US20190022753A1

US20190022753A1 - Method for producing a component, and device

Info

Publication number: US20190022753A1
Application number: US16/070,345
Authority: US
Inventors: Bernd Burbaum; Torsten Neddemeyer
Original assignee: Siemens AG
Current assignee: Siemens Energy Global GmbH and Co KG
Priority date: 2016-02-08
Filing date: 2017-01-26
Publication date: 2019-01-24
Also published as: DE102016201838A1; JP2019512048A; EP3368237B1; CN108602126A; WO2017137262A1; EP3368237A1

Abstract

A method for producing a component for a turbomachine, having the additive build-up of the component by an additive production method from a base material for the component and the introduction of material fibers into a construction for the component during the additive build-up in such a way that the material fibers are oriented in a circumferential direction of the component around a component axis and in such a way that a fiber composite material is produced, including the material fibers and a base material that is solidified by the additive build-up. A corresponding component is produced by the method and a corresponding device is used for producing the component.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the US National Stage of International Application No. PCT/EP2017/051645 filed Jan. 26, 2017, and claims the benefit thereof. The International Application claims the benefit of German Application No. DE 102016201838.8 filed Feb. 8, 2016. All of the applications are incorporated by reference herein in their entirety.

FIELD OF INVENTION

The present invention relates to a method for producing a component part a component for a turbomachine. The present invention furthermore comprises the component and a device for producing the component.
The component can be a turbine disk. The term “turbine disk” is in the present case to be understood as being synonymous to turbine ring or rotor disk. The component can also be a rotor part or a part of a compressor, or compressor of a gas turbine. The component is also advantageously an additively or generatively produced or built-up component.

BACKGROUND OF INVENTION

Known layered, additive or generative production methods are especially selective laser melting (SLM), selective laser sintering (SLS) and electron beam melting (EBM). Additive production methods are for the production of three-dimensional individually formed components by means of their iterative stacking or joining together of layers, layer elements or volumetric elements, for example from of a powder bed. Typical thicknesses of the individual layers lie between 20 μm and 60 μm.
A large number of different materials, for example ceramic materials and/or metallic materials, which can exist both in powder form or granulate form, but also in the form of fluids, e.g. as suspensions, are available as source materials. In generative production methods, the three-dimensional object is formed by a multiplicity of individual material layers which are deposited one after the other on a lowerable build-up platform and then individually subjected to a locally selective solidification process.
A method for selective laser melting is known from EP 1 355 760 B1, for example.
Turbine parts are exposed to particularly high thermal and/or mechanical loads during their application or operation. In this case, thermal and mechanical loads of a gas turbine or of its rotor parts during operation can be interrelated, for example in the form of thermo-mechanical stresses.
In addition to the development of ever temperature-resistant materials, there is therefore also a demand for materials, for example composite materials, which have improved mechanical properties. Whereas in thermally highly loaded regions of a turbine, for example at temperatures of above 600° C., a high degree of strength of the materials is required, in inner regions or inner parts of the turbine, of the compressor or of a corresponding rotor disk a high level of ductility is especially required.

SUMMARY OF INVENTION

It is therefore an object of the present invention to specify means which improve the mechanical properties especially of rotatable turbine parts, and/or to make the operation of the turbine more reliable and/or more efficient.
This object is achieved by means of the subject matter of the independent claims. Advantageous embodiments are the subject matter of the dependent claims.
One aspect of the present invention relates to a method for producing a component for a turbomachine, for example for a gas turbine, such as a rotor disk for a gas turbine, comprising the additive build up of the component by means of an additive production method. The component for the additive build up is especially built up from a matrix or base material, advantageously from a powder-form base material, for the component. The stated material can be a nickel-based, a cobalt-based or an iron-based material.
The method also comprises the introduction of material fibers into a construction for the component during the additive build up in such a way that the material fibers are oriented along, or basically along, a circumferential direction of the component, advantageously around a component axis, and in such a way that a fiber composite material is created, the fiber composite material expediently comprising the material fibers and a base material which is solidified as a result of the additive build up, wherein the material fibers also comprise ceramic material, especially consisting of aluminum oxide, mullite, SiBCN, SiCN or SiC.
In one embodiment, the component is a rotatable part, and especially rotating during operation of the turbomachine.
In one embodiment, the component is a rotationally symmetrical part, or basically rotationally symmetrical part, of the turbomachine, or for the turbomachine.
The circumferential direction advantageously refers in the present case a direction which corresponds to a rotation direction or direction of revolution of the component during its operation, advantageously during its application in the turbomachine. The circumferential direction can be a tangential direction.
The circumferential direction can especially describe a circumference of the component axis or at least partially comprise a geometric directional component along the circumference of the component.
The term “construction” can describe the component itself. An only partially (additively) produced part of the component can especially be meant by this, for example at a point in time during an additive production and in a corresponding facility or device for the additive production.
The material fibers can be principally or predominantly oriented in, or along, the circumferential direction. For example, the material fibers, apart from necessary twists or production-induced deviations from the circumferential direction, can be oriented along this direction and/or introduced into the construction. However, the material fibers do not necessarily have to be oriented concentrically to the component or to other fibers.
By means of the described method, in a particularly advantageous manner, a fiber composite material or a fiber composite substance can at least partially be additively produced or built up, or the corresponding production can be implemented in an additive production process. The known advantages of fiber composite materials can especially be utilized according to the described method for the production and the application especially as a rotor part of a gas turbine, for example of a compressor disk. For example, creep resistance or the resistance to tensile load of the component perpendicularly to the fiber direction can be improved by the use of fiber composite materials.
At the same time, the advantages of additive production technology can also be utilized synergistically in this case.
In one embodiment, the additive production method is a powder bed-based additive production method.
In one embodiment, the additive production method is a beam melting method.
In one embodiment, the additive production method is selective laser melting, selective laser sintering, electron beam melting or laser deposition welding.
In one embodiment, the material fibers are introduced into the construction of the component by means of a robot-controlled or robot-guided device.
In one embodiment, the material fibers, for example as seen along a build-up direction of the component, are arranged or introduced only in one, especially central, radial region of the component and advantageously not across the entire radial extent. This region can especially be a radial “waist region” of the component which during operation of the component is exposed to particularly high mechanical loads.
In one embodiment, the material fibers are interwoven during the additive build up.
In one embodiment, the base material is arranged at least partially between the material fibers.
In one embodiment, the material fibers are provided with a coating before introduction.
A further aspect of the present invention relates to a component for a turbomachine, wherein the component is produced, or can be produced, by means of the described method.
In one embodiment, the component is a rotor part of a turbomachine, for example of a gas turbine.
In one embodiment, the component is a turbine disk which is designed for the mounting of a rotatable part of a turbomachine during operation. The rotatable part can be for example a compressor blade.
A further aspect of the present invention relates to a turbine disk for a turbomachine comprising, for example, a radial region, especially a central or middle radial region, and a fiber composite material, as described above. The fiber composite material also comprises the material fibers and a matrix material, wherein the material fibers are oriented along a circumferential direction of the turbine disk and wherein the material fibers also comprise ceramic material, especially consisting of aluminum oxide, mullite, SiBCN, SiCN or SiC.
The matrix material of the fiber composite material advantageously refers to a base material which is solidified during, or as a result of, the additive production.
In one embodiment, the material fibers comprise one or more of the following materials: carbon, boron, basalt and/or ceramic material, especially consisting of aluminum oxide, mullite, SiBCN, SiCN and SiC.
In one embodiment, the fiber composite material and/or the material fibers comprise carbon (C), silicon carbide (SiC) and/or aluminum oxide, for example Al₂O₃. The fiber composite material and/or the material fibers can comprise the stated materials for example as the principle constituent.
In one embodiment, the matrix material and/or base material comprises carbon, silicon carbide and/or aluminum oxide. The matrix material and/or base material can comprise the stated materials for example as the principle constituent.
In one embodiment, the coating of the material fibers comprises especially carbon and/or boron nitride (BN).
A further aspect of the present invention relates to a device for producing a component for a turbomachine, wherein the device is designed for additively building up the component from for example a powder-form base material. The device also comprises an appliance for introducing material fibers into the construction for the component in such a way that the material fibers are oriented along the circumferential direction of the component and in such a way that the fiber composite material is produced. The fiber composite material expediently comprises—as described above—the material fibers and the solidified base material.
Embodiments, features and/or advantages which in the present case relate to the method can also relate to the device and/or to the component, and vice versa.

BRIEF DESCRIPTION OF THE DRAWINGS

Further details of the invention are described below with reference to the drawing.

FIG. 1 schematically shows a top view of a device for the additive production of a component for a turbomachine.

FIG. 2 schematically shows a sectional or side view of a device for the additive production of a component for a turbomachine.

FIG. 3 schematically shows a cross section through a turbine disk.

DETAILED DESCRIPTION OF INVENTION

FIG. 1 schematically shows a top view of a device 10. The device 10 is a device for the additive production of a component 1. The device 1 is advantageously a device for the layered build up of a component from a powder bed, for example a device for selective laser melting, as shown in FIG. 1. Alternatively, the device 10 can be a device for selective laser sintering and/or for electron beam melting.
A method according to the invention for producing the component 1 is described based on the device 10 and with reference to FIGS. 1 and 2.
The component 1 is especially a rotor part of a turbomachine, such as a gas turbine. The component 1 especially refers to a turbine disk, a turbine ring or a rotor disk of a compressor of the turbine.
The device 10 has a construction platform 8 (cf. FIG. 2) on which is arranged a advantageously powder-form source or base material 2 for the component 1. The base material 2 can for example be a nickel-based, a cobalt-based or an iron-based material.
Shown on the construction platform 8 is a build up of the component. In this case, it can be a partially built-up component and/or can be the component during its additive production. The component 1 is expediently of rotationally symmetrical design, or in the main of rotationally symmetrical design. As the rotor part of a turbomachine or of a compressor thereof, the component is also advantageously rotatable, e.g. rotatable relative to stator components of the turbomachine. The component advantageously rotates during the designated operation of the turbine.
For the additive build up, the device 10 has a solidification device 9. In this case, it can be a solidification device of the prior art. The solidification device 9 is advantageously a computer-controlled or computer-controllable unit which for solidifying the base material 2 is equipped with a laser or an electron beam device (not explicitly identified). For the solidification, the base material 2 is advantageously first of all melted and then solidified.
For applying the base material 2, the device 10 has a coating or deposition device 7. In this case, it can be a doctor blade with which the advantageously powder-form base material 2 can be distributed or deposited on the build platform 8. This can be carried out for example along a coating direction B.
As an element according to the invention, the device 10 is also an appliance 5. The appliance 5 is designed for introducing material fibers 3 into the build up for the component 1, specifically in such a way that the material fibers 3 are oriented at least in the main along a circumferential direction or rotation direction, identified by the designation A, of the component 1 during operation.
The dashed (concentric) circles, which are shown inside the component 1 in FIG. 1, advantageously indicate a region in which the material fibers 3 are arranged and/or introduced. The material fibers are also shown only in sections. With reference to the depicted sections, it is to be seen that the direction of orientation or alignment corresponds to the circumferential direction A.
The appliance 5 is advantageously also designed in such a way that the introduction of the material fibers 3 creates a fiber composite material 4 comprising the material fibers 3 and a solidified base material or matrix material (for the sake of simplicity this is identified by the designation 2 in the same way as the base material. The fiber composite material 4 can be formed by the material fibers 3 and the matrix material.
The appliance 5 is advantageously robot-controlled. As shown in FIG. 1, the appliance 5 can comprise a robot arm which is shown only schematically in the illustration. This robot arm is pivotable for example across the production area of the construction platform 8 or the component 1 in such a way that the material fibers 3 can be “built into” the component, as described above, during the additive build up of the base material. Said robot arm can also be for example of telescopically extendable design.
Within the scope of the present method, the material fibers 3—with the aid of the appliance 5—are introduced into the construction advantageously during the additive build up or the additive production of the component 1 so that the fiber composite material 4 is created and the fibers are oriented in the same way as described above. One fiber layer (cf. FIG. 1) can be introduced per additively built-up and/or solidified layer of base material. This takes place advantageously before the base material 2 is deposited or distributed by means of the coating device 7 so that a corresponding layer can be formed or produced for the fiber composite material. The base material 2 is advantageously deposited in such a way and/or the material fibers are introduced in such a way that base material 2 is at least partially arranged between the material fibers 3.
The material fibers 3 can especially also be interwoven.
It is also provided within the scope of the described method that the material fibers, for example before introduction into the construction by means of the appliance 5, are provided or coated with a coating (not explicitly identified). The coating can be a sliding or lubricant coating, especially in order to enable a sliding movement of the material fibers 3 relative to the matrix material 2, which movement in turn has an effect upon the specific mechanical properties of the fiber composite material 4.
FIG. 2 shows a schematic side view of a device 10. A build-up direction is identified by the designation C. As an alternative to the embodiment of the device of FIG. 1, the device 10—as shown in FIG. 2—can for example also be a device for laser deposition welding, especially laser powder deposition welding. Accordingly, the solidification device 9 in this case advantageously comprises both a laser (not explicitly identified) for solidification of the base material 2 and a powder nozzle (not explicitly identified) by means of which the base material 2 is made available.
FIG. 3 shows, in a simplified cross section, a finished component 1. The component 1—in comparison to the remaining sections—has a narrowed or waisted central, or inner radial region 6. In this region, particularly high mechanical loads can occur during operation of the component 1. An upper, not identified, widening region of the turbine disk 1 is especially provided both in order to keep turbine blades in place, for example during operation of a gas turbine, and to make the turbine blades exchangeable, advantageously by axial sliding into or out of the formed cavities.
The central region 6 comprises the described fiber composite material 4. The central region 6 can consist of the fiber composite material 4. In particular, the material fibers 3 are shown in circular form in the region 6 in the cross-sectional view of FIG. 4. The fiber composite material 4 and/or the component which is provided therewith—in comparison to a turbine disk of the prior art—especially has improved mechanical properties, especially a higher fracture elongation or fracture-elongation loadability, e.g. by up to one percent. By the same token, the component 1 according to the invention, which is produced by the described method, advantageously has a significantly increased crack resistance, an improved thermal shock resistance, and for example improved thermo-mechanical properties.
Furthermore, an extensibility or extension loadability of the component 1 relative to a conventional rotor part of a turbine can be increased by 2%.
The fiber composite material 4—due to the specification of the fiber directions—can have anisotropic and therefore especially mechanical properties.
The component 1 can especially be a rotor disk of a compressor or of a compressor stage of a gas turbine (advantageously upstream of the combustion chamber of the turbine as seen in the flow direction). The component 1 can especially be a compressor rotor disk of the material grade “26NiCrMoV 14-5” or “Cost-E (X 1 2CrMoWVNbN 10-1-1”.
The described material fibers 3 can also comprise one or more of the following materials: carbon, boron, basalt and/or ceramic material, especially aluminum oxide, for example Al₂O₃, mullite, SiBCN, SiCN and SiC.
By the description based on the exemplary embodiments, the invention is not limited to these but covers each new feature and each combination of features. This especially contains each combination of features in the patent claims, even if this feature or this combination itself is not explicitly disclosed in the patent claims or exemplary embodiments.

Claims

1. A method for producing a component for a turbomachine, the method comprising:

additive build up of the component by means of an additive production method from a base material for the component and

introduction of material fibers into a construction for the component during the additive build up in such a way that the material fibers are oriented along a circumferential axis of the component around a component axis and in such a way that a fiber composite material is created,

the fiber composite material comprising the material fibers and a base material which is solidified as a result of the additive build up, wherein the material fibers comprise ceramic material.

2. The method as claimed in claim 1,

wherein the material fibers are introduced by means of a robot-controlled appliance.

3. The method as claimed in claim 1,

wherein the material fibers are introduced only in a central region of the component, as seen along a build-up direction of the component.

4. The method as claimed in claim 1,

wherein the additive production method is selective laser melting, selective laser sintering, electron beam melting or laser deposition welding.

5. The method as claimed in claim 1,

wherein the base material is arranged at least partially between the material fibers.

6. The method as claimed in claim 1,

wherein the material fibers are provided with a coating before introduction.

7. A component for a turbomachine,

wherein the component is produced, by means of the method according to claim 1,

wherein the component is a rotor part of a turbomachine, or of a gas turbine.

8. The component as claimed in claim 7,

wherein the component is a turbine disk for the mounting of a rotating part of a turbomachine, or a compressor blade, during operation.

9. A turbine disk for a turbomachine, comprising:

a fiber composite material comprising material fibers which comprise ceramic material,

wherein the material fibers are oriented along a circumferential direction or the turbine disk around a rotation axis thereof during operation.

10. The turbine disk as claimed in claim 9,

wherein the material fibers comprise one or more of the following materials: carbon, boron and/or basalt.

11. A device for producing a component for a turbomachine, wherein the device is designed for additively building up the component from a base material, the device comprising:

an appliance which is designed for introducing material fibers into a construction for the component in such a way that the material fibers are oriented along a circumferential direction of the component around a component axis and in such a way that a fiber composite material is created, which fiber composite material comprises the material fiber and a solidified base material.

12. The method as claimed in claim 1,

wherein the material fibers comprise ceramic material, consisting of aluminum oxide, mullite, SiBCN, SiCN or SiC.

13. The turbine disk as claimed in claim 9,