EP3322832B1 - Method of forming a protective structure on a turbomachine blade - Google Patents
Method of forming a protective structure on a turbomachine blade Download PDFInfo
- Publication number
- EP3322832B1 EP3322832B1 EP16736885.1A EP16736885A EP3322832B1 EP 3322832 B1 EP3322832 B1 EP 3322832B1 EP 16736885 A EP16736885 A EP 16736885A EP 3322832 B1 EP3322832 B1 EP 3322832B1
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- EP
- European Patent Office
- Prior art keywords
- edging
- forming
- leading edge
- sub
- airfoil portion
- Prior art date
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- 230000001681 protective effect Effects 0.000 title claims description 63
- 238000000034 method Methods 0.000 title claims description 13
- 238000007688 edging Methods 0.000 claims description 57
- 238000005507 spraying Methods 0.000 claims description 38
- 238000010288 cold spraying Methods 0.000 claims description 15
- 238000004372 laser cladding Methods 0.000 claims description 10
- 230000003628 erosive effect Effects 0.000 description 13
- 239000000463 material Substances 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 8
- 239000010410 layer Substances 0.000 description 6
- 229910001347 Stellite Inorganic materials 0.000 description 4
- WAIPAZQMEIHHTJ-UHFFFAOYSA-N [Cr].[Co] Chemical class [Cr].[Co] WAIPAZQMEIHHTJ-UHFFFAOYSA-N 0.000 description 4
- AHICWQREWHDHHF-UHFFFAOYSA-N chromium;cobalt;iron;manganese;methane;molybdenum;nickel;silicon;tungsten Chemical compound C.[Si].[Cr].[Mn].[Fe].[Co].[Ni].[Mo].[W] AHICWQREWHDHHF-UHFFFAOYSA-N 0.000 description 4
- 239000000956 alloy Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- 229910017052 cobalt Inorganic materials 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000010283 detonation spraying Methods 0.000 description 2
- 238000010285 flame spraying Methods 0.000 description 2
- 238000007750 plasma spraying Methods 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910000843 ultimet Inorganic materials 0.000 description 2
- 238000010287 warm spraying Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 238000010284 wire arc spraying Methods 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
Definitions
- Embodiments of the subject matter disclosed herein correspond to turbomachine blades with protective structure, turbomachines (in particular steam turbines), and methods of forming protective structure.
- WO 2008/116757 A2 discloses a compressor blade with a first layer provided on the surface of the blade body in a leading edge area and a second layer that covers the first layer and the remaining non-covered parts of the blade body surface.
- US 2013/236323 A1 discloses a leading edge protection component
- US 2014/272166 A1 discloses an airfoil coating
- EP 2 631 323 A1 discloses a coating for an airfoil blade component
- US 2011/097213 A1 discloses leading edge protection.
- the blades of steam turbines are often subject to liquid droplet erosion.
- Structures for protecting turbomachine blades against erosion, corrosion or wear may consist of layers formed on the surface of the blades or inserts fit in the body of the blades.
- Protective layers may be formed for example by laser cladding or by cold spraying. Both these technologies are effective.
- laser cladding heats the blades and may cause for example residual stress in the blades and/or distortion of the blades and may foster "stress corrosion cracking", while cold spraying hits the blades and may cause for example erosion of the edges of the blades during formation of the layers. It is to be noted that laser cladding is more expensive than cold spraying, but is quicker.
- First embodiments of the subject matter disclosed herein relate to a turbomachine blade.
- the turbomachine blade is provided with an airfoil portion having a leading edge and a trailing edge and first and second sides connecting the leading edge and the trailing edge, and with a protective structure comprising a protective edging and first and second protective stripes; the protective edging is located on the leading edge; the first protective stripe is located on the first side and adjacent to the edging; the second protective stripe is located on the second side and adjacent to the edging; the edging is formed by laser cladding or welding or plasma spraying or detonation spraying or wire arc spraying or flame spraying or high velocity oxyfuel coating spraying or warm spraying; the first and second stripes are formed by cold spraying.
- Second embodiments of the subject matter disclosed herein relate to a turbomachine.
- a turbomachine in particular a steam turbine, comprises a plurality of turbomachine blades as set out above.
- Third embodiments of the subject matter disclosed herein relate to a method of forming protective structure.
- a method of forming a protective structure on a turbomachine blade comprises the following successive steps: (A) providing a turbomachine blade comprising an airfoil portion having a leading edge and a trailing edge and first and second sides connecting the leading edge and the trailing edge, (B) forming a protective edging on the leading edge by laser cladding, and (C) forming first and second protective stripes on the first and second sides adjacently to the edging by cold spraying through at least one spraying nozzle.
- the current invention is limited to the subject-matter of claim 1 and the appended claims.
- Fig. 1 shows a schematic lateral view of a turbomachine blade 1 before forming a protective structure.
- Blade 1 is provided with an airfoil portion 2 having a leading edge 3 and a trailing edge 4 as well as a first side 5 and a second side 6 (shown only in Fig. 5 ) connecting leading edge 3 and the trailing edge 4.
- Airfoil portion 2 has a tip region 21 and a base region 22; base region 22 of airfoil portion 2 is adjacent to base portion 10 of blade 1.
- Fig. 3, Fig. 4 and Fig. 5 show blade 1 after forming a protective structure.
- the protective structure comprises a protective edging 7 (that may be called “bumper” or “buffer”) as well as a first protective stripe 8 and a second protective stripe 9 (shown only in Fig. 5 ); protective edging 7 is located on leading edge 3; first protective stripe 8 is located on first side 5 and adjacent to edging 7; second protective stripe 9 is located, preferably only, on second side 6 and adjacent to edging 7.
- stripes 8 and 9 do not cover edging 7 and are located respectively only on sides 5 and 6.
- stripes 8 and 9 are located respectively on sides 5 and 6, but cover also entirely edging 7; the thickness of stripes 8 and 9 reduces gradually on edging 7 and is zero (or close to zero) in the middle of edging 7.
- the two stripes do not cover edging 171 and are located respectively only on the two sides of the airfoil.
- the two stripes are located respectively on the two sides of the airfoil, but cover also partially edging 172; the thickness of the stripes reduces gradually on the edging and is zero (or close to zero) in the middle of the edging.
- the two stripes are located respectively on the two sides of the airfoil, but cover also entirely edging 173; the thickness of the stripes reduces gradually on the edging and is minimum and low in the middle of the edging.
- the two stripes are located respectively on the two sides of the airfoil, but cover also entirely edging 173; the thickness of the stripes reduces gradually on the edging and is minimum and high in the middle of the edging.
- the edging of the protective structure protrudes from the leading edge of the airfoil portion of the blade.
- Protrusion (at the end of blade manufacturing) varies depending on the manufacturing process (e.g. degree of erosion due to cold spraying).
- protrusion may be in the range of e.g. from 0.05 to 1 mm.
- the cross-section area of the edging (immediately after its formation, e.g. before cold spraying) should take into account the manufacturing process (e.g. degree of erosion due to cold spraying) and may be in the range from 1 mm 2 to 20 mm 2 , more typically in the range from 4 mm 2 to 10 mm 2 .
- the cross-section area of the edging (immediately after its formation, e.g. before cold spraying) should take into account the manufacturing process (e.g. degree of erosion due to cold spraying) and may look like a bulge.
- the external shape of the airfoil portion of the blade at the end of blade manufacturing depends on the external shape of the airfoil portion of the blade before formation of the protective structure and on the overlying protective structure, in particular the protective edging and its erosion during formation of the protective stripes. Therefore, at least the leading edge of the airfoil portion of the blade before formation of the protective structure should be manufactured a bit recessed with respect to the ideal position of the leading edge of the airfoil portion of the blade at the end of blade manufacturing.
- the solution according to the above embodiments is particular useful for thin blades, for example blades having a thin leading edge, for example in the range of 4-8 mm.
- the edging of the protective structure is formed by laser cladding or welding or plasma spraying or detonation spraying or wire arc spraying or flame spraying or high velocity oxyfucl coating spraying or warm spraying (preferably by laser cladding), while the first and second stripes of the protective structure are formed by cold spraying.
- the airfoil portion of the blade may be made of iron, titanium, nickel base alloy or stainless steel; preferably, it is made of stainless steel, for example AISI420.
- the edging of the protective structure may be made of cobalt base alloy or cobalt-chromium alloy; preferably, it is made of Stellite-type material, in particular Stellite 6 or Stellite 12 or Stellite 21, or Ultimet or any of the materials described and claimed in patent application EP1403397 or any of the materials described and claimed in patent application EP1403398 .
- the material of the edging is more resistant to solid particle erosion than the material of the airfoil in order to resist better to the mechanical erosion due to cold spraying.
- the first and second stripes of the protective structure may be made of cobalt base alloy or cobalt-chromium alloy; preferably, they are made of Stellite-type material, in particular Stellite 6 or Stellite 12 or Stellite 21, or Ultimet or any of the materials described and claimed in patent application EP1403397 or any of the materials described and claimed in patent application EP1403398 .
- the material of the first and second stripes is resistant to liquid droplet erosion.
- the material of the first and second stripes may be equal to or different from the material of the edging.
- the edging of the protective structure and the first and second stripes of the protective structure may extend over part (i.e. from preferably 20% to preferably 50%) of the height of the airfoil portion of the blade (see e.g. Fig. 3 and Fig. 10 ).
- the head end of the stripes is at the tip of the airfoil portion and the tail end of stripes is at an intermediate position of the airfoil portion.
- the edging of the protective structure is long equal to or slightly more than the first and second stripes of the protective structure.
- the height of the airfoil portion being the portion of the blade extending from the tip to the root of the blade.
- the first and second stripes of the protective structure may extend over part (i.e. from preferably 5% to preferably 50%) of the width of the airfoil portion of the blade (see e.g. Fig. 3 and Fig. 10 ).
- the stripes extend from leading edge of the airfoil portion of the blade.
- the width of the airfoil portion being the portion of the blade extending from the leading to the trailing edge.
- Blades identical or similar to those that have just been described may advantageously be used in turbomachines in the fields of "Oil & Gas” and “Energy”.
- steam turbines are an ideal application.
- a protective structure identical or similar to those that have just been described may be formed on a turbomachine blade through the following successive steps:
- a "thin leading edge” may have a thickness in the range of e.g. 2-10 mm - as the cross-section of the leading edge is similar to a semicircle, a "thin leading edge” may have a radius in the range of e.g. 1-5 mm.
- the same spraying nozzle may be used for forming both protective stripes.
- a first spraying nozzle may be used for forming a first protective stripe and a second spraying nozzle may be used for forming a second protective stripe; in this case, the first and second protective nozzles may be formed at the same time.
- the stripes of the protective structure may comprise a plurality of parallel (or substantially parallel) segments.
- segments 81 and 91 are transversal (specifically perpendicular) to the leading edge 3.
- segments 181 are parallel (or substantially parallel) to the leading edge 103. It is to be noted that these segments touch each other laterally even if Fig. 4 and Fig. 10 show them as distant.
- the spraying nozzle moves at least from a side (e.g. 5 or 6) of the airfoil portion toward the edging (e.g. 7) for forming a stripe (e.g. 8 or 9) and rotates preferably by at least 40° about the leading edge (e.g. 3) in order to form a stripe (e.g. 8 or 9) adjacent to the leading edge (e.g. 3) and to the edging (e.g. 7).
- the spraying jet is directed highly inclined (preferably perpendicular) to the surface of (the side of) the airfoil; when the spraying nozzle approaches the leading edge the spraying nozzle is gradually rotated so that the spraying jet remains directed highly inclined (preferably perpendicular) to the surface of (the front of) the airfoil.
- step C may comprise (consider e.g. figures 6-9 ):
- step C may comprise:
- step C may comprise:
- step C may comprise also the following sub-steps after sub-step C5:
- the spraying nozzle maintains a constant longitudinal position on the airfoil portion.
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- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Plasma & Fusion (AREA)
- Physics & Mathematics (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Structures Of Non-Positive Displacement Pumps (AREA)
Description
- Embodiments of the subject matter disclosed herein correspond to turbomachine blades with protective structure, turbomachines (in particular steam turbines), and methods of forming protective structure.
-
WO 2008/116757 A2 discloses a compressor blade with a first layer provided on the surface of the blade body in a leading edge area and a second layer that covers the first layer and the remaining non-covered parts of the blade body surface.US 2013/236323 A1 discloses a leading edge protection component,US 2014/272166 A1 discloses an airfoil coating,EP 2 631 323 A1US 2011/097213 A1 discloses leading edge protection. - During operation, the blades of turbomachines are often subject to erosion.
- In particular, the blades of steam turbines are often subject to liquid droplet erosion. Structures for protecting turbomachine blades against erosion, corrosion or wear may consist of layers formed on the surface of the blades or inserts fit in the body of the blades.
- Protective layers may be formed for example by laser cladding or by cold spraying. Both these technologies are effective. Anyway, laser cladding heats the blades and may cause for example residual stress in the blades and/or distortion of the blades and may foster "stress corrosion cracking", while cold spraying hits the blades and may cause for example erosion of the edges of the blades during formation of the layers. It is to be noted that laser cladding is more expensive than cold spraying, but is quicker.
- Therefore, there is a general need for improving the protective structures of turbomachine blades and the methods of forming them.
- This need is particularly high for blades of steam turbines in the fields of "Oil & Gas" (i.e. machines and plants for exploration, production, storage, refinement and distribution of oil and/or gas) and "Energy" (i.e. machines and plants for power generation).
- First embodiments of the subject matter disclosed herein relate to a turbomachine blade.
- According to such embodiments, the turbomachine blade is provided with an airfoil portion having a leading edge and a trailing edge and first and second sides connecting the leading edge and the trailing edge, and with a protective structure comprising a protective edging and first and second protective stripes; the protective edging is located on the leading edge; the first protective stripe is located on the first side and adjacent to the edging; the second protective stripe is located on the second side and adjacent to the edging; the edging is formed by laser cladding or welding or plasma spraying or detonation spraying or wire arc spraying or flame spraying or high velocity oxyfuel coating spraying or warm spraying; the first and second stripes are formed by cold spraying.
- Second embodiments of the subject matter disclosed herein relate to a turbomachine.
- According to such embodiments, a turbomachine, in particular a steam turbine, comprises a plurality of turbomachine blades as set out above.
- Third embodiments of the subject matter disclosed herein relate to a method of forming protective structure.
- According to such embodiments, a method of forming a protective structure on a turbomachine blade comprises the following successive steps: (A) providing a turbomachine blade comprising an airfoil portion having a leading edge and a trailing edge and first and second sides connecting the leading edge and the trailing edge, (B) forming a protective edging on the leading edge by laser cladding, and (C) forming first and second protective stripes on the first and second sides adjacently to the edging by cold spraying through at least one spraying nozzle. The current invention is limited to the subject-matter of claim 1 and the appended claims.
- The accompanying drawings, which are incorporated herein and constitute an integral part of the present specification, illustrate exemplary embodiments and, together with the detailed description, explain these embodiments. In the drawings:
-
Fig. 1 shows a schematic lateral view of an embodiment of a turbomachine blade before forming a protective structure; -
Fig. 2 shows a schematic lateral view of an embodiment of a turbomachine blade during formation of a protective structure; -
Fig. 3 shows a schematic lateral view of an embodiment of a turbomachine blade after forming a protective structure; -
Fig. 4 shows schematically a detail ofFig. 3 ; -
Fig. 5 shows schematically a cross-section view ofFig. 4 ; -
Fig. 6 shows a schematic and partial cross-section view of an embodiment of a turbomachine blade before forming a protective structure; -
Fig. 7 shows a schematic and partial cross-section view of an embodiment of a turbomachine blade during formation of a protective structure (first intermediate stage); -
Fig. 8 shows a schematic and partial cross-section view of an embodiment of a turbomachine blade during formation of a protective structure (second intermediate stage); -
Fig. 9 shows a schematic and partial cross-section view of an embodiment of a turbomachine blade after forming a protective structure; -
Fig. 10 shows a schematic lateral view of an embodiment of a turbomachine blade after forming a protective structure in a way alternative to one ofFig. 3 ; -
Fig. 11 shows first possible schematic and partial cross-section view of an embodiment of a turbomachine blade after forming a protective structure; -
Fig. 12 shows second possible schematic and partial cross-section view of an embodiment of a turbomachine blade after forming a protective structure; -
Fig. 13 shows third possible schematic and partial cross-section view of an embodiment of a turbomachine blade after forming a protective structure; and -
Fig. 14 shows fourth possible schematic and partial cross-section view of an embodiment of a turbomachine blade after forming a protective structure. - The following description of exemplary embodiments refers to the accompanying drawings.
- The following description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
- Reference throughout the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases "in one embodiment" or "in an embodiment" in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
-
Fig. 1 shows a schematic lateral view of a turbomachine blade 1 before forming a protective structure. Blade 1 is provided with anairfoil portion 2 having a leadingedge 3 and atrailing edge 4 as well as afirst side 5 and a second side 6 (shown only inFig. 5 ) connecting leadingedge 3 and thetrailing edge 4.Airfoil portion 2 has atip region 21 and abase region 22;base region 22 ofairfoil portion 2 is adjacent tobase portion 10 of blade 1. -
Fig. 3, Fig. 4 and Fig. 5 show blade 1 after forming a protective structure. The protective structure comprises a protective edging 7 (that may be called "bumper" or "buffer") as well as a firstprotective stripe 8 and a second protective stripe 9 (shown only inFig. 5 );protective edging 7 is located on leadingedge 3; firstprotective stripe 8 is located onfirst side 5 and adjacent to edging 7; secondprotective stripe 9 is located, preferably only, onsecond side 6 and adjacent to edging 7. - In the embodiment of
Fig. 5 ,stripes sides - In the embodiment of
Fig. 9 ,stripes sides stripes - In the embodiment of
Fig. 11 (similar toFig. 5 ), the two stripes do not cover edging 171 and are located respectively only on the two sides of the airfoil. - In the embodiment of
Fig. 12 (similar toFig. 9 ), the two stripes are located respectively on the two sides of the airfoil, but cover also partially edging 172; the thickness of the stripes reduces gradually on the edging and is zero (or close to zero) in the middle of the edging. - In the embodiment of
Fig. 13 , the two stripes are located respectively on the two sides of the airfoil, but cover also entirely edging 173; the thickness of the stripes reduces gradually on the edging and is minimum and low in the middle of the edging. - In the embodiment of
Fig. 14 , the two stripes are located respectively on the two sides of the airfoil, but cover also entirely edging 173; the thickness of the stripes reduces gradually on the edging and is minimum and high in the middle of the edging. - According to these embodiments, the edging of the protective structure protrudes from the leading edge of the airfoil portion of the blade. Protrusion (at the end of blade manufacturing) varies depending on the manufacturing process (e.g. degree of erosion due to cold spraying). Considering the camber line (100 in
figures 11-14 ) of the airfoil portion and its prolongation, protrusion may be in the range of e.g. from 0.05 to 1 mm. - The cross-section area of the edging (immediately after its formation, e.g. before cold spraying) should take into account the manufacturing process (e.g. degree of erosion due to cold spraying) and may be in the range from 1 mm2 to 20 mm2, more typically in the range from 4 mm2 to 10 mm2. The cross-section area of the edging (immediately after its formation, e.g. before cold spraying) should take into account the manufacturing process (e.g. degree of erosion due to cold spraying) and may look like a bulge.
- The external shape of the airfoil portion of the blade at the end of blade manufacturing depends on the external shape of the airfoil portion of the blade before formation of the protective structure and on the overlying protective structure, in particular the protective edging and its erosion during formation of the protective stripes. Therefore, at least the leading edge of the airfoil portion of the blade before formation of the protective structure should be manufactured a bit recessed with respect to the ideal position of the leading edge of the airfoil portion of the blade at the end of blade manufacturing.
- The solution according to the above embodiments is particular useful for thin blades, for example blades having a thin leading edge, for example in the range of 4-8 mm.
- As it will be explained better afterward, the edging of the protective structure is formed by laser cladding or welding or plasma spraying or detonation spraying or wire arc spraying or flame spraying or high velocity oxyfucl coating spraying or warm spraying (preferably by laser cladding), while the first and second stripes of the protective structure are formed by cold spraying.
- The airfoil portion of the blade may be made of iron, titanium, nickel base alloy or stainless steel; preferably, it is made of stainless steel, for example AISI420.
- The edging of the protective structure may be made of cobalt base alloy or cobalt-chromium alloy; preferably, it is made of Stellite-type material, in
particular Stellite 6 or Stellite 12 orStellite 21, or Ultimet or any of the materials described and claimed in patent applicationEP1403397 or any of the materials described and claimed in patent applicationEP1403398 . The material of the edging is more resistant to solid particle erosion than the material of the airfoil in order to resist better to the mechanical erosion due to cold spraying. - The first and second stripes of the protective structure may be made of cobalt base alloy or cobalt-chromium alloy; preferably, they are made of Stellite-type material, in
particular Stellite 6 or Stellite 12 orStellite 21, or Ultimet or any of the materials described and claimed in patent applicationEP1403397 or any of the materials described and claimed in patent applicationEP1403398 . The material of the first and second stripes is resistant to liquid droplet erosion. The material of the first and second stripes may be equal to or different from the material of the edging. - The edging of the protective structure and the first and second stripes of the protective structure may extend over part (i.e. from preferably 20% to preferably 50%) of the height of the airfoil portion of the blade (see e.g.
Fig. 3 andFig. 10 ). Typically, the head end of the stripes is at the tip of the airfoil portion and the tail end of stripes is at an intermediate position of the airfoil portion. Preferably the edging of the protective structure is long equal to or slightly more than the first and second stripes of the protective structure. The height of the airfoil portion being the portion of the blade extending from the tip to the root of the blade. - The first and second stripes of the protective structure may extend over part (i.e. from preferably 5% to preferably 50%) of the width of the airfoil portion of the blade (see e.g.
Fig. 3 andFig. 10 ). Typically, the stripes extend from leading edge of the airfoil portion of the blade. The width of the airfoil portion being the portion of the blade extending from the leading to the trailing edge. - Blades identical or similar to those that have just been described may advantageously be used in turbomachines in the fields of "Oil & Gas" and "Energy". In particular, thanks to their resistance to liquid droplet erosion, steam turbines are an ideal application.
- A protective structure identical or similar to those that have just been described (see
Fig. 3 +4 andFig. 10 ) may be formed on a turbomachine blade through the following successive steps: - A) providing a turbomachine blade comprising an airfoil portion having a leading edge and a trailing edge and first and second sides connecting the leading edge and the trailing edge, (see e.g.
Fig. 1 and Fig. 6 ) - B) forming a protective edging on the leading edge by laser cladding, (see e.g.
Fig. 2 and Fig. 7 )
and - C) forming first and second protective stripes on the first and second sides adjacently to the edging by cold spraying through at least one spraying nozzle, which is a very effective way of forming thin and well adhering layers of materials resistant to erosion.
(see e.g.Fig. 3 and Fig. 5 orFig. 9 ) - In this way, the leading edge of the airfoil is protected by the edging and the cross-section of the airfoil is well covered through cold spraying both laterally and frontally.
- This is particularly advantageous for thin blades, more in particular for blades having a thin leading edge; a "thin leading edge" may have a thickness in the range of e.g. 2-10 mm - as the cross-section of the leading edge is similar to a semicircle, a "thin leading edge" may have a radius in the range of e.g. 1-5 mm. In this way, heating of the blades due to laser cladding is quite low and therefore residual stress in the blades and distortion of the blades and "stress corrosion cracking" in the blades are quite low.
- The same spraying nozzle may be used for forming both protective stripes. Alternatively, a first spraying nozzle may be used for forming a first protective stripe and a second spraying nozzle may be used for forming a second protective stripe; in this case, the first and second protective nozzles may be formed at the same time.
- The stripes of the protective structure may comprise a plurality of parallel (or substantially parallel) segments. In
figures 4-9 ,segments leading edge 3. Infigures 10-14 ,segments 181 are parallel (or substantially parallel) to theleading edge 103. It is to be noted that these segments touch each other laterally even ifFig. 4 andFig. 10 show them as distant. - According to the invention of claim 1, the spraying nozzle moves at least from a side (e.g. 5 or 6) of the airfoil portion toward the edging (e.g. 7) for forming a stripe (e.g. 8 or 9) and rotates preferably by at least 40° about the leading edge (e.g. 3) in order to form a stripe (e.g. 8 or 9) adjacent to the leading edge (e.g. 3) and to the edging (e.g. 7). During the initial part of the motion of the spraying nozzle, the spraying jet is directed highly inclined (preferably perpendicular) to the surface of (the side of) the airfoil; when the spraying nozzle approaches the leading edge the spraying nozzle is gradually rotated so that the spraying jet remains directed highly inclined (preferably perpendicular) to the surface of (the front of) the airfoil.
- As a first alternative, step C may comprise (consider e.g.
figures 6-9 ): - a first sub-step C1A (see
Fig. 8 ) wherein a spraying nozzle moves from a first side (e.g. 5) of the airfoil portion toward the edging (e.g. 70, 71, 72) and rotates by at least 40° and preferably 80-90° thus forming a segment (e.g. 81) of a first stripe (e.g. 8),
and immediately after - a second sub-step C2A (see
Fig. 9 ) wherein a spraying nozzle moves from a second side (e.g. 6) of the airfoil portion toward the edging (e.g. 70, 71, 72) and rotates by at least 40° and preferably 80-90° thus forming a segment (e.g. 91) of a second stripe (9); - In this way, two separate segments are formed at the same level on the two sides of the airfoil portion.
- If sub-steps C1A and C2A are repeated at different levels several times two stripes are formed on the two sides of the airfoil portion, contemporaneously.
- As a second alternative, step C may comprise:
- a first sub-step C1B wherein a spraying nozzle moves from a first side (e.g. 5) of the airfoil portion toward the edging (e.g. 70, 71, 72) and rotates by at least 40° and preferably 80-90° thus forming a segment (e.g. 81) of a first stripe (e.g. 8),
and immediately after - a second sub-step C2B (see
Fig. 9 ) wherein the same spraying nozzle rotates by at least 40° and preferably 80-90°, and moves away from the edging (e.g. 7) to the first side (e.g. 5) of the airfoil portion thus forming another segment (e.g. 81) of the same first stripe (e.g. 8); - In this way, two parallel segments are formed at different levels on the same side of the airfoil portion in two manufacturing operations.
- If sub-steps C1B and C2B are repeated several times one stripe is formed on one side of the airfoil portion. Afterwards, another stripe is formed on the other side of the airfoil portion.
- As a third alternative, step C may comprise:
- a first sub-step C3 wherein a spraying nozzle moves from the first side (e.g. 5) of the airfoil portion toward the edging (e.g. 7) thus forming a segment (e.g. 81) of the first stripe (e.g. 8),
- a second sub-step C4 wherein the same spraying nozzle rotates about the leading edge (e.g. 3) by 80-180° thus forming a (typically thin) connecting segment,
- a third sub-step C5 wherein the same spraying nozzle moves away from the edging (e.g. 7) to the second side (e.g. 6) of the airfoil portion thus forming a segment (e.g. 91) of the second stripe (e.g. 9);
- In this way, two consecutive segments are formed at the same level on the two sides of the airfoil portion.
- If sub-steps C3, C4 and C5 are repeated at different levels several times two stripes are formed on the two sides of the airfoil portion, contemporaneously.
- According to the third alternative, step C may comprise also the following sub-steps after sub-step C5:
- a fourth sub-step C6 wherein the same spraying nozzle moves from the second side (e.g. 6) of the airfoil portion toward the edging (e.g. 7) thus forming a segment of the second stripe (e.g. 9) adjacent to the previous one,
- a fifth sub-step C7 wherein the same spraying nozzle rotates about the leading edge (e.g. 3) by 80-180° thus forming a (typically thin) connecting segment,
- a sixth sub-step C8 wherein the same spraying nozzle moves away from the edging (e.g. 7) to the first side (e.g. 5) of the airfoil portion thus forming a segment of the first stripe adjacent (e.g. 8) to the previous one;
- Preferably, during sub-steps C6, C7 and C8 the spraying nozzle maintains a constant longitudinal position on the airfoil portion.
- In this way, further two segments (adjacent to the first two segments) are formed at the same level on the two sides of the airfoil portion.
- If sub-steps C3, C4, C5, C6, C7 and C8 are repeated at different levels several times two stripes are formed on the two sides of the airfoil portion, contemporaneously.
Claims (7)
- A method of forming a protective structure on a turbomachine blade (1), wherein, the method comprises the following successive steps:A) providing a turbomachine blade (1) comprising an airfoil portion (2) having a leading edge (3) and a trailing edge (4) and first and second sides (5, 6) connecting the leading edge (3) and the trailing edge (4),B) forming a protective edging (7) on the leading edge (3) by laser cladding, andC) forming first and second protective stripes (8, 9) on the first and second sides (5, 6) adjacently to the edging by cold spraying through a spraying nozzle;wherein the spraying nozzle moves at least from a side (5,6) of the airfoil portion (2) toward the edging (7) for forming a stripe (8,9) and rotates about the leading edge (3) in order to form the stripe (8,9) adjacent to the leading edge (3) and to the edging (7).
- The method of claim 1, wherein the first protective stripe (8) is formed before or after or contemporaneously with the second protective stripes (9).
- The method of claim 1 or claim 2, wherein the stripes (8, 9) comprise a plurality of parallel segments (81, 91) transversal to the leading edge (3).
- The method of any preceding claim, wherein, in step C, the spraying nozzle moves from a side (5, 6) of the airfoil portion toward the edging (7) and rotates by at least 40°, preferably 80-90°.
- The method of any preceding claim, wherein step C comprises:a first sub-step C3 wherein the spraying nozzle moves from the first side (5) of the airfoil portion (2) toward the edging (7) thus forming a segment (81) of the first stripe (8),a second sub-step C4 wherein the spraying nozzle rotates about the leading edge (3) by 80-180° thus forming a connecting segment,a third sub-step C5 wherein the spraying nozzle moves away from the edging (7) to the second side (6) of the airfoil portion (2) thus forming a segment (91) of the second stripe (9).
- The method of claim 5, wherein step C comprises the following sub-steps after sub-step C5:a fourth sub-step C6 wherein the spraying nozzle moves from the second side of the airfoil portion toward the edging thus forming a segment of the second stripe adjacent to the previous one,a fifth sub-step C7 wherein the spraying nozzle rotates about the leading edge by 80-180° thus forming a connecting segment,a sixth sub-step C8 wherein the spraying nozzle moves away from the edging to the first side of the airfoil portion thus forming a segment of the first stripe adjacent to the previous one;wherein the spraying nozzle is displaced longitudinally after sub-step C5 and before sub-step C6.
- The method of any preceding claim, wherein the stripes (108) comprise a plurality of parallel segments (181) parallel to the leading edge (103).
Priority Applications (1)
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PL16736885T PL3322832T3 (en) | 2015-07-13 | 2016-07-11 | Method of forming a protective structure on a turbomachine blade |
Applications Claiming Priority (2)
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ITUB2015A002136A ITUB20152136A1 (en) | 2015-07-13 | 2015-07-13 | TURBOMACCHINA PADDLE WITH PROTECTIVE STRUCTURE, TURBOMACCHINA, AND METHOD FOR FORMING A PROTECTIVE STRUCTURE |
PCT/EP2016/066445 WO2017009295A1 (en) | 2015-07-13 | 2016-07-11 | Turbomachine blade with protective structure, turbomachine, and method of forming a protective structure |
Publications (2)
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EP3322832A1 EP3322832A1 (en) | 2018-05-23 |
EP3322832B1 true EP3322832B1 (en) | 2021-08-25 |
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EP (1) | EP3322832B1 (en) |
JP (1) | JP6847059B2 (en) |
BR (1) | BR112018000669B1 (en) |
IT (1) | ITUB20152136A1 (en) |
PL (1) | PL3322832T3 (en) |
WO (1) | WO2017009295A1 (en) |
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FR3090427B1 (en) * | 2018-12-21 | 2023-11-10 | Safran | METHOD FOR MANUFACTURING A CORE |
CN110439623B (en) * | 2019-08-14 | 2024-05-14 | 上海两擎机电科技合伙企业(有限合伙) | Metal edging for aircraft engine fan blade, machining tool and machining method |
CN111020562B (en) * | 2019-12-09 | 2021-07-20 | 山东建筑大学 | Method for preparing amorphous and carbon-based nano-phase reinforced composite material by laser |
CN111793795A (en) * | 2020-06-24 | 2020-10-20 | 浙江工业大学 | Preparation method of cobalt-based anti-cavitation coating based on work hardening plastic deposition |
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FR2612106B1 (en) * | 1987-03-09 | 1989-05-19 | Alsthom | METHOD OF LAYING A PROTECTIVE COATING ON A TITANIUM ALLOY BLADE AND A COATED BLADE |
US5419976A (en) * | 1993-12-08 | 1995-05-30 | Dulin; Bruce E. | Thermal spray powder of tungsten carbide and chromium carbide |
ITMI20022056A1 (en) | 2002-09-27 | 2004-03-28 | Nuovo Pignone Spa | COBALT BASED ALLOY FOR THE COATING OF BODIES SUBJECT TO LIQUID EROSION. |
ITMI20022057A1 (en) | 2002-09-27 | 2004-03-28 | Nuovo Pignone Spa | METHOD FOR TREATING BODIES SUBJECT TO EROSION FROM LIQUIDS AND COATING ANTIEROSION ALLOYS. |
US7601431B2 (en) * | 2005-11-21 | 2009-10-13 | General Electric Company | Process for coating articles and articles made therefrom |
EP1840245A1 (en) * | 2006-03-27 | 2007-10-03 | Siemens Aktiengesellschaft | Matrix and coating system comprising non-stochiometric particles |
US8192792B2 (en) * | 2006-10-27 | 2012-06-05 | United Technologies Corporation | Cold sprayed porous metal seals |
WO2008116757A2 (en) * | 2007-03-27 | 2008-10-02 | Alstom Technology Ltd | Turbomachine blade with erosion and corrosion protective coating and method of manufacturing the same |
US20090193656A1 (en) * | 2008-02-04 | 2009-08-06 | General Electric Company | Steam turbine bucket with erosion durability |
US20110097213A1 (en) * | 2009-03-24 | 2011-04-28 | Peretti Michael W | Composite airfoils having leading edge protection made using high temperature additive manufacturing methods |
JP5377241B2 (en) * | 2009-11-20 | 2013-12-25 | 株式会社東芝 | Gas turbine rotor blade repair method and gas turbine rotor blade |
US20110129351A1 (en) * | 2009-11-30 | 2011-06-02 | Nripendra Nath Das | Near net shape composite airfoil leading edge protective strips made using cold spray deposition |
DE102011077804A1 (en) * | 2011-06-20 | 2012-12-20 | Siemens Aktiengesellschaft | Shovel for a thermal turbomachine |
US9404172B2 (en) * | 2012-02-22 | 2016-08-02 | Sikorsky Aircraft Corporation | Erosion and fatigue resistant blade and blade coating |
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US20140272166A1 (en) * | 2013-03-13 | 2014-09-18 | Rolls-Royce Corporation | Coating system for improved leading edge erosion protection |
JP2014240511A (en) * | 2013-06-11 | 2014-12-25 | 株式会社フジミインコーポレーテッド | Method of producing sprayed coating and material for flame spray |
-
2015
- 2015-07-13 IT ITUB2015A002136A patent/ITUB20152136A1/en unknown
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- 2016-07-11 WO PCT/EP2016/066445 patent/WO2017009295A1/en active Application Filing
- 2016-07-11 EP EP16736885.1A patent/EP3322832B1/en active Active
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JP6847059B2 (en) | 2021-03-24 |
EP3322832A1 (en) | 2018-05-23 |
JP2018527500A (en) | 2018-09-20 |
BR112018000669A2 (en) | 2018-09-18 |
ITUB20152136A1 (en) | 2017-01-13 |
PL3322832T3 (en) | 2021-12-27 |
WO2017009295A1 (en) | 2017-01-19 |
BR112018000669B1 (en) | 2021-12-14 |
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