EP3317039A1 - Procédé de fabrication d'ébauches à canaux intégrés - Google Patents

Procédé de fabrication d'ébauches à canaux intégrés

Info

Publication number
EP3317039A1
EP3317039A1 EP16747734.8A EP16747734A EP3317039A1 EP 3317039 A1 EP3317039 A1 EP 3317039A1 EP 16747734 A EP16747734 A EP 16747734A EP 3317039 A1 EP3317039 A1 EP 3317039A1
Authority
EP
European Patent Office
Prior art keywords
channel
plates
production
components
channels
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Withdrawn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
EP16747734.8A
Other languages
German (de)
English (en)
Inventor
Heiko Neuberger
Axel Von Der Weth
Christian ZEILE
Jörg REY
Francisco Hernandez
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.)
Karlsruher Institut fuer Technologie KIT
Original Assignee
Karlsruher Institut fuer Technologie KIT
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 Karlsruher Institut fuer Technologie KIT filed Critical Karlsruher Institut fuer Technologie KIT
Publication of EP3317039A1 publication Critical patent/EP3317039A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00—Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • 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
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
    • B23H7/02—Wire-cutting
    • 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
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/26—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like

Definitions

  • the present invention relates to a method for the manufacture of blanks with internal channels.
  • State of the art :
  • the penetrations of the component required for threading a cutting wire can be carried out using standard drilling, various deep-hole drilling methods (eg with or without tool rotation in opposition to the tool, as well as the option of fully automated methods with real-time recording of the bore including countermeasures). or Erodier Kunststoff (eroding or drilling) are produced.
  • Erodier Kunststoff eroding or drilling
  • these are bound to typical process limits (ratio between diameter and bore length, as well as the bore center profile as a function of the drilling depth).
  • the object of the present invention is to provide a new method that uses alternative techniques and is not limited by the process limitations of the prior art. Likewise, new components are to be obtained, which can not be produced with the previous method. Last but not least, uses or applications of the new process, the new components and the components produced using the new method should be found. Solution:
  • This object is achieved by a method for the production of blanks with internal channels, comprising introducing a surface channel structure into a plate pairing, joining the plates to form a closed channel structure, threading a cutting wire into the channel structure, further processing by means of wire EDM for the production of the final channel inner wall, respectively manufactured components and the corresponding uses.
  • HIP hot isostatic pressing
  • EB welding is understood to mean electron beam welding.
  • the present invention relates to a method for the production of blanks with the aim of producing thermally highly resilient or highly loaded components.
  • These blanks are flat plates with internal channels, which run in a plane.
  • the method according to the invention relates to the technology used for introducing the channels into the flat plates.
  • the present invention is therefore a process for the production of blanks with internal channels, which are used for further processing by means of wire EDM.
  • FIG. 1 An embodiment of the present invention is shown in FIG. 1
  • Step i) can be carried out such that the channel structure is incorporated only in one of the plates of the plate pair (variant ia-1), or in both plates (variant ia-2).
  • An introduction of channels in only one of the two plates (ia-1) can reduce the processing costs.
  • Variant ia-2) allows on the one hand to edit the two plate halves so that the channels exactly above the other, resulting in a double channel depth compared to the variant ia-1).
  • step i) can be carried out by any method suitable for working out channel structures from the plates. The method used is selected among others according to criteria of economy. In a variant of the present invention, the processing in step i) takes place by means of milling. Step i) may further comprise, as step ib), the cleaning of the contact surfaces, for example by chemical methods, in preparation for the joining process.
  • step ii positioning of the two half-plates in the desired position to each other is included.
  • the consideration of the component requirements / design as well as the parameters of the later used joining method are decisive with regard to the expected plastic deformation of the channels (see step ii).
  • the channels should be connected to one another via transverse channels, since this involves evacuating the internal cavity before joining the plate pairing via a central channel Vacuum connection allows.
  • bores for dowel pins for positioning are advantageously provided or incorporated. How such a plate pairing can look after the optional cleaning (ib) and the positioning (ic) is shown in FIG.
  • step ii) takes place in a variant of the present invention stepwise in two steps with two welding processes: First, in this variant, the edges are stapled in places, then the clamping device removed and finally the edges around along the parting plane of the two half-plates connected iia). Such an approach is illustrated in FIG.
  • the section A-A in FIG. 4 shows that the peripheral weld still does not produce a full connection, the inner region of the plate pairing has not yet been joined here.
  • an EB process is ideally used in this variant, since this is carried out in a vacuum chamber. Also, the heat input compared to other methods is low.
  • the effective depth of the circumferential weld is to be chosen as low as possible in a variant in order to keep the heat input into the component and thus the delay low. Nevertheless, the seam must simultaneously meet the requirement of vacuum tightness.
  • the vacuum connection within the EB chamber is closed with a stopper at the existing vacuum, which can be automatically positioned and welded using EB technology. This ensures that the vacuum in the inner channel structure is maintained.
  • a HIP method is used in a variant of the present invention, wherein a high isostatic pressure from the outside (therefore no distortion of the assembly to fear) at a high temperature causes diffusion processes in the contact surfaces of the components, resulting in a full connection.
  • the illustrative figure 5 again shows a section AA with an indication of the HIP atmosphere and the diffusion weld in the interior of such a component.
  • the processing step iii) the threading of a cutting wire in the channel structure.
  • the frontal areas of the component are separated, so that the ends of the channels are exposed for threading the cutting wire.
  • the component After threading of the cutting wire in the respective channel, the finishing of the channel inner wall by means of wire eroding, processing step iv).
  • the component must be aligned without contact in relation to the cutting wire, in order to exclude a short circuit during EDM machining.
  • the deformed areas of the blank can then be removed by appropriate execution of a wire EDM process, and
  • the result is a final component with in relation to the web width large channel cross-section.
  • Depth to Diameter Ratio The new combination of process steps enables the production of channels in a small cross-section compared to the linear expansion, similar to for example, deep hole drilling. It is with the inventive method the realization of depth to diameter ratios of 1000 and more conceivable that would be difficult to produce with other methods according to the prior art.
  • the potential possible with the present invention is represented in the figure by the field "HIP welding + wire erosion of zone C.”
  • the channels can be made by the wire erosion process with any geometry of cross-sectional area, thus, for example, the production of rectangular channels with a cross section of 2 mm x 2 mm in a length of 2000 mm is possible.
  • Lower tolerances of superficial Abtragsverrahren instead of bore center profile Another advantage is that the channel surface in the raw state from the outside (eg with a milling method) is introduced and thus no course of the ideal channel axis, as typical in drilling process occurs. As a result, the manufacturing tolerance of milled parts now occurs instead of the Bohrungsmittenverlaufes.
  • the precision in the production of milled parts is in the range of hundredths of a millimeter and is also not dependent on depth or location, in contrast to the previously considered bore course.
  • a channel of 2 mm depth and 2000 mm length can now be milled.
  • the position tolerance of the channel surface would move by the introduction by milling in the range of hundredths of a millimeter. According to the prior art, a higher deviation would be expected in a deep hole drilling even with opposite workpiece rotation.
  • a multitude of channels can be produced in one component for the final processing by means of wire EDM. Provided that a detailed process optimization is provided, the workload involved in wire erosion can be minimized through targeted preparation of the raw channels. In addition, by creating computer-supported milling profiles any number of the same components in series can be produced.
  • the ratio between the width and land width of the channels is no longer bound to fixed regularities (for example homogeneous pressure distribution during diffusion welding of the channels in the final geometry).
  • fixed regularities for example homogeneous pressure distribution during diffusion welding of the channels in the final geometry.
  • the channel height, cross-sectional area and web width can be flexibly varied within a component.
  • the realization of intersecting channels in one plane is possible.
  • Thermally highly stressed components for fusion reactors such as, for example, the first wall of Brut-Biankets or HCPB TBMs and internal components such as cooling plates (cf., for example, H. Neuberger, et al., KIT INDUCED ACTIVITIES TO SUPPORT
  • the technology of the present invention can be used for planar or curved radiation shields when high internal channel pressure is required for heat dissipation.
  • the formability of plates with internal channel structure has already been successfully demonstrated.
  • Cooling is required for very high thermal loads on combustion chamber walls.
  • the inventive method for the production of semi-finished products with internal high-pressure channels can be used.
  • a high precision with respect to the remaining wall thickness between the channel interior and the Inside the combustion chamber can be achieved.
  • the limited by the heat resistance of the surrounding chamber walls process temperature can be driven within the combustion chamber near the application limit of the material.
  • a thin wall thickness between combustion chamber and channel inner wall of approx. 1.5 mm (tolerance range approx. +/- 10%) can be realized, which leads to a very high heat dissipation capacity.
  • the flat semifinished products produced by the method combination HIP / EDM according to the invention offer great flexibility with regard to further processing options.
  • the initially flat semi-finished products which are produced using the HIP / erosion process combination can, for example, be further processed by forming processes (by means of a round bending machine, die-forming process) and by welding into tubes with internal channel structures for circulating cooling, as already mentioned. Further processing of a manufactured tube to optimize the geometry (eg required for the production of thermal turbomachines) by means of further forming technology (eg internal high pressure forming IHU) is possible. Corresponding forming and welding processes for the production and connection of plates with channels have already been carried out and successfully demonstrated.
  • FIG. Partial Case Cooling A scheme for the production of a workpiece (circulation cooling with aerodynamically optimized geometry) is shown in FIG. Partial Case Cooling:
  • the technology of the present invention may also be used to fabricate housing segments with active cooling.
  • Corresponding plates can be welded directly into a housing or a module with thermal load at the required location (see combustion chamber wall).
  • An inner lining of areas with increased thermal load with flat or curved plates is also possible
  • FIG. 1 Exemplary representations for this application are illustrated in FIG. 1
  • Tube with axial arrangement of the (cooling) channels can also be used to tubes in To produce segmental construction, which are provided with channels in the axial direction.
  • View 1 in Fig. 11 shows the arrangement of a plurality of starting holes for subsequent processing with wire EDM in a plane, they were prepared with the method steps i) and ii).
  • View 2 of Figure 11 illustrates the face of the component showing the location of the starting holes in relation to the channel surfaces to be made by wire eroding.
  • View 3 of Figure 11 demonstrates the blank with ready-cut channels, view 4 shows a finished segment after cutting out the outer contour.
  • the assembly of several segments into a complete tube by a suitable welding process is illustrated in view 5 of FIG.
  • a modification of this variant is based on the full connection of the contact surfaces within the individual segments in the channel levels as well as the simultaneous joining of all individual segments together in one operation with HIP technology. In this case, however, the use of an enveloping body is required in order to realize the introduction of force between the individual segments.
  • FIG. 12 a possible procedure is shown step by step. Depending on the detailed design of the
  • Positioning of the segments before the HIP process and the execution of the envelope is also a variant with open channel ends during the HIP process (without previous circumferential joining of the shells of each segment) possible.
  • the present invention also relates to the use of the method according to the invention for the production of components for fusion reactors, cold radiation shields, combustion chamber walls, thermal turbomachines, segments for the target of the European Spallation Source (ESS) and housing segments with active cooling.
  • ESS European Spallation Source
  • the present invention also relates to the use of the components produced by the process according to the invention for components for fusion reactors, components for cold radiation shields, components for the production of combustion chamber walls, components in thermal flow machines, components for the production of segments for the target of the ESS and components for Production of housing segments with active cooling.
  • the inventive method is essentially limited only by the size of the available HIP systems or the available wire EDM, for example, there are HIP systems on which you can weld at least components of about 3000 mm, as well as wire erosion, in which components are more similar Can process size, so that components of the invention with 3000 mm ILtule can be produced on such systems.
  • FIG. 1 shows a schematic drawing of the main process steps of the process according to the invention.
  • a plate pairing with a mirror-symmetrical channel structure is produced (left side) with subsequent positioning of the plate pairing with channel structure in the interior (right side).
  • Figure 2 shows a typical arrangement on a half-plate of surface milled channels with cross-connection / transverse channel (A), holes for
  • FIG. 3 is a diagrammatic representation of FIG. 3
  • FIG. 4 shows a plate pairing after cleaning and positioning, with clamping devices for positioning.
  • FIG. 4 illustrates the circumferential welding of the plate pairing and closure of the vacuum connection, the lower half representing the section A-A of the upper half of the figure, and S being the effective depth of the welding process.
  • FIG. 5 is a diagrammatic representation of FIG. 5
  • FIG. 5 shows the diffusion welding of the plate pairing for joining the inner contact region.
  • the element J encircled in the upper half of the figure is reproduced in detail in the lower half and shows the Full connection in the joining area.
  • FIG. 6 is a diagrammatic representation of FIG. 6
  • FIG. 6 in the upper half, the component is shown with the channel openings exposed after removal of the frontal areas and the insertion direction of the cutting wire for the subsequent wire erosion is illustrated in the lower half by means of the arrow.
  • FIG. 7 is a diagrammatic representation of FIG. 7
  • Figure 7 is a schematic representation of the prior art, wherein drilling depth over hole diameter, each in millimeters indicated, applied to various methods.
  • Zone A represents standard drilling techniques, Zone B deep hole drilling / EDM drilling and Zone C HIP welding + wire eroding.
  • FIG. 8 shows a cross section through the component during various stages of processing.
  • A shows the preparation of the half plates by milling.
  • B shows the positioning of the half-plates before joining.
  • C illustrates the joining, for example by means of diffusion welding (HIP), with a deformation of the outer contour of the blank, including the channels and channel webs occurs.
  • D illustrates that the deformed areas (hatched areas) of the component are then removed, and E shows a cross section of the final component with a large channel cross-section relative to the land width.
  • HIP diffusion welding
  • Figure 9 shows an example of the application of the present invention in combination with further joining and forming steps.
  • FIG. 10 shows two examples of housing with partial cooling, wherein the partially cooled housing areas are marked by the bar marks.
  • FIG. 11 illustrates a variant of the production of tubes with axially extending channels in the wall.
  • View 1 shows the arrangement of several starting holes for subsequent processing by means of wire EDM in one plane.
  • View 2 shows a plan view of the face of the component, the position of the starting holes being shown in relation to the channel surfaces to be produced by wire eroding.
  • View 3 demonstrates the blank with ready-cut channels, view 4 shows a finished segment after cutting out the outer contour.
  • View 5 is an enlarged detail view of area A from the finished tube shown in the lower part of FIG.
  • FIG. 12 shows the arrangement of several starting holes for subsequent processing by means of wire EDM in one plane.
  • View 2 shows a plan view of the face of the component, the position of the starting holes being shown in relation to the channel surfaces to be produced by wire eroding.
  • View 3 demonstrates the blank with ready-cut channels
  • view 4 shows a finished segment after cutting out the outer contour.
  • View 5 is an enlarged detail view of area A from the finished tube shown in
  • FIG. 1 illustrates another variant of the production of tubes with axially extending channels in the wall.
  • A the production of inner and outer individual segments is shown, wherein the dashed line in the assembled workpiece represents a circumferential EB seam.
  • B the positioning of the various individual segments is illustrated.
  • C illustrates wrapping in a wrapper for HIP welding.
  • D shows the semifinished product after HIP welding and
  • E illustrates the finish machining by means of wire erosion.
  • FIG. 13 :
  • FIG. 13 shows a workpiece with a combination of an axially traversed region "ax" (left part of the component) and an area with circulating throughflow "around” (right part of the component).
  • the method of the present invention was first performed on a test component having the full length of a HCPB TBM Cooling Plate and 30 start hole channels (full width of the component). By means of this test component it was shown that the core points of the invention function:
  • the channels do not collapse during the diffusion welding process.
  • a cutting wire can be threaded on an erosion machine.
  • a component which contains typical design features of a HCPB TBM Breeder Zone Cooling Plate.
  • the component had a channel length of about 850 mm, a total of 30 channels, arranged at regular intervals along the entire component width of about 200 mm.
  • the plate had channels along the length direction which were connected by transverse channels at the top and bottom. These transverse channels served to evacuate the channels during the joining of the plates in the electron beam welding chamber. The peripheral edge area of the plate was free of channels.
  • a chemical cleaning process was used to clean the contact surfaces to be joined. This procedure was selected for reasons of reproducibility and verifiability by means of EDX analysis (comparison of the surface before and after cleaning) and the cleaning processes already used, such as, for example, Plasma cleaning, cleaning by acetone or cleaning by dry ice preferred.
  • the plates were positioned over dowel pins and mounted with clamps to prevent re-contamination of the contact surfaces during shipping and storage prior to further processing. The stapling was released only after stitching the half plates in the EB welding chamber.
  • the plate pairing was delivered after cleaning for stapling and welding. After stapling, the stapling was removed and performed circumferentially around a weld with a penetration of about 8 mm. Thereafter, the assembly was left in the EB chamber and evacuated the now enclosed inner channels via a previously introduced vent hole for several hours. To support the evacuation process, the plate was superficially heated with the electron beam of the low power plant. Thereafter, the evacuation well was sealed with a stopper.
  • the HIP process was determined using parameters that correspond to previous experiments (eg, 1/8 and 1/4 of the total component size of the HCPB TBM First Wall) in terms of temperature history. However, the process pressure could be significantly increased and maintained for a longer time due to the significantly better ratio between channel and web width within the plate pairing. After the HIP process, another two-step heat treatment was performed (austenitizing and tempering the component).

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Welding Or Cutting Using Electron Beams (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

L'invention concerne un procédé de fabrication d'ébauches à canaux intégrés, comprenant l'intégration d'une structure à canaux en surface dans un appariement de plaques, l'assemblage des plaques pour former une structure à canaux fermée, l'insertion d'un fil de coupe dans la structure à canaux, l'usinage ultérieur par électro-érosion par fil pour la fabrication de la paroi interne à canaux finale, des pièces fabriquées au moyen dudit procédé ainsi que des utilisations correspondantes.
EP16747734.8A 2015-06-30 2016-06-30 Procédé de fabrication d'ébauches à canaux intégrés Withdrawn EP3317039A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102015110522.5A DE102015110522B4 (de) 2015-06-30 2015-06-30 Verfahren zur Herstellung von Rohteilen mit innenliegenden Kanälen
PCT/EP2016/065347 WO2017001583A1 (fr) 2015-06-30 2016-06-30 Procédé de fabrication d'ébauches à canaux intégrés

Publications (1)

Publication Number Publication Date
EP3317039A1 true EP3317039A1 (fr) 2018-05-09

Family

ID=56571294

Family Applications (1)

Application Number Title Priority Date Filing Date
EP16747734.8A Withdrawn EP3317039A1 (fr) 2015-06-30 2016-06-30 Procédé de fabrication d'ébauches à canaux intégrés

Country Status (3)

Country Link
EP (1) EP3317039A1 (fr)
DE (1) DE102015110522B4 (fr)
WO (1) WO2017001583A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107249286A (zh) * 2017-07-13 2017-10-13 王楠楠 一种超薄水冷板及其加工方法

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19623148C2 (de) * 1996-06-10 1998-04-09 Peddinghaus Carl Dan Gmbh Verfahren und Anlage zur Herstellung oder Aufarbeitung von dreidimensionalen, metallischen Hohlformen
DE10249724B4 (de) * 2002-10-25 2005-03-17 Bayer Industry Services Gmbh & Co. Ohg Hochleistungs-Temperierkanäle
FR2850741B1 (fr) * 2003-01-30 2005-09-23 Snecma Propulsion Solide Procede de fabrication d'un panneau de refroidissement actif en materiau composite thermostructural
DE10358201A1 (de) * 2003-12-12 2005-07-07 Robert Bosch Gmbh Verfahren zum Vermessen der Position eines Werkstücks
US8806747B2 (en) * 2008-08-08 2014-08-19 Alliant Techsystems Inc. Method of manufacturing heat exchanger cooling passages in aero propulsion structure
DE102010035606A1 (de) * 2010-08-27 2012-03-01 Albert-Ludwigs-Universität Freiburg Verfahren zum Herstellen einer Mikrostruktur, Mikrostruktur und fluidische Plattform
DE102011005830A1 (de) * 2011-03-21 2012-09-27 Behr Gmbh & Co. Kg Wärmeübertrager
US9238284B2 (en) * 2011-12-20 2016-01-19 Unison Industries, Llc Methods for forming a heat exchanger and portions thereof
FR3005499B1 (fr) * 2013-05-10 2015-06-05 Commissariat Energie Atomique Procede de realisation d'un module d'echangeur de chaleur a au moins deux circuits de circulation de fluide.

Also Published As

Publication number Publication date
WO2017001583A1 (fr) 2017-01-05
DE102015110522A1 (de) 2017-01-05
DE102015110522B4 (de) 2017-04-27

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