade
  • the outside of the blade is cooled by a film, which forms on the surface of the turbine blade. It is goal, To make the film cooling as effective as possible while reducing the amount of cooling air.
  • the invention is based on the object to provide a method for producing a thermally loaded casting of a thermal turbomachine with an integrated cooling structure, which increases the efficiency of the turbomachine.
  • the cooling structure should consist of the same material as the casting and, if possible, can be produced in one step during the casting process.
  • the object is achieved by a method according to the preamble of the independent claim in that a Wax model of the part to be produced is provided, a prefabricated ceramic insert with an open-pore structure is added to the wax model or introduced into a cavity of the wax model, the wax model with the insert is immersed in a ceramic material (slurry), the ceramic material is dried, so that a mold is formed, the wax is removed by a heat treatment, the casting with the mold is produced by a known casting method, and the ceramic material is removed.
  • a Wax model of the part to be produced is provided, a prefabricated ceramic insert with an open-pore structure is added to the wax model or introduced into a cavity of the wax model, the wax model with the insert is immersed in a ceramic material (slurry), the ceramic material is dried, so that a mold is formed, the wax is removed by a heat treatment, the casting with the mold is produced by a known casting method, and the ceramic material is removed.
  • the ceramic insert is prefabricated from a polymer foam having an open-pore structure by immersing the polymer foam in a ceramic material, so that the pores of the polymer foam fill with the ceramic Mateial. Thereafter, the ceramic material is dried and optionally fired to remove the polymer foam (see next but one paragraph).
  • This ceramic insert is attached to the wax model or inserted into a cavity of the wax model and the mold is made as indicated above.
  • the material of this form may also contain a binder.
  • Such a prefabricated, ceramic insert can be heated to a high degree prior to application for the production of the mold, so as to achieve a particular strength. It is also conceivable to burn out the polymer foam of the insert prior to attachment to the wax model.
  • an externally whitening, open-pored cooling structure can be coated with a ceramic protective layer in front of the casting additional, external abrasion and to protect it from the surrounding hot gases. Due to the open-pored structure of the metal foam, the ceramic protective layer adheres very well to it and the possibility of chipping due to the extreme operating conditions is reduced. In addition, the cooling under the ceramic protective layer is still ensured, provided that the cooling structure is not completely penetrated by the ceramic protective layer.
  • a polymer foam with a variable pore size can be used so as to strengthen or reduce cooling of certain areas of the cooling system compared to other areas.
  • the thermally loaded casting may be a nozzle or bucket, a thermal damper, a platform of the nozzle or bucket, or a combustor wall of a gas turbine, or a bucket of a compressor.
  • the invention relates to a method for producing a thermally loaded casting of a thermal turbomachine.
  • This can be, for example, a guide or a blade of a gas turbine or a compressor, a heat recovery segment of a gas turbine, the wall of a combustion chamber or a similar, thermally highly loaded casting.
  • castings are manufactured in generally known from the prior art casting furnaces. Such a casting furnace can be used to produce complex components that can be exposed to high thermal and mechanical stresses. Depending on the process conditions, it is possible to produce the casting body directionally solidified. In this case, it is possible to form it as single crystal ("single crystal", SX) or polycrystalline as columnar crystals which have a preferred direction ("directionally solidified", DS). Of particular importance is that directional solidification occurs under conditions where a molten feedstock is received between a cooled portion Mold and the still molten starting material takes place a strong heat exchange. It may then form a zone of directionally solidified material with a solidification front, which migrates with continuous removal of heat to form the directly solidified Giess stressess by the mold.
  • SX single crystal
  • DS directionally solidified
  • the device consists of a vacuum chamber containing an upper heating chamber and a lower cooling chamber. Both chambers are separated by a baffle.
  • the vacuum chamber receives a mold, which is filled with a melt.
  • a superalloy based on nickel is used.
  • In the middle of the baffle there is an opening through which the mold is slowly moved from the heating chamber into the cooling chamber during the process so that the casting solidifies from the bottom upwards. The downward movement is done by a drive rod on which the mold is mounted.
  • the bottom of the mold is water cooled.
  • Below the baffle means for generating and guiding a gas flow are present. These means provide by the gas flow next to the lower cooling chamber for additional cooling and thus for a larger temperature gradient at the solidification front.
  • the turbine blade 1 of Figure 1 has a cavity 6, from which cooling air 18 is passed through inner cooling holes 8,8b in the double-walled cooling system 7 during operation of the turbomachine.
  • the arrows indicate the flow direction of the cooling air 18.
  • the cooling air 18 then flows both inside the turbine blade into the height and to the trailing edge 3 of the turbine blade 1. It can the cooling system 7 at the trailing edge 3, to outer cooling holes 8,8a or to larger cooling holes 8,8c, both at the front 2, on the pressure side 4 or on the suction side 5 may be present, leave again.
  • Film cooling occurs at the outer cooling holes 8, 8a, while the walls in the interior of the cooling system 7 are cooled by convection.
  • axial ribs 10 may also be present within the cooling system 8, in which case no metal foam 9 is present and in which the cooling air 18 can flow unhindered.
  • FIG. 3 which shows the front edge 2 from the blade root 9 to the blade tip 10 in the form of a longitudinal section through a turbine blade 1 produced according to the invention, reveals the flow direction of the cooling air 18.
  • the cooling air 18 enters the cooling system 7 through internal cooling openings 8, 8b Cavity 6 a.
  • the cooling air 18 then flows through the pores of the metal foam 9, which is located within the cooling system 7.
  • the aim of the invention is now to produce such, filled with open-cell metal foam 9 cooling systems 7 already during the casting process in cast furnaces, as mentioned above, integral with the entire casting.
  • a wax model of the part to be produced is provided.
  • a prefabricated ceramic insert having an open-pore structure is attached to the wax model or inserted into a cavity thereof.
  • a polymer foam is treated with a slurry, so that a separate model of the cooling structure is formed from a ceramic material.
  • the polymer foam is dipped into the slurry so that the pores fill. This is followed by the obligatory drying of the slurry.
  • this insert it must be ensured that the size, that is to say the external dimensions of the polymer foam are not changed or only within small tolerance limits. This can be ensured by the fact that the polymer foam is foamed in a mold, so that the external dimensions and possibly even a complex 3-dimensional shape are fixed. It is also conceivable to fill the slurry into the polymer foam while it is still in this form.
  • This ceramic model or insert is, as described above, attached to the wax model or inserted into a cavity thereof.
  • the polymer foam may be burned out prior to attachment.
  • the material of the above-mentioned form, in which the polymer foam can be foamed to maintain the external composition may contain a binder for improved drying of the slurry.
  • Such an insert may additionally be heated by a heat treatment prior to attachment to the wax model, which further increases the strength.
  • the wax model is immersed with the use in a liquid ceramic material, slip. This forms around the Wax model the casting's later casting mold. Subsequently, the ceramic material is dried, so that the mold with which the casting is produced arises.
  • the casting is made in a known manner with the resulting mold by a known, further described above furnace.
  • the above-mentioned metal foam 9 is formed as a cooling system 7 simultaneously during the solidification of the alloy.
  • the cast part and the metal foam then consist of one part and further process steps for producing the cooling structure do not occur. This type of production avoids by the casting process and the subsequent solidification and a porosity of the superalloy within the metal foam 9, since evenly distributed during filling the liquid alloy within the open-pore mold.
  • the ceramic casting mold can then be removed in a suitable manner, for example by using an acid or an alkali.
  • FIG. 2 schematically shows a section through a turbine blade 1 according to the invention.
  • the cooling structure 7 is present only at the front edge 2 of the turbine blade 1.
  • This cooling structure 7 was created as described above by simply attaching the ceramic insert to the wax model. All other manufacturing steps are the same.
  • the cooling air 18 penetrates from the cavity 6 through the cooling holes 8,8b in the cooling structure 7 a.
  • the cooling structure 7 itself is coated with a ceramic protective layer 11 (Thermal Barrier Coating, TBC). This is done, for example, by a known from the prior art plasma spray method or an equivalent coating method.
  • TBC Thermal Barrier Coating
  • the coating of the porous cooling structure 7 with TBC can be done in various ways (by varying the parameters such as spray angle, distance, particle size, velocity, temperature, etc.).
  • the cooling structure 7 can be completely penetrated with TBC, so that the pores of the metal foam 9 are completely filled. Pores allow very good adhesion of the TBC.
  • the cooling structure 7 may also be covered with TBC only in a layer near the surface, so that there is still a layer underneath the protective layer of TBC into which cooling air 18 can penetrate. It is also conceivable that cooling holes 8 are present within the protective layer 11, through which the cooling air 18 exits to the outside. Due to the open-pore structure of the metal foam 9, the ceramic protective layer 11 adheres very well.
  • the adhesion of the ceramic protective layer 11 to the cooling structure can be improved.
  • the chipping of the TBC during operation of the casting by poor adhesion to the base material is advantageously significantly reduced or prevented.
  • the ceramic protective layer 11 itself is porous enough to allow the passage of cooling air to a sufficient extent, no external cooling holes are required. In this way, no so-called sweat cooling can be achieved, which has proven to be very effective in the cooling effect.
  • Possible cooling holes 8 within the ceramic protective layer 11 may be formed by appropriate masking prior to coating with TBC and unmasking by suitable means thereafter takes place.
  • the masking can be done for example with polymer foam, which is burned out for unmasking.
  • a second way to mask the surface is to provide within the mold that occupy that site. In this case, the ceramic mold is removed at these locations only after coating with TBC.
  • fabricating a metal foam 9, as in FIG. 2 on the outer surface, and the additional coating with TBC are particularly useful at the locations where abrasion by mechanical action may occur, for example at the blade tip of a turbine blade 1 or on a heat dissipation segment, since the open-pore structure of the metal foam 9 is very flexible and not clogged by the abrasion itself. Overall, however, the abrasion is reduced by the flexibility of the metal foam 9.
  • FIGS. 4 to 8 Casting parts, as shown in FIGS. 4 to 8, can also be produced by the method according to the invention.
  • Figures 4 and 5 show a heat rejection segment 14 of a gas turbine.
  • This heat statement 1 can have a double-walled cooling structure 7 (FIG. 4) or also an externally attached metal foam 9 (FIG. 5), which, analogously to the turbine blade of FIG. 2, can be completely or partially coated with a protective layer 11 made of TBC.
  • the heat dissipation segment is traversed by cooling air 18. This is made possible by the open-pore metal foam 9.
  • the cooling air 18 penetrates through cooling holes 8 in the cooling system 7 and leaves it through this again again.
  • FIGS. 6a, 6b show two variants of section VI of FIG. 5.
  • the metal foam 9 can obtain a different pore size by varying the pore size of the polymer foam during the production process.
  • FIG. 6a shows the metal foam 9 1 , 9 2 with a variable pore size. This allows for a stronger or a weaker cooling of individual areas of the casting. As already mentioned above, this is also advantageous for a better hold of the protective layer 11 on the metal foam 9.
  • the protective layer 11 may also be pierced with cooling holes 8 through which the cooling air 18 can flow to the outside.
  • the cooling system 7 consists of several layers of the metal foam 9 and intermediate plates 15.
  • the number of layers metal foam 9 / plate 15 is selected only by way of example and depends on special application.
  • several layers of wax / polymer foam are provided, from which subsequently the casting mold for the casting, as already described above, is manufactured. This leads during production directly to the embodiment shown in Figure 6b.
  • the cooling air 18 penetrates the metal foam 9, can flow within a "plane” and cool by convection or transpiration.
  • the specific design of this cooling system 7 of course depends on the individual case.
  • the cooling holes 8 within the plates 15 are also already produced during manufacture.
  • the castings with an integrated, open-pore cooling system 7 produced by the method according to the invention are also advantageous because the pressure difference of the cooling medium between the external pressure and the internal pressure (inside the cavity 6) greatly influences the effectiveness of the cooling. This pressure difference can be very well adjusted and controlled by the appropriate choice of pores (distribution, size, etc.) of the metal foam 9.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP05111586A 2000-05-17 2001-04-12 Procédé de fabrication d'une pièce moulée à charge thermique élevée Expired - Lifetime EP1645347B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10024302A DE10024302A1 (de) 2000-05-17 2000-05-17 Verfahren zur Herstellung eines thermisch belasteten Gussteils
EP01109115A EP1155760B1 (fr) 2000-05-17 2001-04-12 Procédé de fabrication d'une pièce moulée à charge thermique élevée

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
EP01109115A Division EP1155760B1 (fr) 2000-05-17 2001-04-12 Procédé de fabrication d'une pièce moulée à charge thermique élevée

Publications (2)

Publication Number Publication Date
EP1645347A1 true EP1645347A1 (fr) 2006-04-12
EP1645347B1 EP1645347B1 (fr) 2008-06-11

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EP05111586A Expired - Lifetime EP1645347B1 (fr) 2000-05-17 2001-04-12 Procédé de fabrication d'une pièce moulée à charge thermique élevée
EP01109115A Expired - Lifetime EP1155760B1 (fr) 2000-05-17 2001-04-12 Procédé de fabrication d'une pièce moulée à charge thermique élevée

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EP01109115A Expired - Lifetime EP1155760B1 (fr) 2000-05-17 2001-04-12 Procédé de fabrication d'une pièce moulée à charge thermique élevée

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US (1) US6412541B2 (fr)
EP (2) EP1645347B1 (fr)
DE (3) DE10024302A1 (fr)

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DE10024302A1 (de) 2001-11-22
DE50108928D1 (de) 2006-04-20
EP1645347B1 (fr) 2008-06-11
EP1155760B1 (fr) 2006-02-15
US20010042607A1 (en) 2001-11-22
DE50114026D1 (de) 2008-07-24
US6412541B2 (en) 2002-07-02

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