US20120039718A1 - Casting apparatus for producing a turbine rotor blade of a gas turbine and turbine rotor blade - Google Patents

Casting apparatus for producing a turbine rotor blade of a gas turbine and turbine rotor blade Download PDF

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Publication number
US20120039718A1
US20120039718A1 US13/265,185 US201013265185A US2012039718A1 US 20120039718 A1 US20120039718 A1 US 20120039718A1 US 201013265185 A US201013265185 A US 201013265185A US 2012039718 A1 US2012039718 A1 US 2012039718A1
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US
United States
Prior art keywords
turbine rotor
rotor blade
casting
blade
blade root
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/265,185
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English (en)
Inventor
Fathi Ahmad
Uwe Paul
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens AG
Original Assignee
Siemens AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens AG filed Critical Siemens AG
Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: AHMAD, FATHI, PAUL, UWE
Publication of US20120039718A1 publication Critical patent/US20120039718A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082—Sprues, pouring cups
    • 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
    • B22C9/108—Installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • 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
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F01D5/08—Heating, heat-insulating or cooling means
    • F01D5/081—Cooling fluid being directed on the side of the rotor disc or at the roots of the blades
    • 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
    • F01D5/30—Fixing blades to rotors; Blade roots ; Blade spacers
    • F01D5/3007—Fixing blades to rotors; Blade roots ; Blade spacers of axial insertion type
    • 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

Definitions

  • the invention relates to a casting apparatus for producing a turbine rotor blade of a gas turbine according to the claims. Furthermore, the invention relates to a turbine rotor blade according to the claims.
  • a casting apparatus comprises a plurality of mold shells arranged in a cluster for simultaneously casting a plurality of turbine rotor blades.
  • Each mold shell is hollow in form here, with the cavity representing the negative mold of the turbine rotor blade to be produced. Since turbine rotor blades, in particular the rotor blades of front turbine stages, generally have to be cooled, they are likewise hollow in form.
  • a cooling medium can be conducted through the cavities of the turbine rotor blade during operation, and therefore the turbine rotor blades have a particularly long service life and do not sustain premature, thermally induced damage on account of the hot-gas flow which flows past them. Cooling air is supplied here via openings arranged in the blade root, which are connected in terms of flow to the cavity or the cavities of the rotor blade.
  • the mold shell for producing such a turbine rotor blade therefore usually comprises one or more casting cores, which are arranged in the cavity of the casting apparatus. What the casting cores leave behind in the cast turbine rotor blade after they have been removed are the cavities through which the coolant flows during operation of the gas turbine.
  • the casting apparatus prefferably has at least one inlet channel, usually called a feeder, through which the casting material can be fed into the cavity of the mold shell during casting of the rotor blade. Consequently, the inlet channel issues by way of its inlet opening into that surface which delimits the cavity of the mold shell.
  • a feeder usually called a feeder
  • the object directed to the casting apparatus is achieved by a casting apparatus designed according to the features of the claims.
  • the object relating to the turbine rotor blade is achieved by a turbine rotor blade designed as claimed in the claims.
  • the invention is based on the realization that the formation of cracks in the walls of the cooling channels in the region of the turbine rotor blade on the blade root side during solidification of the melt is production-related.
  • turbine rotor blades are cast vertically as standard, with the cavity in the mold shell being formed in such a manner that the negative mold of the main blade part of the turbine rotor blade is formed at the bottom, and the platform and the blade root are formed thereabove.
  • top and “bottom” refer here to the horizontal plane.
  • the inlet for the molten casting material is usually likewise located at the top, since it has been found to be advantageous for turbine rotor blades to be produced in a top-cast method in which the location of the last solidification of the casting material is at the top and therefore at the higher-mass blade root.
  • the inlet channel runs transversely to the longitudinal axis of the turbine rotor blade and therefore approximately parallel to the horizontal plane, in order to specify a casting apparatus of lesser height.
  • the continued supply of molten casting material completely fills the cavities for the main blade part, the platform and the blade root of the turbine rotor blade with liquid, hot casting material.
  • the blade root usually has a symmetrical form in the form of a hammer or in the form of a fir tree, and the cooling channels are usually positioned centrally in the blade root, the conventional casting apparatuses always encountered situations in which the liquid casting material flowing into the cavity of the mold shell impinged transversely on the casting cores positioned upstream of the inlet opening.
  • the molten casting material came into contact with the root region of the centrally positioned casting core. This had the effect that the casting cores experienced greater heating at the point of impingement of the hot casting material than in other regions.
  • hotter regions of the casting cores are also referred to as hot spots.
  • the other regions of the casting cores were not heated to such a great extent.
  • delayed solidification of the casting material occurred in those regions of the casting material which adjoined the locally hotter regions of the casting cores, as compared with cooler regions of the casting cores.
  • the delayed solidification of the casting material in the corresponding regions led to disturbances in the microstructure of the solidified material which, during operation, promoted the formation of cracks and crack propagation.
  • the invention proposes that hot, liquid casting material has to be fed into the cavity of the mold shell, during casting of the turbine rotor blade, such that it does not impinge directly on casting cores.
  • the intention is for the casting material to flow into the cavity freely and without disturbances and to impinge on the base of the mold shell, which finals the blade tip.
  • the inlet is usually arranged centrally in the region of the blade root at the end face, this requires the casting cores to be arranged eccentrically, with respect to the longitudinal axis of the blade root. This leads to a casting apparatus in which that part of the cavity into which an imaginary extension of the inlet channel protrudes is free of casting cores at least on the inlet opening side.
  • a casting apparatus therefore prevents the hot casting material flowing in from impinging transversely on casting cores as it is being introduced into the cavity of the mold shell, and avoids the resultant creation of hot casting core regions, so-called hot spots. Locally delayed solidification of the casting material also no longer occurs during cooling by virtue of hotter casting core regions being avoided.
  • the solidification of the casting material is thus made more uniform overall, and therefore imperfections in the microstructure of the turbine rotor blade material can be avoided. By avoiding the imperfections, the formation of cracks and propagation of cracks in the material of turbine rotor blades which surrounds the cooling channel portions on the blade root side during operation are effectively avoided. This reduces the amount of rejects and increases the service life of turbine rotor blades.
  • the eccentric positioning thereof in the mold shell has the effect that the openings of cooling channels in the blade root of the turbine rotor blade are likewise arranged eccentrically, with respect to the, generally symmetrical, outer contour of the blade root.
  • the symmetry relates to the blade root contour, which is in the form of a fir tree or in the form of a hammer in cross section.
  • the surface of the mold shell has a contour for the blade root of the turbine rotor blade which is minor-symmetrical along a blade root center.
  • the contour here is in the form of a fir tree or in the form of a hammer.
  • the inlet channel is arranged centrally and one of the casting cores is arranged eccentrically at least in the region of the inlet opening—both with respect to a blade root center which, by definition, lies centrally between the lateral, undulating surfaces or contours of the blade root.
  • the inlet channel is issue into that part of the surface of the cavity of the mold shell which forms the negative of the end face of the blade root of the turbine rotor blade. It is thereby possible to form a sufficiently large inlet channel.
  • a top-cast method for turbine rotor blades with the blade root arranged at the top makes it possible to cast turbine rotor blades of which the region having the greatest volume, specifically the blade root, solidifies last. Shrinkage of the casting material, which possibly occurs during solidification, can be compensated for by the afterflow of molten casting material from the gate region.
  • a compact casting apparatus can therefore be specified.
  • the casting cores which are located furthest away from the inlet opening and the portions of which are arranged in the rotor blade region of the turbine rotor blade can also lie in the imaginary extension of the inlet channel, if the casting material flowing into the cavity does not reach them.
  • FIG. 1 is a perspective illustration showing a casting apparatus with casting cores arranged according to the invention therein, and
  • FIG. 2 is a perspective illustration showing a turbine rotor blade according to the invention for a gas turbine.
  • FIG. 1 is a perspective, diagrammatic illustration showing part of a casting apparatus 10 for producing a turbine rotor blade of a gas turbine.
  • the casting apparatus 10 comprises at least one mold shell 12 with a cavity 14 .
  • the cavity 14 is delimited by a surface 16 , which represents the negative mold of the turbine rotor blade to be produced.
  • a total of six casting cores 18 are arranged in the cavity 14 .
  • the casting cores 18 here are always arranged in pairs. There are a total of three pairs of casting cores. It goes without saying that a larger or a smaller number of (pairs of) casting cores can also be present in the mold shell 12 .
  • an inlet channel 20 is provided in the mold shell 12 for the introduction of the liquid casting material.
  • the inlet opening 22 of said inlet channel issues into the surface 16 which delimits the cavity 14 .
  • the cavity 14 is formed in the mold shell 12 in such a manner that the negative mold of the main blade part tip of the turbine rotor blade is arranged right at the bottom.
  • the part of the surface arranged thereabove forms the negative of the main rotor blade part.
  • the part of the surface is contoured such that the negative mold of the platform of the turbine rotor blade is formed. Adjoining the latter, and therefore arranged right at the top with respect to the horizontal plane, the rest of the surface 16 forms the contour of the blade root.
  • the inlet channel 20 issues into that part of the surface which specifies an end face of the blade root.
  • the inlet channel 20 has a rectilinear longitudinal extent immediately upstream of the inlet opening 22 in the casting apparatus shown.
  • the longitudinal extent of the inlet channel 20 runs approximately parallel or at a slight inclination with respect to the horizontal plane.
  • the casting cores 18 are not shown in their entirety in FIG. 1 .
  • FIG. 1 merely shows those portions of the casting cores 18 which are arranged in the uppermost part of the cavity 14 , which specifies the negative mold of the blade root.
  • the form, contour and nature of the casting cores 18 in the region on the platform side or in the region on the side of the main blade part are not of further interest for the invention and can therefore be designed as desired, for example in meandering form, rectilinearly or else with only a slight curvature. In this case, the respective cooling channels can also be brought together again in part.
  • the casting cores 18 which form a respective pair are spaced apart from one another.
  • the distance A between them is sufficiently large that hot, liquid casting material does not impinge directly on the casting cores 18 as the cavity 14 is being filled.
  • the hot casting material fed into the cavity 14 flows through between two directly adjacent casting cores 18 .
  • the intention is therefore to avoid contact between inflowing liquid casting material and the casting core surface in the root region as far as possible.
  • the locally elevated casting core temperature was the cause of crack phenomena, occurring in the prior art, on the walls of cooling channels of turbine rotor blades.
  • the imaginary extension of the longitudinal extent of the inlet channel 20 consequently extends into the free region between the two casting cores 18 of a pair of casting cores.
  • the imaginary extension of the inlet channel is completely free of casting cores 18 .
  • this assumes that the coverage of the inflowing hot casting material is not so great that the inflowing jet can impinge thereon.
  • FIG. 2 is a perspective view showing a turbine rotor blade 30 , which has been produced using the casting apparatus shown in FIG. 1 .
  • the turbine rotor blade 30 has a blade root 32 , which is contoured in the form of a fir tree in longitudinal section and on which a platform 34 is arranged.
  • the platform 34 is adjoined by an aerodynamically curved main blade part 36 , which ends at a detached main blade part tip 38 .
  • the turbine rotor blade 30 therefore extends along a longitudinal axis 40 from the blade root 32 to the main blade part tip 38 .
  • the longitudinal axis 40 here is arranged in such a manner that it runs centrally or symmetrically with respect to the contour of the blade root 32 in the form of a fir tree.
  • the openings 44 are arranged on both sides of the blade root center, which is defined in cross section by the longitudinal axis 40 and also lies centrally between the lateral, undulating surfaces of the blade root. Here, they lie in two rows each with three openings 44 .
  • the openings 44 serve for the introduction of a coolant into the interior of the turbine rotor blade 30 .
  • Each opening 44 here forms an end of a cooling channel of the turbine rotor blade 30 .
  • the course of the openings within the turbine rotor blade 30 is not of further importance for the invention.
  • the invention prevents nonuniform, local overheating of the casting cores 18 in the vicinity of the inlet as the cavity 14 is being filled. At the same time, it is possible for better filling to take place, since casting cores 18 no longer block the inlet opening 22 . A collision between inflowing hot casting material and casting cores 18 is prevented by the use of the invention. In addition, the unhindered afterflow of hot casting material (feed) from the inlets can further improve the solidification, and this reduces residual stress and avoids crack formation.
  • the invention relates to a casting apparatus 10 for producing a turbine rotor blade 30 of a gas turbine, wherein the mold shell 12 , the inlet thereof and the casting cores 18 arranged therein are oriented with respect to one another in such a way that a casting material flowing into the cavity 14 of the mold shell 12 does not impinge directly on casting cores 18 . So-called hot spots on casting cores 18 are thereby avoided, which until now have had negative effects on the solidification of the casting material. Particularly in the region of the blade root 32 of the turbine rotor blade 30 to be produced, it is therefore possible to obtain improved solidification of the casting material, reducing disturbance in the microstructure of the solidified casting material. On account of the reduction or prevention of the disturbances, the formation of cracks and the propagation of cracks in the region of the cooling channel portions on the blade root side are avoided, increasing the service life of the turbine rotor blade 30 .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US13/265,185 2009-04-20 2010-04-15 Casting apparatus for producing a turbine rotor blade of a gas turbine and turbine rotor blade Abandoned US20120039718A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP09005533.6 2009-04-20
EP09005533A EP2243574A1 (de) 2009-04-20 2009-04-20 Giessvorrichtung zum Herstellen einer Turbinenlaufschaufel einer Gasturbine und Turbinenlaufschaufel
PCT/EP2010/054930 WO2010121939A1 (de) 2009-04-20 2010-04-15 Giessvorrichtung zum herstellen einer turbinenlaufschaufel einer gasturbine und turbinenlaufschaufel

Publications (1)

Publication Number Publication Date
US20120039718A1 true US20120039718A1 (en) 2012-02-16

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Family Applications (1)

Application Number Title Priority Date Filing Date
US13/265,185 Abandoned US20120039718A1 (en) 2009-04-20 2010-04-15 Casting apparatus for producing a turbine rotor blade of a gas turbine and turbine rotor blade

Country Status (4)

Country Link
US (1) US20120039718A1 (zh)
EP (2) EP2243574A1 (zh)
CN (1) CN102458715A (zh)
WO (1) WO2010121939A1 (zh)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113719323A (zh) * 2021-07-09 2021-11-30 北京航空航天大学 一种燃气轮机涡轮叶片复合冷却结构

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010054513A1 (de) * 2010-12-15 2012-06-21 Claas Guss Gmbh Gusskern und Verfahren zur Beeinflussung des Erstarrungsverhaltens eines Gussteils
EP2735387A1 (de) * 2012-11-22 2014-05-28 Siemens Aktiengesellschaft Gussform mit angeschrägten Stirnseiten bei inneren Wänden
CN103567450B (zh) * 2013-10-29 2015-05-20 浙江大学 功能梯度材料半固态粉末成形装置
CN106890945A (zh) * 2015-12-17 2017-06-27 通用电气公司 模芯组件及熔模铸造方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3204303A (en) * 1963-06-20 1965-09-07 Thompson Ramo Wooldridge Inc Precision investment casting
US5820774A (en) * 1996-10-28 1998-10-13 United Technologies Corporation Ceramic core for casting a turbine blade
US20060024163A1 (en) * 2004-07-30 2006-02-02 Keith Sean R Method and apparatus for cooling gas turbine engine rotor blades
US20070177976A1 (en) * 2006-01-31 2007-08-02 United Technologies Corporation Microcircuits for small engines

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5465780A (en) * 1993-11-23 1995-11-14 Alliedsignal Inc. Laser machining of ceramic cores
EP1041246A1 (de) * 1999-03-29 2000-10-04 Siemens Aktiengesellschaft Kühlmitteldurchströmte, gegossene Gasturbinenschaufel sowie Vorrichtung und Verfahren zur Herstellung eines Verteilerraums der Gasturbinenschaufel
US7467922B2 (en) * 2005-07-25 2008-12-23 Siemens Aktiengesellschaft Cooled turbine blade or vane for a gas turbine, and use of a turbine blade or vane of this type
US7413403B2 (en) * 2005-12-22 2008-08-19 United Technologies Corporation Turbine blade tip cooling

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3204303A (en) * 1963-06-20 1965-09-07 Thompson Ramo Wooldridge Inc Precision investment casting
US5820774A (en) * 1996-10-28 1998-10-13 United Technologies Corporation Ceramic core for casting a turbine blade
US20060024163A1 (en) * 2004-07-30 2006-02-02 Keith Sean R Method and apparatus for cooling gas turbine engine rotor blades
US20070177976A1 (en) * 2006-01-31 2007-08-02 United Technologies Corporation Microcircuits for small engines

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113719323A (zh) * 2021-07-09 2021-11-30 北京航空航天大学 一种燃气轮机涡轮叶片复合冷却结构

Also Published As

Publication number Publication date
WO2010121939A1 (de) 2010-10-28
CN102458715A (zh) 2012-05-16
EP2243574A1 (de) 2010-10-27
EP2421666A1 (de) 2012-02-29

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AS Assignment

Owner name: SIEMENS AKTIENGESELLSCHAFT, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:AHMAD, FATHI;PAUL, UWE;REEL/FRAME:027086/0063

Effective date: 20111014

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION