US20010042607A1 - Process for producing a thermally loaded casting - Google Patents
Process for producing a thermally loaded casting Download PDFInfo
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- US20010042607A1 US20010042607A1 US09/836,297 US83629701A US2001042607A1 US 20010042607 A1 US20010042607 A1 US 20010042607A1 US 83629701 A US83629701 A US 83629701A US 2001042607 A1 US2001042607 A1 US 2001042607A1
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- casting
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Classifications
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- 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
- B22C7/023—Patterns made from expanded plastic materials
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/043—Removing the consumable pattern
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
- F01D5/182—Transpiration cooling
- F01D5/183—Blade walls being porous
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
- F01D5/186—Film cooling
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
- F01D5/187—Convection cooling
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/21—Manufacture essentially without removing material by casting
- F05D2230/211—Manufacture essentially without removing material by casting by precision casting, e.g. microfusing or investment casting
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/606—Directionally-solidified crystalline structures
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/611—Coating
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/612—Foam
Definitions
- the invention relates to a process for producing a thermally loaded casting of a thermal turbomachine according to the preamble of claim 1 .
- metal felts in turbine blades. This is disclosed, for example, in document DE-C2-32 03 869 or in DE-C2-32 35 230. This use of a metal felt has the task of providing a (internal) cooling system. At the same time, this metal felt can serve as protection against abrasion from external mechanical loads, in particular if it has been arranged on the outer side of the turbine blade and has been coated with a ceramic protective layer.
- a turbine blade with similar properties is also known from European Document EP-B1-132 667.
- the invention is based on the object of providing a process for producing a thermally loaded casting of a thermal turbomachine with an integrated cooling structure which increases the efficiency of the turbomachine.
- the cooling structure is to consist of the same material as the casting and as far as possible it is also to be possible to produce it in a step which is part of the casting process.
- the object is achieved by a process in accordance with the preamble of claim 1 in that a wax model of the part to be cooled is prepared, at least one polymer foam is prepared, which is fixed to the wax model or is introduced into a cavity in the wax model, the at least one polymer foam and the wax model are immersed in a ceramic material, the ceramic material accumulating around the wax model and the polymer foam also being filled with the ceramic material, the ceramic material is dried, so that a casting mold is formed, the wax and the at least one polymer foam are removed by a heat treatment, the casting is produced using the casting mold by a known casting process, and the ceramic material is removed.
- the object is achieved in a similar way.
- a ceramic insert is prefabricated from a polymer foam with an open-cell structure. This ceramic insert is attached to the wax model or is introduced into a cavity in the wax model and the casting mold is produced as described above.
- the material of this mold may also contain a binder.
- a prefabricated ceramic insert of this type can be heated considerably before being used for production of the casting mold, in order in this way to achieve a particular strength. It is also conceivable to burn out the polymer foam of the insert prior to application to the wax model.
- the object according to the invention is achieved by separate production of the casting and the open-cell cooling structure.
- the two parts are joined to one another by soldering or welding.
- an open-cell cooling structure which faces outward to be covered with a ceramic protective layer, in order to protect the casting from additional external abrasion and from the hot gases which surround it. Because of the open-cell structure of the metal foam, the ceramic protective layer adheres very well thereto and the possibility of flaking caused by the extreme operating conditions is reduced. In addition, cooling below the ceramic protective layer is still ensured provided that the ceramic protective layer does not penetrate all the way through the cooling structure.
- the process will advantageously be a casting process for producing a single-crystal or directionally solidified component.
- the thermally loaded casting may, for example, be a guide vane or a rotor blade, a heat-accumulation segment, a platform for the guide vane or the rotor blade or a combustion-chamber wall of a gas turbine or a rotor blade of a compressor.
- FIG. 1 shows part of a cooled turbine blade which has been produced using the process according to the invention
- FIG. 2 shows a cross section through a turbine blade according to the invention
- FIG. 3 shows a longitudinal section through a turbine blade according to the invention
- FIG. 4 shows a section through an embodiment of a heat shield according to the invention
- FIG. 5 shows a section through a second embodiment of a heat shield according to the invention
- FIG. 6 a shows a variation of excerpt VI in FIG. 5
- FIG. 6 b shows a second variation of excerpt VI in FIG. 5
- FIG. 7 shows a guide vane according to the invention with cooled platforms
- FIG. 8 shows a cooled wall of a combustion chamber which has been produced using the process according to the invention.
- the invention relates to a process for producing a thermally loaded casting for a thermal turbomachine.
- This casting may, specifically, be, for example, a guide vane or rotor blade of a gas turbine or a compressor, a heat-accumulation segment of a gas turbine, the wall of a combustion chamber or a similar casting which is subjected to high thermal loads.
- These castings and the process according to the invention for their production are explained in more detail below with reference to the enclosed figures.
- a common feature of all these castings is that they need to be cooled on account of the external thermal loading and for this reason include an integrated open-cell cooling system.
- the castings are produced using casting furnaces which are generally known from the prior art.
- a casting furnace of this type can be used to produce components which are of complex design and can be exposed to high thermal and mechanical loads.
- SX single crystal
- DS directionally solidified
- a zone of directionally solidified material to form with a solidification front which, under the ongoing extraction of heat, migrates through the casting mold, forming the directly solidified casting.
- the document EP-A1-749 790 has disclosed, by way of example, a process of this type and a device for producing a directionally solidified casting.
- the device comprises a vacuum chamber which includes an upper heating chamber and a lower cooling chamber. The two chambers are separated by a baffle.
- the vacuum chamber accommodates a casting mold which is filled with a molten material.
- a nickel-based superalloy is used to produce thermally and mechanically loadable parts, such as in the case of guide vanes and rotor blades of gas turbines.
- a nickel-based superalloy is used.
- In the middle of the baffle there is an opening, through which the casting mold is slowly moved from the heating chamber into the cooling chamber during the process, so that the casting is directionally solidified from the bottom upward.
- the downward movement takes place by means of a drive rod on which the casting mold is mounted.
- the base of the casting mold is of water-cooled design.
- Means for generating and guiding a gas flow are present beneath the baffle. By means of the gas flow next to the lower cooling chamber, these means provide additional cooling and therefore a greater temperature gradient at the solidification front.
- a further process for the production of a directionally solidified casting is known from the document U.S. Pat. No. 3,763,926.
- a casting mold which has been filled with a molten alloy is immersed continuously in a bath which has been heated to approximately 260° C.
- the result is a particularly rapid dissipation of heat from the casting mold.
- LMC liquid metal cooling
- the process according to the invention for producing a turbine blade 1 relates to a cooling system 7 which is integrated in the turbine blade 1 and is partially or completely filled with an open-cell metal foam 9 .
- the turbine blade 1 in FIG. 1 has a cavity 6 , from which, while the turbomachine is operating, cooling air 18 is passed through inner cooling holes 8 , 8 b into the cooling system 7 , which is of double-walled design.
- the arrows indicate the direction of flow of the cooling air 18 .
- the cooling air 18 then flows both upward inside the turbine blade and onto the rear edge 3 of the turbine blade 7 .
- FIG. 3 which shows the front edge 2 of the blade root 9 through to the blade tip 10 in the form of a longitudinal section through a turbine blade 1 according to the invention, discloses the direction of flow of the cooling air 18 .
- the cooling air 18 enters the cooling system 7 through inner cooling openings 8 , 8 b of the cavity 6 .
- the cooling air 18 then flows through the cells of the metal foam 9 which is situated inside the cooling system 7 .
- the ceramic material penetrates into the cells of the polymer foam.
- the slurry penetrates all the way through the polymer foam, since it is an open-cell foam.
- the ceramic material is then dried, so that the casting mold, which is used to produce the casting, is formed.
- the wax and also the polymer foam are removed by a suitable heat treatment, i.e. are burnt out.
- the casting mold is fired, i.e. in this way it acquires its strength.
- the casting is produced using the casting mold which has been formed in this way by a known casting furnace, which has been described in more detail above, in a known way.
- the liquid alloy penetrates without problems not only into the casting mold itself but also into the cells which have been formed by the polymer foam and form the subsequent cooling system, the abovementioned metal foam 9 is formed, as cooling system 7 , at the same time as the solidification of the alloy.
- the casting and the metal foam then comprise a single part and there are no further process steps involved in the production of the cooling structure.
- this type of production also avoids porosity of the superalloy inside the metal foam 9 , since the liquid alloy is distributed uniformly within the open-cell casting mold (formed by the polymer foam) as early as during the filling step.
- the ceramic casting mold can then be removed in a suitable way, for example by using an acid or an alkali.
- FIG. 2 diagrammatically depicts a section through a turbine blade 1 according to the invention.
- the cooling structure 7 is only present on the front edge 2 of the turbine blade 1 .
- This cooling structure 7 was created, as has already been described above, by simply attaching the polymer foam to the wax model. All the other process steps of the production are the same.
- the cooling air 18 penetrates from the cavity 6 , through the cooling holes 8 , 8 b , into the cooling structure 7 .
- the cooling structure 7 itself is coated with a ceramic protective layer 11 (thermal barrier coating, TBC). This takes place, for example, using a plasma spraying process which is known from the prior art or an equivalent coating process.
- TBC thermal barrier coating
- the coating of the porous cooling structure 7 with TBC can take place in various ways (by varying the parameters such as spraying angle, spraying distance, spraying particle size, spraying velocity, spraying temperature, etc.). TBC can penetrate all the way through the cooling structure 7 , so that the cells of the metal foam 9 are completely filled. Cells allow very good adhesion of the TBC.
- the cooling structure 7 may also be covered with TBC only in a layer which lies close to the surface, so that beneath the TBC protective layer there is still a layer into which cooling air 18 can penetrate. It is also conceivable for cooling holes 8 to be present inside the protective layer 11 , through which the cooling air 18 emerges to the outside.
- the ceramic protective layer 11 adheres very well thereto.
- the adhesion of the ceramic protective layer 11 to the cooling structure can be improved still further by coarsening of the cell size toward the outside (where the protective layer 11 is applied).
- the flaking of the TBC while the casting is in operation as a result of poor adhesion to the base material is advantageously significantly reduced or prevented.
- the ceramic protective layer 11 is sufficiently porous for it to allow cooling air to pass through to a sufficient extent, there is no need for any external cooling holes. In this way, it is possible to achieve a so-called sweat cooling, which has proven highly effective in terms of its cooling action.
- Possible cooling holes 8 inside the ceramic protective layer 11 may have formed as a result of suitable masking taking place prior to the coating with TBC, and unmasking using suitable means taking place thereafter.
- the masking may, for example, take place using polymer foam which is burnt out for unmasking.
- a second possibility of masking the surface consists in providing locations which occupy this position inside the casting mold. In this case, the ceramic casting mold at these locations is only removed after coating with TBC.
- a metal foam 9 as in FIG. 2, at the outer surface and the additional coating with TBC is appropriate in particular at the locations at which abrasion may occur as a result of a mechanical action, for example at the blade tip of a turbine blade 1 or at a heat-accumulation segment, since the open-cell structure of the metal foam 9 is highly flexible and does not become blocked by the abrasion itself. Overall, however, the abrasion is reduced by the flexibility of the metal foam 9 .
- the polymer foam before it is attached to the wax model or before it is introduced into a cavity which is situated in the wax model, is treated with a slurry, so that a separate model of the cooling structure made from a ceramic material is formed.
- the polymer foam is immersed in the slurry, so that the cells fill up. This is followed by the obligatory drying of the slurry.
- this insert it should be ensured that the size, i.e. the external dimensions, of the polymer foam are not affected or are affected only within narrow tolerance limits.
- the material of the abovementioned mold in which the polymer foam can be foamed in order to maintain the external dimensions can contain a binder for improved drying of the slurry.
- An insert of this type can additionally be heated by a heat treatment before being attached to the wax model, which further increases the strength. In the ceramic body, this takes place by means of a sintering operation. Overall, the casting mold becomes stronger and denser.
- FIGS. 4 and 5 show a heat-accumulation segment 14 of a gas turbine.
- This heat-accumulation segment 1 may have a double-walled cooling structure 7 (FIG. 4) or an externally applied metal foam 9 (FIG. 5), which in a similar way to the turbine blade shown in FIG. 2 may be partially or completely coated with a protective layer 11 of TBC.
- cooling air 18 flows through the heat-accumulation segment. This is made possible by the open-cell metal foam 9 . The cooling air 18 penetrates through cooling holes 8 into the cooling system 7 and leaves it again through these holes.
- FIGS. 6 a , 6 b show two variants of the excerpt VI from FIG. 5.
- the metal foam 9 can acquire a different cell size by varying the cell size of the polymer foam during the production process.
- FIG. 6 a shows the metal foam 9 1 , 9 2 with a variable cell size. This allows greater or lesser cooling of individual regions of the casting. As has already been mentioned above, this is also advantageous for better attachment of the protective layer 11 to the metal foam 9 .
- the protective layer 11 may also have cooling holes 8 passing through it, through which the cooling air 18 can flow to the outside.
- the cooling system 7 comprises a plurality of layers of the metal foam 9 , with plates 15 between them.
- the number of layers of metal foam 9 /plate 15 is selected purely by way of example and is dependent on the specific application. Even during production as described above, a plurality of layers of wax/polymer foam are prepared, from which the casting mold for the casting is then produced, as described in more detail above. During production, this leads directly to the exemplary embodiment illustrated in FIG. 6 b .
- the cooling air 18 penetrates through the metal foam 9 , can flow within a “plane” and can cool by convection or transpiration.
- cooling holes 8 through which the cooling air 18 can change plane.
- the specific design of this cooling system 7 is, of course, dependent on the individual case.
- the cooling holes 8 within the plates 15 are likewise formed as early as during production.
- the castings with an integrated, open-cell cooling system 7 which are produced using the process according to the invention are also advantageous because the pressure difference in the cooling medium between the external pressure and the internal pressure (inside the cavity 6 ) has a considerable influence on the efficiency of cooling.
- This pressure difference can be set and controlled very accurately by suitably selecting the cells (distribution, size, etc.) of the metal foam 9 .
- the casting and the porous cooling structure 7 can be produced by separate casting processes and can subsequently be joined together by soldering or welding.
- the porous cooling structure 7 is produced by the abovementioned polymer foam and the slurry, if appropriate using a mold.
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Abstract
Description
- The invention relates to a process for producing a thermally loaded casting of a thermal turbomachine according to the preamble of
claim 1. - It has long been known to provide parts of thermal turbomachines which are exposed to hot gas, i.e. for example turbine blades of gas turbines, with cooling-air bores or with cooling structures, in order firstly to be able to increase the temperature of the hot gas and secondly to extend the service life of the parts in question. On the one hand, the inner side or a cooling system which is of double-walled design and is used for a turbine blade, for example, is cooled by cooling air as a result of the heat being dissipated to the outside. On the other hand, the outer side of the blade is cooled by a film which forms on the surface of the turbine blade. The aim is to make the film cooling as effective as possible and, at the same time, to reduce the amount of cooling air.
- Gas turbine blades which operate with film cooling are known, for example, from the publications DE 43 28 401 and U.S. Pat. No. 4,653,983.
- Furthermore, it is known to use metal felts in turbine blades. This is disclosed, for example, in document DE-C2-32 03 869 or in DE-C2-32 35 230. This use of a metal felt has the task of providing a (internal) cooling system. At the same time, this metal felt can serve as protection against abrasion from external mechanical loads, in particular if it has been arranged on the outer side of the turbine blade and has been coated with a ceramic protective layer. A turbine blade with similar properties is also known from European Document EP-B1-132 667.
- However, a less advantageous feature of these blades is that they do not comprise a single part, but rather the metal felt always has to be fitted in a further process step.
- The invention is based on the object of providing a process for producing a thermally loaded casting of a thermal turbomachine with an integrated cooling structure which increases the efficiency of the turbomachine. The cooling structure is to consist of the same material as the casting and as far as possible it is also to be possible to produce it in a step which is part of the casting process.
- According to the invention, the object is achieved by a process in accordance with the preamble of
claim 1 in that a wax model of the part to be cooled is prepared, at least one polymer foam is prepared, which is fixed to the wax model or is introduced into a cavity in the wax model, the at least one polymer foam and the wax model are immersed in a ceramic material, the ceramic material accumulating around the wax model and the polymer foam also being filled with the ceramic material, the ceramic material is dried, so that a casting mold is formed, the wax and the at least one polymer foam are removed by a heat treatment, the casting is produced using the casting mold by a known casting process, and the ceramic material is removed. - In a second embodiment, the object is achieved in a similar way. As a distinguishing factor, however, a ceramic insert is prefabricated from a polymer foam with an open-cell structure. This ceramic insert is attached to the wax model or is introduced into a cavity in the wax model and the casting mold is produced as described above.
- To maintain the external mass of the cooling structure, it is advantageously conceivable to use a prefabricated mold in which the polymer foam is foamed. The slurry can be applied to the polymer foam when it is still in the mold. In this way, it is even possible to form complicated three-dimensional forms of the cooling structure. For better drying of the slurry which is still liquid, the material of this mold may also contain a binder.
- A prefabricated ceramic insert of this type can be heated considerably before being used for production of the casting mold, in order in this way to achieve a particular strength. It is also conceivable to burn out the polymer foam of the insert prior to application to the wax model.
- In a third embodiment, the object according to the invention is achieved by separate production of the casting and the open-cell cooling structure. In a further process step, the two parts are joined to one another by soldering or welding.
- Furthermore, it is possible for an open-cell cooling structure which faces outward to be covered with a ceramic protective layer, in order to protect the casting from additional external abrasion and from the hot gases which surround it. Because of the open-cell structure of the metal foam, the ceramic protective layer adheres very well thereto and the possibility of flaking caused by the extreme operating conditions is reduced. In addition, cooling below the ceramic protective layer is still ensured provided that the ceramic protective layer does not penetrate all the way through the cooling structure.
- In all the abovementioned embodiments it is advantageously possible to use a polymer foam of variable cell size, in order in this way to cool certain regions of the cooling system to a greater or lesser extent than other regions. The process will advantageously be a casting process for producing a single-crystal or directionally solidified component. The thermally loaded casting may, for example, be a guide vane or a rotor blade, a heat-accumulation segment, a platform for the guide vane or the rotor blade or a combustion-chamber wall of a gas turbine or a rotor blade of a compressor.
- In the drawing:
- FIG. 1 shows part of a cooled turbine blade which has been produced using the process according to the invention,
- FIG. 2 shows a cross section through a turbine blade according to the invention,
- FIG. 3 shows a longitudinal section through a turbine blade according to the invention,
- FIG. 4 shows a section through an embodiment of a heat shield according to the invention,
- FIG. 5 shows a section through a second embodiment of a heat shield according to the invention,
- FIG. 6a shows a variation of excerpt VI in FIG. 5, FIG. 6b shows a second variation of excerpt VI in FIG. 5,
- FIG. 7 shows a guide vane according to the invention with cooled platforms, and
- FIG. 8 shows a cooled wall of a combustion chamber which has been produced using the process according to the invention.
- Only the elements which are significant to the invention are illustrated. Identical elements are provided with the same reference numerals in different drawings. The direction of flow is indicated by arrows.
- The invention relates to a process for producing a thermally loaded casting for a thermal turbomachine. This casting may, specifically, be, for example, a guide vane or rotor blade of a gas turbine or a compressor, a heat-accumulation segment of a gas turbine, the wall of a combustion chamber or a similar casting which is subjected to high thermal loads. These castings and the process according to the invention for their production are explained in more detail below with reference to the enclosed figures. A common feature of all these castings is that they need to be cooled on account of the external thermal loading and for this reason include an integrated open-cell cooling system.
- The castings are produced using casting furnaces which are generally known from the prior art. A casting furnace of this type can be used to produce components which are of complex design and can be exposed to high thermal and mechanical loads. Depending on process conditions, it is possible to produce the casting in directionally solidified form. It is possible to produce the casting as a single crystal (SX) or in polycrystalline form as columnar crystals which have a preferred direction (directionally solidified, DS). It is particularly important for the directional solidification to take place under conditions in which considerable heat exchange takes place between a cooled part of a casting mold which accommodates molten starting material and the starting material which is still molten. It is then possible for a zone of directionally solidified material to form with a solidification front which, under the ongoing extraction of heat, migrates through the casting mold, forming the directly solidified casting.
- The document EP-A1-749 790 has disclosed, by way of example, a process of this type and a device for producing a directionally solidified casting. The device comprises a vacuum chamber which includes an upper heating chamber and a lower cooling chamber. The two chambers are separated by a baffle. The vacuum chamber accommodates a casting mold which is filled with a molten material. To produce thermally and mechanically loadable parts, such as in the case of guide vanes and rotor blades of gas turbines, by way of example a nickel-based superalloy is used. In the middle of the baffle there is an opening, through which the casting mold is slowly moved from the heating chamber into the cooling chamber during the process, so that the casting is directionally solidified from the bottom upward. The downward movement takes place by means of a drive rod on which the casting mold is mounted. The base of the casting mold is of water-cooled design. Means for generating and guiding a gas flow are present beneath the baffle. By means of the gas flow next to the lower cooling chamber, these means provide additional cooling and therefore a greater temperature gradient at the solidification front.
- A similar process which, in addition to heating and cooling chamber, operates with additional gas cooling, is also known, for example, from the U.S. Pat. No. 3,690,367.
- A further process for the production of a directionally solidified casting is known from the document U.S. Pat. No. 3,763,926. In this process, a casting mold which has been filled with a molten alloy is immersed continuously in a bath which has been heated to approximately 260° C. The result is a particularly rapid dissipation of heat from the casting mold. This and other similar processes are known under the term LMC (liquid metal cooling).
- It is advantageous for the invention to utilize this type of casting furnace to produce single-crystalline or directionally solidified castings, but the invention is not restricted thereto.
- The process according to the invention for producing a
turbine blade 1, as is shown, for example, in various embodiments in FIGS. 1 to 3, relates to acooling system 7 which is integrated in theturbine blade 1 and is partially or completely filled with an open-cell metal foam 9. Theturbine blade 1 in FIG. 1 has acavity 6, from which, while the turbomachine is operating, coolingair 18 is passed throughinner cooling holes 8, 8 b into thecooling system 7, which is of double-walled design. The arrows indicate the direction of flow of the coolingair 18. The coolingair 18 then flows both upward inside the turbine blade and onto therear edge 3 of theturbine blade 7. It is able to leave thecooling system 7 again at therear edge 3, atouter cooling holes 8, 8 a or else atlarger cooling openings 8, 8 c, both of which may be present on thefront side 2, on thepressure side 4 or on theintake side 5. At theouter cooling holes 8, 8 a, film cooling is established, while the walls in the interior of thecooling system 7 are cooled by convection. As can be seen at the cut-away section in FIG. 1, depending on the application it is also possible foraxial ribs 10 to be present inside thecooling system 8, in which ribs there is nometal foam 9 and in which ribs the coolingair 18 can flow unimpeded. - FIG. 3, which shows the
front edge 2 of theblade root 9 through to theblade tip 10 in the form of a longitudinal section through aturbine blade 1 according to the invention, discloses the direction of flow of the coolingair 18. The coolingair 18 enters thecooling system 7 throughinner cooling openings 8, 8 b of thecavity 6. The coolingair 18 then flows through the cells of themetal foam 9 which is situated inside thecooling system 7. - It is now an object of the invention to manufacture
cooling systems 7 of this type which are filled with open-cell metal foam 9 integrally with the overall casting as early as during the casting process, using casting furnaces as have been mentioned above. To do this, a wax model of the part to be cooled is prepared. An open-cell polymer foam, which may, for example, be a polyurethane foam, is fixed to the wax model of the part which is to be cast or is introduced into a cavity which may be present in the wax model. It is also possible to fix together various wax/polymer models to form an overall model. The polymer foam and the wax model are then immersed in a liquid ceramic material, which is also known as a slurry. In the process, not only is the subsequent casting mold for the casting formed around the wax model, but also the ceramic material penetrates into the cells of the polymer foam. The slurry penetrates all the way through the polymer foam, since it is an open-cell foam. The ceramic material is then dried, so that the casting mold, which is used to produce the casting, is formed. After the drying of the slurry, the wax and also the polymer foam are removed by a suitable heat treatment, i.e. are burnt out. In this process step, the casting mold is fired, i.e. in this way it acquires its strength. The casting is produced using the casting mold which has been formed in this way by a known casting furnace, which has been described in more detail above, in a known way. Since, during the filling step, the liquid alloy penetrates without problems not only into the casting mold itself but also into the cells which have been formed by the polymer foam and form the subsequent cooling system, theabovementioned metal foam 9 is formed, as coolingsystem 7, at the same time as the solidification of the alloy. Advantageously, the casting and the metal foam then comprise a single part and there are no further process steps involved in the production of the cooling structure. By dint of the casting process and the subsequent solidification, this type of production also avoids porosity of the superalloy inside themetal foam 9, since the liquid alloy is distributed uniformly within the open-cell casting mold (formed by the polymer foam) as early as during the filling step. - The ceramic casting mold can then be removed in a suitable way, for example by using an acid or an alkali.
- With the process described, it is also possible to create a structure as can be seen in FIG. 2, which diagrammatically depicts a section through a
turbine blade 1 according to the invention. In this case, thecooling structure 7 is only present on thefront edge 2 of theturbine blade 1. Thiscooling structure 7 was created, as has already been described above, by simply attaching the polymer foam to the wax model. All the other process steps of the production are the same. In the exemplary embodiment shown in FIG. 2, the coolingair 18 penetrates from thecavity 6, through the cooling holes 8, 8 b, into thecooling structure 7. Thecooling structure 7 itself is coated with a ceramic protective layer 11 (thermal barrier coating, TBC). This takes place, for example, using a plasma spraying process which is known from the prior art or an equivalent coating process. - Naturally, prior to the coating with the TBC from the prior art, a known heat treatment, which is not referred to in more detail here, of the blank casting is required. It is also conceivable for a metallic protective layer, such as MCrAlY, to be applied prior to the coating with TBC, using known means.
- The coating of the
porous cooling structure 7 with TBC can take place in various ways (by varying the parameters such as spraying angle, spraying distance, spraying particle size, spraying velocity, spraying temperature, etc.). TBC can penetrate all the way through thecooling structure 7, so that the cells of themetal foam 9 are completely filled. Cells allow very good adhesion of the TBC. Thecooling structure 7 may also be covered with TBC only in a layer which lies close to the surface, so that beneath the TBC protective layer there is still a layer into which coolingair 18 can penetrate. It is also conceivable forcooling holes 8 to be present inside theprotective layer 11, through which the coolingair 18 emerges to the outside. On account of the open-cell structure of themetal foam 9, the ceramicprotective layer 11 adheres very well thereto. The adhesion of the ceramicprotective layer 11 to the cooling structure can be improved still further by coarsening of the cell size toward the outside (where theprotective layer 11 is applied). The flaking of the TBC while the casting is in operation as a result of poor adhesion to the base material is advantageously significantly reduced or prevented. - If the ceramic
protective layer 11 is sufficiently porous for it to allow cooling air to pass through to a sufficient extent, there is no need for any external cooling holes. In this way, it is possible to achieve a so-called sweat cooling, which has proven highly effective in terms of its cooling action. -
Possible cooling holes 8 inside the ceramicprotective layer 11 may have formed as a result of suitable masking taking place prior to the coating with TBC, and unmasking using suitable means taking place thereafter. The masking may, for example, take place using polymer foam which is burnt out for unmasking. A second possibility of masking the surface consists in providing locations which occupy this position inside the casting mold. In this case, the ceramic casting mold at these locations is only removed after coating with TBC. - The production of a
metal foam 9, as in FIG. 2, at the outer surface and the additional coating with TBC is appropriate in particular at the locations at which abrasion may occur as a result of a mechanical action, for example at the blade tip of aturbine blade 1 or at a heat-accumulation segment, since the open-cell structure of themetal foam 9 is highly flexible and does not become blocked by the abrasion itself. Overall, however, the abrasion is reduced by the flexibility of themetal foam 9. - In a second embodiment of the process according to the invention, the polymer foam, before it is attached to the wax model or before it is introduced into a cavity which is situated in the wax model, is treated with a slurry, so that a separate model of the cooling structure made from a ceramic material is formed. The polymer foam is immersed in the slurry, so that the cells fill up. This is followed by the obligatory drying of the slurry. When producing this insert, it should be ensured that the size, i.e. the external dimensions, of the polymer foam are not affected or are affected only within narrow tolerance limits. This can also be ensured by foaming the polymer foam in a mold, so that the external dimensions and, under certain circumstances, also a complex three-dimensional shape are fixedly predetermined. It is also conceivable to introduce the slurry into the polymer foam while it is still in this mold. This ceramic model or this insert, as has already been described above, is fixed to the wax model or is introduced into a cavity before the overall casting mold is produced and the wax/polymer foam is burnt out. Optionally, the polymer foam may be burnt out before the attachment or introduction.
- The material of the abovementioned mold in which the polymer foam can be foamed in order to maintain the external dimensions can contain a binder for improved drying of the slurry.
- An insert of this type can additionally be heated by a heat treatment before being attached to the wax model, which further increases the strength. In the ceramic body, this takes place by means of a sintering operation. Overall, the casting mold becomes stronger and denser.
- With the process according to the invention, it is also possible to produce castings as illustrated in FIGS.4 to 8. FIGS. 4 and 5 show a heat-
accumulation segment 14 of a gas turbine. This heat-accumulation segment 1 may have a double-walled cooling structure 7 (FIG. 4) or an externally applied metal foam 9 (FIG. 5), which in a similar way to the turbine blade shown in FIG. 2 may be partially or completely coated with aprotective layer 11 of TBC. In both embodiments, coolingair 18 flows through the heat-accumulation segment. This is made possible by the open-cell metal foam 9. The coolingair 18 penetrates throughcooling holes 8 into thecooling system 7 and leaves it again through these holes. - FIGS. 6a, 6 b show two variants of the excerpt VI from FIG. 5. As can be seen from FIG. 6a, the
metal foam 9 can acquire a different cell size by varying the cell size of the polymer foam during the production process. FIG. 6a shows themetal foam protective layer 11 to themetal foam 9. As described above, theprotective layer 11 may also havecooling holes 8 passing through it, through which the coolingair 18 can flow to the outside. - While the casting is in operation, it may be necessary to filter the cooling air, in order to prevent the fine-cell structure from becoming blocked by contaminants which are situated in the cooling air, thus reducing the cooling capacity.
- In FIG. 6b, which shows a second variant of excerpt VI from FIG. 5, the
cooling system 7 comprises a plurality of layers of themetal foam 9, withplates 15 between them. The number of layers ofmetal foam 9/plate 15 is selected purely by way of example and is dependent on the specific application. Even during production as described above, a plurality of layers of wax/polymer foam are prepared, from which the casting mold for the casting is then produced, as described in more detail above. During production, this leads directly to the exemplary embodiment illustrated in FIG. 6b. The coolingair 18 penetrates through themetal foam 9, can flow within a “plane” and can cool by convection or transpiration. Although the various planes are separated by theplates 15, there are coolingholes 8 through which the coolingair 18 can change plane. Generally, the specific design of thiscooling system 7 is, of course, dependent on the individual case. The cooling holes 8 within theplates 15 are likewise formed as early as during production. - The statements which have been made also apply to the
guide vane 16 which is illustrated in FIG. 7 and has two cooledplatforms 17, and the combustion-chamber wall 19 which is shown in FIG. 8 and is likewise cooled. Further exemplary embodiments, which are not illustrated by figures, include the cooled castings (blades etc.) of a compressor. - The castings with an integrated, open-
cell cooling system 7 which are produced using the process according to the invention are also advantageous because the pressure difference in the cooling medium between the external pressure and the internal pressure (inside the cavity 6) has a considerable influence on the efficiency of cooling. This pressure difference can be set and controlled very accurately by suitably selecting the cells (distribution, size, etc.) of themetal foam 9. - As a third exemplary embodiment of the process according to the invention, the casting and the
porous cooling structure 7 can be produced by separate casting processes and can subsequently be joined together by soldering or welding. Theporous cooling structure 7 is produced by the abovementioned polymer foam and the slurry, if appropriate using a mold. -
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turbine blade 1 -
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Claims (16)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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DE10024302.9 | 2000-05-17 | ||
DE10024302 | 2000-05-17 | ||
DE10024302A DE10024302A1 (en) | 2000-05-17 | 2000-05-17 | Process for producing a thermally stressed casting |
Publications (2)
Publication Number | Publication Date |
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US20010042607A1 true US20010042607A1 (en) | 2001-11-22 |
US6412541B2 US6412541B2 (en) | 2002-07-02 |
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US09/836,297 Expired - Lifetime US6412541B2 (en) | 2000-05-17 | 2001-04-18 | Process for producing a thermally loaded casting |
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US (1) | US6412541B2 (en) |
EP (2) | EP1645347B1 (en) |
DE (3) | DE10024302A1 (en) |
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Also Published As
Publication number | Publication date |
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US6412541B2 (en) | 2002-07-02 |
EP1155760B1 (en) | 2006-02-15 |
DE50108928D1 (en) | 2006-04-20 |
DE10024302A1 (en) | 2001-11-22 |
EP1645347A1 (en) | 2006-04-12 |
EP1155760A1 (en) | 2001-11-21 |
EP1645347B1 (en) | 2008-06-11 |
DE50114026D1 (en) | 2008-07-24 |
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