US20120207608A1 - Final-stage rotor blade of a steam turbine - Google Patents

Final-stage rotor blade of a steam turbine Download PDF

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Publication number
US20120207608A1
US20120207608A1 US13/498,450 US201013498450A US2012207608A1 US 20120207608 A1 US20120207608 A1 US 20120207608A1 US 201013498450 A US201013498450 A US 201013498450A US 2012207608 A1 US2012207608 A1 US 2012207608A1
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US
United States
Prior art keywords
turbine blade
erosion
erosion component
component
fiber
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
US13/498,450
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English (en)
Inventor
Christoph Ebert
Detlef Haje
Albert Langkamp
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Siemens AG
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Siemens AG
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Filing date
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Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EBERT, CHRISTOPH, LANGKAMP, ALBERT, HAJE, DETLEF
Publication of US20120207608A1 publication Critical patent/US20120207608A1/en
Abandoned legal-status Critical Current

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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/284—Selection of ceramic materials
    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/286—Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion
    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0087—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • 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
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
    • F05D2300/133—Titanium
    • 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
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/21—Oxide ceramics
    • 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
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/22—Non-oxide ceramics
    • F05D2300/226—Carbides
    • F05D2300/2262—Carbides of titanium, e.g. TiC
    • 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
    • F05D2300/40—Organic materials
    • F05D2300/44—Resins
    • 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
    • F05D2300/603—Composites; e.g. fibre-reinforced
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making

Definitions

  • the invention relates to a turbine blade.
  • the invention furthermore relates to a method for making a turbine blade.
  • Turbine blades and in particular turbine blades of steam turbines, are currently made predominantly of steel. Because of the great weight of steel turbine blades and the resulting high centrifugal forces, the speed of rotation and the maximum blade length of final-stage rotor blades are restricted. As a result of this, the surface area of the outflow of the exhaust casing, and hence the output and efficiency of the turbine, are limited. To increase the output and efficiency of future turbines, more and more thought is being applied to the use of final-stage rotor blades made from fiber-reinforced composite material. Fiber-reinforced composite materials have the advantage of high specific strength at the same time as low weight.
  • Turbine blades made from fiber-reinforced composite materials are made by compressing and adhering to one another at least two layers of fiber mats of the same or different materials.
  • Suitable fiber mats are, in particular, glass-reinforced fibers or carbon-reinforced fibers. Since fiber-reinforced composite materials only have high strength in the direction of the fibers, the layers of fibers have to be aligned individually to suit the load.
  • the fiber mats are made from a plurality of fiber mats which have different main directions of the fibers and are laid one on top of the other, to achieve strength in a plurality of directions.
  • the individual fiber mats are connected to one another by means of a matrix, conventionally a synthetic resin.
  • a matrix conventionally a synthetic resin.
  • the proportion of matrix must be sufficiently high for the fiber mats to be fixedly connected to one another.
  • too great a proportion of matrix results in a loss of strength in the fiber-reinforced composite material.
  • the currently most commonly used open method for making fiber-reinforced composite blades is the hand layup method.
  • the fiber intermediates are laid in the impregnation mold by hand and wetted with the matrix.
  • air is removed from the laminate, by pressing against it with the aid of a roller.
  • This is intended to remove from the layers of fiber mat not only air present in the laminate structure but also excess matrix material.
  • the procedure is repeated until the desired layer thickness is achieved.
  • the component must cure. Curing is performed through a chemical reaction between the matrix material and a curing agent added to the matrix material.
  • the advantage of the hand layup method is the small tool and low equipment outlay. However, this is offset against a low quality of component (low fiber content) and the high level of manual effort, which requires trained laminators.
  • Hand layup can also be performed as a closed method.
  • the closed method is performed using a vacuum press. Once the fiber mats have been introduced into the impregnation mold, the mold is covered with a release film, a suction fleece and a vacuum film. A vacuum is generated between the vacuum film and the mold. This has the effect of compressing the composite. Any air still included is removed by suction, and the excess matrix material is absorbed by the suction fleece. This means that a higher quality of component can be achieved than with the open hand layup method.
  • the prepreg method is a further closed method.
  • fiber mats which are pre-impregnated with matrix material and have thus already been wetted are laid in the impregnation mold.
  • the resin is no longer liquid but has a solid, slightly tacky consistency.
  • Air is then removed from the composite by means of a vacuum bag and it is then cured, often in an autoclave, under pressure and heat.
  • the prepreg method is one of the most expensive manufacturing methods. However, it also enables one of the highest levels of quality of component.
  • the vacuum infusion method is a further closed method for making fiber-reinforced composite blades.
  • the dry fiber layers are laid in an impregnation mold coated with release agent.
  • a release fabric and a distribution medium are placed over this, and this facilitates even flow of the matrix material.
  • a vacuum sealing tape seals the film to the impregnation mold, and the component is then evacuated with the aid of a vacuum pump.
  • the air pressure presses together the parts that have been laid in the mold and fixes them.
  • the suction applied draws the tempered liquid matrix material into the fiber material.
  • the supply of matrix material is stopped and the wetted fiber-reinforced composite material can be cured and removed from the impregnation mold.
  • the advantage of this method is that the fibers are wetted evenly and with almost no air inclusion, and so the components produced are of high quality and there is good reproducibility
  • the curing times for the individual methods are in each case dependent on the matrix material (resin) that is selected and the curing temperature.
  • An object of the present invention is thus to provide a turbine blade, in particular a final-stage blade, for a steam turbine which is made at least in certain regions from fiber-reinforced composite material, which offers a high level of protection against erosion. Furthermore, it is an object of the present invention to specify a method for making a turbine blade of this kind.
  • the turbine blade according to the invention in particular a final-stage blade for a steam turbine, wherein the turbine blade is made at least in certain regions from fiber-reinforced composite material, is characterized in that the turbine blade has at least one anti-erosion component.
  • the anti-erosion component is arranged such that it effectively protects the fiber-reinforced composite material against erosion corrosion. To this end, it is arranged at least at those points on the turbine blade which are under particular load from erosion.
  • the turbine blade can be made from fiber-reinforced composite material without there being any reduction in the load from erosion by comparison with turbine blades made from steel.
  • the weight is significantly reduced because fiber-reinforced composite material is used, as a result of which the centrifugal load is significantly reduced, in particular in the foot region of the turbine blade, which is under very heavy load. Consequently, the blade can be made longer and hence the surface area of the outflow of the exhaust casing can be made larger and the speed of rotation of the turbine increased. This makes the steam turbine more efficient.
  • An advantageous embodiment of the invention provides for the anti-erosion component to be inserted into the blade contour of the turbine blade.
  • the term “inserted” means that the turbine blade is constructed such that the blade contour is produced by the turbine blade itself and the anti-erosion component. Because the anti-erosion component is inserted into the blade contour of the turbine blade, no change is made to the flow conditions at the turbine blade, as would be the case with an anti-erosion component which was merely attached to the turbine blade. This means that the flow behavior at the turbine blade and thus in the turbine as a whole remains unchanged.
  • a further advantageous embodiment of the invention provides for the anti-erosion component to be inserted into the blade contour of the turbine blade such that a smooth transition is created between the anti-erosion component and the turbine blade.
  • the smooth transition between the anti-erosion component and the turbine blade avoids edges which could weaken the turbine blade. Moreover, this also avoids edges at the surface of the turbine blade which would result in a displacement of flow.
  • the inserted anti-erosion component is preferably connected to the turbine blade by laminating and/or gluing and/or securing means, in particular screws, rivets or pins.
  • the anti-erosion components secured in this way ensure a reliable and permanent connection with the turbine blade even at high peripheral speeds and with high centrifugal forces. This is particularly important because anti-erosion components flying off could cause substantial damage to the turbine blade.
  • a particularly advantageous embodiment of the invention provides for the anti-erosion component to be made from carbide, titanium or ceramic.
  • Carbide, titanium and ceramic are particularly resistant to erosion and are thus particularly well suited as material for the anti-erosion component. As a result of using these materials, the service life of the anti-erosion component can be considerably extended compared with other materials.
  • a further preferred embodiment of the invention provides for an intermediate layer, in particular an elastic and/or viscoelastic intermediate layer, to be arranged between the anti-erosion component and the turbine blade.
  • an intermediate layer in particular an elastic and/or viscoelastic intermediate layer
  • Very hard materials bring with them the risk that, because it is very brittle, the material will tend to break up.
  • Using an intennediate layer, in particular an elastic and/or viscoelastic intermediate layer means that the impact energy of the droplets is absorbed or reduced by the intermediate layer, as a result of which the risk of the hard outer layer of the anti-erosion component breaking up is reduced.
  • a further advantageous embodiment of the invention provides for the anti-erosion component to have a multi-layer structure.
  • the multi-layer structure may be made of different metal layers, different layers of fiber material or a combination of both.
  • a judicious selection of material for the individual layers may allow different properties of the layers to be combined in advantageous ways.
  • the outermost layer should in this case be as hard as possible, and the underlying layers should to the greatest possible extent absorb the impact energy of the droplets and absorb the structure-borne sound waves which are generated by the impact of the droplets, such that they cannot have an effect on the base material of the turbine blade.
  • a particularly advantageous embodiment of the invention provides for an anti-erosion component to be arranged at least at the leading edge and/or the trailing edge of the turbine blade.
  • an anti-erosion component to be arranged at least at the leading edge and/or the trailing edge of the turbine blade.
  • attaching an anti-erosion component to the trailing edge may also be useful.
  • the trailing edge of the turbine blade is not at risk of erosion in normal operation of the turbine.
  • water is sprayed into the steam turbine to prevent overheating.
  • the water is conventionally sprayed in against the trailing edge of the turbine blade. This can have the result that in some circumstances the trailing edge of the turbine blade is also subject to erosion.
  • an anti-erosion component at the trailing edge may reduce the impact of erosion.
  • fiber intermediates and the anti-erosion component are laid in the impregnation mold, care must be taken that the anti-erosion component and the fiber intermediates are arranged such that, once the fiber intermediate is impregnated with matrix material, a turbine blade is created into the contour whereof the anti-erosion component can be completely integrated.
  • fiber intermediates here means, among other things, fabrics, fiber fabrics or fiber mats.
  • resin is suitable, in particular synthetic resin.
  • the method according to the invention for making the turbine blade has the great advantage that the turbine blade can be constructed with the anti-erosion component integrated, in one method step. There is no need to attach an anti-erosion component subsequently.
  • a particularly advantageous method for making a turbine blade provides for the anti-erosion component to be laminated into the turbine blade during impregnation.
  • laminated in means that the anti-erosion component is fixedly connected to the turbine blade by the matrix material.
  • a further advantageous method for making the turbine blade provides, as an additional method step, for the anti-erosion component, after it has been laminated in, to be secured to the turbine blade by additional securing means, in particular screws, rivets or pins.
  • additional securing has the advantage that even if laminating-in is faulty, the anti-erosion component cannot become detached. It is absolutely imperative to avoid the anti-erosion component becoming detached since this can cause major damage to the turbine blade or to the turbine as a whole.
  • a further advantageous method for making the turbine blade provides for the anti-erosion component to be provided, before impregnation, with a release agent and, after impregnation, to be secured to the turbine blade by gluing and/or additional securing means, in particular screws, rivets or pins.
  • the subsequent attachment of the anti-erosion component has the advantage that it can still be trimmed by machining before the final securing, or positioning of the anti-erosion component on the turbine blade can easily be corrected.
  • a second method according to the invention for making a turbine blade using an impregnation mold is characterized in that the impregnation mold is constructed such that, after impregnation, a recess which is constructed to complement the anti-erosion component is present at the points on the turbine blade at which an anti-erosion component is to be attached, and in that the method has the following method steps:
  • the subsequent attachment of the anti-erosion component has the advantage that it can still be trimmed by machining before the final securing, or positioning of the anti-erosion component on the turbine blade can easily be corrected.
  • FIG. 1 shows a side view of a turbine blade according to the invention
  • FIG. 2 shows a detail view of a leading edge of a turbine blade according to the invention with a one-piece anti-erosion component
  • FIG. 3 shows a detail view of a leading edge of a turbine blade according to the invention with an anti-erosion component and an intermediate layer made from an elastic and/or viscoelastic material;
  • FIG. 4 shows a detail view of a leading edge of a turbine blade according to the invention, wherein the anti-erosion component has a multi-layer structure.
  • FIG. 1 shows a turbine blade 1 which can be used in particular as a final-stage rotor blade for a steam turbine.
  • the turbine blade 1 is made from a fiber-reinforced composite material.
  • a plurality of layers of fiber mats are arranged on top of one another. So that the advantages of the fibers—that is to say the high tensile force in the direction of the fibers—can be utilized, the mats are laid on top of one another such that the main direction of the fibers is aligned with the main direction of load on the turbine blade 1 .
  • a suitable fiber material is in particular glass-reinforced fiber or carbon-reinforced fiber.
  • the fiber mats are embedded in a matrix.
  • the matrix is preferably made from a synthetic resin and ensures that the fiber mats are connected to one another. However, the matrix cannot absorb high tensile forces.
  • the turbine blade 1 Because turbine blades made from fiber-reinforced composite material are highly susceptible to erosion corrosion, the turbine blade 1 has an anti-erosion component 2 at the leading edge 6 .
  • the leading edge 6 is at most risk of erosion because it is essentially here that the water droplets impact.
  • the anti-erosion component 2 is only attached in the upper half of the leading edge 6 . Erosion has the greatest effect in this region of the leading edge 6 , since it is here that the highest peripheral speeds occur when the turbine is in operation.
  • the anti-erosion component 2 is inserted into the blade contour of the turbine blade 1 such that a smooth transition with no edges is created between the anti-erosion component 2 and the turbine blade 1 .
  • the anti-erosion component can be laminated in directly when the turbine blade is made or indeed can be connected to the turbine blade later by gluing or additional securing means, in particular screws, rivets or pins. Once laminated in, the anti-erosion component 2 can additionally be secured using securing elements to ensure that the anti-erosion component 2 is reliably secured to the turbine blade 1 . If during operation of the turbine the anti-erosion component were to become detached, for example because of faulty lamination, it could cause substantial damage to the turbine blades 1 and it is therefore imperative that it be avoided.
  • the anti-erosion component 2 should be made from carbide, titanium or ceramic.
  • the high level of hardness of these materials ensures a high resistance to erosion and hence a long service life of the anti-erosion component 2 .
  • the anti-erosion component 2 is manufactured such that it is inserted seamlessly into the blade contour of the turbine blade 1 , there is no need for subsequent machining of the anti-erosion component 2 . This brings considerable advantages, since it is extremely difficult for the hard materials to be machined subsequently, and this entails substantial manufacturing work.
  • the turbine blade 1 additionally has a second anti-erosion component 2 at the trailing edge 7 of the turbine blade 1 .
  • the anti-erosion component 2 at the trailing edge 7 of the turbine blade 1 is provided for ventilation mode. In the ventilation mode of the steam turbine, to prevent overheating water is sprayed onto the turbine blade 1 from behind. During this, in unfavorable conditions it may happen that water droplets impact on the trailing edge 7 of the turbine blade 1 . These then result in increased erosion effects at the trailing edge 7 . For this reason, an anti-erosion component 2 is provided at the trailing edge 7 of the turbine blade 1 .
  • the turbine blade made from fiber-reinforced composite material may also be used in the wet steam region of a steam turbine. This has not hitherto been possible.
  • the weight of the turbine blade may be significantly reduced. Reducing the weight of the turbine blade has the result that the centrifugal load on the turbine blade, particularly in the sensitive region of the blade foot, may be reduced or, with the same tensile load, the blade may be made longer and hence the outflow cross-section of the exhaust casing may be made larger.
  • An increase in the cross-section of the exhaust casing and an increase in the speed of rotation of the turbine result in greater efficiency of the steam turbine.
  • the turbine blade 1 which is described is made entirely from fiber-reinforced composite material. However, a construction in which only a partial region is made from fiber-reinforced composite material is also conceivable. Thus, for example, the turbine blade could be made from fiber-reinforced composite material and the blade foot could be made from steel or titanium.
  • FIG. 2 shows a detail view of the turbine blade 1 illustrated in FIG. 1 .
  • the detail view shows a side view of the turbine blade 1 shown in FIG. 1 .
  • the turbine blade 1 is prepared such that once the anti-erosion component 2 has been inserted, the original blade contour of the turbine blade 1 is produced.
  • there is a smooth transition between the anti-erosion component 2 and the turbine blade 1 without edges of any kind. The flow conditions at the turbine blade 1 are thus entirely retained, and a deflection of the flow at the transition from the anti-erosion component 2 to the turbine blade 1 is avoided.
  • connection between the turbine blade 1 and the anti-erosion component 2 is made by laminating in the anti-erosion component 2 and securing it with additional securing means 3 , in particular screws, rivets or pins.
  • additional securing means 3 provide additional security against the anti-erosion component 2 becoming detached, in particular in the event of faulty lamination.
  • FIG. 3 shows a detail view of a second exemplary embodiment of a turbine blade.
  • the detail view shows the leading edge 6 of the turbine blade 1 in side view.
  • the intermediate layer 4 is an elastic and/or viscoelastic intermediate layer.
  • the impact of droplets on the anti-erosion component 2 creates powerful structure-borne sound waves which are propagated within the anti-erosion component 2 and the turbine blade 1 .
  • the structure-borne sound waves may on the one hand result in parts of the anti-erosion component 2 breaking off. At the same time, the structure-borne sound waves may result in damage to the turbine blade 1 and the fiber-reinforced composite material.
  • the elastic and/or viscoelastic intermediate layer 4 absorbs the structure-borne sound waves.
  • the structure-borne sound waves cannot propagate in the fiber-reinforced composite material and result in destruction of the material there.
  • the impact of droplets, or the impact energy of dripping is absorbed by the intermediate layer, as a result of which the risk of material breaking off in the region of the anti-erosion component 2 is reduced.
  • the intermediate layer 4 and the anti-erosion component 2 are, in this case too, constructed such that there is a smooth transition to the turbine blade 1 .
  • the intermediate layer 4 and the anti-erosion component 2 can be laminated in at the same time as manufacture or indeed be connected to the turbine blade 1 later by additional securing elements.
  • FIG. 4 shows a third exemplary embodiment of a turbine blade 1 in a detail view.
  • the detail view shows the leading edge 6 of the turbine blade 1 in side view.
  • the anti-erosion component 2 has a multi-layer structure.
  • the multi-layer structure should always be selected such that the outer layer is an erosion-resistant layer which is as hard as possible and the underlying layers absorb as well as possible the structure-borne sound waves which are generated by the impact of droplets.
  • various fiber mats and various metals can be used as the layer material.
  • the multi-layer structure comprises a total of four different layers 2 , 4 , 10 , 11 .
  • the multi-layer structure is a graduated structure of different fiber-reinforced composite materials.
  • the outer layer 2 is in this case made from a very hard material which is not susceptible to erosion. Care must be taken here that the very hard layer is not too brittle, in order to avoid the risk of its breaking up.
  • a second elastic and/or viscoelastic layer 4 which ensures that structure-borne sound waves generated by the droplets are largely absorbed.
  • the next layer 10 is a glass mat, and the underlying layer 11 is a glass fabric. The glass mat and the glass fabric ensure that there is a particularly good connection with the fiber-reinforced composite material of the turbine blade 1 , and additionally provide for the absorption of structure-borne sound waves.
  • the individual fiber-reinforced composite materials 2 , 4 , 10 , 11 of the anti-erosion component 2 may be laminated onto the base material of the turbine blade and thereafter form a permanent composite with the turbine blade 1 .
  • the individual fiber mats are constructed such that a smooth transition is created between the turbine blade 1 and the multi-layer anti-erosion component 2 .
  • the blade contour corresponds to a blade contour as used conventionally, that is with no anti-erosion components.
  • the anti-erosion components 2 do not bring about any change in the blade profile, and the flow properties of the turbine blade are retained.
  • the manufacture of a turbine blade having one or more anti-erosion components 2 takes place using an impregnation mold.
  • the impregnation mold provides the foam of the turbine blade to be made.
  • the fiber intermediates are laid in the impregnation mold together with the anti-erosion component 2 .
  • the anti-erosion component 2 may be fixed to the impregnation mold.
  • the impregnation procedure is performed.
  • the resin is introduced into the fiber intermediates. This introduction may be carried out using an open or a closed method. The various methods have already been explained in detail in the introduction to the description, so more detail will not be given here.
  • the turbine blade 1 has to cure.
  • the cure time is dependent on the matrix material selected and on the ambient temperature.
  • the turbine blade 1 can be removed from the impregnation mold.
  • the anti-erosion component 2 can be connected to the turbine blade 1 in various ways. On the one hand, the anti-erosion component 2 can be laminated directly to the turbine blade 1 . In this case, the connection between the anti-erosion component 2 and the turbine blade 1 is made by means of the matrix material. Additional securing by means of securing means 3 , in particular screws, rivets or pins, may be performed subsequently.
  • Another method for making the turbine blade 1 provides for the anti-erosion component 2 to be provided with a release agent before the impregnation. As a result of this, during the impregnation procedure the anti-erosion component 2 is not connected to the turbine blade 1 .
  • the anti-erosion component 2 is secured to the turbine blade in a further method step, by gluing and/or additional securing means 3 such as screws, rivets or pins.
  • a further method for making a turbine blade 1 having an anti-erosion component 2 provides for an impregnation mold to be used which has a recess at the point at which the anti-erosion component 2 is later to be attached. Once the turbine blade 1 has cured, the anti-erosion component 2 can be incorporated by gluing and/or additional securing means 3 such as screws, rivets or pins.
  • Attaching the anti-erosion component 2 subsequently has the advantage that if fitting is imprecise this can be corrected before the actual securing. Machining the anti-erosion component 2 before it is secured to the turbine blade 1 is easier to accomplish, in particular with the hard materials which are preferably used, such as carbide, titanium or ceramic, which can substantially only be machined by grinding.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Ceramic Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
US13/498,450 2009-09-30 2010-09-21 Final-stage rotor blade of a steam turbine Abandoned US20120207608A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102009047798.5 2009-09-30
DE102009047798A DE102009047798A1 (de) 2009-09-30 2009-09-30 Turbinenschaufel, insbesondere Endstufenlaufschaufel für eine Dampfturbine
PCT/EP2010/063871 WO2011039075A1 (fr) 2009-09-30 2010-09-21 Aube mobile d'étage final d'une turbine à vapeur

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US20120207608A1 true US20120207608A1 (en) 2012-08-16

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US (1) US20120207608A1 (fr)
EP (1) EP2483526B1 (fr)
DE (1) DE102009047798A1 (fr)
WO (1) WO2011039075A1 (fr)

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US20140003907A1 (en) * 2012-06-28 2014-01-02 Alstom Technology Ltd Cooling system and method for an axial flow turbine
FR3011875A1 (fr) * 2013-10-11 2015-04-17 Snecma Aube de turbomachine a profil asymetrique
US9328612B2 (en) 2011-09-30 2016-05-03 Alstom Technology Ltd Retrofitting methods and devices for large steam turbines
FR3049002A1 (fr) * 2016-03-21 2017-09-22 Snecma Pale de turbomachine aeronautique comprenant un element rapporte en materiau composite formant bord de fuite et procede de fabrication d'une telle pale
FR3049001A1 (fr) * 2016-03-21 2017-09-22 Snecma Turbomachine aeronautique a helice non carenee munie de pales ayant un element rapporte en materiau composite colle sur leur bord d'attaque
US10125617B2 (en) 2014-06-11 2018-11-13 Rolls-Royce Plc Composite structure and a method of fabricating the same
CN112607003A (zh) * 2020-11-25 2021-04-06 常州市长昊机械有限公司 一种易收纳式航空叶片

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WO2012038217A1 (fr) * 2010-09-21 2012-03-29 Siemens Aktiengesellschaft Aube de turbine pourvue d'une couche céramique de protection contre l'érosion et destinée à un étage basse pression d'une turbine à vapeur
CH705171A1 (de) 2011-06-21 2012-12-31 Alstom Technology Ltd Turbinenschaufel mit einem Schaufelblatt aus Verbundwerkstoff und Verfahren zum Herstellen davon.
DE102012223220A1 (de) * 2012-12-14 2014-06-18 Leichtbau-Zentrum Sachsen Gmbh Turbinenschaufel, insbesondere Endstufenlaufschaufel für eine Dampfturbine
EP2746428B1 (fr) 2012-12-20 2017-09-13 General Electric Technology GmbH Revêtement de composants de turbine
JP6968006B2 (ja) 2018-03-09 2021-11-17 三菱重工業株式会社 前縁カバー部材、前縁カバー部材ユニット、複合材翼、前縁カバー部材の製造方法及び複合材翼の製造方法
DE102019216073B4 (de) * 2019-09-23 2021-12-16 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur Herstellung einer Leichtbau-Turbinenschaufel als Verbundbauteil sowie eine mit dem Verfahren hergestellte Leichtbau-Turbinenschaufel

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Cited By (10)

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Publication number Priority date Publication date Assignee Title
US9328612B2 (en) 2011-09-30 2016-05-03 Alstom Technology Ltd Retrofitting methods and devices for large steam turbines
US20140003907A1 (en) * 2012-06-28 2014-01-02 Alstom Technology Ltd Cooling system and method for an axial flow turbine
FR3011875A1 (fr) * 2013-10-11 2015-04-17 Snecma Aube de turbomachine a profil asymetrique
US9784112B2 (en) 2013-10-11 2017-10-10 Snecma Turbine engine vane with asymmetrical profile
US10125617B2 (en) 2014-06-11 2018-11-13 Rolls-Royce Plc Composite structure and a method of fabricating the same
FR3049002A1 (fr) * 2016-03-21 2017-09-22 Snecma Pale de turbomachine aeronautique comprenant un element rapporte en materiau composite formant bord de fuite et procede de fabrication d'une telle pale
FR3049001A1 (fr) * 2016-03-21 2017-09-22 Snecma Turbomachine aeronautique a helice non carenee munie de pales ayant un element rapporte en materiau composite colle sur leur bord d'attaque
WO2017162964A1 (fr) * 2016-03-21 2017-09-28 Safran Aircraft Engines Turbomachine aéronautique à hélice non carénée munie de pales ayant un élément rapporte en matériau composite colle sur leur bord d'attaque
US11401823B2 (en) * 2016-03-21 2022-08-02 Safran Aircraft Engines Aircraft turbomachine provided with an unducted propeller with blades having a composite-material insert bonded to their leading edges
CN112607003A (zh) * 2020-11-25 2021-04-06 常州市长昊机械有限公司 一种易收纳式航空叶片

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EP2483526A1 (fr) 2012-08-08
EP2483526B1 (fr) 2015-09-16
WO2011039075A1 (fr) 2011-04-07
DE102009047798A1 (de) 2011-04-14

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