EP2081721A1 - Procédé de fabrication d'une aube de turbine de construction légère - Google Patents

Procédé de fabrication d'une aube de turbine de construction légère

Info

Publication number
EP2081721A1
EP2081721A1 EP07817695A EP07817695A EP2081721A1 EP 2081721 A1 EP2081721 A1 EP 2081721A1 EP 07817695 A EP07817695 A EP 07817695A EP 07817695 A EP07817695 A EP 07817695A EP 2081721 A1 EP2081721 A1 EP 2081721A1
Authority
EP
European Patent Office
Prior art keywords
blade
wall
thickness
blade element
region
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.)
Withdrawn
Application number
EP07817695A
Other languages
German (de)
English (en)
Inventor
Hermann Klingels
Albin Platz
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.)
MTU Aero Engines AG
Original Assignee
MTU Aero Engines GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by MTU Aero Engines GmbH filed Critical MTU Aero Engines GmbH
Publication of EP2081721A1 publication Critical patent/EP2081721A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00—Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/10—Working turbine blades or nozzles

Definitions

  • the present invention relates to a method for producing a lightweight turbine blade for a gas turbine having at least one cavity (2), the method comprising at least casting a Schaufelelemtes (1) with a blade wall and at least one of these enclosed cavity (2) ,
  • the invention further relates to a blade element made by the method according to the present invention.
  • European Patent Specification EP 1 052 370 B1 discloses a method for producing a blade element for a gas turbine, wherein the blade elements are produced by means of a casting method.
  • the method described herein includes manufacturing customized fluidic surfaces on integrally bladed rotor assemblies. The process also applies to the manufacture of new parts and can be applied to the entire blade surface, including its transition to the adjacent components.
  • the method further relates to joints, which arise by welding, gluing, soldering or other joining method and a subsequent material processing, for example by ablation, require.
  • ablate wear which are caused for example during welding, and adapt to the desired contour of the blade element surface.
  • the known methods for producing blade elements for high, medium and low-pressure turbine stages of gas turbines usually comprise a precision casting method, wherein the blade elements are made of Ni or Co base alloys.
  • the blades are formed as hollow blades, through which a cooling medium is passed, which emerges from cooling channels, which are provided in the blade wall of the blade element.
  • Uncooled buckets on the other hand, are partly cast off as full buckets and, on the other hand, due to mechanical forces. and for weight reasons also designed as hollow blades.
  • vanes In the design of the vanes, individual vanes, which are mostly used for high-pressure turbines, are distinguished from vanes of medium-pressure turbines and low-pressure turbines, which are embodied in segments having a plurality of aerodynamic profiles and an inner and outer shroud.
  • outer shroud In blades, however, there are versions without outer shroud, which are preferably used in high pressure turbines. The blades with an outer shroud are preferably used in mid-pressure and low-pressure turbines.
  • the minimum thicknesses of the blade wall from 0.8 mm to 1.0 mm can not be undershot. Also, the minimum thicknesses of the blade trailing edges are limited to about 0.6 mm to 0.8 mm in the minimum thickness.
  • the mean stress due to the fly-force load in any section of the blade element depends on the radial position of the cutting plane, the considered cross-sectional area and the fly-force loading by the blade part lying radially outside the cutting plane. The farther the imaginary cutting line is displaced outwards, the lower the flying force load of the remaining blade area, and the lower the stress level that forms at a given cross-sectional area.
  • the minimum wall thickness that can be realized by casting is fixed. From a mechanical-dynamic point of view, however, the wall thickness could be significantly lower in many areas of the blade element. A reduction of the wall thickness would be particularly advantageous in the radially outer region. Lower wall thicknesses for blade elements with a cavity in areas which are not utilized in terms of their mechanical load capacity, a significant weight reduction of the blade elements can be achieved. The weight reduction is not only in the reduced blade weight too but also in the consequent reduction in flylash loading of the disks on which the vane elements are located and the reduced demand on the housing of the gas turbine.
  • the efficiency of gas turbines is determined inter alia by the thickness of the blade trailing edges.
  • the blade trailing edges with the exception of the locally narrow locations near the shrouds, are often not very heavily utilized mechanically.
  • a reduction in the wall thickness of the blade elements of, for example, 0.1 mm can cause atoxinssradverêtung of about 0.1%.
  • the invention includes the technical teaching that, following the casting process, the blade wall is at least partially reduced in thickness by material processing.
  • the minimum wall thickness of the blade wall is not limited to the minimum wall thickness necessary for a stable casting process.
  • the blade wall which extends in the sense of the present invention over the entire cross section of the vane element provided with a cavity, and thus also includes the blade trailing edge, can be reduced by the material processing after the casting process in order to adapt it to an optimal mechanical stress.
  • the material processing can be limited to parts of the surface of the blade wall, so that only individual areas in the Schaufelwandung can be reduced in thickness. This can be done contiguously, wherein the individual areas can also be processed separately at different locations.
  • the thickness of the blade wall is reduced by a removal method.
  • the removal method may include an EDM, an ECM and / or a PECM method.
  • Electrochemical machining processes are particularly suitable for machining high-temperature turbine materials, which consist of Ni or Co base alloys and are difficult to chip.
  • a preferred variant of the electrochemical removal method can be seen in die sinking, in which electrodes are formed on the desired contour to be generated, the shape of which can be imaged in the desired blade wall of the blade element.
  • the PECM process describes what is known as "Pulsed Eletrochemical Machining" and describes a recent electrochemical removal process using a pulsed current, which method can be considered particularly suitable for the present application.
  • the blade wall in this process is at least partially poured with an oversize, and wherein the excess is removed by the material processing and after the material processing has the finished dimension.
  • the excess can be chosen arbitrarily large, however, it is advantageous to provide the excess at least in the head region of the blade body with the minimum technically producible Schaufelwandungsdicke by casting, so as not to unnecessarily prolong the duration of material processing by the removal process.
  • the material The contract does not have to be restricted to the areas of the blade element in which the casting wall thickness of the minimum blade wall thickness is to be undercut by the removal method. It is also conceivable that in order to avoid curvature jumps in the surface of the blade wall and to avoid occurring steps, the entire surface of the blade element is provided with an excess to subsequently remove all areas. The material removal can be locally different. Also with regard to a uniform surface over the entire blade wall, removal over the entire outside of the blade element is advantageous.
  • this extends radially from an inner foot region to an outer head region, wherein the oversize to be removed on the blade wall during casting is placed in the head region.
  • the excess to be removed arises due to production due to a thickness of the blade wall, which describes the minimum castable by casting wall thickness.
  • a reduction in the thickness of the blade wall in the head region is particularly advantageous, since here the flying forces no longer occur at the same height as in the foot region of the blade element.
  • the geometry of the blade element can be described by an axially forward profile nose region up to a rear profile trailing edge region. It is envisaged to lay the excess to be removed in the casting process in the profile trailing edge region.
  • An overall consideration of the blade element makes it clear that the area to be removed essentially extends from the head area into the profile trailing edge area. stretches, and the foot area, passing into the profile nose area, has no ablation.
  • the regions to be removed above the surface of the blade element can also be determined by the fact that they have locally different material thicknesses and the material thickness to be removed is adapted to thermal stresses that are minimal in the material of the blade wall.
  • the distribution of the material thickness of the blade wall after the removal process has a distribution which leads to minimal thermal stresses during operation of the blade element.
  • the material distribution for the minimum thermal stress can be optimized. This results in improved cooling, which at the same time leads to an extension of the service life of the blade elements.
  • a further advantageous embodiment provides that a surface structure is introduced into the blade wall by the removal method. This can be done, for example, by the fact that the sinking electrode in the ECM method or in the PECM method has the negative of the surface structure which is introduced into the blade wall during the method.
  • an increase in efficiency can be achieved by introducing a structure deviating from a smooth surface for reasons of flow optimization and a positive influencing of the flow boundary layer in regions near the surface of the blade wall.
  • surfaces which are structured according to the principle of a sharkskin or else according to the principle of controlled stall are mentioned here.
  • the casting of the cavity is carried out with a core mold and the removal method by means of at least one sinking electrode, wherein the sinking electrode after the Core or the core generated by the core is aligned to minimize wall thickness tolerances in the blade wall.
  • a further advantageous embodiment of the invention provides that the blade element is subjected to a thermal treatment comprising a HIP process before the removal process.
  • the HIP process describes a hot isostatic compression of the material of the blade element in order to prevent the exposure of voids and pores possibly present in the casting.
  • the present invention further relates to a blade element made by the described method.
  • the blade element has in regions on a treated by a Abtragsvons blade wall, the blade wall at least partially a thickness of 0.2 mm to 0.7 mm, preferably from 0.4 mm to 0.6 mm and particularly preferably 0.5 mm , having. These orders of magnitude are not readily achievable by means of a precision casting process or an MIM process which describes a metal injection molding process.
  • the blade element according to the present invention is characterized by wall thicknesses which are significantly below the said minimum wall thicknesses which can be achieved by casting technology.
  • the thickness of the blade wall decreases from the foot region to the head region, the minimum wall thickness in the head region being 0.3 mm to 0.6 mm, preferably 0.4 mm to 0.5 mm and particularly preferably 0.45 mm.
  • this decreases in thickness from the profile nose region to the profile trailing edge region, wherein the minimum wall thickness in the profile trailing edge region is 0.2 mm to 0.5 mm, preferably 0.3 mm to 0.45 mm and particularly preferably 0, 4 mm.
  • the surface of the blade elements in the regions where the thickness of the blade wall is less than 0.6 mm to 0.8 mm thick have a surface machined with an ECM and / or PECM process.
  • Figure 1 is a side view of a blade element, which has partially processed by means of a Abtragvons surface.
  • FIG. 2 shows an illustration of a first cross section of the blade element according to FIG. 1, wherein the position of the cross section lies in the foot region of the blade element;
  • Fig. 3 is a representation of a second cross-section of the blade element according to FIG. 1, wherein the position of the cross section is in the head region of the blade element.
  • the blade element 1 shows a blade element, which is provided with the reference numeral 1.
  • the blade element 1 is shown in a side view, in which the radial extent of the blade element 1 lies in the vertical and the axial extent in the horizontal.
  • the lower region of the blade element 1 is marked with the foot region 4 and the upper region with the head region 5.
  • the region of the blade element 1, which is processed by the casting process by means of a removal process, is indicated by a hatched area.
  • the hatched region therefore extends over the head region 5 into the foot region 4, wherein in the head region 5 the entire width of the blade element 1 is machined in the axial direction, whereas in the foot region 4 only the profile trailing edge region 7 is machined.
  • the profile nose region (6) is therefore not processed in the foot region 4.
  • the core mold 8 is shown, which is responsible for the creation of the cavity. mes - not visible in FIG. 1 - is produced within the blade element 1.
  • the cross-sectional view from FIG. 2 is indicated by a sectional plane II-II, wherein the cross-sectional view according to FIG. 3 is indicated by the sectional plane III-III in the head region 5 of the blade element 1.
  • FIG. 2 shows the cross-section of the blade element 1 in the cross-sectional plane II - IL
  • the cavity 2 is introduced through the operating cooling air into the blade element 1, which by-not shown- cooling holes within the blade wall 3. for cooling the Outside of the blade wall 3 is passed.
  • the profile nose region located axially opposite to the flow direction is represented by the reference numeral 6, so that the blade element 1 extends into the profile trailing edge region according to reference numeral 7.
  • the sectional plane II - II with reference to FIG. 1, only the profile trailing edge region 7 is processed by a removal process.
  • the reduced by the Abtragvons wall thickness of the blade wall 3 in the profile trailing edge region 7 is indicated by a dashed line.
  • the dot-dash line represents the cross-section of the blade element 1 produced by means of the casting process, wherein the continuous line in the region of the blade trailing edge represents the finished contour of the blade element 1 after the removal process.
  • the blade element 1 is shown in cross-section, wherein the sectional plane with view of Fig. 1 in the plane III - III in the head portion 5 of the blade element 1 is located.
  • the reference numeral 6 denotes the profile nose region and the reference numeral 7, the profile trailing edge region, between which the blade wall 3 extends.
  • the cavity 2 extends over a larger region of the cross-section of the blade element 1, the wall thickness of the blade wall 3 being significantly smaller than in the cross-section according to FIG. 2.
  • the minimum section of the blade wall 3 that can be realized by casting is shown by the dotted line, which extends over the entire outer surface of the blade wall 3 and the entire surface of the outside of the Bucket element 1 in the head area 5 encloses.
  • the entire outer area of the blade wall 3 is now removed, so that the minimum wall thickness that can be realized by casting is reduced over the entire cross section of the blade element 1.
  • the minimum wall thickness which is significantly below 0.8 mm, is represented by the solid line and describes the finished shape of the blade element 1.
  • the invention is not limited in its execution to the above-mentioned preferred embodiment. Rather, a number of variants is conceivable, which makes use of the illustrated solution even with fundamentally different types of use.

Landscapes

  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

L'invention concerne un procédé de fabrication d'une aube de turbine de construction légère pour une turbine à gaz. Le procédé comprend au moins l'étape consistant à mouler un élément de turbine (1) doté d'une paroi d'aube (3) et d'au moins une cavité (2) entourée par cette paroi. Selon l'invention, à la suite du moulage, l'épaisseur de la paroi d'aube (3) est au moins partiellement réduite par usinage de matière. Ce procédé de fabrication d'un élément de turbine (1) permet ainsi à la fois d'adapter l'épaisseur de la paroi d'aube (3) à la sollicitation mécanique de l'élément de turbine (1), et de réduire le poids de l'élément de turbine (1).
EP07817695A 2006-10-26 2007-10-17 Procédé de fabrication d'une aube de turbine de construction légère Withdrawn EP2081721A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102006050440A DE102006050440A1 (de) 2006-10-26 2006-10-26 Verfahren zum Herstellen einer Leichtbau-Turbinenschaufel
PCT/DE2007/001860 WO2008049393A1 (fr) 2006-10-26 2007-10-17 Procédé de fabrication d'une aube de turbine de construction légère

Publications (1)

Publication Number Publication Date
EP2081721A1 true EP2081721A1 (fr) 2009-07-29

Family

ID=39148816

Family Applications (1)

Application Number Title Priority Date Filing Date
EP07817695A Withdrawn EP2081721A1 (fr) 2006-10-26 2007-10-17 Procédé de fabrication d'une aube de turbine de construction légère

Country Status (4)

Country Link
US (1) US20100202889A1 (fr)
EP (1) EP2081721A1 (fr)
DE (1) DE102006050440A1 (fr)
WO (1) WO2008049393A1 (fr)

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Publication number Priority date Publication date Assignee Title
DE102008008894A1 (de) * 2008-02-13 2009-08-20 Man Turbo Ag Verfahren zur Herstellung eines Bauteiles für eine thermische Maschine
DE102011077198A1 (de) * 2011-06-08 2012-12-13 Mahle International Gmbh Verfahren zum Herstellen eines metallischen Hohlventils mit verbesserter Kühlung
ITCO20120054A1 (it) * 2012-10-31 2014-05-01 Nuovo Pignone Srl Metodi per produrre pale di turbomacchine mediante wire electric discharge machining, pale e turbomacchine
US8720526B1 (en) * 2012-11-13 2014-05-13 Siemens Energy, Inc. Process for forming a long gas turbine engine blade having a main wall with a thin portion near a tip
DE102013213416B4 (de) * 2013-07-09 2017-11-09 MTU Aero Engines AG Schaufel für eine Gasturbomaschine
US20170274451A1 (en) * 2014-10-24 2017-09-28 Siemens Aktiengesellschaft Electrochemical machining inner contours of gas turbine engine components
US11168566B2 (en) 2016-12-05 2021-11-09 MTU Aero Engines AG Turbine blade comprising a cavity with wall surface discontinuities and process for the production thereof
US11346226B2 (en) 2016-12-23 2022-05-31 Borgwarner Inc. Turbocharger and turbine wheel
JP7124652B2 (ja) * 2018-11-13 2022-08-24 株式会社豊田自動織機 ＴｉＡｌ合金製翼車の製造方法
CN113530606A (zh) * 2021-07-12 2021-10-22 西安热工研究院有限公司 一种汽轮机叶片水蚀治理方法

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US4159407A (en) * 1974-03-23 1979-06-26 Rolls-Royce (1971) Limited Methods and apparatus for electrically machining a work piece
DE19922012C1 (de) * 1999-05-12 2000-10-19 Mtu Muenchen Gmbh Verfahren zur Fertigung angepaßter, strömungstechnischer Oberflächen
EP1057565B1 (fr) * 1999-06-02 2006-03-29 General Electric Company Procédé pour réduire l'épaissseur d'une aube de turbine par usinage par électroérosion
US6355156B1 (en) * 2000-09-29 2002-03-12 General Electric Company Method of monitoring electrochemical machining process and tool assembly therefor
SE521759C2 (sv) * 2000-11-09 2003-12-02 Volvo Aero Corp Förfarande för framställning av ett blad till en gasturbinkomponent samt framställning av en gasturbinkomponent
US6717095B2 (en) * 2002-04-18 2004-04-06 General Electric Company Coolant side surface roughness on airfoil castings by electrical discharge machining (EDM)
US7214901B1 (en) * 2006-01-17 2007-05-08 General Electric Company Duplex electrical discharge machining

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Also Published As

Publication number Publication date
US20100202889A1 (en) 2010-08-12
DE102006050440A1 (de) 2008-04-30
WO2008049393A1 (fr) 2008-05-02

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