EP4021663B1 - Verbessertes verfahren zur herstellung eines keramischen kerns zur herstellung von turbomaschinenschaufeln und keramischer kern - Google Patents

Verbessertes verfahren zur herstellung eines keramischen kerns zur herstellung von turbomaschinenschaufeln und keramischer kern Download PDF

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Publication number
EP4021663B1
EP4021663B1 EP20775042.3A EP20775042A EP4021663B1 EP 4021663 B1 EP4021663 B1 EP 4021663B1 EP 20775042 A EP20775042 A EP 20775042A EP 4021663 B1 EP4021663 B1 EP 4021663B1
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Prior art keywords
orifice
ceramic
manufacturing
core
ceramic core
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English (en)
French (fr)
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EP4021663A1 (de
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Adrien Bernard Vincent ROLLINGER
Alice Marie Lydie AGIER
Gaël Philippe François BATTISTONI
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Safran SA
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Safran SA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/103—Multipart cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns

Definitions

  • This presentation concerns the field of the manufacture of turbomachine blades using the lost-wax casting technique, in particular the manufacture of the ceramic cores used for the manufacture of these blades using this technique.
  • the present disclosure relates to a process for the manufacture of such a ceramic core, intended for the manufacture of hollow turbine engine blades according to the lost wax casting technique.
  • the blades present in turbomachines in particular turbine blades, for example low pressure, generally comprise internal cavities necessary for cooling these blades.
  • these cavities are formed, before the formation of the wax mold, by means of ceramic cores, the shape of which corresponds to the desired shape of the cavities in the final piece.
  • a portion of such a core 10 is shown schematically in the figure 1 .
  • These ceramic cores generally comprise a first part 20, the first part 20 being a functional part corresponding to the future cavities of the blade and having the shape thereof (only the upper end of the first part, corresponding to the tip, or head of dawn, is visible on the figure 1 ), and a second part 30, called for example a dome, serving as a region for holding the core 10.
  • the core 10 is held in a fixed position with respect to the ceramic mold via a non-functional portion of this second part 30.
  • the second part 30 also comprises a functional portion, at its lower end, serving in particular to form the contour of the bathtub from dawn to the end of the process of making it.
  • the first part 20 must be spaced from the second part 30, while being integral with the latter and maintained by the latter.
  • thin rods 40 are placed between these two parts, and hold these parts integral with each other and fixed relative to each other, while leaving a space S between these two parts.
  • the cast metal penetrating into this space S between these two parts will correspond to the bottom wall of the top bath of the blade, at the end of the manufacturing process of the blade.
  • Such an example kernel is disclosed in the document FR2889088 .
  • the rods 40 are directly placed in a mold and a ceramic paste is injected around.
  • the complexity of certain ceramic cores requires appropriate manufacturing techniques, such as additive manufacturing.
  • This technique in which the core is built layer by layer, does not allow the insertion of the rods during manufacture. It is therefore necessary to provide orifices in the core during the additive manufacturing of the latter, in order to be able to insert the rods therein a posteriori. Nevertheless, the insertion of these rods first requires cleaning, that is to say emptying the holes provided for this purpose, of the excess ceramic material which is deposited there during the printing of the core.
  • junction portion is formed at the same time as the first part and the second part during additive manufacturing, and therefore comprises the same material as these parts.
  • the junction portion may be a 3D printed manufacturing device, called a “printing medium”, forming a junction portion between these two parts during printing.
  • the junction portion makes it possible to maintain these two parts secured to each other and fixed relative to each other temporarily, before the insertion of the rods.
  • the contact between the junction portion and the first and second parts may be discontinuous.
  • the junction portion may comprise a plurality of studs or spikes interposed between these two parts. This configuration facilitates subsequent removal of this junction portion, after positioning the positioning rods.
  • the manufacture of the blank by additive manufacturing is carried out such that the blank thus obtained comprises the first part, the second part, and the junction portion.
  • this manufacture provides for the presence of at least one through hole.
  • through or “opening”, it is understood that the orifice opens on either side of the blank, as opposed to a blind hole comprising a bottom.
  • the orifice passes through the second part, the junction portion and the first part, opening out at each of its ends into a region outside the blank of the core, around the latter.
  • the configuration of the present disclosure makes it possible to easily expel these residues through an open end of the orifice, by applying pressure, for example by injecting a mixture of solvent and pulsed air, at the other open end of the orifice. 'orifice. It is thus possible to carry out the cleaning of the orifice effectively, by dispensing with the use of unsuitable tools such as drill bits, thus limiting the scrap rate of the cores.
  • the junction portion comprises a passage putting the through-orifice in fluid communication with a space outside the core blank.
  • This passage facilitates the cleaning of the through hole. Indeed, when the orifice is cleaned by injecting a solvent, for example, at the two ends of the orifice, the ceramic paste residues dissolved in the solvent can be evacuated through this passage.
  • the through hole comprises a first rectilinear portion extending from the first end, and a second rectilinear portion presenting an angle less than 180° with respect to the first rectilinear portion, and extending from the second end.
  • the first rectilinear portion extends through the second part from the first end to the junction portion, through the junction portion and part of the first part.
  • the second rectilinear portion extends in the first part between the end of the first portion rectilinear located in the first part, and the second end.
  • the first rectilinear portion and the second rectilinear portion form between them a bend having an angle of less than 180°, this bend preferably being arranged in the first part.
  • the length of the first rectilinear portion can be determined according to the length of the positioning rod to be inserted. The presence of this bend makes it possible to shorten the length of the second rectilinear portion of the orifice, and in particular makes it possible to reach the outside of the core.
  • the angle between the first and the second rectilinear portion is greater than or equal to 100°, preferably comprised between 110° and 120°.
  • the diameter of the first rectilinear portion of the through hole is between 0.15 and 0.3 mm.
  • the diameter of the first rectilinear portion can be determined according to the diameter of the positioning rod to be inserted. Preferably, a clearance must exist between the positioning rod and the orifice.
  • the diameter of the second rectilinear portion of the through hole is between 0.4 and 0.6 mm.
  • the through hole may have a circular section.
  • unsolidified residues of ceramic paste remain in the orifice. Cleaning removes these residues to allow insertion of the positioning rod. Furthermore, the elimination of the junction portion can be carried out by sintering the ceramic using a suitable tool, for example a high precision grinding wheel making it possible to release the space between the first part and the second part. .
  • the cleaning of the through hole is carried out by injecting pulsed air and/or a solvent into at least one end of the hole.
  • the pulsed air and/or the solvent injected at one end of the orifice is evacuated, carrying away the ceramic paste residues, through the other end of the orifice and/or through the passage in the portion of junction.
  • the pulsed air and/or the solvent injected at the two ends of the orifice, simultaneously or not, is evacuated, carrying the ceramic paste residues, through the passage in the junction portion.
  • through hole cleaning is accomplished by mechanically inserting a cleaning means into at least one end of the hole.
  • This technique of mechanical insertion of a cleaning means can be carried out alone, or in addition to the pulsed air and/or the solvent.
  • the cleaning step and the insertion step are performed simultaneously.
  • the fact of inserting the rod at one end of the through orifice makes it possible to push the ceramic residues, these residues being able to escape through the other end of the orifice.
  • the rod thus acts itself as a mechanical cleaning means.
  • the positioning rods are alumina rods.
  • the alumina rods are a ceramic material with the advantage of being resistant to the same thermal stresses as the rest of the part and having the same chemical properties on shakeout. They also allow a high tensile/compressive strength to ensure the dimensional stability of the bottom thickness of the tub, as well as a solid grip between the first and the second part.
  • rods comprising molybdenum can be used.
  • the plugging of the through hole is carried out by applying a ceramic paste to the two ends of said hole.
  • the filling of the two ends of the orifice makes it possible, on the one hand, to avoid an undesired infiltration of the wax during the manufacture of the wax mold, and on the other hand, to obtain a uniform surface state of the ceramic core. , especially on the first part. This ensures that the final piece does not have any irregularities.
  • the method comprises, after the filling, a hardening step making it possible to harden the ceramic paste.
  • the hardening step comprises, for example, exposure under a UV lamp to harden the ceramic paste used for filling. This makes it possible to improve the overall rigidity of the ceramic core, when its manufacture is finished.
  • the positioning rods are coated with ceramic glue.
  • This presentation also relates to a use of a ceramic core obtained by the method according to any one of the embodiments of this presentation, for the manufacture of hollow turbine blades for a turbomachine using the lost-wax casting technique. .
  • FIGS. 2A and 2B schematically represent samples of a ceramic core, in the form of test specimens, making it possible to illustrate the cleaning of an orifice of this core.
  • FIG 2A schematically represents a technique for cleaning an orifice 50 according to the prior art. Orifice 50 is blind.
  • the hatched part represents the ceramic core, more precisely, the polymerized paste forming the ceramic core.
  • the latter comprises a first part 20, a second part 30, and a junction portion 60.
  • the shaded part represents the unpolymerized ceramic paste remaining in the orifice 50 after the printing of the blank of the core.
  • the core blank is produced layer by layer, starting with the first part 20 for example, then the junction portion 60, then the second part 30, providing for the presence of the orifice(s) 50.
  • the junction portion 60 has a serrated shape, limiting the contact surface between the junction portion 60 and the first part 20 and/or the second part 30.
  • the junction portion 60 can thus comprise a plurality of teeth 61, under the form of pins or studs, interposed between these two parts.
  • the orifice 50 is blind and comprises a bottom 51.
  • the orifice cleaning operation is carried out, for example, by means of a drill bit 70, the passage of which through the orifice 50 makes it possible to evacuate the dough. Such a technique leads to the deterioration or breakage of many ceramic cores.
  • the orifice 50 comprises a first rectilinear portion 50a extending through the second part 30, the junction portion 60 and the first part 20, and a second rectilinear portion 50b extending through the first part 20 from the end of the first rectilinear portion 50a, and opening onto an outer face of the first part 20.
  • the first rectilinear portion 50a is preferably longer than the second rectilinear portion 50b, and is intended to receive a positioning rod.
  • the angle ⁇ between the first and the second rectilinear portion 50a, 50b is less than 180°, and greater than or equal to 100°, preferably between 110° and 120°.
  • a passage 62 is provided in the junction portion 60.
  • This passage 62 may be an orifice, or a local absence of teeth 61, making it possible to place the orifice 50 in fluid communication with a region external to the core. ceramic, and surrounding it.
  • This passage 62 makes it possible to facilitate the operation of cleaning the orifice 50. Indeed, at the end of the additive manufacturing, the cleaning of the orifice 50 can be carried out by injecting pulsed air at one or at the two ends of the orifice 50. The pressure exerted at the ends of the orifice 50 allows the evacuation of the unpolymerized paste present in the orifice, through the passage 62 of the junction portion 60 (cf. arrows on there figure 2A ).
  • a solvent can be injected, or a mixture of air and solvent.
  • a cylindrical tool of suitable diameter can be used to push the paste, in addition or instead of air and/or solvent.
  • FIG. 3 represents a schematic view of a part of a ceramic core 10 according to the present description, made by additive manufacturing, comprising a first part 20, a second part 30, and a junction portion 60.
  • the first part 20 has the shape of the desired cavities obtain at the end of the manufacture of the turbine blade.
  • On the picture 3 only the upper end of the first part 20, corresponding to the upper end, or top, of the blade, is visible.
  • the second part 30, or dome allows the maintenance of the ceramic core 10 during the production of the wax model, and during the casting of the metal in a ceramic shell mould.
  • the first part 20 and the second part 30 are spaced apart by a distance S of between 0.4 and 1.4 mm.
  • three through holes 50 extend through the second part 30, the junction portion 60 and the first part 20.
  • Each of these holes 50 comprises a first rectilinear portion 50a opening onto an outer face of the second part 30 , and a second rectilinear portion 50b (only one of which is visible on the picture 3 ) opening an outer face of the first part 20.
  • a positioning rod 40 is inserted into each of these holes 50.
  • These positioning rods 40 can be alumina rods, and can have a length of 13 mm and a diameter of 0.6mm. Nevertheless, these dimensions are not limiting, and can be modified according to the considered geometry of the core.
  • a first step in the manufacture of a ceramic core 10 comprises the manufacture of a blank of the core by additive manufacturing (step S1).
  • the blank comprises the first part 20, the junction portion 60 and the second part 30.
  • Additive manufacturing provides for the presence of the through holes 50, and of the passage(s) 62 in the junction portion 60.
  • the orifices 50 are cleaned, that is to say emptied of the residues of unpolymerized ceramic paste remaining in the orifices 50 (step S2).
  • pulsed air and/or solvent for example, is injected at the ends of the orifices 50.
  • the residual paste is thus evacuated through the passage 62 of the junction portion 60.
  • a positioning rod 40 is then inserted into each through hole 50 (step S3). More specifically, a positioning rod 40 is inserted into the first rectilinear portion 50a of each through hole.
  • the rods 40 are inserted from the top, that is to say from the end of the orifice 50 opening onto an external face of the second part 30, and pushed into the orifice 50 so as to extend to both in the second part 30 and in the first part 20.
  • the rods 40 can be coated beforehand with ceramic glue. This glue solidifies during the heat treatment described below, and allows optimal coating of the rod.
  • step S4 After the placement of the positioning rods 40 in the orifices 50, the latter are sealed (step S4).
  • This filling is carried out using a ceramic paste, so as to obtain a smooth surface state, on the external faces of the first and second parts 20 and 30. This makes it possible to avoid surface irregularities later on the model. in wax, and on the final piece.
  • Filling is followed by a step of hardening the ceramic paste, making it possible to solidify the paste added in step S4 (step S5).
  • This step can be carried out depending on the properties of the paste, depending on whether it is, for example, photosensitive or thermosensitive, by means in particular of a source of UV light or a source of heat.
  • the curing step is carried out by exposure to UV light.
  • the core 10 can also follow a heat treatment step, comprising debinding and sintering.
  • the method finally includes removing the junction portion 60 (step S6).
  • This elimination is facilitated by the serrated shape of the junction part 60, and can be carried out by any suitable tool, which can be inserted between the first part and the second part.
  • the first part 20 and the second part 30 are held together, and positioned relative to each other, by the positioning rods 40 only.
  • the ceramic core 10 thus obtained can then be used in the manufacture of hollow turbine engine blades using the lost wax casting technique.
  • the ceramic core 10 can be placed in a wax mould, being held by the second part 30, to form the wax model having the shape of the final piece, with the cavities formed by the first part 20 of the core.
  • the wax model is then dipped several times in a slip to form the ceramic mould.
  • the molten metal is poured into the ceramic mold and around the ceramic core, the latter being again held in a fixed position by means of the second part 30.
  • the ceramic mold and the ceramic core 10 are then eliminated, for example by shake-out, in order to obtain the final part.
  • the elimination of the ceramic also includes the elimination of the positioning alumina rods 40, removed during shake-out, then leaving small orifices through the bath at the top of the blade, at the place where found these rods. These orifices serve in particular as holes for removing dust or for evacuating the air present in the cavities of the blade.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Claims (13)

  1. Verfahren zur Herstellung eines Rohlings eines keramischen Kerns (10), der zur Herstellung hohler Turbomaschinenschaufeln gemäß der Wachsausschmelztechnik bestimmt ist, wobei der Rohling durch additive Fertigung hergestellt wird und umfasst:
    - mindestens einen ersten Teil (20), der zur Bildung der Hohlräume der hohlen Schaufeln bestimmt ist,
    - mindestens einen zweiten Teil (30), der ausgelegt ist, um die Positionierung des Kerns (10) in einer Wachsform zu gestatten, wobei der zweite Teil (30) und der erste Teil (20) über einen zeitweiligen Verbindungsabschnitt (60), der zwischen dem ersten Teil (20) und dem zweiten Teil (30) angeordnet ist, zueinander positioniert und gehalten werden,
    - mindestens eine Durchgangsöffnung (50), die sich durch den zweiten Teil (30), den zeitweiligen Verbindungsabschnitt (60) und den ersten Teil (20) erstreckt, wobei ein erstes Ende der Durchgangsöffnung (50) auf einer Außenfläche des zweiten Teils (30) ausmündet und ein zweites Ende der Durchgangsöffnung (50) auf einer Außenfläche des ersten Teils (20) ausmündet.
  2. Verfahren nach Anspruch 1, wobei der zeitweilige Verbindungsabschnitt (60) einen Durchgang (62), der die Durchgangsöffnung (50) in Fluidkommunikation versetzt, und einen zum Kernrohling äußeren Raum umfasst.
  3. Verfahren nach Anspruch 1 oder 2, wobei die Durchgangsöffnung (50) einen ersten geraden Abschnitt (50a) umfasst, der sich ab dem ersten Ende erstreckt, und einen zweiten geraden Abschnitt (50b), der einen Winkel (β) kleiner als 180° im Verhältnis zum ersten geraden Abschnitt (50a) aufweist und sich ab dem zweiten Ende erstreckt.
  4. Verfahren nach Anspruch 3, wobei der Winkel (β) zwischen dem ersten und dem zweiten geraden Abschnitt (50a, 50b) größer oder gleich 100° ist, vorzugweise zwischen 110° und 120° liegt.
  5. Verfahren nach einem der Ansprüche 1 bis 4, wobei der Durchmesser des ersten geraden Abschnitts (50a) der Durchgangsöffnung (50) zwischen 0,15 und 0,3 mm liegt.
  6. Verfahren zur Herstellung eines keramischen Kerns (10), der zur Herstellung hohler Turbomaschinenschaufeln gemäß der Wachsausschmelztechnik bestimmt ist, wobei das Verfahren einen Schritt der Herstellung eines Rohlings durch das Verfahren nach einem der Ansprüche 1 bis 5 umfasst und ebenfalls nach der Herstellung des Rohlings umfasst:
    - die Reinigung der Durchgangsöffnung (50),
    - das Einführen mindestens einer Positionierungsstange (40) in die Durchgangsöffnung (50),
    - das Wiederverschließen der Durchgangsöffnung (50),
    - das Entfernen des zeitweiligen Verbindungsabschnitts (60).
  7. Verfahren nach Anspruch 6, wobei die Reinigung der Durchgangsöffnung (50) durch eine Einleitung von gepulster Luft und/oder eines Lösungsmittels in mindestens ein Ende der Öffnung (50) durchgeführt wird.
  8. Verfahren nach Anspruch 6 oder 7, wobei die Positionierungsstangen (40) Aluminiumoxidstangen sind.
  9. Verfahren nach einem der Ansprüche 6 bis 8, wobei das Wiederverschließen der Durchgangsöffnung (50) durch Auftragen einer Keramikpaste auf die zwei Enden der Öffnung (50) durchgeführt wird.
  10. Verfahren nach einem der Ansprüche 6 bis 9, das nach dem Wiederverschließen einen Schritt des Härtens umfasst, der erlaubt, dass die für das Wiederverschließen der Öffnung (50) verwendete Keramikpaste aushärtet.
  11. Verfahren nach einem der Ansprüche 6 bis 10, wobei die Positionierungsstangen (40) vor ihrem Einführen mit Keramikkleber beschichtet werden.
  12. Rohling eines keramischen Kerns, der zur Herstellung von hohlen Turbomaschinenschaufeln gemäß der Wachsausschmelztechnik bestimmt ist, umfassend:
    - mindestens einen ersten Teil (20), der zur Bildung der Hohlräume der hohlen Schaufeln bestimmt ist,
    - mindestens einen zweiten Teil (30), der ausgelegt ist, um die Positionierung des Kerns (10) in einer Wachsform zu gestatten, wobei der zweite Teil (30) und der erste Teil (20) über einen zeitweiligen Verbindungsabschnitt (60), der zwischen dem ersten Teil (20) und dem zweiten Teil (30) angeordnet ist, zueinander positioniert und gehalten werden,
    - mindestens eine Durchgangsöffnung (50), die sich durch den zweiten Teil (30), den zeitweiligen Verbindungsabschnitt (60) und den ersten Teil (20) erstreckt, wobei ein erstes Ende der Durchgangsöffnung (50) auf einer Außenfläche des zweiten Teils (30) ausmündet und ein zweites Ende der Durchgangsöffnung (50) auf einer Außenfläche des ersten Teils (20) ausmündet.
  13. Verfahren zur Herstellung einer hohlen Turbomaschinenschaufel gemäß der Wachsausschmelztechnik, umfassend:
    - die Herstellung eines keramischen Kerns (10) durch ein Verfahren nach einem der Ansprüche 6 bis 11,
    - die Herstellung eines Wachsmodells, das die Form des endgültigen Teils aufweist, durch Anordnen des im vorhergehenden Schritt erhaltenen keramischen Kerns (10) in einer Wachsform,
    - die Herstellung einer Keramikform durch mehrmaliges Eintauchen des im vorhergehenden Schritt erhaltenen Wachsmodells in eine Masse,
    - das Gießen, nach Entfernen des Wachses, von geschmolzenem Metall in die Keramikform und um den keramischen Kern,
    - das Entfernen der Keramikform und des keramischen Kerns (10).
EP20775042.3A 2019-08-30 2020-08-27 Verbessertes verfahren zur herstellung eines keramischen kerns zur herstellung von turbomaschinenschaufeln und keramischer kern Active EP4021663B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1909534A FR3100143B1 (fr) 2019-08-30 2019-08-30 Procédé amélioré de fabrication d’un noyau céramique pour la fabrication d’aubes de turbomachine
PCT/FR2020/051507 WO2021038174A1 (fr) 2019-08-30 2020-08-27 Procede ameliore de fabrication d'un noyau ceramique pour la fabrication d'aubes de turbomachine

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EP4021663A1 EP4021663A1 (de) 2022-07-06
EP4021663B1 true EP4021663B1 (de) 2023-07-05

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US (1) US11745255B2 (de)
EP (1) EP4021663B1 (de)
CN (1) CN114340815B (de)
FR (1) FR3100143B1 (de)
WO (1) WO2021038174A1 (de)

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FR3121372B1 (fr) * 2021-03-30 2023-03-31 Safran Système d’insertion de tiges dans une ébauche de noyau céramique pour la fabrication d’aubes de turbomachine

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FR3047767B1 (fr) * 2016-02-12 2019-05-31 Safran Procede de formation de trous de depoussierage pour aube de turbine et noyau ceramique associe
CN107199312B (zh) * 2017-07-13 2023-05-09 广西玉柴机器股份有限公司 集成缸盖的快速铸造及成形方法
CN109482819A (zh) * 2018-11-16 2019-03-19 中国航发西安动力控制科技有限公司 铝合金壳体的铸造方法

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FR3100143A1 (fr) 2021-03-05
EP4021663A1 (de) 2022-07-06
FR3100143B1 (fr) 2021-11-12
CN114340815A (zh) 2022-04-12
CN114340815B (zh) 2023-12-05
WO2021038174A1 (fr) 2021-03-04
US20220288671A1 (en) 2022-09-15
US11745255B2 (en) 2023-09-05

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