JP2015517416A - Wear-resistant article - Google Patents

Abstract

The present disclosure generally relates to wear resistant articles, such as turbine fan blades, disk rotors, and the like, to which a composite lubricating sheet is bonded and which have improved frictional properties at high temperatures.

Description

  The present disclosure relates generally to wear resistant articles and, more particularly, to wear resistant articles having a composite lubricating sheet bonded thereto.

  Abrasion resistant articles generally prevent or reduce friction and wear caused by their relative movement when in continuous contact with other objects under high loads and / or high frictional forces. Used for.

  A first aspect of the invention is an abrasion resistant article comprising a composite lubricating sheet bonded to a metal substrate, the composite lubricating sheet being at least partially impregnated with a resin, an aromatic polyamide yarn, The present invention relates to a wear-resistant article comprising a fabric comprising an aromatic polyamide yarn and a mixed yarn having a low friction yarn, and a metal layer adhered to one side of the fabric.

  A second aspect of the present invention is a turbine engine comprising at least one component having a composite lubricating sheet bonded thereon, the composite lubricating sheet being at least partially impregnated with a resin and an aromatic polyamide yarn. And a fabric comprising a mixed yarn having an aromatic polyamide yarn and a low friction yarn, and a metal layer adhered to one side of the resin impregnated fabric.

  These and other features of the present invention will be more readily understood from the following description, in which various aspects of the invention are described in detail with reference to the accompanying drawings, which illustrate various embodiments of the invention. Let's go.

FIG. 1 illustrates one embodiment of the wear-resistant article of the present disclosure. FIG. 2 illustrates another embodiment of an abrasion resistant article, showing an article having a turbine fan blade 52 and a composite lubricating sheet (CLS) 8 bonded thereto. FIG. 3 illustrates another embodiment of an abrasion resistant article, showing an article having a disk rotor 102 and CLS 8 bonded thereto.

  It should be noted that the drawings of the present invention are not drawn to scale. The drawings are only intended to illustrate exemplary embodiments of the invention and therefore do not limit the scope of the invention. In the drawings, like numbering represents like elements between the drawings.

  Articles used in the aerospace industry, particularly turbine engines, are often subjected to high pressure loads and high frictional forces between the article and the object in contact with the article, whereby in the turbine engine the article and / or object Due to the fatigue stress, the surface is worn and cracks are formed. Wear resistance of articles to extend the life of articles and / or objects in contact with articles, shorten turbine engine maintenance periods, and increase the operating time of equipment, assemblies, airplanes, etc. in which such articles are incorporated There is a need to improve performance. Abrasion means that the properties of the solid surface are degraded by the action of other surfaces. The decreasing properties can include, but are not limited to, thickness, smoothness, hardness, strength, and / or integrity. It has been found that the wear resistance of an article can be improved or increased by bonding a composite lubricating sheet having a metal layer onto the article.

  One embodiment of an abrasion resistant article according to the present disclosure is shown in FIG. Referring to FIG. 1, there is shown an abrasion resistant article 2 having a metal substrate 4 and a composite lubricating sheet (CLS) 8 adhered thereon. Reference 5 implies that the metal substrate 4 can continue beyond 5 and form a larger and more complete metal substrate. The metal substrate 4 can be a component integrated into the turbine engine. In one embodiment, the metal substrate 4 may be a part selected from mechanical parts that wear, or components thereof, such as, but not limited to, turbine fan blades, disk rotors and disk rotor assemblies. In other embodiments, the metal substrate 4 may be a turbine fan blade. In other embodiments, the metal substrate 4 can be a disk rotor. The metal substrate 4 may comprise a metal selected from titanium, aluminum, steel, nickel, and alloys of the foregoing. In other embodiments, the metal substrate 4 may comprise titanium. In other embodiments, the metal substrate 4 may comprise steel. In another embodiment, the metal substrate 4 can include aluminum.

  The CLS 8 may include a cloth 6 and a metal layer 7 bonded to one surface of the cloth 6. The fabric 6 is at least partially impregnated with resin and may include aromatic polyamide yarns and mixed yarns having aromatic polyamide yarns and low friction yarns. Aromatic polyamide yarns can be a bundle of fibers, including fibers containing aromatic polyamide, used to make fabrics. Aromatic polyamide yarns include poly (para-phenylene terephthalamide), poly (meta-phenylene terephthalamide), poly (meta-phenylene isophthalamide), poly (para-phenylene isophthalamide), combinations thereof, and copolymers thereof. Yarn made from (but not limited to) may be included.

  The low friction yarn may be a yarn having a coefficient of friction (COF) for itself that is less than the COF for the aromatic polyamide yarn itself. The low friction yarn may comprise graphite or a fluoropolymer. In one embodiment, the low friction yarn may comprise graphite fibers or fluoropolymer fibers. In one embodiment, the fluoropolymer fiber can be a polytetrafluoroethylene fiber. The resin-impregnated cloth 6 may be at least partially impregnated with a resin selected from, but not limited to, a phenol resin, an epoxy resin, or a polyimide resin. In one embodiment, the phenolic resin can include phenol-formaldehyde.

  The metal layer 7 may comprise a metal selected from titanium, aluminum, steel and nickel. In one embodiment, the metal layer 7 can be titanium. In other embodiments, the metal layer 7 can be steel. Metal layer 7 may have a thickness in the range of about 20 microns to about 1,000 microns. In one embodiment, the metal layer 7 can have a thickness in the range of about 50 microns to about 250 microns. In other embodiments, the metal layer 7 may have a thickness in the range of about 70 microns to about 100 microns. In other embodiments, the metal layer 7 may have a thickness of about 90 microns.

  The metal layer 7 can be in the form of a metal foil. In one embodiment, the metal foil may be a thin flexible sheet of titanium, aluminum, steel or nickel. In one embodiment, the metal layer 7 can be a titanium foil. In other embodiments, the metal foil can have a thickness in the range of about 20 microns to about 1,000 microns. In other embodiments, the metal foil can have a thickness in the range of about 50 microns to about 250 microns. In other embodiments, the metal foil can have a thickness in the range of about 70 microns to about 100 microns. In other embodiments, the metal foil may have a thickness of about 90 microns. The metal layer 7 can be bonded to one surface of the resin-impregnated cloth 6.

  In one embodiment, the metal layer 7 may be a pure metal containing a single metal element. In other embodiments, the metal layer 7 may be a metal alloy including two or more metal elements. When two or more metal elements are part of metal 7, any element can be a greater or more dominant element in weight percent. Examples of the elements contained in the metal layer 7 include, but are not limited to, titanium, iron, aluminum, copper, nickel, zinc, tungsten, molybdenum, tin, and cobalt. Any of the above elements can be more or predominant elements in weight percent.

  The metal layer 7 may have a Vickers hardness HV of about 30 or more when a load of 100 g is applied for 20 seconds in accordance with ASTM E-384. In one embodiment, the metal layer 7 can have a Vickers HV of about 100 or greater. In other embodiments, the metal layer 7 may have a Vickers HV of about 200 or greater. In other embodiments, the metal layer 7 may have a Vickers HV of about 300 or greater.

  Examples of the composite lubricating sheet 8 having the titanium metal layer 7 are described in E.I. I. Product grade Vespel® ASB-0670, available from du Pont de Nemours and Company. Other product grade Vespel® composite lubrication sheets 8 may include a metal layer 7 of steel, aluminum or nickel.

  The composite lubricating sheet (CLS) 8 can have a thickness in the range of 30 microns to 3 mm. In embodiments, CLS8 may have a thickness in the range of 50 microns to 1 mm. In other embodiments, the thickness can range from 100 microns to 750 microns.

  CLS8 has a compression ratio in the range of 0.1% (0.001) to about 20% (0.20) when pressure is applied by pressing to about 450 MPa at about 127 microns / min and then released. possible. The compression ratio refers to the proportion of the thickness that is reduced by compression under specific conditions. In one embodiment, the composite lubricating sheet 8 may have a compression ratio in the range of 1% (0.010) to about 5.7% (0.057). In other embodiments, the compression ratio can range from 1.3% (0.013) to about 3% (0.030). The compressibility embodiment can be measured by applying pressure by pressing to about 450 MPa at about 127 microns / min and then releasing.

  The CLS 8 can be bonded to the metal substrate 4 to form the wear resistant article 2. CLS8 adhesion can be achieved by physical or chemical bonding. Adhesives such as thermoplastic adhesives, thermosetting adhesives, and other adhesives known in the art may also be used. In particular, the metal layer 7 can be bonded to the metal substrate 4. In one embodiment, the thermosetting adhesive can be an epoxy adhesive. The adhesive layer can have a thickness in the range of about 2 microns to 2,000 microns. In one embodiment, the thickness can range from about 10 microns to 100 microns. In other embodiments, the thickness can range from about 20 microns to 80 microns.

  Before the CLS 8 is bonded to the metal substrate 4, the surface of the metal layer 7 to be bonded to the metal substrate 4 and / or the surface of the metal substrate 4 may be surface-treated. The surface treatment can be performed by any method known in the field of treating metal surfaces. In one embodiment, the surface treatment can be performed by a peening method. As a typical method of the peening method, there is a method in which a large number of small particles collide with the surface. One example of the peening method is shot peening. A shot peened and roughened surface may have a characteristic roughness that can be identified by the formation of small holes in the surface. In other embodiments, the surface treatment may include sandblasting the surface of the metal layer 7 to be adhered to the metal substrate 4 and / or sandblasting the surface of the metal substrate 4. In other embodiments, the surface treatment may include chemically etching the surface of the metal layer 7 to be adhered to the metal substrate 4 and / or chemically etching the surface of the metal substrate 4. In other embodiments, the surface treatment may include belt grinding the surface of the metal layer 7 to be adhered to the metal substrate 4 and / or belt grinding the surface of the metal substrate 4.

  In order to treat the surface of the metal layer 7 and / or the surface of the metal substrate 4, the above surface treatments may be performed in combination. For example, the surface of the metal layer 7 to be bonded to the metal substrate 4 may be first shot peened, and then the shot peened surface may be processed by sandblasting before being bonded to the metal substrate 4.

  In normal use, the wear resistant article 2 disclosed herein is generally subject to vibration, reciprocation and / or circular motion under high pressure loads via the resin-impregnated cloth 6 of the composite lubricating sheet 8. Underneath, it can be placed in continuous contact and motion with other objects. The high pressure load can range from about 100 MPa to about 600 MPa. The wear resistant article 2 in persistent contact with other objects may have a coefficient of friction (COF) in the range of 0.01 to 0.1. In one embodiment, the COF can be less than about 0.05. In other embodiments, the COF may be less than 0.04.

  The usefulness of the wear resistant article 2 can be demonstrated by measuring the durability of the CLS 8 under controlled pressure and wear conditions. For wear under pressure, for example, an object having a surface to be worn, such as a titanium block having a known roughness, is prepared, and a composite lubricating sheet 8 is adhered to the surface to be worn (this adhesion is worn with the metal layer 7). Prepare an object having a wear surface, such as another titanium block, between the titanium surface and wear of the resin-impregnated cloth 6 of CLS8 and the other object under a pressure in the range of about 210 MPa to about 500 PMa. It can be shown by performing surface alignment and making the CLS 8 resin impregnated fabric 6 in permanent contact with the surface of other objects.

  The present disclosure may be further defined by the following examples. It should be understood that the following examples illustrate embodiments of the present disclosure, but are presented for illustrative purposes only. From the above discussion and the following examples, those skilled in the art can ascertain the essential features of the present disclosure and adapt to various uses and conditions without departing from the spirit and scope of the present disclosure. Various changes and modifications can be made to the present disclosure.

  Table 1 shows the Vickers hardness (HV) for the metal layer 7 of the composite lubricating sheet (CLS) 8. The values shown in Table 1 are for the metal layer 7 in the form of a metal foil. Vickers hardness is described in ASTM E-384, which is incorporated herein by reference in its entirety. Unless otherwise noted, HV in Table 1 means HV 0.1 / 20, measured by applying 100 grams of force for 20 seconds.

  The CLS 8 of the present disclosure may be resistant to crushing due to compressive force. In one embodiment, a suitable test for resistance to pressure is to determine the compression factor that a strong compressive force produces. Table 2 shows the percentage value of the compression ratio for CLS 8 having various metal layers 7 and the description item (10) of CLS 8 not including the metal layer for comparison.

  In Table 2, CLS test samples 2, 3 and 4 are E.C. I. A sample representative of product grade Vespel® ASB-0670 available from du Pont de Nemours and Company, the metal layer being titanium. CLS test samples 1, 5 and 6 are samples representative of another product grade Vespel® composite lubricant sheet 8 and the metal layer 7 is steel (Fe) and aluminum. The CLS test sample C1 is a comparative sample that does not have the metal layer 7.

  CLS8 compressibility percentage values were measured using an Mitsutoyo IP54 micrometer and an Instron 1332 fatigue tester equipped with an 8800 controller. A Mitutoyo IP54 micrometer was used to measure the thickness of the CLS by first measuring the initial thickness of a square CLS about 25 mm × about 25 mm. An Instron 1332 fatigue tester was used to apply a compressive load to the square CLS. The measured square CLS was then compressed to 450 MPa with a Ti block having a 10 mm × 10 mm shot peened surface at 0.05 inches / minute (1270 microns / minute) using an Instron 1332 fatigue tester. did. When the pressure of 450 MPa was reached, the pressure was released and the final thickness of the square CLS was measured using a Mitutoyo IP54 micrometer within 1 minute.

  The CLS 8 of the present disclosure may have resistance to crushing due to compressive force and abrasion due to rubbing / frictional force. In one embodiment, a suitable resistance test against compressive force and simultaneously applied frictional force is to measure the minimum number of strokes that the CLS 8 can withstand before failure. Table 3 shows the minimum number of strokes of the CLS 8 having the titanium metal layer 7 and the CLS 8 not including the metal layer for comparison.

  In Table 3, CLS test samples 1 and 2 are E. coli. I. A sample representative of product grade Vespel® ASB-0670 available from du Pont de Nemours and Company, the metal layer being titanium. The CLS test sample C1 is a comparative sample and does not have the metal layer 7.

  The minimum number of strokes of CLS8 used with the metal substrate was measured using an Instron 1321 fatigue tester equipped with an 8800 controller. The minimum number of strokes was reported as the number of 1.2 mm long test strokes reciprocating at 10 Hz made by the relative movement of the article with respect to the CLS 8 resin-impregnated fabric layer 6.

  Prior to the evaluation of wear under pressure, the CLS8 resin-impregnated cloth layer 6 was lightly coated by spraying or applying a fluorochemical-containing lubricant to the surface of the resin-impregnated cloth layer 6 with a lubricant. Spraying or coating forms a thin translucent to opaque lubricant coating.

  CLS8 was bonded to a stationary metal substrate with an epoxy-based adhesive, such as NB 101, available from Newport Adhesives and Composites, Inc., Irvine, CA. The stationary metal substrate was a sandblasted 20 mm × 20 mm titanium block with one surface peened and cured with Rockwell hardness C33. The metal layer of CLS8 was bonded to the titanium block with the resin-impregnated cloth layer 6 of CLS8 facing the side opposite to the titanium block. The adhesive was cured in an oven under low pressure (about 5 psi), including a first heating step to about 79 ° C. in 90 minutes, followed by a second heating step to about 149 ° C. in one hour. Thereafter, the titanium block was placed on the lower carrier of the Instron 1321 with the CLS 8 facing up.

  A second titanium block having a peening hardened surface (Rc33) of approximately 10 mm x 10 mm size is placed on the upper carrier of the Instron 1321 and reversibly contacted in parallel with the CLS8 located in the center of the titanium block of the lower carrier. I tried to make it. The pressure between the blocks was increased to 400 MPa, and a reciprocating stroke was applied at a stroke rate of 1.2 mm long at a rate of 10 times forward and 10 times backward per second. The test was conducted until fracture started, that is, until the corner of the 10 mm × 10 mm titanium block penetrated the resin-impregnated cloth layer 6 of CLS8. The minimum number of strokes represents the number of strokes until the test piece breaks. The larger the minimum number of strokes, the better the performance of CLS8.

  Comparing CLS Examples 1 and 2 with a titanium metal layer with Example 3 without a metal layer, Test Samples 1 and 2 showed an improvement of about 100 times. Under the test conditions, a value with a minimum stroke exceeding 10,000 indicates that it is durable enough to withstand, for example, an engine maintenance cycle.

  Another embodiment of the wear-resistant article according to the present invention is shown in FIG. Referring to FIG. 2, an abrasion resistant article 50 having a turbine fan blade 52 and a composite lubricating sheet 8 adhered thereon is shown. The turbine fan blade 52 may be a component that is integral to the turbine engine. In one embodiment, turbine fan blade 52 may include a metal selected from titanium, aluminum, and steel. In other embodiments, the turbine fan blade 52 may include titanium.

  Embodiments of the composite lubricating sheet 8 have already been described, the entirety of which is hereby incorporated by reference. The composite lubricating sheet 8 may be bonded to the fan blade base 54 of the turbine fan blade 52. The composite lubricating sheet 8 may protect the fan blade base 54 from degradation when the wear resistant article 50 is used with, for example, the disk rotor 56. The forces and loads that occur between the fan blade base 54 and the disk rotor 56 during operation of the turbine engine are known in the art. The performance characteristics of the composite lubricating sheet 8 have already been described, the entirety of which is hereby incorporated by reference. In other embodiments, the composite lubricating sheet 8 may be bonded to a metal substrate such as a shim, a metal layer, or any other component that is already bonded to the fan blade base 54. The shim, metal layer, etc. may comprise a metal selected from titanium or steel.

  Another embodiment of the wear-resistant article according to the present invention is shown in FIG. Referring to FIG. 3, an abrasion resistant article 100 having a disk rotor 102 and a composite lubricating sheet 8 adhered thereon is shown. The disk rotor 102 may be a component that is integrated into the turbine engine. In one embodiment, the disk rotor 102 may include a metal selected from titanium, aluminum, and steel. In other embodiments, the disk rotor 102 may include titanium.

  Embodiments of the composite lubricating sheet 8 have already been described, the entirety of which is hereby incorporated by reference. The composite lubricating sheet 8 can be bonded to the recessed area 104 of the disk rotor 102. The composite lubricating sheet 8 may protect the disk rotor 102 and / or the fan blade base 54 from degradation when the wear resistant article 100 is used with the fan blade 52. The forces and loads that occur between the fan blade base 54 and the disk rotor 102 during operation of the turbine engine are known in the art. The performance characteristics of the composite lubricating sheet 8 have already been described, the entirety of which is hereby incorporated by reference.

  An embodiment of a turbine engine according to the present invention will be described. The turbine engine may include at least one component having a composite lubricating sheet adhered thereon. The at least one component can include, but is not limited to, a turbine fan blade, a disk rotor, and a disk rotor assembly. Embodiments and performance characteristics of composite lubricating sheets have already been described and are incorporated herein by reference in their entirety. Embodiments of turbine fan blades and disk rotors having composite lubricating sheets bonded therein have already been described.

  As used herein, the terms “first”, “second” and the like do not indicate order, quantity or importance, but are used to distinguish one component from another, and Thus, the terms “a” and “an” do not indicate a quantitative limitation, but indicate that there is at least one item mentioned. The modifier “about” used with a quantity is a generic state value and has the meaning indicated by the context (eg, including the degree of error associated with the measurement of a particular quantity). As used herein, the suffix “(s)” is intended to include both the singular and plural terms of the term it modifies, thereby including one or more of the terms ( For example, the metal (s) includes one or more metals. Ranges disclosed herein include both ends and are independently combined (eg, a range of “up to about 25 wt%, more specifically about 5 wt% to about 20 wt%” Including all endpoints and intermediate values in the range of 5% to about 25% by weight).

  While various embodiments are described herein, one of ordinary skill in the art can devise various embodiments of the components, variations or improvements made thereto, and these are within the scope of the present invention. It will be understood from the description. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the substantial scope thereof. Thus, the present invention is not intended to be limited to the specific embodiments disclosed as the best mode contemplated for carrying out the invention, but is intended to include all embodiments falling within the scope of the appended claims. ing.

Claims (20)

A wear-resistant article comprising a composite lubricating sheet bonded to a metal substrate,
The composite lubricating sheet is
A fabric at least partially impregnated with resin and comprising an aromatic polyamide yarn and a mixed yarn having said aromatic polyamide yarn and a low friction yarn;
A wear-resistant article comprising: a metal layer bonded to one side of the fabric.   The article of claim 1, wherein the metal substrate comprises a part selected from the group consisting of a disk rotor and a turbine fan blade.   The article of claim 1, wherein the metal substrate is an integral part of a turbine engine.   The article of claim 1, wherein the metal substrate comprises a metal selected from the group consisting of titanium, aluminum, steel, nickel, and alloys thereof.   The article of claim 4, wherein the metal substrate is titanium.   The article of claim 1, wherein the resin is a phenol-formaldehyde resin.   The aromatic polyamide yarn is poly (para-phenylene terephthalamide), poly (meta-phenylene terephthalamide), poly (meta-phenylene isophthalamide), poly (para-phenylene isophthalamide), combinations thereof, and The article of claim 1 selected from the group consisting of copolymers.   The article of claim 1, wherein the low friction yarn comprises graphite fibers or fluoropolymer fibers.   The article of claim 8, wherein the fluoropolymer fiber comprises polytetrafluoroethylene.   The article of claim 1, wherein the metal layer is a metal selected from the group consisting of titanium, aluminum, steel, and nickel.   The article of claim 10, wherein the metal layer is titanium.   The article of claim 1, wherein the metal layer has a thickness in the range of about 50 microns to about 250 microns.   The article of claim 1, wherein the metal layer has a Vickers hardness HV of about 30 or greater when a load of about 100 g is applied for about 20 seconds in accordance with ASTM E-384.   The composite lubricating sheet of claim 1, having a compressibility in the range of 0.1% to about 20% when pressure is applied by pressing to about 450 MPa at about 127 microns / min and then released. Goods.   The composite lubricant sheet further includes an adhesive layer between the cloth and the metal layer, and the adhesive layer includes an adhesive selected from the group consisting of a thermoplastic adhesive or a thermosetting adhesive. The article according to 1. A turbine engine comprising at least one component having a composite lubricating sheet bonded thereon,
The composite lubricating sheet is
A fabric at least partially impregnated with resin and comprising an aromatic polyamide yarn and a mixed yarn having said aromatic polyamide yarn and a low friction yarn;
A metal layer bonded to one surface of the resin-impregnated cloth;
Including a turbine engine. The aromatic polyamide yarn is poly (para-phenylene terephthalamide), poly (meta-phenylene terephthalamide), poly (meta-phenylene isophthalamide), poly (para-phenylene isophthalamide), combinations thereof, and Selected from the group consisting of copolymers,
And the low friction yarn comprises graphite or a fluoropolymer,
The engine according to claim 16.   The engine according to claim 16, wherein the metal layer is a metal selected from the group consisting of titanium, aluminum, steel, and nickel.   The engine of claim 16, wherein the metal layer has a Vickers hardness HV of about 30 or greater when a load of about 100 g is applied for about 20 seconds in accordance with ASTM E-384.   17. The composite lubricating sheet of claim 16, having a compressibility in the range of 0.1% to about 20% when pressure is applied by pressing to about 450 MPa at about 127 microns / min and then released. engine.