EP3166739B1 - Improved method for manufacturing a shell mold for production by lost-wax casting of bladed elements of an aircraft turbine engine - Google Patents

Description

TECHNICAL AREA

The invention relates to the field of cluster manufacture of aircraft turbomachine blown elements, by the lost wax molding technique. Each bladed element may be a sector comprising a plurality of blades, such as a low pressure distributor sector, or may be an individual blade, such as a compressor or turbine moving wheel blade.

The invention relates more particularly to the manufacture of the shell in the form of a cluster, in which the metal is intended to be cast in order to obtain turbomachine bladed elements.

The invention relates to all types of aircraft turbomachines, in particular turbojets and turboprops.

STATE OF THE PRIOR ART

From the prior art, it is known to use the lost wax molding technique to simultaneously manufacture a plurality of aircraft turbomachine blower elements, such as moving blades. Such a technique is for example described in the document FR 2 985 924 .

As a reminder, lost wax precision casting consists of waxing, by injection into tools, a model of each of the desired bladed elements. The assembly of these models on wax casting arms, themselves connected to a metal wax dispenser, makes it possible to form a cluster which is then immersed in different substances in order to form around it a shell of wax. ceramic of substantially uniform thickness.

The process is continued by melting the wax, which then leaves its exact imprint in the ceramic, into which the molten metal is poured, via a pouring cup assembled on the metal dispenser. After cooling the metal, the shell is destroyed and the metal parts are separated and finished.

This technique offers the advantage of dimensional accuracy, making it possible to reduce or even eliminate certain machining operations. In addition, it offers a very good surface appearance.

In practice, the carapace is made not only around the wax model, but also around the casting cup assembled to this model. The bucket typically has an end surface on a lid, which surface is downwardly oriented during passage through the drying tunnel to solidify the shell. During this drying, the whole moving in the tunnel undergoes vibrations. Due to these vibrations and the large mass of the carapace part covering the bucket cover, falling shell blocks are often observed. These blocks are then on the ground and need to be evacuated, for example using expensive treadmills. Alternatively, for the evacuation of these blocks outside the installation, it can be implemented frequent cleaning interventions. However, these interventions are also expensive, and may pose health, safety and environmental risks (HSE risks).

STATEMENT OF THE INVENTION

The invention therefore aims to at least partially overcome the disadvantages mentioned above, relating to the achievements of the prior art.

1. a) réalisation d'un ensemble autour duquel la carapace est destinée à être formée, l'ensemble comprenant un modèle en cire ainsi qu'un dispositif destiné à former ultérieurement un godet de coulée de métal, ledit dispositif présentant une surface d'extrémité ;
2. b) dépôt d'une couche d'enrobage en cire chaude autour d'au moins une partie dudit ensemble, de manière à ce que ladite couche d'enrobage recouvre au moins une partie de la surface d'extrémité du dispositif destiné à former ultérieurement le godet de coulée de métal ; puis
3. c) formation de la carapace autour dudit ensemble.

To do this, the invention first of all relates to a method for manufacturing a shell for the embodiment by lost-wax molding of a plurality of aircraft turbomachine bladed elements, said shell-shaped cluster comprising a plurality of shell-bladed elements each for obtaining one of said turbomachine-bladed elements, said method comprising the following steps:

1. a) providing an assembly around which the shell is intended to be formed, the assembly comprising a wax model and a device for subsequently forming a metal casting cup, said device having an end surface;
2. b) depositing a warm wax coating layer around at least a portion of said assembly, so that said coating layer covers at least a portion of the end surface of the device for subsequent formation the metal casting bucket; then
3. c) forming the shell around said assembly.

According to the invention, the method further comprises, between steps b) and c), the implementation of a step of structuring the coating layer covering said end surface, this structuring step aimed at reinforcing the adhesion between this layer and the shell to be formed, and comprising the production of recesses and projections on the still malleable coating layer.

Thus, the invention cleverly provides a structuring of the coating layer after deposition, to create a favorable terrain for better adhesion of the shell to be formed around this coating layer.

The risks of falling carapace blocks are thus considerably reduced. Therefore, it is no longer necessary to implement expensive means of evacuation of fallen blocks, such as treadmills as proposed in the prior art. This advantageously results in a reduction in the costs of the installation dedicated to the implementation of the shell manufacturing process.

The invention also has at least one of the following optional features, taken alone or in combination.

The step of structuring the coating layer is carried out by inserting a plurality of printing elements into said still malleable coating layer, causing the formation of said projections around the printing elements, then by withdrawal of the latter revealing the hollows, each surrounded by one of said projections.

The printing elements are pads, preferably with an outer surface head having a generally spherical cap shape, for example a general shape of a half-sphere.

The ratio between the maximum outside diameter of each pad, and the outer diameter of the end surface of the device, is less than 20.

The number of pads is between 3 and 20.

The step of structuring the coating layer is carried out by applying a pressure of a support carrying the plurality of printing elements against said still malleable coating layer. Said pressure application is performed by moving said assembly against the remaining fixed support. Alternatively, it is the support that could be set in motion to come to contact the coating layer, without departing from the scope of the invention.

The step of forming the shell around said assembly comprises at least one drying operation carried out at least in part with said end surface oriented downwards, and preferably with said shell, surrounding the assembly, displaced within a drying station.

The carapace formation step is performed by dipping.

The subject of the invention is also a process for manufacturing by lost-wax molding a plurality of aircraft turbomachine bladed elements, this process comprising the production of a shell by a process as described above, followed by by a casting of metal in the carapace.

Other advantages and features of the invention will become apparent in the detailed non-limiting description below.

BRIEF DESCRIPTION OF THE DRAWINGS

• la figure 1 représente une vue en perspective d'un élément aubagé de turbomachine destiné à être obtenu par la mise en oeuvre du procédé selon la présente invention, ledit élément aubagé se présentant sous la forme d'une aube mobile de turbine haute pression ;
• la figure 2 représente une vue en perspective d'un modèle en cire servant à la fabrication d'une carapace pour la réalisation, par moulage à cire perdue, d'aubes du type de celle montrée sur la figure 1 ;
• les figures 3 à 10 représentent schématiquement différentes étapes du procédé de fabrication de la carapace ; et
• la figure 11 représentent une vue schématique d'une telle carapace obtenue par mise en oeuvre du procédé de fabrication schématisé sur les figures précédentes.

This description will be made with reference to the appended drawings among which:

• the figure 1 is a perspective view of a turbomachine bladed element to be obtained by the implementation of the method according to the present invention, said bladed element being in the form of a high pressure turbine blade;
• the figure 2 represents a perspective view of a wax model for the manufacture of a shell for producing, by lost-wax molding, blades of the type of that shown in FIG. figure 1 ;
• the Figures 3 to 10 schematically represent different steps of the carapace manufacturing process; and
• the figure 11 represent a schematic view of such a shell obtained by implementing the manufacturing method schematized in the preceding figures.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

With reference to the figure 1 , there is shown an example of a moving blade 1 of high pressure turbine for aircraft turbomachine. Conventionally, this blade 1 comprises a blade 2 extending from an end 4 forming a blade root, and comprising a platform 8 for delimiting a main stream of gas flow.

The aim of the invention is to manufacture the blade 1 from a shell intended to be made by a process specific to the invention, a preferred embodiment of which will now be described with reference to FIGS. Figures 2 to 10 . Nevertheless, it is noted that the invention can also be applied to the manufacture of compressor blades, or to the manufacture of compressor or turbine stator blades, made alone or in sectors comprising a plurality of blades.

For the manufacture of the carapace, it is first made a wax model, also called replica, and around which a ceramic shell is intended to be formed later.

On the figure 2 , the wax model 100 is shown in a flipped position relative to the position in which the shell is then filled with metal. This returned position facilitates the assembly operation of the various constituent elements of the wax model, which will now be described.

The model 100 firstly comprises a portion for the distribution of metal, referenced 12a. It takes a full revolutionary form, cylindrical or conical, central axis 14a which coincides with the central axis of the entire model wax 100. This axis 14a is oriented vertically, and therefore considered to represent the direction of height. This distribution portion 12a is directly attached to a specific tool 16, above which it is located.

The portion 12a terminates upwardly with a larger diameter end 18a, from which a plurality of portions 20a radially extend for the formation of several sprues. The portions 20a are here three in number, distributed at 120 ° around the axis 14a. Each portion 20a therefore has a first end 21a connected to the widened end 18a of the dispensing portion 12a, and extends straight or slightly curved to a second end 22a.

For each arm portion 20a, a wax / ceramic holding reinforcement 23a may be provided between the dispensing portion 12a and the second end 22a of the portion 20a.

In addition, from each second end 22a, there is attached a wax replica of the turbine blade shown in FIG. figure 1 . This replica therefore comprises a blade 2a, extending from an end 4a forming a blade root, and comprising a platform 8a. On the figure 2 , the replicas of blades have been represented only schematically.

It is noted that if the replicas have been represented with the blade root 4a arranged downwards with respect to the blade 2a in the position of the figure 3 , this foot 4a could alternately be arranged at the top, so that once the carapace turned to perform the casting of the metal, it reaches the foot only after passing through the blade portion.

The wax vanes 1a extend upwards, being arranged around the axis 14a, and also around a central wax support 24a extending along the same axis from the end 18a of the portion 12a. The support 24a preferably takes the form of an axis rod 14a, which extends to near the blade heads 2a.

As is visible on the figure 2 for each wax blade 1a, a wax / ceramic holding reinforcement 25a may be provided between the upper end of the central support rod 24a, and the blade head. In the same way, wax / ceramic retention reinforcements (not shown) can connect together the adjacent blade heads of the different blades 1a.

The wax vanes form the peripheral wall of the wax replica 100. They are spaced circumferentially from each other, and define an interior space centered on the axis 14a, which is therefore the central support rod 24a.

As has been schematized on the figure 3 once the wax replica 100 has been made, a device 32a is assembled thereon to subsequently form a casting cup of metal in the shell. The device 32a comprises a conically shaped element 34a centered on the axis 14a and flaring downwards from a small section secured to the lower end of the dispensing portion 12a. The conical element 34a is preferably made hollow, and closed at its lower end by a cover 36a, the outer surface 40a forms an end surface of the device 32a. Alternatively, the device 32a could be made full, in a wax intended to be eliminated later during the removal of the wax model 100.

Optionally, reinforcing elements 42a can then be made between the device 32a and the arms 20a.

The wax model 100 and the device 32a together form an assembly 200 around which the shell is intended to be formed. Nevertheless, before the step of forming the shell, there is provided a step of depositing a coating layer of hot wax, as has been schematized on the figure 4 . This depositing step is also called "dip seal". It aims to partially soak the assembly 200 in a tray 44 of liquid hot wax 46, so as to allow good adhesion of the shell formed later. As an indication, the soaking is here carried out so as to immerse all of the device 32a in the hot wax 46, and possibly a lower part of the wax model 100. Also, after this soaking step, a wax coating layer hot 46 covers the entire end surface 40a defined by the cover 36a of the device 32a, as has been schematized on the figure 5 . A warm wax coating layer 46 also covers the outer surface of the conical member 34a.

One of the peculiarities of the invention consists in structuring at least the layer 46 covering the end surface 40a, when this layer is still malleable, that is to say before it has been completely cooled.

To do this, there is provided a tool as shown on the Figures 5, 5a, 5b and 6 . It is a support 50 carrying a plurality of printing elements 52 in the form of pads, with an outer surface 54 head semi-spherical. The number of these pads 52, their size and their disposition are selected according to the needs met. As an indicative example, the number of pads 52 projecting from the support 50 may be between 3 and 20, while the ratio between their outer diameter D1 and the outside diameter D2 of the cover is preferably less than 20.

To perform the step of structuring the coating layer 46, the assembly 200 is moved against the support 52 remaining fixed on a dedicated station 58, schematized on the figure 6 . The displacement of the assembly 200 against the support 50 carrying the pads 52 is preferably vertically downwards, with the end surface 40a oriented horizontally. The pressure applied causes the pads 52 to be inserted in the layer 46, creating around them a backflow of wax. This discharge, in the form of a bead surrounding each stud 52, generates a projection 60. After removal of the pads 52, the latter give way to recesses 62 shown on the figure 7 each depression being surrounded by a projection 60.

The depth of the recesses 62 is less than the thickness of the coating layer 46, so that wax is in the bottom of each recess. The structuring made possible, in a clever and inexpensive way, to reinforce the adhesion between the layer 46 covering the end surface 40a of the cover 36a, and the shell intended to be formed later. This structuring is added to the optional presence of an initial structuring of the end surface 40a of the cover 36a, for example by means of an embossing 64 as visible on the figure 7 . However, it must be made clear that this embossing 64 is covered by the coating layer 46, which tends to attenuate the reliefs of the embossing, and thus to reduce the adhesion power. The structuring of the invention, generated after the deposition of the layer coating 46, can effectively enhance the adhesion of this layer to the carapace formed later.

In this respect, with reference to figures 8 and 9 it is then implemented the step of forming the ceramic shell, by soaking the assembly 200 in successive baths 68, one of which is schematized on the figure 8 . This step is known as such and will not be further described, apart from the fact that during its production, the carapace 300 in formation is deposited in the hollows 62 and around the beads 60 of the diaper. 46. These elements act as anchoring points of the shell, thus promoting its adhesion to the lid 36a.

During the formation of the shell 300, at least one drying operation is performed to harden it. This operation, schematized on the figure 10 , consists in scrolling one or more shells 300 in a drying station also called drying tunnel 70, with the carapaces 300 suspended above the ground 72. During this setting in motion, the end surface 40a of the cover is oriented horizontally, downwards, but the risks of stalling shell blocks is greatly reduced by the patterning 60, 62 previously made on the coating layer 46 covering the end surface 40a.

After drying, the carapace 300 that is obtained is schematically represented on the figure 11 . It also has a general shape of a cluster, and of course includes elements similar to those of the wax replica 100 and 32a device mentioned above. These shell elements will now be described, with the carapace shown in a returned position relative to the position in which it is then filled with metal.

It is first bucket 32b, then the metal distributor, referenced 12b. The latter therefore has a hollow, cylindrical or conical, hollow shape with a central axis 14b coinciding with the central axis of the shell 300. This axis 14b is oriented vertically, and therefore considered as representing the direction of the height.

The distributor 12b terminates upwardly with a hollow end 18b of larger diameter, from which a plurality of metal casting arms 20b radially extend. The arms 20b are here three in number, distributed at 120 ° around the axis 14b. Each arm 20b therefore has a first end 21b connected to the widened end of the distributor 12b, and extends straight or slightly curved to a second end 22b.

Each arm 20b is therefore intended to be hollow and form a metal supply conduit after removal of the wax 20a. Here too, a holding reinforcement 23b may be provided between the dispensing portion 12b and the second end 22b of each arm 20b.

From each second end 22b is a bladed shell element 1b. These elements 1b are said to be bladed because, after removal of the wax replica 1a, they each internally form an imprint corresponding to one of the blades 1.

The bladed element 1b, also known as the blade of a shell, thus comprises a portion of blade 2b delimiting adjacent blade cavities, this portion 2b extending from an end 4b forming a blade root, and comprising a platform 8b. On the figure 11 the shell vanes 1b have been shown only schematically.

The bladed elements 1b therefore extend upwards, being arranged around the axis 14b, and also around a central support 24b extending along the same axis from the end 18b of the distributor 12b. The support 24b preferably takes the form of a hollow cylinder of axis 14b, which extends to near the ends 6b of the bladed elements 1b.

In addition, for each bladed element 1b, a holding reinforcement 25b may be provided between the upper end of the central support rod 24b, and the blade head. In the same way, wax / ceramic retention reinforcements (not shown) can connect the adjacent blade heads of the different shell blades 1b to each other. Finally, reinforcing elements 42b are arranged between the bucket 32b and the casting arms 20b.

After obtaining the shell 300 and the removal of the replica wax 100 enclosed in it, and the removal of the lid initially closing the bucket, the shell is preheated at high temperature in a dedicated oven, for example at 1150 ° C, to promote the fluidity of the metal in the shell during casting.

At the exit of the preheating of the shell, metal leaving a melting furnace is poured into the cavities via the bucket 32b shown, with the shell in the inverted position with respect to that shown on FIG. figure 11 , that is to say with the bucket 32b open upwards and still the axis 14b vertically oriented.

The molten metal therefore successively borrows the bucket 32b, the distributor 12b, the casting arms 20b, then the bladed shell 1b, simply flowing by gravity. It is noted that prior to casting, the central support 24b preferably has its end closed so as not to be filled with metal, and so that the cast metal necessarily passes through the arms 20b before entering the bladed elements 1b. The reinforcements 23b, 25b, 42b are preferably solid, ceramic, and therefore not traversed by the molten metal during casting in the shell 300.

After cooling the metal, the shell is destroyed, and the blades 1 are separated from the cluster for possible machining and finishing operations and control.

Of course, various modifications may be made by those skilled in the art to the invention which has just been described, solely by way of non-limiting examples.

Claims (10)

1. Method for manufacturing a shell mold (300) for the production by lost-wax casting of a plurality of bladed elements (1) of an aircraft turbine engine, said shell mold in cluster form comprising a plurality of bladed shell mold elements (1b) each intended to obtain one of said bladed turbine engine elements (1), said method comprising the following steps:

   a) creating an assembly (200) about which the shell mold is intended to be formed, the assembly including a wax pattern (100) as well as a device (32a) for subsequently forming a cup for pouring metal (32b), said device having an end surface (40a);

   c) forming the shell mold (300) about said assembly (200);

   characterized in that the method further includes, in addition to steps b) and c), le following step:
   b) depositing a hot wax coating layer (46) around at least one portion of said assembly (200), such that said coating layer (46) covers at least one portion of the end surface (40a) of the device intended to subsequently form the cup for pouring metal;
   and in that the method further includes, between steps b) and c), the implementation of a step of structuring the coating layer (46) covering said end surface (40a), this structuring step being intended to reinforce the adhesion between this layer (46) and the shell mold to be formed, and including the production of recesses (62) and projections (60) on the still-malleable coating layer.
2. Method according to claim 1, characterized in that the step for structuring the coating layer (46) is implemented by inserting a plurality of imprinting elements (52) in said still-malleable coating layer, causing the formation of said projections (60) about the imprinting elements, then by removing the latter revealing recesses (62), each surrounded by one of said projections (60).
3. Method according to claim 2, characterized in that the imprinting elements are studs (52), preferably with an external surface head (54) having a general spherical cap shape.
4. Method according to claim 3, characterized in that the ratio between the maximum external diameter (D1) of each stud (52), and the external diameter (D2) of the end surface (40a) of the device (32a), is less than 20.
5. Method according to claim 3 or claim 4, characterized in that the number of studs (52) is between 3 and 20.
6. Method according to any one of claims 2 to 5, characterized in that the step for structuring the coating layer (46) is implemented by applying a pressure from a supporting member (50) bearing the plurality of imprinting elements (52), against said still-malleable coating layer (46).
7. Method according to claim 6, characterized in that said application of pressure is performed by moving said assembly (200), against the supporting member (50) remaining stationary.
8. Method according to any one of the preceding claims, characterized in that the step for forming the shell mold (300) about said assembly (200) includes at least one drying operation performed at least in part with said end surface (40a) facing downward, and preferably with said shell mold, surrounding the assembly, moved inside a drying station (70).
9. Method according to any one of the preceding claims, characterized in that the step for forming the shell mold (300) is performed by dip coating.
10. Method for manufacturing by lost-wax casting a plurality of bladed elements (1) of an aircraft turbine engine, characterized in that it includes the production of a shell mold (300) using a method according to any one of the preceding claims, followed by casting of metal in the shell mold.

Images