EP2355947A2 - Repair method - Google Patents

Repair method

Info

Publication number
EP2355947A2
EP2355947A2 EP09771488A EP09771488A EP2355947A2 EP 2355947 A2 EP2355947 A2 EP 2355947A2 EP 09771488 A EP09771488 A EP 09771488A EP 09771488 A EP09771488 A EP 09771488A EP 2355947 A2 EP2355947 A2 EP 2355947A2
Authority
EP
European Patent Office
Prior art keywords
gas turbine
process chamber
metal powder
repaired
separating surface
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Withdrawn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
EP09771488A
Other languages
German (de)
French (fr)
Inventor
Roland Huttner
Karl-Heinz Dusel
Erwin Bayer
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 EP2355947A2 publication Critical patent/EP2355947A2/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • 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
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/28—Supporting or mounting arrangements, e.g. for turbine casing
    • F01D25/285—Temporary support structures, e.g. for testing, assembling, installing, repairing; Assembly methods using such structures
    • 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
    • F01D5/005—Repairing methods or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/70—Recycling
    • B22F10/73—Recycling of powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • 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
    • F05D2230/60—Assembly methods
    • F05D2230/68—Assembly methods using auxiliary equipment for lifting or holding
    • 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a repair method for gas turbine components, in particular for gas turbine blades. Furthermore, the invention relates to a process chamber for the repair method according to the invention.
  • Gas turbine components such as gas turbine blades of an integrally bladed gas turbine rotor are subject to wear during operation. Wear can make it necessary to repair the gas turbine components after damage by removing damaged portions of the gas turbine components from them and renewing them after removing the damaged portions.
  • stator-side rotor blades of integrally bladed gas turbine rotors are subject to wear, in particular due to oxidation, corrosion, erosion, and bird strike or even hail, so that damaged portions thereof must be removed and replaced after removal.
  • stator-side components such as guide vanes or housing structures are subject to wear, which may require a repair of the same.
  • DE 3909733 A1 discloses a method for repairing, for example, integrally bladed gas turbine rotors, in which a damaged section of the gas turbine blade to be repaired is removed and renewed after removal of the same by welding a replacement part.
  • a damaged section of the gas turbine blade to be repaired is removed and renewed after removal of the same by welding a replacement part.
  • inductive pressure welding is used.
  • rotor blades of a gas turbine rotor can be repaired by renewing same by laser powder build-up welding after removal of a damaged portion from the blade.
  • laser powder build-up welding it is difficult to ensure adequate contour accuracy.
  • the present invention is based on the problem of providing a novel repair method for gas turbine components, in particular for gas turbine blades.
  • the repair method for gas turbine components comprises at least the following steps: a) provision of a gas turbine component to be repaired; b) removing a damaged portion of the gas turbine engine component to be repaired to form a planar interface; c) at least partially arranging the gas turbine component to be repaired in a process chamber, such that the planar separation surface extends approximately horizontally within the process chamber; d) filling the process chamber with a material compatible with the material of the gas turbine component to be repaired metal powder, namely up to the level of the interface; e) building the removed portion on the parting surface by coating metal powder on the parting surface and fusing the metal powder applied to the parting surface layer by layer with the parting surface.
  • a repair of gas turbine components can be realized while ensuring a high contour accuracy.
  • a damaged portion removed from a gas turbine component to be repaired can be renewed with a minimum of oversize.
  • Another advantage of the method according to the invention is that a high quality of the forming material structure can be ensured.
  • the method according to the invention can be automated and therefore enables good reproducibility. Furthermore, the method allows cost-effective repair of gas turbine components compared to other repair methods.
  • a process chamber according to the invention is defined in claim 8. Preferred embodiments of the invention will become apparent from the dependent claims and the description below. Exemplary embodiments of the invention will be explained in more detail with reference to the drawing, without being limited thereto. Showing:
  • FIG. 1 shows a representation to illustrate the method according to the invention and a process chamber according to the invention in the repair of an integrally bladed gas turbine rotor.
  • FIG. 2 a longitudinal section through the arrangement of Fig. 1; and FIG. 3 shows a cross section through the arrangement of FIG. 1.
  • the invention relates to a repair method for gas turbine components, in particular for gas turbine blades.
  • the method is particularly suitable for repairing gas turbine blades of an integrally bladed gas turbine rotor and for repairing complex housing structures of a gas turbine.
  • a gas turbine component to be repaired is provided. Subsequently, in a second step of the method according to the invention, a damaged section is removed from the gas turbine component to be repaired, namely with the formation of an approximately planar separation surface.
  • the gas turbine component to be repaired is positioned at least in sections in a third step in a process chamber, namely such that the planar parting surface is oriented or extends approximately horizontally.
  • the process chamber is filled with metal powder, wherein the metal powder is compound-compatible with the material of the gas turbine component to be repaired.
  • This filling of the process chamber with the metal powder takes place up to the level of the separating surface, ie until the edges of the separating surface are reached.
  • the process chamber can be evacuated or flooded with inert gas or inert gas.
  • the section removed from the gas turbine component is reconstructed on the separation surface in a sixth step of the process according to the invention, namely by applying metal powder layer by layer to the separation surface and by fusing the metal powder applied in layers to the separation surface the interface.
  • This layer-by-layer application of metal powder and fusion thereof with the interface is done in several steps until the removed section has been rebuilt.
  • the fusion of the metal powder applied in layers with the separating surface takes place by using a thermal energy source, in particular using a laser or an electron beam.
  • the erf ⁇ ndungssiee method allows a contour accurate construction of the removed, damaged section on the separation surface with minimal oversize. It forms a high quality of the material structure.
  • smoothing of the rebuilt portion may occur to form the original contour on the repaired gas turbine component.
  • the repair method according to the invention is particularly suitable for the repair of
  • Gas turbine blades such. B. rotor-side blades or stator-side vanes.
  • the repair method of the invention finds use in the repair of blades of an integrally bladed gas turbine rotor. Also can
  • FIGs. 1 to 3 illustrate the invention for the preferred application in the repair of an integrally bladed gas turbine rotor 10 in the region of a blade 11 thereof.
  • a connection portion 19 of the blade 11 in a process chamber 12 wherein the connection portion 19 of the blade 11 via an insertion opening of the process chamber 12 in such a receiving space 13 of the process chamber 12 is introduced, that a parting surface 20 of the blade 11 within the process chamber 12 and within the receiving space 13 thereof extends horizontally.
  • the insertion opening of the process chamber 12 is assigned a sealing device 14 in order to seal the connecting section 19 of the moving blade 11, which is inserted into the receiving space 13 of the same via the insertion opening of the process chamber 12, with respect to the insertion opening.
  • the process chamber 12 can be inserted into the same metal powder via a filling opening 18 and positioned on the separating surface 20 of the blade 11, wherein the process chamber 12 is applied to the separating surface 20 of the blade 11 by means of a translationally displaceable slide 15
  • Metal powder can be made uniform. Alternatively, by processing the process chamber or reducing the volume, the powder in the process chamber can be used for the layer application.
  • the method according to the invention can be carried out particularly preferably in the repair of integrally bladed gas turbine rotors.
  • the process chamber 12 is characterized by a small, compact design, which makes it possible to selectively and safely repair a damaged blade of an integrally bladed gas turbine rotor.
  • the connecting section 19 of the moving blade 11 introduced into the process chamber 12 can be sealed.
  • the slider 15 serves to equalize the metal powder applied to the parting surface 20 of the connecting section 19 of the moving blade 11 and also to even out a surface of a powder bed 21 positioned in the receiving space 13.
  • a section removed from the damaged moving blade 11 can be arranged in layers or layers are renewed in layers, wherein for this purpose the process chamber 12 relative to the blade 11 in the micron range is relatively displaced.
  • a metering device by means of which the metal powder can be introduced via the insertion opening 18 into the receiving space 13 of the process chamber 12, and a beam source, which serves to fuse the metal powder with the material of the blade 11 to be repaired, not shown.
  • a blade 11 of an integrally bladed gas turbine rotor 10 can be selectively renewed.
  • Process chamber are positioned, but only the damaged and to be renewed Blade 11 is arranged in the process chamber 12. Thereby, a local powder bed for selectively renewing the blade 11 of an integrally bladed gas turbine rotor 10 is provided. Interference contours, such as with respect to the parting surface 20 of the damaged blade 11 projecting, adjacent blades do not hinder the repair of the damaged blade 11th
  • the separating surface 20 within the process chamber 12 is realigned by means of a relative movement between the process chamber 12 and the gas turbine rotor 10, with subsequent new metal powder the introduction port 18 of the process chamber is inserted therein to renew the powder layer on the separation surface 20 of the blade 11.
  • the metal powder applied to the separating surface 20 of the blade 11 to be repaired is in turn uniformed by means of the slider 15, in order to then build up a new layer on the connecting region of the blade 11. This relative movement and the layered construction of the blade 11 to be repaired takes place in the ⁇ m range.

Abstract

The invention relates to a repair method for gas turbine components, particularly for gas turbine blades, comprising at least the following steps: a) providing a gas turbine component to be repaired; b) removing a damaged section from the gas turbine component to be repaired to form a level separating surface; c) arranging the gas turbine component to be repaired in a process chamber at least in regions such that the level separating surface runs approximately horizontally inside the process chamber; d) filling the process chamber with a metal powder compatible for bonding with the material of the gas turbine component to be repaired, specifically up to the level of the separating surface; e) building the removed section on the separating surface by applying the metal powder in layers onto the separating surface and by melting the metal powder applied in layers onto the separating surface to the separating surface.

Description

Reparaturverfahren repair procedures
Die Erfindung betrifft ein Reparaturverfahren für Gasturbinenbauteile, insbesondere für Gasturbinenschaufeln. Des Weiteren betrifft die Erfindung eine Prozesskammer für das er- findungsgemäße Reparaturverfahren.The invention relates to a repair method for gas turbine components, in particular for gas turbine blades. Furthermore, the invention relates to a process chamber for the repair method according to the invention.
Gasturbinenbauteile wie zum Beispiel Gasturbinenschaufeln eines integral beschaufelten Gasturbinenrotors unterliegen während des Betriebs einem Verschleiß. Durch den Verschleiß kann es erforderlich werden, die Gasturbinenbauteile nach Beschädigung dadurch zu reparieren, dass beschädigte Abschnitte der Gasturbinenbauteile von denselben entfernt sowie nach dem Entfernen der beschädigten Abschnitte dieselben erneuert werden.Gas turbine components such as gas turbine blades of an integrally bladed gas turbine rotor are subject to wear during operation. Wear can make it necessary to repair the gas turbine components after damage by removing damaged portions of the gas turbine components from them and renewing them after removing the damaged portions.
So sind zum Beispiel die rotorseitigen Laufschaufeln integral beschaufelter Gasturbinenrotoren während des Betriebs einem Verschleiß insbesondere durch Oxidation, Korrosion, Erosion sowie Vogelschlag oder auch Hagelschlag ausgesetzt, sodass beschädigte Abschnitte derselben entfernt sowie nach dem Entfernen erneuert werden müssen. Auch sta- torseitige Bauteile wie zum Beispiel Leitschaufeln oder Gehäusestrukturen unterliegen einem Verschleiß, der eine Reparatur derselben erforderlich machen kann.For example, during operation, the rotor-side rotor blades of integrally bladed gas turbine rotors are subject to wear, in particular due to oxidation, corrosion, erosion, and bird strike or even hail, so that damaged portions thereof must be removed and replaced after removal. Also, stator-side components such as guide vanes or housing structures are subject to wear, which may require a repair of the same.
Aus der DE 3909733 Al ist ein Verfahren zum Reparieren von zum Beispiel integral beschaufelten Gasturbinenrotoren bekannt, bei welchem ein beschädigter Abschnitt der zu reparierenden Gasturbinenschaufel entfernt und nach dem Entfernen derselbe durch Anschweißen eines Ersatzteils erneuert wird. Hierbei kommt vorzugsweise induktives Pressschweißen zum Einsatz.DE 3909733 A1 discloses a method for repairing, for example, integrally bladed gas turbine rotors, in which a damaged section of the gas turbine blade to be repaired is removed and renewed after removal of the same by welding a replacement part. Here, preferably inductive pressure welding is used.
Aus der Praxis ist es ferner bekannt, z. B. Laufschaufeln eines Gasturbinenrotors dadurch zu reparieren, dass nach dem Entfernen eines beschädigten Abschnitts von der Laufschaufel derselbe durch Laserpulverauftragsschweißen erneuert wird. Bei der Reparatur über La- serpulverauftragsschweißen bereitet jedoch die Gewährleistung einer ausreichenden Kon- turgenauigkeit Schwierigkeiten.From practice, it is also known, for. For example, rotor blades of a gas turbine rotor can be repaired by renewing same by laser powder build-up welding after removal of a damaged portion from the blade. When repairing laser powder build-up welding, however, it is difficult to ensure adequate contour accuracy.
BESTÄTIGUNGSKOPIE Es besteht daher Bedarf an einem Verfahren zum Reparieren von Gasturbinenbauteilen, mit welchem unter Gewährleistung einer hohen Konturgenauigkeit eine Reparatur möglich ist.CONFIRMATION COPY There is therefore a need for a method for repairing gas turbine components, with which a repair is possible while ensuring high contour accuracy.
Hiervon ausgehend liegt der vorliegenden Erfindung das Problem zu Grunde ein neuartiges Reparaturverfahren für Gasturbinenbauteile, insbesondere für Gasturbinenschaufeln, zu schaffen.On this basis, the present invention is based on the problem of providing a novel repair method for gas turbine components, in particular for gas turbine blades.
Dieses Problem wird durch ein Reparaturverfahren gemäß Anspruch 1 gelöst. Erfindungs- gemäß umfasst das Reparaturverfahren für Gasturbinenbauteile, insbesondere für Gasturbinenschaufeln, zumindest die folgenden Schritte: a) Bereitstellen eines zu reparierenden Gasturbinenbauteils; b) Entfernen eines beschädigten Abschnitts von dem zu reparierenden Gasturbinenbauteil unter Ausbildung einer ebenen Trennfläche; c) zumindest bereichsweise Anordnen des zu reparierenden Gasturbinenbauteils in einer Prozesskammer, derart, dass die ebene Trennfläche innerhalb der Prozesskammer in etwa horizontal verläuft; d) Befüllen der Prozesskammer mit einem zum Werkstoff des zu reparierenden Gasturbinenbauteils verbindungskompatiblen Metallpulver, nämlich bis zum Niveau der Trennfläche; e) Aufbauen des entfernten Abschnitts auf der Trennfläche durch schichtweise Auftragen von Metallpulver auf die Trennfläche und durch Verschmelzen des schichtweise auf die Trennfläche aufgetragenen Metallpulvers mit der Trennfläche.This problem is solved by a repair method according to claim 1. According to the invention, the repair method for gas turbine components, in particular for gas turbine blades, comprises at least the following steps: a) provision of a gas turbine component to be repaired; b) removing a damaged portion of the gas turbine engine component to be repaired to form a planar interface; c) at least partially arranging the gas turbine component to be repaired in a process chamber, such that the planar separation surface extends approximately horizontally within the process chamber; d) filling the process chamber with a material compatible with the material of the gas turbine component to be repaired metal powder, namely up to the level of the interface; e) building the removed portion on the parting surface by coating metal powder on the parting surface and fusing the metal powder applied to the parting surface layer by layer with the parting surface.
Mit dem erfindungsgemäßen Verfahren kann eine Reparatur von Gasturbinenbauteilen unter Gewährleistung einer hohen Konturgenauigkeit realisiert werden. Ein von einem zu reparierenden Gasturbinenbauteil entfernter, beschädigter Abschnitt kann mit geringstem Aufmaß erneuert werden. Ein weiterer Vorteil des erfindungsgemäßen Verfahrens besteht darin, dass eine hohe Qualität des sich ausbildenden Werkstoffgefüges gewährleistet werden kann. Das erfindungsgemäße Verfahren ist automatisierbar und ermöglicht daher eine gute Reproduzierbarkeit. Ferner erlaubt das Verfahren im Vergleich zu anderen Reparaturverfahren eine kostengünstige Reparatur von Gasturbinenbauteilen.With the method according to the invention, a repair of gas turbine components can be realized while ensuring a high contour accuracy. A damaged portion removed from a gas turbine component to be repaired can be renewed with a minimum of oversize. Another advantage of the method according to the invention is that a high quality of the forming material structure can be ensured. The method according to the invention can be automated and therefore enables good reproducibility. Furthermore, the method allows cost-effective repair of gas turbine components compared to other repair methods.
Eine erfindungsgemäße Prozesskammer ist in Anspruch 8 definiert. Bevorzugte Weiterbildungen der Erfindung ergeben sich aus den Unteransprüchen und der nachfolgenden Beschreibung. Ausfuhrungsbeispiele der Erfindung werden, ohne hierauf beschränkt zu sein, an Hand der Zeichnung näher erläutert. Dabei zeigt:A process chamber according to the invention is defined in claim 8. Preferred embodiments of the invention will become apparent from the dependent claims and the description below. Exemplary embodiments of the invention will be explained in more detail with reference to the drawing, without being limited thereto. Showing:
Fig. 1 eine Darstellung zur Verdeutlichung des erfindungsgemäßen Verfahrens und einer erfindungsgemäßen Prozesskammer bei der Reparatur eines integral beschaufelten Gasturbinenrotors;1 shows a representation to illustrate the method according to the invention and a process chamber according to the invention in the repair of an integrally bladed gas turbine rotor.
Fig. 2: einen Längsschnitt durch die Anordnung der Fig. 1 ; und Fig. 3 : einen Querschnitt durch die Anordnung der Fig. 1.Fig. 2: a longitudinal section through the arrangement of Fig. 1; and FIG. 3 shows a cross section through the arrangement of FIG. 1.
Die Erfindung betrifft ein Reparaturverfahren für Gasturbinenbauteile, insbesondere für Gasturbinenschaufeln. Besonders eignet sich das Verfahren zur Reparatur von Gasturbinenschaufeln eines integral beschaufelten Gasrurbinenrotors sowie zur Reparatur komple- xer Gehäusestrukturen einer Gasturbine.The invention relates to a repair method for gas turbine components, in particular for gas turbine blades. The method is particularly suitable for repairing gas turbine blades of an integrally bladed gas turbine rotor and for repairing complex housing structures of a gas turbine.
In einem ersten Schritt des erfindungsgemäßen Verfahrens wird ein zu reparierendes Gasturbinebauteil bereitgestellt. Nachfolgend wird in einem zweiten Schritt des erfindungsgemäßen Verfahrens vom zu reparierenden Gasturbinenbauteil ein beschädigter Abschnitt entfernt, nämlich unter Ausbildung einer in etwa ebenen Trennfläche.In a first step of the method according to the invention, a gas turbine component to be repaired is provided. Subsequently, in a second step of the method according to the invention, a damaged section is removed from the gas turbine component to be repaired, namely with the formation of an approximately planar separation surface.
Nach dem Abtrennen des beschädigten Abschnitts vom zu reparierenden Bauteil unter Ausbildung der ebenen Trennfläche wird das zu reparierende Gasturbinebauteil zumindest abschnittsweise in einem dritten Schritt in einer Prozesskammer positioniert, nämlich der- art, dass die ebene Trennfläche in etwa horizontal ausgerichtet ist bzw. verläuft.After separating the damaged portion from the component to be repaired to form the planar parting surface, the gas turbine component to be repaired is positioned at least in sections in a third step in a process chamber, namely such that the planar parting surface is oriented or extends approximately horizontally.
Darauffolgend wird in einem vierten Schritt des erfindungsgemäßen Verfahrens die Prozesskammer mit Metallpulver befüllt, wobei das Metallpulver zum Werkstoff des zu reparierenden Gasturbinebauteils verbindungskompatibel ist. Dieses Befüllen der Prozesskam- mer mit dem Metallpulver erfolgt bis zum Niveau der Trennfläche, also bis zum Erreichen von Kanten der Trennfläche. Darauffolgend kann in einem fünften Schritt des erfindungsgemäßen Verfahrens die Prozesskammer evakuiert oder mit Schutzgas bzw. Inertgas geflutet werden.Subsequently, in a fourth step of the method according to the invention, the process chamber is filled with metal powder, wherein the metal powder is compound-compatible with the material of the gas turbine component to be repaired. This filling of the process chamber with the metal powder takes place up to the level of the separating surface, ie until the edges of the separating surface are reached. Subsequently, in a fifth step of the method according to the invention, the process chamber can be evacuated or flooded with inert gas or inert gas.
Anschließend an das Evakuieren bzw. Fluten der Prozesskammer mit Inertgas wird in einem sechsten Schritt des erfindungsgemäßen Verfahrens der vom Gasturbinebauteil entfernte Abschnitt auf der Trennfläche neu aufgebaut, nämlich durch schichtweise Auftragen von Metallpulver auf die Trennfläche und durch Verschmelzen des schichtweise auf die Trennfläche aufgetragenen Metallpulvers mit der Trennfläche.Subsequent to the evacuation or flooding of the process chamber with inert gas, the section removed from the gas turbine component is reconstructed on the separation surface in a sixth step of the process according to the invention, namely by applying metal powder layer by layer to the separation surface and by fusing the metal powder applied in layers to the separation surface the interface.
Dieses schichtweise Auftragen von Metallpulver und Verschmelzen desselben mit der Trennfläche erfolgt in mehreren Schritten, bis der entfernte Abschnitt neu aufgebaut worden ist. Das Verschmelzen des schichtweise aufgetragenen Metallpulvers mit der Trennfläche erfolgt unter Verwendung einer thermischen Energiequelle, insbesondere unter Ver- wendung eines Lasers oder eines Elektronenstrahls.This layer-by-layer application of metal powder and fusion thereof with the interface is done in several steps until the removed section has been rebuilt. The fusion of the metal powder applied in layers with the separating surface takes place by using a thermal energy source, in particular using a laser or an electron beam.
Das erfϊndungsgemäße Verfahren erlaubt ein konturgenaues Aufbauen des entfernten, beschädigten Abschnitts auf der Trennfläche mit geringstem Aufmaß. Es bildet sich eine hohe Qualität des Werkstoffgefüges aus.The erfϊndungsgemäße method allows a contour accurate construction of the removed, damaged section on the separation surface with minimal oversize. It forms a high quality of the material structure.
Anschließend an das Aufbauen des entfernten Abschnitts kann ein Glätten des neu aufgebauten Abschnitts erfolgen, umso die Originalkontur am reparierten Gasturbinenbauteil auszubilden.Subsequent to building the removed portion, smoothing of the rebuilt portion may occur to form the original contour on the repaired gas turbine component.
Das erfindungsgemäße Reparaturverfahren eignet sich insbesondere zur Reparatur vonThe repair method according to the invention is particularly suitable for the repair of
Gasturbinenschaufeln wie z. B. rotorseitigen Laufschaufeln oder statorseitigen Leitschaufeln.Gas turbine blades such. B. rotor-side blades or stator-side vanes.
Vorzugsweise findet das erfindungsgemäße Reparaturverfahren bei der Reparatur von Laufschaufeln eines integral beschaufelten Gasturbinenrotors Verwendung. Auch könnenPreferably, the repair method of the invention finds use in the repair of blades of an integrally bladed gas turbine rotor. Also can
Gehäusestrukturen mit dem erfindungsgemäßen Verfahren repariert werden. Fig. 1 bis 3 verdeutlichen die Erfindung für den bevorzugten Anwendungsfall bei der Reparatur eines integral beschaufelten Gasturbinenrotors 10 im Bereich einer Laufschaufel 11 desselben. Nach dem Entfernen eines beschädigten Abschnitts von der Laufschaufel 11 wird, wie insbesondere Fig. 2 und 3 entnommen werden kann, ein Anbindungsabschnitt 19 der Laufschaufel 11 in einer Prozesskammer 12 angeordnet, wobei der Anbindungsabschnitt 19 der Laufschaufel 11 über eine Einführöffnung der Prozesskammer 12 derart in einen Aufnahmeraum 13 der Prozesskammer 12 eingeführt wird, dass eine Trennfläche 20 der Laufschaufel 11 innerhalb der Prozesskammer 12 bzw. innerhalb des Aufnahmeraums 13 derselben horizontal verläuft.Housing structures are repaired by the method according to the invention. Figs. 1 to 3 illustrate the invention for the preferred application in the repair of an integrally bladed gas turbine rotor 10 in the region of a blade 11 thereof. After removing a damaged portion of the blade 11, as can be seen in particular Fig. 2 and 3, a connection portion 19 of the blade 11 in a process chamber 12, wherein the connection portion 19 of the blade 11 via an insertion opening of the process chamber 12 in such a receiving space 13 of the process chamber 12 is introduced, that a parting surface 20 of the blade 11 within the process chamber 12 and within the receiving space 13 thereof extends horizontally.
Der Einführöffnung der Prozesskammer 12 ist dabei gemäß Fig. 2 und 3 eine Dichteinrichtung 14 zugeordnet, um den Anbindungsabschnitt 19 der Laufschaufel 11, der über die Einführöffnung der Prozesskammer 12 in den Aufnahmeraum 13 derselben eingeführt ist, ge- genüber der Einführöffnung abzudichten.According to FIGS. 2 and 3, the insertion opening of the process chamber 12 is assigned a sealing device 14 in order to seal the connecting section 19 of the moving blade 11, which is inserted into the receiving space 13 of the same via the insertion opening of the process chamber 12, with respect to the insertion opening.
Zur Erneuerung der beschädigten Laufschaufel 11 ist über eine Einfüllöffnung 18 der Prozesskammer 12 in dieselbe Metallpulver einführbar und auf der Trennfläche 20 der Laufschaufel 11 positionierbar, wobei mit Hilfe eines translatorisch verschiebbaren Schiebers 15 der Prozesskammer 12 das auf die Trennfläche 20 der Laufschaufel 11 aufgetrageneTo renew the damaged blade 11, the process chamber 12 can be inserted into the same metal powder via a filling opening 18 and positioned on the separating surface 20 of the blade 11, wherein the process chamber 12 is applied to the separating surface 20 of the blade 11 by means of a translationally displaceable slide 15
Metallpulver vergleichmäßigt werden kann. Alternativ kann durch Verfahren der Prozesskammer oder Volumenverringerung das in der Prozesskammer befindliche Pulver für den Schichtauftrag verwendet werden.Metal powder can be made uniform. Alternatively, by processing the process chamber or reducing the volume, the powder in the process chamber can be used for the layer application.
Durch Verschieben des Schiebers 15 in Richtung des in Fig. 2 gezeigten Doppelpfeils kann auf die Trennfläche 20 der Laufschaufel 11 überschüssig aufgetragenes Metallpulver von der Trennfläche 20 abgeschoben werden. Mit Hilfe des Schiebers 15 ist es möglich, auf der Trennfläche 20 eine exakt definierte Schicht von Metallpulver bereitzustellen, und zwar bevor das Metallpulver mit dem Werkstoff der zu reparierenden Laufschaufel 11 ver- schmolzen wird. Mit Hilfe des Schiebers 15 von der Trennfläche 20 der Laufschaufel 11 überschüssig abgeschobenes Metallpulver kann in einem Überlaufbereich 16 der Prozesskammer 12 gesammelt und über eine dem Überlaufbereich 16 zugeordnete Ausnehmung 17 aus dem Überlaufbereich 16 entfernt werden.By displacing the slider 15 in the direction of the double arrow shown in FIG. 2, excess metal powder applied to the separating surface 20 of the blade 11 can be pushed off the separating surface 20. With the aid of the slide 15, it is possible to provide a precisely defined layer of metal powder on the separating surface 20, specifically before the metal powder is melted with the material of the blade 11 to be repaired. With the aid of the slider 15 excessively deported metal powder from the separating surface 20 of the blade 11 can be collected in an overflow region 16 of the process chamber 12 and removed from the overflow region 16 via a recess 17 assigned to the overflow region 16.
Mit der in Fig. 1 bis 3 dargestellten erfϊndungsgemäßen Prozesskammer 12 kann das erfindungsgemäße Verfahren bei der Reparatur von integral beschaufelten Gasturbinenrotoren besonders bevorzugt ausgeführt werden. Die Prozesskammer 12 zeichnet sich durch eine kleine, kompakte Bauweise aus, wodurch es möglich ist, eine beschädigte Laufschaufel ei- nes integral beschaufelten Gasturbinenrotors selektiv und sicher zu reparieren. Über die vorzugsweise elastische Dichteinrichtung 14 kann der in die Prozesskammer 12 eingeführte Anbindungsabschnitt 19 der Laufschaufel 11 abgedichtet werden.With the inventive process chamber 12 shown in FIGS. 1 to 3, the method according to the invention can be carried out particularly preferably in the repair of integrally bladed gas turbine rotors. The process chamber 12 is characterized by a small, compact design, which makes it possible to selectively and safely repair a damaged blade of an integrally bladed gas turbine rotor. By way of the preferably elastic sealing device 14, the connecting section 19 of the moving blade 11 introduced into the process chamber 12 can be sealed.
Der Schieber 15 dient der Vergleichmäßigung des auf die Trennfläche 20 des Anbindungs- abschnitts 19 der Laufschaufel 11 aufgetragenen Metallpulvers und auch der Vergleichmäßigung einer Oberfläche eines im Aufnahmeraum 13 positionierten Pulverbetts 21. Mit der Prozesskammer 12 kann ein von der beschädigten Laufschaufel 11 entfernter Abschnitt schichtweise bzw. lagenweise erneuert werden, wobei hierzu die Prozesskammer 12 gegenüber der Laufschaufel 11 im μm-Bereich relativ verlagerbar ist. Eine Möglichkeit, diese Relativbewegung zwischen der Prozesskammer 12 und der Laufschaufel 11 zu realisieren, sind z. B. Piezoaktuatoren.The slider 15 serves to equalize the metal powder applied to the parting surface 20 of the connecting section 19 of the moving blade 11 and also to even out a surface of a powder bed 21 positioned in the receiving space 13. With the process chamber 12, a section removed from the damaged moving blade 11 can be arranged in layers or layers are renewed in layers, wherein for this purpose the process chamber 12 relative to the blade 11 in the micron range is relatively displaced. One way to realize this relative movement between the process chamber 12 and the blade 11, z. B. piezo actuators.
In Fig. 1 bis 3 sind eine Dosiereinrichtung, mit Hilfe derer das Metallpulver über die Einführöffnung 18 in den Aufnahmeraum 13 der Prozesskammer 12 eingeführt werden kann, sowie eine Strahlquelle, die dem Verschmelzen des Metallpulvers mit dem Werkstoff der zu reparierenden Laufschaufel 11 dient, nicht gezeigt.In Fig. 1 to 3, a metering device, by means of which the metal powder can be introduced via the insertion opening 18 into the receiving space 13 of the process chamber 12, and a beam source, which serves to fuse the metal powder with the material of the blade 11 to be repaired, not shown.
Mit der erfindungsgemäßen Prozesskammer 12 kann, wie bereits erwähnt, insbesondere eine Laufschaufel 11 eines integral beschaufelten Gasturbinenrotors 10 selektiv erneuert werden. Hierzu muss nicht der gesamte integral beschaufelte Gasturbinenrotor 10 in einerWith the process chamber 12 according to the invention, as already mentioned, in particular a blade 11 of an integrally bladed gas turbine rotor 10 can be selectively renewed. For this purpose, not the entire integrally bladed gas turbine rotor 10 in one
Prozesskammer positioniert werden, vielmehr wird nur die beschädigte und zu erneuernde Laufschaufel 11 in der Prozesskammer 12 angeordnet. Hierdurch wird ein lokales Pulverbett zur selektiven Erneuerung der Laufschaufel 11 eines integral beschaufelten Gasturbinenrotors 10 bereitgestellt. Störkonturen, wie z.B. gegenüber der Trennfläche 20 der beschädigten Laufschaufel 11 vorstehende, benachbarte Laufschaufeln behindern dabei nicht das Reparieren der beschädigten Laufschaufel 11.Process chamber are positioned, but only the damaged and to be renewed Blade 11 is arranged in the process chamber 12. Thereby, a local powder bed for selectively renewing the blade 11 of an integrally bladed gas turbine rotor 10 is provided. Interference contours, such as with respect to the parting surface 20 of the damaged blade 11 projecting, adjacent blades do not hinder the repair of the damaged blade 11th
Nach dem Auftragen einer definierten Pulverschicht auf die Trennfläche 20 der Laufschaufel 11 und nach dem Verschmelzen dieser Pulverschicht mit der Laufschaufel 11 wird über eine Relativbewegung zwischen Prozesskammer 12 und Gasturbinenrotor 10 die Trennflä- che 20 innerhalb der Prozesskammer 12 neu ausgerichtet, wobei anschließend neues Metallpulver über die Einführöffnung 18 der Prozesskammer in dieselbe eingeführt wird, um die Pulverschicht auf der Trennfläche 20 der Laufschaufel 11 erneuern. Über den Schieber 15 wird das auf der Trennfläche 20 der zu reparierenden Laufschaufel 11 aufgetragene Metallpulver wiederum vergleichmäßigt, um dann eine neue Schicht auf dem Anbindungsbe- reich der Laufschaufel 11 aufzubauen. Diese Relativbewegung sowie das schichtweise Aufbauen der zu reparierenden Laufschaufel 11 erfolgt im μm-Bereich. After the application of a defined powder layer to the parting surface 20 of the moving blade 11 and after fusion of this powder layer with the moving blade 11, the separating surface 20 within the process chamber 12 is realigned by means of a relative movement between the process chamber 12 and the gas turbine rotor 10, with subsequent new metal powder the introduction port 18 of the process chamber is inserted therein to renew the powder layer on the separation surface 20 of the blade 11. The metal powder applied to the separating surface 20 of the blade 11 to be repaired is in turn uniformed by means of the slider 15, in order to then build up a new layer on the connecting region of the blade 11. This relative movement and the layered construction of the blade 11 to be repaired takes place in the μm range.

Claims

Ansprüche claims
1. Prozesskammer für die Reparatur eines Gasturbinenbauteils, welches nach Entfernen eines beschädigten Abschnitts eine ebene Trennfläche aufweist, wobei der entfernte Abschnitt durch schichtweises Auftragen von Metallpulver auf die Trennfläche und durch Verschmelzen des Metallpulvers mit der Trennfläche wider aufgebaut wird, insbesondere für die Reparatur einer Laufschaufel eines integral beschaufelten Gasturbinenrotors, mit einer Einführöffhung, um einen die Trennfläche aufweisenden Abschnitt eines zu reparierenden Gasturbinenbauteils in die Prozesskammer einzu- führen, wobei der Einführöffnung eine Dichteinrichtung (14) zugeordnet ist, die denA process chamber for repairing a gas turbine component having a planar interface after removal of a damaged section, the remote section being constructed by applying metal powder layer by layer to the interface and fusing the metal powder to the interface, particularly for repair of a blade an integrally bladed gas turbine rotor, with an Einführöffhung to introduce a portion having the separating surface of a gas turbine component to be repaired in the process chamber, wherein the insertion opening is associated with a sealing device (14), the
Abschnitt des Gasturbinenbauteils gegenüber der Einführöffhung abdichtet, und mit einem in die Prozesskammer hineinragenden und parallel zur Trennfläche bewegbaren Schieber (15), um auf die Trennfläche aufgetragenes Metallpulver zu vergleichmäßigen und so auf der Trennfläche vor dem Verschmelzen des Metallpulvers mit dem Werkstoff des zu reparierenden Gasturbinenbauteils eine definierte, gleichmäßige Metallpulverschicht bereitzustellen.Seals portion of the gas turbine engine relative to the Einführöffhung, and with a projecting into the process chamber and movable parallel to the separating surface slide (15) to uniformly applied to the separation surface metal powder and so on the interface before the fusion of the metal powder with the material of the repaired gas turbine component to provide a defined uniform metal powder layer.
2. Prozesskammer nach Anspruch 1 , dadurch gekennzeichnet, dass dieselbe gegenüber dem zu reparierenden Gasturbinenbauteil relativ verlagerbar ist.2. Process chamber according to claim 1, characterized in that it is relatively displaceable relative to the gas turbine component to be repaired.
3. Prozesskammer nach Anspruch 1 oder 2, gekennzeichnet durch eine Einfüllöffnung (18) für das auf die Trennfläche aufzutragende Metallpulver.3. Process chamber according to claim 1 or 2, characterized by a filling opening (18) for the metal powder to be applied to the separating surface.
4. Prozesskammer nach einem der Ansprüche 1 bis 3, gekennzeichnet durch einen Überlaufbereich (16) für auf die Trennfläche überschüssig aufgetragenes und mit dem Schieber (15) von der Trennfläche abgeschobenes Metallpulver. 4. Process chamber according to one of claims 1 to 3, characterized by an overflow area (16) for excessively applied to the separation surface and with the slide (15) deported from the separation surface metal powder.
EP09771488A 2008-11-07 2009-11-05 Repair method Withdrawn EP2355947A2 (en)

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US8708682B2 (en) 2014-04-29

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