EP3495612B1 - Procédé de fabrication de composant composite - Google Patents

Procédé de fabrication de composant composite Download PDF

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Publication number
EP3495612B1
EP3495612B1 EP17205758.0A EP17205758A EP3495612B1 EP 3495612 B1 EP3495612 B1 EP 3495612B1 EP 17205758 A EP17205758 A EP 17205758A EP 3495612 B1 EP3495612 B1 EP 3495612B1
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EP
European Patent Office
Prior art keywords
parts
metal
manufacturing
fibres
metal matrix
Prior art date
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Active
Application number
EP17205758.0A
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German (de)
English (en)
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EP3495612A1 (fr
Inventor
Hartmut Hähnle
Jürgen Gerhard Hoffmann
Michele Pesce
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.)
Ansaldo Energia IP UK Ltd
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Ansaldo Energia IP UK Ltd
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Priority to EP17205758.0A priority Critical patent/EP3495612B1/fr
Priority to CN201811487079.XA priority patent/CN109877318B/zh
Publication of EP3495612A1 publication Critical patent/EP3495612A1/fr
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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/14Form or construction
    • F01D5/147Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/28Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282Selecting composite materials, e.g. blades with reinforcing filaments
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00Details, component parts, or accessories
    • F04D29/02Selection of particular materials
    • F04D29/023Selection of particular materials especially adapted for elastic fluid pumps
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00Details, component parts, or accessories
    • F04D29/26Rotors specially for elastic fluids
    • F04D29/32Rotors specially for elastic fluids for axial flow pumps
    • F04D29/321Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
    • F04D29/324Blades
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00Details, component parts, or accessories
    • F04D29/40Casings; Connections of working fluid
    • F04D29/52Casings; Connections of working fluid for axial pumps
    • F04D29/54Fluid-guiding means, e.g. diffusers
    • F04D29/541Specially adapted for elastic fluid pumps
    • F04D29/542Bladed diffusers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/60Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603Composites; e.g. fibre-reinforced
    • F05D2300/6032Metal matrix composites [MMC]

Definitions

  • the present invention relates to a composite component and a method for manufacturing the same.
  • the composite component is used in a gas turbine; for example the composite component is a compressor blade or vane or a turbine blade or vane for a gas turbine.
  • Metal matrix composite materials have metal or ceramic reinforcing fibers embedded in a metal matrix; metal matrix composite materials have high strength and, compared to non-metal matrix composite materials, they can typically operate in a wider range of temperatures, do not absorb moisture, have better electrical and thermal conductivity, are less sensitive to stress concentration, for example due to notching effects or impacts of foreign objects. Metal matrix composite materials have a lower density and higher specific strength than non-metal matrix composite materials, thus they allow light weight construction.
  • US 2013/0 259 701 A1 discloses a reinforcing edge of a turbomachine blade having a reinforcing structure of three-dimensionally woven ceramic fibers and a metal or metal alloy matrix.
  • Non-metal matrix composite materials are also known, like carbon fiber composites such as carbon-fiber-reinforced carbon (CFRC); these non-metal matrix composite materials can withstand high temperatures but they cannot be exposed to an oxidizing atmosphere at high temperatures, are sensitive to impact damages, their life time or failure is difficult to predict and current inspection technologies do not allow a prediction of the remaining life time.
  • CFRRC carbon-fiber-reinforced carbon
  • the inventors of the present description have found a way to combine the advantages of the metal matrix composite materials with those of the non-metal matrix composite materials.
  • EP 2 474 638 A2 discloses a method for manufacturing a composite component for a gas turbine that comprises at least a first part made out of a metal matrix reinforced with carbon fibres. The first part is joined to at least a second part made out of metal without carbon fibres.
  • EP 3 170 587 A2 teaches providing metal powder, providing carbon fibres, simultaneously manufacturing the first parts and the second parts by local laser melting technology, such as SLM or direct laser melting.
  • SLM local laser melting technology
  • Other examples of known methods are disclosed in US 6 144 008 A , in US 9 32 446 B2 , in EP 2 703 605 A2 , in EP 3 020 918 A1 and in EP 1 920 869 A1 .
  • the present invention concerns a method for manufacturing a composite gas turbine blade or vane in accordance with the accompanying claims.
  • a composite component 1 for a gas turbine is a compressor blade or vane or a turbine blade or vane; other components are possible, such as heat shields, etc, however such components do not fall under the scope of the invention
  • the component 1 comprises at least a first part 2 made out of a metal matrix 3 reinforced with carbon fibres 4; the at least a first part 2 is joined to at least a second part 6 made out of metal 7 without reinforcing carbon fibres.
  • the metal of the metal matrix 3 of the first part 2 can be different from the metal 7 of the second part 6.
  • the metal of the first and second parts 2, 6 can be selected according to the properties desired, such as weight, erosion resistance, corrosion or oxidation resistance, etc.
  • the metal of the metal matrix 3 of the first part 2 can be the same as the metal 7 of the second part 6. This solution can be preferred if the manufacturing process so requires or in case the first and second parts 2, 6 require metal having the same properties.
  • Components exposed to high temperature gases of a gas turbine e.g. compressor or turbine blades or vanes
  • Components made out of traditional metal matrix composite materials cannot be provided with cooling systems (at the current state of the art), therefore the application of traditional metal matrix composite materials in gas turbine components is limited due to the maximum temperature the metal matrix can withstand.
  • one or more second parts 6 can comprise at least a cooling element 8.
  • the cooling element 8 is preferably a channel, which can carry a cooling fluid, such as air.
  • the turbine or compressor blade or vane has a nose 9 that is defined by a second part 6 and opposite sides that are defined by first parts 2.
  • An intermediate section of the component 1 can be defined by an additional second part 6 and the terminal part with the trailing edge can be defined by a first part 2, e.g. to be able to manufacture a thin but at the same time strong trailing edge.
  • the composite component 1 can withstand high temperatures, because the first parts 2 include fibres able to withstand high stress also at high temperature.
  • these first parts can be cooled by the second parts that are provided with the cooling elements 8.
  • a first example of the method for manufacturing the composite component which does not fall under the scope of the claims comprises ( figures 2 through 3 ): manufacturing at least a first part 2 and a second part 6, then joining the at least a first part 2 and second part 6.
  • Manufacturing of the first and second parts 2, 6 according to this embodiment of the method occurs separately, i.e. the first parts 2 are manufactured separately from the second parts 6; this allows to advantageously select the best method for manufacturing each part 2 or 6, according to the required features thereof.
  • possible manufacturing methods for the first and/or second parts are casting, additive manufacturing such as SLM (selective laser melting), machining, spray deposition, etc.
  • Joining the first part 2 to the second part 6 comprises laser welding or laser deposition welding.
  • first parts 2 are manufactured by casting or SLM or spray deposition of metal on the carbon fibres.
  • second parts 6 are casted or are manufactured by SLM or are manufactured by spray deposition.
  • the first parts 2 and second parts 6 are then welded together (reference 10 identifies the welding).
  • a second example of the method for manufacturing the composite component which does not fall under the scope of the claims comprises:
  • this method allows manufacturing of first parts 2 whose features (e.g. material or geometrical features or manufacturing method or mechanical/thermal treatments) are independent from those of the second parts 6, because the first parts 2 are built before and thus independently of the second parts 6.
  • features e.g. material or geometrical features or manufacturing method or mechanical/thermal treatments
  • first parts 2 when the first parts 2 are manufactured, they can be provided with fibres that protrude from them ( figure 5 ), such that when the first parts 2 are housed in the mold 11 and the second parts 6 are casted, the protruding fibres promote holding of the first parts 2 to the second parts 6.
  • first parts 2 are manufactured first, e.g. by casting, additive manufacturing such as SLM (selective laser melting), spray deposition, machining, etc.. Then these first parts 2 are housed in the mold 11 where metal is introduced to manufacture also the second parts 6 directly joined to the first parts 2.
  • additive manufacturing such as SLM (selective laser melting), spray deposition, machining, etc.
  • the cooling elements 8 can be made during casting of the second part 6; alternatively or in addition, the cooling elements 8 can be realized e.g. by machining or in other ways after casting of the second parts 6.
  • a third example of the method for manufacturing the composite component 1 which does not fall under the scope of the claims comprises:
  • Bonding of the first part 2 to the second parts 6 is in this embodiment particularly effective, because all parts 2, 6 are made at the same time in the mold 11.
  • the fibre structure 16 makes it easier and faster handling of the fibres.
  • the method for manufacturing the composite component comprises:
  • This method allows manufacturing of complex three dimensional shapes with high tensile strength.
  • the design of the first parts 2 can be easily optimized as load carrying sections and the design of the second parts 6 can be easily optimized in view of the required cooling.
  • the powder in order to carry out the SLM process, can be deposited by electrostatic deposition, this allows to easily fill in gaps between fibres and to also build in vertical or inclined or downwards direction.
  • the angle A of the laser beam 18 with the support plane 19 of the fibres is between 10-90 degree and preferably between 30-70 degree, with a thickness of the metal powder layer h less than 0.5 times the diameter D of the fibres and preferably the thickness of the metal powder layer is less than 0.3 times the diameter D of the fibres.
  • the distance d between the fibres is greater than 0.6 times the diameter D of the fibres and preferably 0.8 times and is less than 2 times the diameter D of the fibres and preferably 1.2 times.
  • the diameter DL of the laser beam is greater than 1.1 times the diameter D of the fibres and preferably it is 1.5 times greater than the diameter D, such that the laser beam heats the fibres and extends beyond their sides to melt the metal powder.
  • the advantages of an impact resistant metal matrix are combined with light weight temperature resistant fibers.
  • the surface of the metal matrix allows inspection and detection of crack initiation.
  • the leading edge can be defined by a first part 2 (to allow for intense cooling via the cooling element 8) and the trailing edge can be defined by a second part 6, to be able to provide a strong, thin trailing edge.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Powder Metallurgy (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Claims (4)

  1. Procédé destiné à fabriquer une aube ou une pale composite de turbine à gaz (1), l'aube ou la pale composite de turbine à gaz (1) comprenant des premières parties (2) réalisées à partir d'une matrice métallique (3) renforcée de fibres de carbone (4), les premières parties étant jointes à des secondes parties (6) réalisées à partir de métal (7) sans fibres de carbone, le procédé comprenant les étapes suivantes :
    fournir une poudre métallique,
    fournir des fibres de carbone (4), fabriquer simultanément les premières parties (2) et les secondes parties (6) avec une technologie de fusion locale par laser, telle qu'une SLM, ou de fusion directe par laser,
    où l'aube ou la pale de turbine à gaz (1) présente un nez (9) qui est défini par l'une desdites secondes parties (6) comprenant un canal de refroidissement (8), des côtés opposés définis par lesdites premières parties (2), une section intermédiaire définie par l'une desdites secondes parties (6) comprenant un canal de refroidissement (8), et une partie terminale comprenant le bord de fuite est définie par l'une desdites premières parties (2).
  2. Procédé selon la revendication 1, caractérisé en ce que le métal de la matrice métallique (3) de l'une au moins des premières parties (2), est différent du métal (7) de l'une au moins des secondes parties (6).
  3. Procédé selon la revendication 1, caractérisé en ce que le métal de la matrice métallique (3) de l'une au moins des premières parties (2), est identique au métal (7) de l'une au moins des secondes parties (6).
  4. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que, pour exécuter le processus de SLM, la poudre est déposée par dépôt électrostatique.
EP17205758.0A 2017-12-06 2017-12-06 Procédé de fabrication de composant composite Active EP3495612B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP17205758.0A EP3495612B1 (fr) 2017-12-06 2017-12-06 Procédé de fabrication de composant composite
CN201811487079.XA CN109877318B (zh) 2017-12-06 2018-12-06 复合构件及用于制造其的方法

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP17205758.0A EP3495612B1 (fr) 2017-12-06 2017-12-06 Procédé de fabrication de composant composite

Publications (2)

Publication Number Publication Date
EP3495612A1 EP3495612A1 (fr) 2019-06-12
EP3495612B1 true EP3495612B1 (fr) 2021-05-12

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EP17205758.0A Active EP3495612B1 (fr) 2017-12-06 2017-12-06 Procédé de fabrication de composant composite

Country Status (2)

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EP (1) EP3495612B1 (fr)
CN (1) CN109877318B (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2582148A (en) * 2019-03-12 2020-09-16 Airbus Operations Ltd Impact resistant panels
US11732586B2 (en) * 2020-05-14 2023-08-22 Toyota Motor Engineering & Manufacturing North America, Inc. Metal matrix composite turbine rotor components

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6144008A (en) * 1996-11-22 2000-11-07 Rabinovich; Joshua E. Rapid manufacturing system for metal, metal matrix composite materials and ceramics
US9327446B2 (en) * 2012-12-10 2016-05-03 Rolls-Royce Plc Joint structure and method
EP3170587A2 (fr) * 2015-10-28 2017-05-24 Airbus Operations GmbH Composant métallique renforcé par fibres pour aéronef ou vaisseau spatial et procédés de production de composants métalliques renforcés par des fibres

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GB1284538A (en) * 1968-11-19 1972-08-09 Rolls Royce Blade for a fluid flow machine
US5439750A (en) * 1993-06-15 1995-08-08 General Electric Company Titanium metal matrix composite inserts for stiffening turbine engine components
GB0428368D0 (en) * 2004-12-24 2005-02-02 Rolls Royce Plc A composite blade
US7758313B2 (en) * 2006-02-13 2010-07-20 General Electric Company Carbon-glass-hybrid spar for wind turbine rotorblades
US7775772B2 (en) * 2006-11-08 2010-08-17 General Electric Company System for manufacturing a rotor having an MMC ring component and an airfoil component having MMC airfoils
US7780420B1 (en) * 2006-11-16 2010-08-24 Florida Turbine Technologies, Inc. Turbine blade with a foam metal leading or trailing edge
CN100507065C (zh) * 2007-04-10 2009-07-01 中北大学 碳纤维增强镍基复合材料及其制备方法
GB0908707D0 (en) * 2009-05-21 2009-07-01 Rolls Royce Plc Reinforced composite aerofoil blade
FR2965202B1 (fr) 2010-09-28 2012-10-12 Snecma Procede de fabrication d'une piece et piece massive composite obtenue par ce procede
US8387504B2 (en) * 2011-01-06 2013-03-05 General Electric Company Fiber-reinforced Al-Li compressor airfoil and method of fabricating
FR2989991B1 (fr) * 2012-04-30 2016-01-08 Snecma Renfort structurel metallique d'aube de turbomachine
GB201215299D0 (en) * 2012-08-29 2012-10-10 Rolls Royce Plc A Metallic foam material
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Patent Citations (3)

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Publication number Priority date Publication date Assignee Title
US6144008A (en) * 1996-11-22 2000-11-07 Rabinovich; Joshua E. Rapid manufacturing system for metal, metal matrix composite materials and ceramics
US9327446B2 (en) * 2012-12-10 2016-05-03 Rolls-Royce Plc Joint structure and method
EP3170587A2 (fr) * 2015-10-28 2017-05-24 Airbus Operations GmbH Composant métallique renforcé par fibres pour aéronef ou vaisseau spatial et procédés de production de composants métalliques renforcés par des fibres

Also Published As

Publication number Publication date
CN109877318A (zh) 2019-06-14
CN109877318B (zh) 2023-08-04
EP3495612A1 (fr) 2019-06-12

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