US3068556A - Method of making jet turbine buckets - Google Patents

Method of making jet turbine buckets Download PDF

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US3068556A
US3068556A US39749A US3974960A US3068556A US 3068556 A US3068556 A US 3068556A US 39749 A US39749 A US 39749A US 3974960 A US3974960 A US 3974960A US 3068556 A US3068556 A US 3068556A
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molybdenum
bucket
sheath
boot
turbine
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US39749A
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Bruce E Kramer
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
    • 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
    • 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
    • Y10T29/49336—Blade making
    • Y10T29/49337—Composite blade

Definitions

  • AM/e wwlaif NML drive a blower for furnishing air to the burners.
  • the present invention relates to turbine buckets and, as illustrated herein, relates more particularly to turbine buckets adapted for use at high temperatures, and forms a division of my co-pending parent application, Serial No. 766,370, filed October 9, 1958, now Patent No. 3,032,316.
  • Turbine buckets must have sufiicient strength, toughness, creep resistance and resistance to oxidizing gases to enable the bucket to operate efiiciently without deformation or corrosion.
  • Molybdenum isone of the metals which exhibits high strength, toughness and creep resistance at temperatures above 1400 F. Molybdenum, however, cannot be used at higher temperatures since the trioxide of molybdenum, which is formed under the oxidizing conditions present in a jet turbine, sublimes very rapidly at temperatures in excess of 1463 F. and a molybdenum turbine bucket will disappear in a matter of minutes.
  • the present invention contemplates the application of high temperature coatings in a manner to avoid the problems noted above.
  • a sheath formed of molybdenum wire screen or sheet arranged to enclose molybdenum alloy turbine bucket airfoil is proposed.
  • the molybdenum wire screen or sheet metal sheath is coated on the outside with an appropriate cermet or ceramic and then sintered at the appropriate high temperature.
  • the molybdenum alloy turbine bucket is flame sprayed with a suitable brazing alloy which is fused on the turbine bucket airfoil.
  • the coated and sintered molybdenum boot is then placed over the molybdenum bucket and brazed in an autoclave by usual means.
  • Another object of the invention is to provide a simple and effective method for providing turbine bucket airfoils with a coated boot which will withstand relatively high temperatures.
  • a suitable brazing alloy is flame sprayed and fused on the turbine bucket airfoil.
  • a boot of sheet molybdenum or wire mesh is constructed to envelop completely the turbine bucket airfoil.
  • the molybdenum boot is removed and coated on the outside with an appropriate cermet or ceramic.
  • the coated molybdenum boot is sintered at the appropriate temperature.
  • the coated and sintered boot is placed over the molybdenum bucket and brazed in an autoclave by usual means.
  • FIGURE 1 is a view of a turbine bucket constructed according to the present invention
  • FIGURE 2 is a view in section taken along the lines IIII of FIGURE 1;
  • FIGURE 3 is an enlarged sectional View taken along the line IIIIII of FIGURE 2.
  • the bucket 10 comprises a body 12 formed of molybdenum metal or a high temperature molybdenum alloy having its bucket or airfoil surface covered with a boot 14 formed, as shown, of molybdenum wire screen.
  • the boot 14 could be formed of a thin sheet of molybdenum metal or molybdenum alloy. It is preferred, however, to use molybdenum wire screen since it may be more readily shaped to fit the airfoil section of the molybdenum bucket 10.
  • the body 12 of the bucket 10 is provided, preferably, with a fir tree root 18 for securing the same in the turbine wheel.
  • the airfoil section of the bucket is coated by a flame spraying method by the use of a suitable brazing alloy 20.
  • a brazing alloy containing any suitable metal such as silver solder, copper or nickel is sprayed and fused on the airfoil surface of the bucket to provide an effective means by which the boot 14 is secured to the bucket 12.
  • the flame spraying method is preferred but other suitable methods may be used if so desired.
  • the boot 14 is shaped to fit closely about the airfoil surface of the bucket 12. After the boot 14 has been shaped, it is removed from the bucket 12 and coated on the outside with a suitable ceramic 16 having physical properties sufiicient to withstand the high temperature conditions of a jet engine.
  • a preferred corrosion resistant, shock resistant, and abrasion resistant ceramic 20 may be formed of Ni- Cr C CrAl O Cr--CrB, specially compounded ccramic glass and pure oxides such as A1 0 and ZIOZ. The selected material is preferably reduced to a fine powder and uniformly dispersed to form a slip by wet mixing.
  • the slip is applied to the outer surface of the boot 14 and is fired or sintered at high temperatures ranging from 2700" F. to about 4000 F. Firing or sintering at such high temperatures permits the use of a Wide variety of refractory metals, intermetallics, cermets and ceramics which were precluded from use when the corrosion resisting coating was applied directly to the airfoil section of the turbine bucket blade.
  • the boot 14 After the boot 14 has been coated and sintered, it is placed over the molybdenum turbine bucket 12. The assembly is then brazed in an autoclave by usual means to fuse the coated boot 14 to the molybdenum turbine bucket 12.
  • the above method of forming a coated turbine bucket blade presents many important advantages over prior methods.
  • the use of a molybdenum boot formed of Wire screen presents additional advantages since better bonding between the bucket and the boot 14 results from the flow of brazing alloy around individual wires of the mesh or screen.
  • the use of a screen provides a boot which compensates for thermal expansion differences by providing a coating with sufficient ability to absorb thermal stress.
  • the screen may be readily shaped about the turbine bucket and provides a ductile metallic matrix in which the refractory metals and ceramics can be impregnated.
  • the present invention presents the advantages to a great degree when wire screen is used, but they are also present, although to a lesser degree, when molybdenum sheet metal is used to form the boot.
  • the fact that the coating is produced or constructed apart from the molybdenum turbine bucket permits sintering of the coating at extremely high temperatures without harm to the turbine bucket.
  • molybdenum or molybdenum alloy turbine buckets can be coated with maa terials having superior high temperature strength, oxidation resistance and abrasion resistance.
  • a method of forming oxidation resistant blades for jet engines which comprises forming a core of high strength, high temperature metal alloy, said core comprising a root section and an airfoil blade section, applying a brazing alloy to said blade section, forming a high temperature high strength metal sheath about said blade section, removing said sheath from said blade section, applying a ceramic slip to the outer face of said sheath, sintering said ceramic slip to provide an oxidation resistant coating, replacing said coated sheath on said blade section, and bonding said coated sheath to said blade section.
  • a method of forming oxidation resistant blades for jet engines which comprises forming a core of high strength, high temperature metal alloy, said core comprising a root section and an airfoil blade section, applying a brazing alloy to said airfoil blade section, forming a high temperature high strength sheath about said blade section, removing said formed sheath from said blade section, coating the outer surface of said sheath with a ceramic slip, sintering said slip to form an oxidation resistant coating for said sheath, replacing said coated sheath on said blade, and heating said sheath and said blade in an autoclave to bond said sheath to said blade.
  • a method of forming oxidation resistant blades for jet engines which comprises forming a core of high strength, high temperature metal alloy, said core comprising a root section and an airfoil blade section, applying a brazing alloy to said airfoil blade section, forming a high temperature high strength sheath about said blade section, removing said sheath from said blade section, coating the outer surface of said sheath with a ceramic slip, sintering said slip at temperature range from 2700" F. to 4000 F. to form a corrosion resistant coating for said sheath, replacing said coated sheath on said blade, and heating said composite structure in an autoclave to bond said sheath to said blade.

Description

Dec. 18, 1962 B. E. KRAMER 3,068,556
METHOD OF MAKING JET TURBINE BUCKETS Original Filed Oct. 9, 1958 INV EN TOR.
ac: 4'. AM/e wwlaif NML drive a blower for furnishing air to the burners.
Patented Dec. 18, 1952 3,068,556 METHOD OF MAKING JET TURBINE BUCKETS Bruce E. Kramer, Loveland, Ohio, assignor to the United States of America as represented by the Secretary of the Air Force Original application Oct. 9, 1958, Ser. No. 766,370, now Patent No. 3,032,316, dated May 1, 1962. Divided and this application June 29, 1960, Ser. No. 39,749
3 Claims. (Cl. 29156.8)
The present invention relates to turbine buckets and, as illustrated herein, relates more particularly to turbine buckets adapted for use at high temperatures, and forms a division of my co-pending parent application, Serial No. 766,370, filed October 9, 1958, now Patent No. 3,032,316.
Iet engines and the like are usually provided with an axial flow turbine which is operated by exhaust gases to These turbines operate at excessively high temperatures somewhat above 2000 F. Turbine buckets must have sufiicient strength, toughness, creep resistance and resistance to oxidizing gases to enable the bucket to operate efiiciently without deformation or corrosion.
Molybdenum isone of the metals which exhibits high strength, toughness and creep resistance at temperatures above 1400 F. Molybdenum, however, cannot be used at higher temperatures since the trioxide of molybdenum, which is formed under the oxidizing conditions present in a jet turbine, sublimes very rapidly at temperatures in excess of 1463 F. and a molybdenum turbine bucket will disappear in a matter of minutes.
The application of coatings to molybdenum alloys is restricted to relatively low temperatures, about 2200 F., because the molybdenum alloys re'crystallize above that temperature with the loss of many desirable physical properties. This low temperature coating application precludes the use of a wide variety of refractory metals, intermetallics, cermets and ceramics; because to be effective, they require firing or sintering temperatures ranging from 2700 F. to 4000 F.
The present invention contemplates the application of high temperature coatings in a manner to avoid the problems noted above. To this end, it is proposed to provide a sheath formed of molybdenum wire screen or sheet arranged to enclose molybdenum alloy turbine bucket airfoil. The molybdenum wire screen or sheet metal sheath is coated on the outside with an appropriate cermet or ceramic and then sintered at the appropriate high temperature. As disclosed herein, the molybdenum alloy turbine bucket is flame sprayed with a suitable brazing alloy which is fused on the turbine bucket airfoil. The coated and sintered molybdenum boot is then placed over the molybdenum bucket and brazed in an autoclave by usual means.
Another object of the invention is to provide a simple and effective method for providing turbine bucket airfoils with a coated boot which will withstand relatively high temperatures. To this end, a suitable brazing alloy is flame sprayed and fused on the turbine bucket airfoil. A boot of sheet molybdenum or wire mesh is constructed to envelop completely the turbine bucket airfoil. The molybdenum boot is removed and coated on the outside with an appropriate cermet or ceramic. The coated molybdenum boot is sintered at the appropriate temperature. Finally, the coated and sintered boot is placed over the molybdenum bucket and brazed in an autoclave by usual means.
With the above and other objects and features in view, the invention will now be described in connection with the accompanying drawings in which:
FIGURE 1 is a view of a turbine bucket constructed according to the present invention;
FIGURE 2 is a view in section taken along the lines IIII of FIGURE 1; and
FIGURE 3 is an enlarged sectional View taken along the line IIIIII of FIGURE 2.
As illustrated in FIGURE 1, the bucket 10 comprises a body 12 formed of molybdenum metal or a high temperature molybdenum alloy having its bucket or airfoil surface covered with a boot 14 formed, as shown, of molybdenum wire screen. It is evident, however, that the boot 14 could be formed of a thin sheet of molybdenum metal or molybdenum alloy. It is preferred, however, to use molybdenum wire screen since it may be more readily shaped to fit the airfoil section of the molybdenum bucket 10. The body 12 of the bucket 10 is provided, preferably, with a fir tree root 18 for securing the same in the turbine wheel.
The airfoil section of the bucket is coated by a flame spraying method by the use of a suitable brazing alloy 20. A brazing alloy containing any suitable metal such as silver solder, copper or nickel is sprayed and fused on the airfoil surface of the bucket to provide an effective means by which the boot 14 is secured to the bucket 12. The flame spraying method is preferred but other suitable methods may be used if so desired.
After the brazing alloy coating 20 has been applied to the airfoil surface of the bucket body 12, the boot 14 is shaped to fit closely about the airfoil surface of the bucket 12. After the boot 14 has been shaped, it is removed from the bucket 12 and coated on the outside with a suitable ceramic 16 having physical properties sufiicient to withstand the high temperature conditions of a jet engine. A preferred corrosion resistant, shock resistant, and abrasion resistant ceramic 20 may be formed of Ni- Cr C CrAl O Cr--CrB, specially compounded ccramic glass and pure oxides such as A1 0 and ZIOZ. The selected material is preferably reduced to a fine powder and uniformly dispersed to form a slip by wet mixing.
The slip is applied to the outer surface of the boot 14 and is fired or sintered at high temperatures ranging from 2700" F. to about 4000 F. Firing or sintering at such high temperatures permits the use of a Wide variety of refractory metals, intermetallics, cermets and ceramics which were precluded from use when the corrosion resisting coating was applied directly to the airfoil section of the turbine bucket blade.
After the boot 14 has been coated and sintered, it is placed over the molybdenum turbine bucket 12. The assembly is then brazed in an autoclave by usual means to fuse the coated boot 14 to the molybdenum turbine bucket 12.
The above method of forming a coated turbine bucket blade presents many important advantages over prior methods. The use of a molybdenum boot formed of Wire screen presents additional advantages since better bonding between the bucket and the boot 14 results from the flow of brazing alloy around individual wires of the mesh or screen. Further, the use of a screen provides a boot which compensates for thermal expansion differences by providing a coating with sufficient ability to absorb thermal stress. In addition, the screen may be readily shaped about the turbine bucket and provides a ductile metallic matrix in which the refractory metals and ceramics can be impregnated.
The present invention presents the advantages to a great degree when wire screen is used, but they are also present, although to a lesser degree, when molybdenum sheet metal is used to form the boot. In any event, the fact that the coating is produced or constructed apart from the molybdenum turbine bucket permits sintering of the coating at extremely high temperatures without harm to the turbine bucket. As a result, molybdenum or molybdenum alloy turbine buckets can be coated with maa terials having superior high temperature strength, oxidation resistance and abrasion resistance.
Having thus described my invention, What I claim as new-and desire to secure by Letters Patent of the United States is:
1. A method of forming oxidation resistant blades for jet engines, which comprises forming a core of high strength, high temperature metal alloy, said core comprising a root section and an airfoil blade section, applying a brazing alloy to said blade section, forming a high temperature high strength metal sheath about said blade section, removing said sheath from said blade section, applying a ceramic slip to the outer face of said sheath, sintering said ceramic slip to provide an oxidation resistant coating, replacing said coated sheath on said blade section, and bonding said coated sheath to said blade section.
2. A method of forming oxidation resistant blades for jet engines, which comprises forming a core of high strength, high temperature metal alloy, said core comprising a root section and an airfoil blade section, applying a brazing alloy to said airfoil blade section, forming a high temperature high strength sheath about said blade section, removing said formed sheath from said blade section, coating the outer surface of said sheath with a ceramic slip, sintering said slip to form an oxidation resistant coating for said sheath, replacing said coated sheath on said blade, and heating said sheath and said blade in an autoclave to bond said sheath to said blade.
3. A method of forming oxidation resistant blades for jet engines, which comprises forming a core of high strength, high temperature metal alloy, said core comprising a root section and an airfoil blade section, applying a brazing alloy to said airfoil blade section, forming a high temperature high strength sheath about said blade section, removing said sheath from said blade section, coating the outer surface of said sheath with a ceramic slip, sintering said slip at temperature range from 2700" F. to 4000 F. to form a corrosion resistant coating for said sheath, replacing said coated sheath on said blade, and heating said composite structure in an autoclave to bond said sheath to said blade.
References Cited in the file of this patent UNITED STATES PATENTS 2,648,520 Sehmitt Aug. I1, 1953 2,650,903 Garrison et a1. Sept. 1, 1953 2,763,919 Kempe et al Sept. 25, 1956 2,787,049 Stalker Apr. 2, 1957 2,823,151 Yntema et a1 Feb. 11, 1958 2,924,004 Wehrrnann et al. Feb. 9, 1960 2,958,505 Frank Nov. 1, 1960
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3215511A (en) * 1962-03-30 1965-11-02 Union Carbide Corp Gas turbine nozzle vane and like articles
US3233985A (en) * 1961-07-10 1966-02-08 Wmf Wuerttemberg Metallwaren Method for the production of an improved metal/ceramic material and articles
US3357850A (en) * 1963-05-09 1967-12-12 Gen Electric Vibration damping turbomachinery blade
US4023249A (en) * 1975-09-25 1977-05-17 General Electric Company Method of manufacture of cooled turbine or compressor buckets
US4334495A (en) * 1978-07-11 1982-06-15 Trw Inc. Method and apparatus for use in making an object
US4471008A (en) * 1981-08-21 1984-09-11 Mtu Motoren-Und-Turbinen Union Munchen Gmbh Metal intermediate layer and method of making it
US20120163118A1 (en) * 2010-12-22 2012-06-28 Ekato Ruehr- Und Mischtechnik Gmbh Stirrer organ in composite construction

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2648520A (en) * 1949-08-02 1953-08-11 Heinz E Schmitt Air-cooled turbine blade
US2650903A (en) * 1947-07-05 1953-09-01 Westinghouse Electric Corp Protection of molybdenum against oxidation
US2763919A (en) * 1950-07-28 1956-09-25 Thompson Prod Inc Coated refractory body
US2787049A (en) * 1952-05-23 1957-04-02 Stalkcr Dev Company Process of fabricating blades for turbines, compressors and the like
US2823151A (en) * 1953-10-14 1958-02-11 Fansteel Metallurgical Corp Highly refractive molybdenum bodies
US2924004A (en) * 1960-02-09 Refractory metal bodies
US2958505A (en) * 1958-11-20 1960-11-01 Robert G Frank Turbine bucket blades

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2924004A (en) * 1960-02-09 Refractory metal bodies
US2650903A (en) * 1947-07-05 1953-09-01 Westinghouse Electric Corp Protection of molybdenum against oxidation
US2648520A (en) * 1949-08-02 1953-08-11 Heinz E Schmitt Air-cooled turbine blade
US2763919A (en) * 1950-07-28 1956-09-25 Thompson Prod Inc Coated refractory body
US2787049A (en) * 1952-05-23 1957-04-02 Stalkcr Dev Company Process of fabricating blades for turbines, compressors and the like
US2823151A (en) * 1953-10-14 1958-02-11 Fansteel Metallurgical Corp Highly refractive molybdenum bodies
US2958505A (en) * 1958-11-20 1960-11-01 Robert G Frank Turbine bucket blades

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3233985A (en) * 1961-07-10 1966-02-08 Wmf Wuerttemberg Metallwaren Method for the production of an improved metal/ceramic material and articles
US3215511A (en) * 1962-03-30 1965-11-02 Union Carbide Corp Gas turbine nozzle vane and like articles
US3357850A (en) * 1963-05-09 1967-12-12 Gen Electric Vibration damping turbomachinery blade
US4023249A (en) * 1975-09-25 1977-05-17 General Electric Company Method of manufacture of cooled turbine or compressor buckets
US4334495A (en) * 1978-07-11 1982-06-15 Trw Inc. Method and apparatus for use in making an object
US4358471A (en) * 1978-07-11 1982-11-09 Trw Inc. Control apparatus
US4471008A (en) * 1981-08-21 1984-09-11 Mtu Motoren-Und-Turbinen Union Munchen Gmbh Metal intermediate layer and method of making it
US20120163118A1 (en) * 2010-12-22 2012-06-28 Ekato Ruehr- Und Mischtechnik Gmbh Stirrer organ in composite construction
US8985962B2 (en) * 2010-12-22 2015-03-24 SICcast Mineralguss GmbH & Co. KG Stirrer organ in composite construction
US9089934B2 (en) 2010-12-22 2015-07-28 SICcast Mineralguss GmbH & Co. KG Stirrer organ in composite construction

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