EP2620516B1 - Method and apparatus of heat treating an integrally bladed rotor - Google Patents
Method and apparatus of heat treating an integrally bladed rotor Download PDFInfo
- Publication number
- EP2620516B1 EP2620516B1 EP12199843.9A EP12199843A EP2620516B1 EP 2620516 B1 EP2620516 B1 EP 2620516B1 EP 12199843 A EP12199843 A EP 12199843A EP 2620516 B1 EP2620516 B1 EP 2620516B1
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- EP
- European Patent Office
- Prior art keywords
- ibr
- heater
- heat
- blade
- blades
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- 238000000034 method Methods 0.000 title claims description 21
- 230000007613 environmental effect Effects 0.000 claims description 10
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 8
- 239000011261 inert gas Substances 0.000 claims description 7
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 229910052786 argon Inorganic materials 0.000 claims description 4
- 239000001307 helium Substances 0.000 claims description 4
- 229910052734 helium Inorganic materials 0.000 claims description 4
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims 2
- 238000010438 heat treatment Methods 0.000 description 18
- 239000000463 material Substances 0.000 description 6
- 238000003466 welding Methods 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 229910001069 Ti alloy Inorganic materials 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 230000002411 adverse Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- -1 for example Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000003507 refrigerant Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/34—Methods of heating
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints
-
- 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
- F01D5/34—Rotor-blade aggregates of unitary construction, e.g. formed of sheet laminae
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2221/00—Treating localised areas of an article
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/16—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of other metals or alloys based thereon
- C22F1/18—High-melting or refractory metals or alloys based thereon
-
- 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
-
- 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/70—Treatment or modification of materials
- F05D2300/701—Heat treatment
Definitions
- IBR integrally bladed rotors
- blisk bladed disks
- Heat treatment is typically performed by exposing the entire IBR or a portion of the IBR (e.g. the weld region) to a predetermined thermal cycle.
- the technique of heat treating the entire IBR is commonly known in the art of IBR manufacture.
- IBRs are typically made of either titanium alloys such as Ti-6-4, Ti-6-2-4-2, Ti-6-2-4-6 alloys or nickel based alloys such as Alloy 718 alloy or IN-100.
- the IBR is a critical rotating component within an engine, and the engineering, materials, manufacturing, and quality requirements are extremely rigorous.
- the selected portion of the IBR receiving heat treatment must meet a prescribed thermal cycle and the remaining IBR component must not be exposed to temperatures that exceed a specific peak temperature to ensure that the material properties meet engineering requirements.
- the selected portion of the IBR receiving localized heat treatment must be protected from oxidation due to exposure to high temperature.
- WO 2005/071227 A1 discloses a method for locally heat treating a blade of an integrally bladed rotor using an induction coil as a heating element. The process is carried out under protective atmosphere.
- a process for using at least one IR heater to heat treat selected portions of an integrally bladed rotor (IBR) having a plurality of blades wherein the at least one IR heater comprises a device for heat treating a metal component having: a housing providing an axially extending cavity at least one parabolic mirror formed in the axially extending cavity; and at least one IR heat source for providing IR heat rays in a direction toward the at least one parabolic mirror, the process comprising: mounting an IBR on a fixture having a rotor engaging portion; mounting the at least one IR heater on one of the IBR blades; moving the fixture having an IBR into an environmental chamber; evacuating air from the chamber and adding an inert gas; heat treating the blade having the IR heater; lifting the IR heater from the blade and indexing the IBR to position another blade in alignment with the IR heater; mounting the IR heater on the another blade and heat treating the another blade, repeating the steps
- an apparatus for heat treating selected portions of an integrally bladed rotor (IBR) having a plurality of blades comprising: an environmental chamber; a fixture for mounting an IBR having a rotor engaging portion; the fixture for mounting the IBR being moveable into the environmental chamber; an IR heater mounted on a heater support unit being adapted to moveably mount the heater on one of the IBR blades and remove it from the blade; the chamber having a vent for evacuating air and adding an inert gas; the heater support unit being adapted to lift the IR heater from the blade and the fixture being adapted to index the IBR to position another blade on the IBR; and a control unit for controlling the heater support unit and the heater position on or off the IBR blade, wherein the IR heater comprises at least one parabolic mirror formed in an axially extending cavity; and at least one IR heat source for providing IR heat rays in a direction toward the at least one parabolic mirror; wherein the
- the present disclosure concerns a process and system for using a directional (focused) infrared (IR) heater to heat treat specific areas on the blades of IBR devices using a holding fixture for mounting the IBR, an environmental chamber for performing the heat treatment, a heater support unit that positions the heater on the IBR blades, and a control unit for precisely indexing the support unit on to successive blades until all the repaired blades are heat treated.
- IR infrared
- This heat treatment is done using a heater that is capable of placement of infrared heat sources on the individual integral blades in an inert environment which in one form may use parabolic mirrors to focus heat only onto the desired area.
- the process of this invention provides for localized heat treatments for integrally bladed rotors (IBR) as shown in FIG. 1 .
- the IBR to be treated is loaded on a holding fixture as seen in step 111.
- the heater support unit is mounted onto the IBR holding fixture and the IR heater is lowered on to the first blade of the IBR in step 113.
- the IBR is then placed in an environmental chamber in step 115.
- the chamber is closed, evacuated and backfilled with an inert gas such as, for example, argon or helium in step 117.
- the selected blade is heat treated in step 119.
- step 121 the heater is lifted, the IBR is indexed to present the next repaired blade, the heater is lowered and that blade is heat treated. Step 121 is repeated so that all of the individual repaired blades on the IBR are heat treated. Once this is done, the chamber is opened and the IBR is removed, as noted in step 123.
- FIG. 2A and 2B illustrate a device for carrying out the process of this invention as shown in FIG. 1 .
- An IBR, 21, shown in FIG. 3 is placed on a mounting fixture 211 in FIG. 2B .
- Heater 10 generally in FIG. 3 is lowered on to a first selected blade 11 by heater support unit 217 using control panel 219.
- Loaded mounting fixture 211 is placed on tracks 213 and is moved into environmental chamber 215.
- Tracks 213 can be configured in other manners as long as it is capable of moving mounting fixture 211 into and out of chamber 215 as needed.
- Door 221 is closed and chamber 215 is evacuated via vent 223. Both door 221 and back wall 225 of chamber 215 have windows 227 so the operation can be observed as heater 10 is lowered on to successive blades 23 of FIG. 3 .
- the process and system of this invention provides a means for critical hardware such as IBR units to receive the desired thermal cycle at the specific location where it is needed.
- An indexing component of the process and system treats every blade without opening the chamber. The heat treatment takes place in a protective environment to avoid formation of undesirable constituents such as alpha case.
- the process and system of this invention is suitable for OEM manufacture and for repair of existing IBR systems.
- Heater 10 is described in EP 2548974 A1 .
- other heaters having other designs may be used. It is necessary that the heater be able to be placed on and removed from each IBR blade as the blades are sequentially indexed. The heater must be able to heat treat the desired region of each blade without allowing undesired heat to affect the remaining portion of the blade. Following is a description of FIGS. 3-5 .
- Device 10 is positioned proximate an integrally bladed rotor (IBR) airfoil 11 for heating a portion of the IBR airfoil 11 and thereby eliminate overall part exposure to heat.
- Device 10 includes a pair of infrared (IR) lamp housings 13 and 15, each with an IR lamp generating IR rays that are reflected off parabolic mirrors 17 and 19, respectively, to contact IBR 11 and heat treat that blade without exposing any other part of IBR airfoil 11 to unwanted heat.
- IR infrared
- FIG. 3 illustrates a complete integrally bladed rotor with rotor hub 21 supporting a plurality of other airfoils 23.
- Device 10 is positioned on airfoil 11 and includes electrical contacts 25 connected to a power source, not shown, for actuation of IR lamps 27 that are held in place by clips 29. Rays from IR lamps 27 are focused by mirrors 17 and 19 as an elongated band of IR radiation on a specific portion of airfoil 11, in this instance the portion of airfoil 11 attached to rotor hub 21.
- the width of the band of focused IR radiation may be any width that permits complete heat treatment of the desired portions of the component. Band widths may range from about 6 mm to about 18 mm, and may be about a 12 mm band width. Other widths may also be accommodated depending on, for example, the size of the parts, the material being heat treated.
- Device 10 also includes tubes or passages 33, shown more clearly in Fig. 5 , that are connected to a source of water or other cooling medium, not shown, to cool portions of device 10 to prevent distortion and a resulting uneven heating.
- Other cooling devices such as fans and refrigerants may also be used.
- dotted lines 37 that represent the extent of unfocused IR rays from lamps 27, and dashed lines 39 represent the extent of IR rays focused by mirrors 17 and 19 onto the portion of airfoil 11 that is to be heat treated, such as to relieve stress in the metal after welding airfoil 11 to rotor hub 21.
- the present invention was used to heat treat and stress relieve a plurality of IBR blades without adversely heating other critical areas of the IBR.
- replacement blades have been attached to an IBR by focusing the heat only at the desired location, e.g., where the replacement blade is attached to the IBR.
- the device of this invention is suitable for OEM manufacture and for repair of existing IBR systems.
Description
- Heat treatment of integrally bladed rotors (IBR) or bladed disks (blisk) is required to obtain appropriate material properties and to relieve residual stresses due to fusion welding processes such as, for example, electron beam welding, laser welding, or arc welding, as well as solid state bonding processes such as linear friction welding.
- Heat treatment is typically performed by exposing the entire IBR or a portion of the IBR (e.g. the weld region) to a predetermined thermal cycle. The technique of heat treating the entire IBR is commonly known in the art of IBR manufacture.
- During blade repair operations, it may be necessary to locally heat treat the repaired areas of the integrally bladed rotors that have been exposed to elevated temperatures resulting from repair operations. In the finished machine condition, conventional heat treatment is not always possible due to concerns with part distortion. Additional risk factors for conventional heat treatment, of a repaired finished machined integrally bladed rotor are, (a) it may create unnecessary risk due to the potential for surface contamination throughout the entire part and (b) some areas of the IBR should not be exposed to additional temperature exposure that results in material property debit. Because of these concerns, local heat treatment has been considered to be a preferred option.
- IBRs are typically made of either titanium alloys such as Ti-6-4, Ti-6-2-4-2, Ti-6-2-4-6 alloys or nickel based alloys such as Alloy 718 alloy or IN-100. The IBR is a critical rotating component within an engine, and the engineering, materials, manufacturing, and quality requirements are extremely rigorous.
- There are two major technical challenges associated with the local heat treatment of an IBR, in addition to the business challenge that the manufacturing process be affordable. First, the selected portion of the IBR receiving heat treatment must meet a prescribed thermal cycle and the remaining IBR component must not be exposed to temperatures that exceed a specific peak temperature to ensure that the material properties meet engineering requirements. Second, the selected portion of the IBR receiving localized heat treatment must be protected from oxidation due to exposure to high temperature.
-
WO 2005/071227 A1 discloses a method for locally heat treating a blade of an integrally bladed rotor using an induction coil as a heating element. The process is carried out under protective atmosphere. - According to a first aspect of the present invention, there is provided a process for using at least one IR heater to heat treat selected portions of an integrally bladed rotor (IBR) having a plurality of blades, wherein the at least one IR heater comprises a device for heat treating a metal component having: a housing providing an axially extending cavity at least one parabolic mirror formed in the axially extending cavity; and at least one IR heat source for providing IR heat rays in a direction toward the at least one parabolic mirror, the process comprising: mounting an IBR on a fixture having a rotor engaging portion; mounting the at least one IR heater on one of the IBR blades; moving the fixture having an IBR into an environmental chamber; evacuating air from the chamber and adding an inert gas; heat treating the blade having the IR heater; lifting the IR heater from the blade and indexing the IBR to position another blade in alignment with the IR heater; mounting the IR heater on the another blade and heat treating the another blade, repeating the steps including indexing and heat treating of the IBR blades until all its blades are heat treated; and removing the IBR from the chamber; wherein the step of mounting the at least one IR heater comprises: positioning two IR heat sources in opposite directions such that the at least one parabolic mirror of each IR heat source is positioned to focus a band of the IR heat rays onto opposite sides of the blade.
- According to a second aspect of the present invention, there is provided an apparatus for heat treating selected portions of an integrally bladed rotor (IBR) having a plurality of blades, the apparatus comprising: an environmental chamber; a fixture for mounting an IBR having a rotor engaging portion; the fixture for mounting the IBR being moveable into the environmental chamber; an IR heater mounted on a heater support unit being adapted to moveably mount the heater on one of the IBR blades and remove it from the blade; the chamber having a vent for evacuating air and adding an inert gas; the heater support unit being adapted to lift the IR heater from the blade and the fixture being adapted to index the IBR to position another blade on the IBR; and a control unit for controlling the heater support unit and the heater position on or off the IBR blade, wherein the IR heater comprises at least one parabolic mirror formed in an axially extending cavity; and at least one IR heat source for providing IR heat rays in a direction toward the at least one parabolic mirror; wherein the at least one IR heater is mounted at least in part by positioning two IR heat sources in opposite directions such that the at least one parabolic mirror of each IR heat source is positioned to focus a band of the IR heat rays onto opposite sides of a metal component.
- The present disclosure concerns a process and system for using a directional (focused) infrared (IR) heater to heat treat specific areas on the blades of IBR devices using a holding fixture for mounting the IBR, an environmental chamber for performing the heat treatment, a heater support unit that positions the heater on the IBR blades, and a control unit for precisely indexing the support unit on to successive blades until all the repaired blades are heat treated.
- This heat treatment is done using a heater that is capable of placement of infrared heat sources on the individual integral blades in an inert environment which in one form may use parabolic mirrors to focus heat only onto the desired area.
-
-
FIG. 1 is a block diagram showing the process of this invention. -
FIG. 2A is a perspective view of the environmental chamber of this invention. -
FIG. 2B is a perspective view of the mounting fixture of this invention. -
FIG. 3 is a perspective view showing the IR heater of this invention. -
FIG. 4 is a plan view showing the device of this invention focused on a single integrally bladed rotor. -
FIG. 5 is a section view taken along line 4-4 ofFIG. 4 . - The process of this invention provides for localized heat treatments for integrally bladed rotors (IBR) as shown in
FIG. 1 . The IBR to be treated is loaded on a holding fixture as seen instep 111. The heater support unit is mounted onto the IBR holding fixture and the IR heater is lowered on to the first blade of the IBR instep 113. The IBR is then placed in an environmental chamber instep 115. The chamber is closed, evacuated and backfilled with an inert gas such as, for example, argon or helium instep 117. The selected blade is heat treated instep 119. Instep 121, the heater is lifted, the IBR is indexed to present the next repaired blade, the heater is lowered and that blade is heat treated.Step 121 is repeated so that all of the individual repaired blades on the IBR are heat treated. Once this is done, the chamber is opened and the IBR is removed, as noted instep 123. -
FIG. 2A and2B illustrate a device for carrying out the process of this invention as shown inFIG. 1 . An IBR, 21, shown inFIG. 3 is placed on amounting fixture 211 inFIG. 2B .Heater 10 generally inFIG. 3 is lowered on to a first selectedblade 11 byheater support unit 217 usingcontrol panel 219. - Loaded
mounting fixture 211 is placed ontracks 213 and is moved intoenvironmental chamber 215.Tracks 213 can be configured in other manners as long as it is capable of moving mountingfixture 211 into and out ofchamber 215 as needed. -
Door 221 is closed andchamber 215 is evacuated viavent 223. Bothdoor 221 andback wall 225 ofchamber 215 havewindows 227 so the operation can be observed asheater 10 is lowered on tosuccessive blades 23 ofFIG. 3 . - The process and system of this invention provides a means for critical hardware such as IBR units to receive the desired thermal cycle at the specific location where it is needed. An indexing component of the process and system treats every blade without opening the chamber. The heat treatment takes place in a protective environment to avoid formation of undesirable constituents such as alpha case. The process and system of this invention is suitable for OEM manufacture and for repair of existing IBR systems.
-
Heater 10 is described inEP 2548974 A1 . In addition other heaters having other designs may be used. It is necessary that the heater be able to be placed on and removed from each IBR blade as the blades are sequentially indexed. The heater must be able to heat treat the desired region of each blade without allowing undesired heat to affect the remaining portion of the blade. Following is a description ofFIGS. 3-5 . -
Device 10 is positioned proximate an integrally bladed rotor (IBR)airfoil 11 for heating a portion of theIBR airfoil 11 and thereby eliminate overall part exposure to heat.Device 10 includes a pair of infrared (IR)lamp housings parabolic mirrors IBR 11 and heat treat that blade without exposing any other part ofIBR airfoil 11 to unwanted heat. -
FIG. 3 illustrates a complete integrally bladed rotor withrotor hub 21 supporting a plurality ofother airfoils 23.Device 10 is positioned onairfoil 11 and includeselectrical contacts 25 connected to a power source, not shown, for actuation ofIR lamps 27 that are held in place byclips 29. Rays fromIR lamps 27 are focused bymirrors airfoil 11, in this instance the portion ofairfoil 11 attached torotor hub 21. The width of the band of focused IR radiation may be any width that permits complete heat treatment of the desired portions of the component. Band widths may range from about 6 mm to about 18 mm, and may be about a 12 mm band width. Other widths may also be accommodated depending on, for example, the size of the parts, the material being heat treated. -
Device 10 also includes tubes orpassages 33, shown more clearly inFig. 5 , that are connected to a source of water or other cooling medium, not shown, to cool portions ofdevice 10 to prevent distortion and a resulting uneven heating. Other cooling devices such as fans and refrigerants may also be used. - Also shown in
FIG. 5 are dottedlines 37 that represent the extent of unfocused IR rays fromlamps 27, and dashedlines 39 represent the extent of IR rays focused bymirrors airfoil 11 that is to be heat treated, such as to relieve stress in the metal after weldingairfoil 11 torotor hub 21. - It is known that heat treatment in the presence of oxygen can cause titanium alloys to become embrittled if the temperature exceeds 1,000 °F (538 °C). In addition to embrittlement, the material properties of titanium alloys changes if it is exposed to a temperature exceeding 800 °F (427 °C), but as will be understood the actual temperature depends on the specific alloy. Oxygen contamination at referenced temperatures can be avoided by proper protection such as the use of inert shielding gas such as argon and helium. The present invention ensures that the portion(s) of the product being treated will receive desired thermal treatment but generally remain below 1,000 °F (538 °C) and even below 800 °F (427 °C).
- The present invention was used to heat treat and stress relieve a plurality of IBR blades without adversely heating other critical areas of the IBR. In addition, replacement blades have been attached to an IBR by focusing the heat only at the desired location, e.g., where the replacement blade is attached to the IBR. The device of this invention is suitable for OEM manufacture and for repair of existing IBR systems.
Claims (11)
- A process for using at least one IR heater (27) to heat treat selected portions of an integrally bladed rotor (IBR) (10) having a plurality of blades (11,23),
wherein the at least one IR heater (27) comprises a device for heat treating a metal component having:a housing (13,15) providing an axially extending cavity;at least one parabolic mirror (17,19) formed in the axially extending cavity; andat least one IR heat source (27) for providing IR heat rays in a direction toward the at least one parabolic mirror,the process comprising:mounting an IBR (10) on a fixture (211) having a rotor engaging portion;mounting the at least one IR heater (27) on one of the IBR blades (11);moving the fixture having an IBR into an environmental chamber (215);evacuating air from the chamber and adding an inert gas;heat treating the blade having the IR heater (27);lifting the IR heater from the blade (11) and indexing the IBR to position another blade in alignment with the IR heater;mounting the IR heater (27) on the another blade (11) and heat treating the another blade,repeating the steps including indexing and heat treating of the IBR blades until all its blades are heat treated; andremoving the IBR from the chamber (215);wherein the step of mounting the at least one IR heater (27) comprises:positioning two IR heat sources in opposite directions such that the at least one parabolic mirror of each IR heat source (27) is positioned to focus a band of the IR heat rays onto opposite sides of the blade (11). - The process of claim 1, wherein the inert gas is selected from argon, helium and mixtures thereof.
- The process of claim 1 or 2, wherein the fixture (211) mounting an IBR (10) is adapted to move into and out of the chamber (215).
- The process of claim 1, 2 or 3, wherein the IR heat source (27) and parabolic mirror (17,19) are sized to direct the IR heat rays along the junction between the airfoil (11) and the integrally bladed rotor device (10).
- The process of claim 1, 2, 3 or 4, wherein the IR heat rays are focused into an elongated band having a band width of from about 6 mm to about 18 mm.
- A apparatus for heat treating selected portions of an integrally bladed rotor (IBR) (10) having a plurality of blades (11,23), the apparatus comprising:an environmental chamber (215);a fixture (211) for mounting an IBR (10) having a rotor engaging portion;the fixture for mounting the IBR being moveable into the environmental chamber;an IR heater (27) mounted on a heater support unit (217) being adapted to moveably mount the heater on one of the IBR blades (11) and remove it from the blade;the chamber having a vent (223) for evacuating air and adding an inert gas;the heater support unit being adapted to lift the IR heater (27) from the blade and the fixture being adapted to index the IBR to position another blade (11) on the IBR; anda control unit (219) for controlling the heater support unit (217) and the heater position on or off the IBR blade (11),wherein the IR heater comprises:at least one parabolic mirror (17,19) formed in an axially extending cavity; andat least one IR heat source (27) for providing IR heat rays in a direction toward the at least one parabolic mirror (17,19);wherein the at least one IR heater (27) is mounted at least in part by positioning two IR heat sources in opposite directions such that the at least one parabolic mirror (17,19) of each IR heat source (27) is positioned to focus a band of the IR heat rays onto opposite sides of a metal component (11).
- The apparatus of claim 6, wherein the inert gas is selected from argon, helium and mixtures thereof.
- The apparatus of claim 6 or 7, wherein the IR heat source (27) and parabolic mirror (17,19) are sized to direct the IR heat rays along the junction between the airfoil (11) and the integrally bladed rotor apparatus (10).
- The apparatus of claim 6, 7 or 8, wherein the IR heat rays are focused into an elongated band having a band width of from about 6 mm to about 18 mm.
- The apparatus of any of claims 6 to 9, wherein the fixture (211) is mounted on at least one track (213) and adapted to move into and out of the chamber (215).
- A system for heat treating selected portions of an integrally bladed rotor (IBR) (10) having a plurality of blades (11), the system comprising:an apparatus as claimed in any of claims 6 to 10; and an IBR mounted on the fixture,wherein the heater support unit is configured to attach an IR heater on one of the IBR blades,and wherein the control unit is configured to operate the IR heater for heat treating the blade and to operate the heater support unit to index and heat treat all of the IBR blades.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US13/361,283 US8437628B1 (en) | 2011-07-18 | 2012-01-30 | Method and apparatus of heat treating an integrally bladed rotor |
Publications (3)
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EP2620516A2 EP2620516A2 (en) | 2013-07-31 |
EP2620516A3 EP2620516A3 (en) | 2013-08-14 |
EP2620516B1 true EP2620516B1 (en) | 2017-02-08 |
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EP12199843.9A Active EP2620516B1 (en) | 2012-01-30 | 2012-12-31 | Method and apparatus of heat treating an integrally bladed rotor |
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SG (1) | SG192328A1 (en) |
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DK177974B1 (en) * | 2013-09-09 | 2015-02-09 | Broen As | Plant and method for relaxing annealing of a workpiece comprising heat-sensitive parts, as well as relaxation-annealed workpiece |
US10633731B2 (en) * | 2018-01-05 | 2020-04-28 | United Technologies Corporation | Method for producing enhanced fatigue and tensile properties in integrally bladed rotor forgings |
US10935037B2 (en) | 2018-01-05 | 2021-03-02 | Raytheon Technologies Corporation | Tool for simultaneous local stress relief of each of a multiple of linear friction welds of a rotor forging |
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JP3945156B2 (en) | 2000-12-19 | 2007-07-18 | マツダ株式会社 | Car suspension equipment |
DE102004002965A1 (en) * | 2004-01-21 | 2005-08-11 | Mtu Aero Engines Gmbh | Method and apparatus for repairing integrally bladed rotors |
US7977611B2 (en) * | 2007-07-19 | 2011-07-12 | United Technologies Corporation | Systems and methods for providing localized heat treatment of metal components |
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