EP2483011B1 - Verbessertes wachsausschmelzverfahren zur herstellung einer ringförmigen turbinenmotoranordnung mit schaufeln, metallform und wachsstruktur zur implementierung solch eines verfahrens - Google Patents

Verbessertes wachsausschmelzverfahren zur herstellung einer ringförmigen turbinenmotoranordnung mit schaufeln, metallform und wachsstruktur zur implementierung solch eines verfahrens Download PDF

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Publication number
EP2483011B1
EP2483011B1 EP10763672.2A EP10763672A EP2483011B1 EP 2483011 B1 EP2483011 B1 EP 2483011B1 EP 10763672 A EP10763672 A EP 10763672A EP 2483011 B1 EP2483011 B1 EP 2483011B1
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EP
European Patent Office
Prior art keywords
core
wax
metal
cavity
mould
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EP10763672.2A
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English (en)
French (fr)
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EP2483011A1 (de
Inventor
Christian Bariaud
Yannick Collin
Eric Herzer
David Mathieu
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.)
Safran Aircraft Engines SAS
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SNECMA SAS
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Classifications

    • 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
    • F01D9/00—Stators
    • F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • F01D9/04—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector
    • F01D9/041—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector using blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
    • 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
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/108—Installation of cores
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/284—Selection of ceramic materials
    • 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

Definitions

  • the present invention relates to the manufacture of a stator bladed annular assembly for a turbomachine, such as an aircraft turbomachine.
  • the figure 1 represents such a bladed assembly 10, sometimes called distributor or rectifier according to its function within the turbomachine.
  • This bladed assembly 10 typically comprises two coaxial annular structures or ferrules, respectively inner 12 and outer 14, which are connected to one another by a plurality of blades 16.
  • the invention relates more particularly to the manufacture of a bladed assembly comprising at least one blade 18 incorporating a cavity, of generally elongate shape in the radial direction, intended for example for the measurement of physical parameters, such as the pressure and the temperature of the device. the air flowing along the dawn, possibly via orifices 20 of this dawn.
  • the stator turbomachine stator sets are generally made by a "lost wax" type casting process, in which a wax model having the shape of the bladed assembly to be manufactured is previously produced, to then allow the manufacture of a cement mold by overmoulding of this model in wax. After removal of the wax, a metal alloy is poured into the cement mold obtained previously to form, after cooling and demolding, the desired bladed assembly.
  • the preliminary embodiment of the wax model is carried out by means of a metal mold having substantially the shape of the bladed assembly to be manufactured.
  • an elongated core is inserted into the portion of the metal mold which defines the aforementioned blade to form the impression of the cavity.
  • This core 22 is made of ceramic so that it has a thermal resistance sufficient to withstand the high temperatures inherent in the casting of the aforementioned metal alloy, and to allow the subsequent removal of the core by a conventional chemical process.
  • Wax is then injected under pressure into the metal mold equipped with the core so as to form, while cooling, a model of the bladed assembly to be manufactured, in which the core is coated with the wax and occupies the space corresponding to the aforementioned cavity.
  • the core is mounted on the metal mold so as to be held firmly in position, to limit as much as possible the risk of deformation of the core under the pressure of the wax, which would degrade the accuracy of the shape of the wax model, and therefore of the bladed assembly obtained at the end of the manufacturing process.
  • the maintenance of the core is generally ensured by two studs 24 and 26 ( figure 2 ) respectively formed at both ends of the core and protruding from the metal mold to allow their gripping by appropriate support means.
  • the realization of the cement mold is then performed by overmolding the wax model obtained previously and equipped with the core, in such a way that the cement includes the two tenons of this core which protrude out of the wax model. After solidification of this cement and removal of the wax, a cement mold is obtained with the core, which is now maintained by the cement mold itself.
  • the core is removed, generally by a chemical method, and the metal part obtained is demolded to form an annular assembly. bladed.
  • brazed parts in the inner ferrules of these sets induces in these ferrules irregularities of shape and structure likely to reduce the mechanical strength and therefore the life of these ferrules.
  • the invention aims in particular to provide a simple, economical and effective solution to these problems.
  • the improvement of the rigidity of the core makes it possible to increase the injection pressure of the wax, as well as to reduce the rate of defective wax patterns due to kernel deformation.
  • This method of manufacturing a bladed annular assembly thus uses the wax model manufacturing method described above, wherein the core is mounted on the metal mold only by its radially outer end.
  • the radially outer end of the core is embedded in the solidified refractory material and thus allows the connection of the core to the mold made in this material, while the radially inner end of the core extends inside this mold, away from the radially inner end of the portion of this mold defining the blade having the aforementioned cavity, and therefore remote from the radially inner shell of the mold.
  • the radially inner end of the core does not form an orifice in the inner shell of the bladed annular assembly obtained by this method. It is therefore no longer necessary to provide an orifice filling operation at this inner shroud, which allows a reduction in the manufacturing cost of the turbomachine stator bladed annular assemblies, and an improvement in the service life of these sets.
  • the method of manufacturing a turbomachine stator turbomachine annular assembly further comprises extracting said metal core from said wax model and then placing it in the formed cavity. in the wax by said metal core, a core of the same shape made of ceramic.
  • the core made of ceramic has a better thermal resistance and is therefore better suited to the subsequent casting step of the molten metal alloy.
  • the ceramic core can be removed, at the end of the process, by a conventional chemical method.
  • the metal core has a tapered section towards its radially inner end.
  • the tapered shape of the metal core facilitates its removal from the wax model by limiting the risk of damaging this model.
  • the rigidity of this metal core also makes it possible to limit the risks of kernel breakage during its extraction.
  • the metal core is replaced by a ceramic core as described above, the latter has the same shape as the metal core and the tapered nature of this shape facilitates the insertion of this ceramic core into the impression previously formed by the metal core.
  • the process according to the invention can be carried out without performing the above-mentioned step of exchanging cores, in particular when the metal constituting the metal core has a sufficiently high melting point with respect to the melting point of the alloy.
  • the invention also relates to a metal mold intended for the manufacture, by a method of the type described above, of a turbomachine stator turbomachine stator annular wax model comprising two coaxial shrouds, respectively radially inner and radially outer, ferrules interconnected by a plurality of blades, at least one having an internal cavity, the mold comprising, in a portion which defines said blade comprising the cavity, a generally elongated core having a radially external end mounted on the metal mold for forming the cavity of said cavity, characterized in that the core is made of metal and is positioned so that its radially inner end is housed in said portion of the mold defining the blade comprising said cavity, at a distance from the radially inner end of said portion of the mold.
  • the invention also relates to a wax model for manufacturing, by a method of the type described above, a turbomachine stator turbomachine annular assembly comprising two coaxial ferrules, respectively radially inner and radially outer ferrules connected together.
  • the model comprising, in a portion which defines said vane comprising the cavity, a generally elongate core having a radially outer end protruding from the model, to form the cavity of said cavity, characterized in that the core is made of metal and is positioned so that its radially inner end is housed in said portion of the model defining the blade comprising said cavity, at a distance from the radially inner end of said portion of the model.
  • the organization chart of the figure 4 illustrates a process according to the invention for the manufacture of a turbomachine stator turbomachine annular assembly of the same type as the bladed assembly shown in FIG. figure 1 , and thus comprising two coaxial ferrules, respectively internal 12 and external 14, connected between they by a plurality of blades 16, at least one blade 18 integrates a cavity.
  • This process comprises four successive main phases, designated by the respective references 30, 32, 34 and 36 on the flow chart of the figure 4 .
  • the first phase 30 consists in the preparation, in a conventional manner, of a metal mold of the bladed assembly to be manufactured
  • the second phase 32 consists in the manufacture of a wax model of the bladed assembly by means of this metal mold
  • the third phase 34 in the production of a cement mold, or more generally of any suitable refractory material, by overmolding the wax model
  • the fourth phase 36 in the manufacture of the bladed assembly by means of the cement mold aforesaid.
  • the second phase 32 comprises a step 38 of placing, in the metal mold, a core which differs from the conventional core of the figure 2 in that it is made of a metal, for example a steel, and in that it is devoid of tenon at its end intended to be positioned radially inward in the mold.
  • the figure 5 illustrates a core 40 of this type, and shows in particular its end 42, which is intended to be positioned radially outward in the mold and which is provided with a pin 44 similar to the stud 24 of the core of the figure 2 of conventional type, and its end 46, which is intended to be positioned radially towards the inside in the mold and which is devoid of tenon.
  • This core 40 has a tapered cross section towards its end 46, as shown in FIG. figure 5 , which is made possible in particular by the absence of tenon at this end.
  • the core 40 is installed in the portion of the metal mold defining the blade of the bladed assembly which integrates a cavity, so that the pin 44 of the end 42 of this core projects out of the mold passing through an orifice of the wall of this mold defining the radially outer shell of the bladed assembly, and so that the other end 46 of this core extends inside the mold, at a distance, radially towards the outside, of the wall of this mold defining the radially inner ferrule of the bladed assembly.
  • the next step 48 of the second phase 32 of the method consists in the pressure injection of a wax into the metal mold equipped with the metal core 40 described above, in a conventional manner, until the mold is filled with wax, the core then being embedded in the wax except for its stud protruding from the metal mold.
  • the rigidity of the metal core allows the latter not to deform during the wax injection despite the pressure exerted on the core by the latter.
  • FIG. 7 illustrates in particular the position of the radially inner end 46 of the core 40, which is at a distance, radially outwardly, from the radially inner shell 52 which forms the radially inner end of the blade 58.
  • the second phase 32 of this process is continued by a step 60 consisting of removing the metal core 40 from the wax model, and replacing it with a core of the same shape. made of ceramic, and thus having a better thermal resistance.
  • the withdrawal of the metal core 40 is achieved by a displacement of this core in substantially rectilinear translation radially outwardly of the model.
  • the tapered, radially inward shape of the metal core 40 makes it possible to reduce at best the risk of damage to the wax during this extraction.
  • the replacement of the metal core 40 by the ceramic core is intended to enable the core to better withstand the subsequent casting of a molten metal alloy, and to facilitate the removal of this core by a conventional chemical method to the end of the manufacturing process, as will become clearer in the following.
  • the second phase 32 of the method is completed by a step 62 of demolding the wax model 50 incorporating the ceramic core.
  • the process then continues with the third phase 34, which comprises a step 64 for producing a cement mold, or the like, by overmolding the wax model 50 obtained previously. More specifically, this wax model 50 is coated with cement in such a way that the cement includes the tenon of the ceramic core incorporated in this model.
  • the third phase 34 ends with a step 66 of removing the wax, in a conventional manner comprising for example the heating of this wax, so as to obtain a cement mold equipped with the aforementioned ceramic core, whose tenon is embedded in the mold so as to ensure a rigid retention of this core.
  • the fourth phase 36 of the process comprises a step 68 of casting a molten metal alloy in the cement mold obtained previously.
  • the core equipping the mold makes it possible to form the cavity of the corresponding blade 18 of the bladed annular assembly.
  • the following step 70 consists, after cooling of the metal alloy in the mold, in a demolding of the thus obtained bladed assembly and in an elimination of the ceramic core, by a conventional method, preferably of the chemical type.
  • the inner ferrule of this set does not include an orifice formed by the core, after the elimination of the latter.
  • the method according to the invention thus makes it possible to save a final step of filling the inner ferrule of the annular bladed assemblies, and makes it possible to improve the regularity of the shape and structure of this ferrule.
  • the method according to the invention may, alternatively, be implemented without performing the step 60 of removing the metal core and replacing this core with a ceramic core. In this case, the whole process is carried out using the same metal core.
  • the metal core then has a sufficiently high melting point relative to that of the cast metal alloy to withstand the high temperatures inherent in the casting of the molten metal alloy during step 68.
  • the method according to the invention can be used for the manufacture of integral bladed annular assemblies such as the assembly described above, or for the manufacture of assemblies formed of a plurality circumferentially mounted sectors end-to-end, in which case each of the sectors comprising a blade provided with an internal cavity can be realized by means of this method.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Claims (7)

  1. Verfahren zur Herstellung eines Wachsmodells (50) einer ringförmigen Turbomaschinen-Statorbeschaufelung (10), bestimmt zur Herstellung einer Gussform dieser Beschaufelung, wobei das Modell (50) zwei koaxiale Ringe, jeweils in radialer Richtung innen (52) und in radialer Richtung außen (54), umfasst, und diese Ringe miteinander verbunden sind durch eine Vielzahl von Schaufeln (56), von denen eine (58) wenigstens einen Innenhohlraum enthält, wobei das genannte Verfahren mit Hilfe einer im Wesentlichen einer Form des genannten Modells (50) der ringförmigen Beschaufelung entsprechenden metallischen Gussform sukzessive umfasst :
    - Platzierung (38) eines Kerns (40), dazu bestimmt, in einem Teilstück der genannten metallischen Gussform, das die den genannten Hohlraum enthaltende Schaufel (58) definiert, den Formhohlraum auszubilden, wobei der in die genannte metallische Gussform montierte Kern (40) eine generell längliche Form mit einem in radialer Richtung äußeren Ende (42) aufweist ;
    - Einspritzung (48) eines Wachses in die mit dem genannten Kern (40) ausgerüstete metallische Gussform ;
    - nach Abkühlung des genannten Wachses: Entformung (62) des hergestellten, mit dem genannten Kern (40) ausgerüsteten Wachsmodells (50) ;
    dadurch gekennzeichnet, dass der Kern (40) aus Metall ist und so positioniert wird, dass sein in radialer Richtung inneres Ende (46) in dem genannten, die Schaufel (58) definierenden, den genannten Hohlraum enthaltenden Teigstück sitzt, mit Abstand von dem in radialer Richtung inneren Ende dieses Teilstückes der Gussform.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der genannte Metallkern (40) sich radial in Richtung seines inneren Endes (46) verjüngt.
  3. Verfahren zur Herstellung einer ringförmigen Turbomaschinen-Statorbeschaufelung (10) mit zwei koaxialen Ringen, jeweils in radialer Richtung innen (12) und in radialer Richtung außen (14), miteinander verbunden durch eine Vielzahl von Schaufeln (16), von denen wenigstens eine (18) einen Innenhohlraum enthält, wobei das genannte Verfahren sukzessive umfasst :
    - einen Schritt (32) zur Herstellung eines Wachsmodells (50) der genannten ringförmigen Statorbeschaufelung (10) durch ein Verfahren nach einem der Anspruche 1 oder 2;
    - einen Schritt (34) zur Herstellung einer Gussform aus einem refraktären Material durch Ausgießen (64) des genannten Wachsmodells (50), sodann Beseitigung (66) des Wachses;
    - einen Schritt (68) zum Gießen einer Metalllegierungsschmelze in die genannte Gussform aus refraktärem Material, um die genannte ringförmige Beschaufelung (10) zu formen;
    - nach Abkühlung der genannten Metalllegierung einen Schritt (70) zum Entformen der genannten ringförmigen Beschaufelung (10) und zum Beseitigen des genannten Kerns (40).
  4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass das Verfahren vor dem Schritt (34) zur Herstellung der Gussform aus refraktärem Material außerdem einen Schritt (60) zum Entfernen des genannten Metallkerns (40) aus dem genannten Wachsmodell (50) umfasst, um dann in den durch den genannten Metallkern (40) in dem Wachs ausgebildeten Hohlraum einen aus Keramik hergestellten Kern derselben Form einzusetzen.
  5. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass das refraktäre Material ein Zement ist.
  6. Metallische Gussform, um durch ein Verfahren nach Anspruch 1 oder 2 ein Wachsmodell (50) einer ringförmigen Turbomaschinen-Statorbeschaufelung herzustellen, die zwei koaxiale Ringe, jeweils in radialer Richtung innen (52) und in radialer Richtung außen (54), umfasst, und diese Ringe miteinander verbunden sind durch eine Vielzahl von Schaufeln (56), von denen wenigstens eine (58) einen Innenhohlraum enthält, wobei die Gussform in einem Teilstück, welches die den genannten Hohlraum enthaltende Schaufel (58) definiert, einen Kern (40) von generell länglicher Form mit einem in radialer Richtung äußeren Ende (42) enthält, der in die metallische Gussform montiert ist, um den genannten Formhohlraum auszubilden,
    dadurch gekennzeichnet, dass der Kern (40) aus Metall ist und so positioniert ist, dass sein in radialer Richtung inneres Ende (46) in dem genannten, die Schaufel (58) definierenden, den genannten Hohlraum enthaltenden Teilstück sitzt, mit Abstand von dem in radialer Richtung inneren Ende des genannten Teilstücks der genannten Gussform.
  7. Wachsmodell (50), um durch ein Verfahren nach einem der Ansprüche 3 bis 5 eine ringförmige Turbomaschinen-Statorbeschaufelung (10) herzustellen, die zwei koaxiale Ringe, jeweils in radialer Richtung innen (12) und in radialer Richtung außen (14), umfasst, und diese Ringe miteinander verbunden sind durch eine Vielzahl von Schaufeln (16), von denen wenigstens eine (18) einen Innenhohlraum enthält, wobei das Modell (50) in einem Teilstück (58), das die genannte, den genannten Hohlraum enthaltende Schaufel (18) definiert, einen Kern (40) von generell länglicher Form mit einem in radialer Richtung äußeren (42), aus dem Modell (50) herausstehenden Ende (42) enthält, um den genannten Formhohlraum auszubilden,
    dadurch gekennzeichnet, dass der Kern (40) aus Metall ist und so positioniert ist, dass sein in radialer Richtung inneres Ende (46) in dem genannten, die Schaufel (18) definierenden, den genannten Hohlraum enthaltenden Teilstück (58) des Modells (50) sitzt, mit Abstand von dem in radialer Richtung inneren Ende (52) des genannten Teilstücks (58) des Modells (50).
EP10763672.2A 2009-10-01 2010-09-30 Verbessertes wachsausschmelzverfahren zur herstellung einer ringförmigen turbinenmotoranordnung mit schaufeln, metallform und wachsstruktur zur implementierung solch eines verfahrens Active EP2483011B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0956850A FR2950825B1 (fr) 2009-10-01 2009-10-01 Procede ameliore de fabrication d'un ensemble annulaire aubage de turbomachine a la cire perdue, moule metallique et modele en cire pour la mise en oeuvre d'un tel procede
PCT/EP2010/064573 WO2011039315A1 (fr) 2009-10-01 2010-09-30 Procede ameliore de fabrication d'un ensemble annulaire aubage de turbomachine a la cire perdue, moule metallique et modele en cire pour la mise en oeuvre d'un tel procede

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Publication Number Publication Date
EP2483011A1 EP2483011A1 (de) 2012-08-08
EP2483011B1 true EP2483011B1 (de) 2013-07-31

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US (1) US8397790B2 (de)
EP (1) EP2483011B1 (de)
JP (1) JP5511967B2 (de)
CN (1) CN102574199B (de)
BR (1) BR112012007348A2 (de)
CA (1) CA2776201C (de)
FR (1) FR2950825B1 (de)
RU (1) RU2534594C2 (de)
WO (1) WO2011039315A1 (de)

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US8397790B2 (en) 2013-03-19
EP2483011A1 (de) 2012-08-08
CA2776201C (fr) 2017-04-25
US20120180972A1 (en) 2012-07-19
CN102574199A (zh) 2012-07-11
FR2950825A1 (fr) 2011-04-08
RU2012117789A (ru) 2013-11-10
CN102574199B (zh) 2014-08-06
WO2011039315A1 (fr) 2011-04-07
CA2776201A1 (fr) 2011-04-07
JP2013506558A (ja) 2013-02-28
FR2950825B1 (fr) 2011-12-09
RU2534594C2 (ru) 2014-11-27
BR112012007348A2 (pt) 2016-10-04
JP5511967B2 (ja) 2014-06-04

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