WO2012051978A2

WO2012051978A2 - Component, and method for developing, repairing and/or constructing such a component

Info

Publication number: WO2012051978A2
Application number: PCT/DE2011/001727
Authority: WO
Inventors: Manuel Hertter; Andreas Jakimov; Mihaela-Sorina Seitz; Marcin Olbrich; Erwin Bayer; Jürgen Kraus; Bertram Kopperger; Klaus Broichhausen; Hans Banhirl; Wolfgang Werner; Eberhard Knodel
Original assignee: Mtu Aero Engines Gmbh
Priority date: 2010-10-13
Filing date: 2011-09-12
Publication date: 2012-04-26
Also published as: DE102010048336A1; WO2012051978A3

Abstract

The invention relates to a method for developing, repairing and/or constructing a component, especially a vane element of a gas turbine, said method comprising the following steps: a component is provided; and at least part of the component is constructed by means of kinetic cold gas compacting.

Description

Component and method for forming, repairing and / or constructing such

component

The present invention relates to a component and a method for forming, repairing and / or constructing such a component, in particular a blade element of a gas turbine, e.g. a gas turbine of an aircraft engine ,, compaction by means of kinetic cold gas.

In general, the manufacture of blades, such as blades of aircraft engines, such as turbine blades or compressor blades, is relatively expensive. Therefore, such blades are usually repaired in the event of damage or wear, if possible.

This means that a damaged or worn blade is not necessarily always replaced with a new, but only in the event that the blade is no longer usable or no longer repairable. The repair of blades is done so far usually by means of the so-called "patching" or by build-up welding. In this case, a portion of the blade, which has a damaged portion, is removed from the blade by a cut. Often, this relates to a portion of the blade tip includes, as often occur in the blade tip damage or wear. However, this can also be done by means of standardized spare parts. Following this, the severed damaged segment is replaced by a correspondingly identical intact segment or supplemented by welding. A new segment is usually made separately and possibly formed with an oversize and joined to the rest of the bucket. In particular, in cases in which the new segment has an excess, then a processing takes place, by means of which the desired shape is generated.

These known methods for blade repair, which is typically performed manually, is associated with relatively high costs. In addition, when "patching" or build-up welding, a melted layer is produced which has lower strength.

Furthermore, WO 2008/003295 A2, for example, discloses a method for repairing and / or replacing individual elements of a component of a gas turbine. In this case, a replacement element is connected to a component by means of inductive low-frequency or high-frequency pressure welding. Against this background, the invention now has the object of providing a simple possibility of repairing elements, in particular blade elements of gas turbines, for example of gas turbines of aircraft engines, etc.

According to the invention, a method is now provided for forming, repairing and / or assembling or replacing a gas turbine component, as well as a corresponding device. More specifically, a method is provided for forming, repairing, and / or assembling or replacing a component, in particular a vane element, eg, a turbine or a compressor, a gas turbine casing element or a gas turbine disk element, the method comprising the steps:

A) providing a component, and

B) building at least a part or substantially of the entire component by means of kinetic cold gas compacting.

The method has the advantage that a fine-grained forging structure can be achieved by the kinetic cold gas compacting. Furthermore, kinetic cold gas compacting provides minimally invasive and individual repair of damaged or worn areas of gas turbine components, such as gas turbine components. Shovel elements, possible. This means that only the damaged areas can be removed and the missing material can be individually supplemented by cold gas spraying. Advantageous embodiments and modifications of the invention will become apparent from the dependent claims and the description with reference to the drawings.

In an embodiment of the present invention, the damaged and / or worn portion of the component is first removed, and then the remote portion is sprayed layer-by-layer on the component and the removed portion is filled by kinetic cold gas compaction. In this case, the filled area can be formed with an oversize and later be reworked accordingly, so that it has a nominal dimension. According to a further embodiment of the invention, the damaged and / or wear-prone area of the component is first removed and then inserted into the remote area of the component a corresponding part and connected by means of kinetic Kaltgaskompaktieren with the component. This has the advantage that a larger area which has previously been removed from the component can be easily replaced or refilled.

In another embodiment according to the invention, one or more layers which are applied to the component by the kinetic cold gas compacting are subsequently processed or reworked, for example by means of milling and / or an electrochemical method. This has the advantage that the predetermined contour can be formed, wherein the contour, for example, can have a more uniform structure, in that sprayed-on layers are reworked. Furthermore, the adhesion conditions for the next layer can be further improved, for example by deliberately thawing the surface of the component.

In a further embodiment according to the invention, the separating surfaces or separating edges, on which the damaged or wear-prone area of the component has been removed, are activated, in particular by plasma cleaning or by mechanical blasting, such as, for example, particle blasting. In this way, the connection between the component and the filled by kinetic cold gas compacting area can be further improved.

The invention will be explained in more detail with reference to the exemplary embodiments indicated in the schematic figures of the drawings. FIG. 1 shows a perspective view of a component to be repaired, here blade element; FIG. and

Fig. 2 is a flow diagram of the repair of a component, here blade element, according to the invention. The invention will be described in more detail below with reference to a blade element as an example of a gas turbine component. Instead of a blade element, however, any other element of a gas turbine can be provided as a gas turbine component, for example a gas turbine housing element, a gas turbine disk element, etc., to name only two further examples of gas turbine components. FIG. 1 shows a greatly simplified view of a blade element 10 as a gas turbine component which is repaired in accordance with the method according to the invention and is provided, for example, as a component 22 as an BLIS blade element on a disk. The invention is not limited to the specific illustration of the blade element 10 in FIG. Instead, the greatly simplified representation of the blade element 10 serves as a gas turbine component only for explaining the invention. As shown in FIG. 1, the blade element 10, for example in the region of the blade tip 12, has a region 14 with damage. According to the invention, a damaged component, eg a blade element 10, for example a so-called BLISK (bladed disc) blade element or a bling ring blade element, is thereby repaired by the blade element 10 or gas turbine component or its Blade profile or gas turbine component profile by means of kinetic Kaltgaskompaktiern (K3) is at least partially built or supplemented.

For this purpose, in the first embodiment of the blade element 10 shown in FIG. 1, for example, the region 14 is first removed or cut out, which has damage and / or corresponding wear. The removed or to be removed area 16 which contains the damaged area is indicated in FIG. 1 with a dashed line. This line indicates the separation edge or separation region 22 at which the region is cut out or severed. The contour of the area to be removed 16 can be varied as desired and is not limited to the contour shown in FIG. On the blade element 10, areas damaged or affected by wear can be removed at various locations, or individual areas can be combined to form a region 16 to be removed and severed from the blade element 10 in one piece, if damaged areas or areas subject to wear, e.g. lie close to each other. Subsequently, the missing region 16 is supplemented or fully filled again by means of kinetic cold-gas compacting, as will be described below with reference to FIG. 2. Before that, the separating edge or the separating region 22 can initially optionally be additionally activated after the separation of the region 16 to be separated, for example by blasting or plasma cleaning, before the kinetic cold gas compacting takes place.

Likewise, however, a blade element part 18 can also be inserted into this separated region 16 and then connected to the blade element 10 via kinetic cold gas compacting. The blade element part 18 can be prefabricated corresponding to the contour of the cut-out region 16, as shown in FIG. The blade element part 18 is also greatly simplified and not to scale shown in Fig. 1. FIG. 2 now shows a flowchart of the repair of a gas turbine component, eg here a blade element, according to the invention, wherein a blade element can be repaired, as shown in FIG.

As described above, for example, the damaged area of the gas turbine component, in this case the blade element, is first removed in FIG. 1 in a first step S1. In a next step S2, the separation area where the damaged area has been removed can optionally be additionally activated. The activation of the separation surface can be effected for example by means of radiation or a plasma cleaning or by means of another suitable method or combination of methods. In a further step S3, the missing material in the cut-out region of the blade element to be repaired is supplemented by kinetic cold gas compacting (K3), for example with an oversize or, in an alternative embodiment, a blade element part is inserted into this region in a step S3 * and then connected via kinetic cold gas compacting with the remaining blade element in a step S3 **.

In this process, material particles or powder of metal or a metal alloy are sprayed, in layers or in zones in the remote area of the blade element, in order to form the blade element, e.g. build up layer by layer in this area or to connect an inserted blade element part with the blade element. In this case, the layers can each be constructed from the same material particles or material powders or combination of material particles or material powders or layers of different material particles or material powders or material particle combinations or material powder combinations can be combined. Furthermore, the layers can be applied or provided in such a way that a smooth transition between the layers is given or the layers are separated from one another.

The powder of metal or a metal alloy has ceramic particles or ceramic powder, polymer powder or particles of another non-conductive material in an alternative embodiment. In the kinetic Kaitgaskompaktieren the powder or powder mixture is applied via a spray nozzle, in particular a Laval nozzle, on the blade element. An injection material jet is achieved by an expansion of a carrier gas and by the supply of the powder mixture. If necessary, the carrier gas can be preheated to a predetermined process temperature. The heating of the carrier gas, for example air, nitrogen, helium and / or water vapor, etc., before coating serves primarily to increase the outflow velocity in the spray nozzle and to improve the forging properties of the powder particles.

Due to the kinetic Kaitgaskompaktieren no melt for the blade element is necessary, but it can be mixed together different materials or material powder, with a wide range of material combinations or Werkstoffmi loops can be achieved. Furthermore, the blade element can be produced with regions having different properties, for example the blade element can be formed with an armor of the leading edge or an erosion protection, as well as with an armor of the fin region and / or an armor of so-called Z-notches, etc In addition, short fiber reinforcements can be used in the construction of blade elements. If required, at least one or even each layer may additionally be processed prior to the spraying of the next layer in order, for example, to produce the desired geometry of the blade element and / or to provide the best possible adhesion conditions for the next spray layer through a specifically structured surface, for example by a Thawing or ablation of the uppermost particle layer. The processing of the respective layer may, for example, be at least partially machined, e.g. by milling, and / or by means of an electrochemical process.

In the case of a new part production of a gas turbine component, for example blade element here, a gas turbine component, in this case a blade element or airfoil, can be generatively sprayed with an oversize by the kinetic Kaitgaskompaktieren. As an example, one or more bumps or projections in the base body, eg a disk base body in a BLISK ("bladed disc") blade element or a ring base body in the case of a BLING (bladed ring) blade element, can optionally additionally be formed. milled, for example, on which or which then the measuring shovel element splints is sprayed on. As described above, if required, at least one or even each layer may additionally be processed prior to the spraying of the next layer in order, for example, to produce the desired geometry of the blade element and / or to achieve the best possible adhesion conditions for a next spray layer through a specifically structured surface create. Likewise, however, only at the end of the spraying of all

Layers are produced by an electrochemical process and / or by a milling process, the final contour of the blade element. This applies accordingly if, as described above, only a cut-out region of a blade element is supplemented. Again, the blade element can be obtained only at the end by an electrochemical process or by milling its final contour.

In addition to the blade construction on at least one prepared hump or jump, it is also possible to jump directly to e.g. On a disc or a ring, the blade element can be sprayed on, for example, with a slurry by kinetic cold gas compacting. In this case, a subsequent milling or lowering, for example, an annular space of a B LI SK blade element with the thinning of the blade element can be connected to a predetermined nominal size. The method is also suitable for supplementing components so as to be able to strongly rejuvenate the blanks z. B. housings. The invention is not limited to milling or an electrochemical method for machining a blade element. In principle, any other method or combination of methods suitable for appropriately machining the vane element may be used. with the desired contour and / or to achieve optimal adhesion conditions by creating a specifically structured surface.

The supplementing of the cut-out damaged and / or worn area of the blade element by means of kinetic cold gas compacting has the advantage that in the kinetic cold gas-compacted layer or layers no melt structure is formed or exists but a fine-grained forging structure. Furthermore, kinetic cold gas compaction allows minimally invasive and individual repair of damaged or worn areas. In addition, the erfindugnsgemäße method allows a generative structure of forging blades, for example, for BLISK. In addition, the choice of materials more strongly to the needs or purpose of the respective blade element be adapted, for example, because different powder compositions can be forged together.

Furthermore, the respective blade element can be subjected to further processing steps following the kinetic cold gas compacting. For example, the blade element may be subjected to a heat treatment, etc.

Although the present invention has been described above with reference to the preferred embodiments, it is not limited thereto, but modifiable in many ways. In particular, the Ausfüihrungsbeispiele described above can be combined with each other, in particular individual features thereof. As already described above, instead of a blade element as a gas turbine component, any other element or part of a gas turbine can also be designed, repaired or replaced as a gas turbine component in accordance with the method according to the invention.

Claims

P a n t a n s p r e c h e

Method for forming, repairing and / or constructing a component (10), in particular a blade element (10) of a gas turbine, the method comprising the following steps:

Providing a component (10); and

Building at least a part of the component (10) by means of a kinetic Kaltgaskom- paktierens.

A method according to claim 1, characterized in that the method further comprises the following steps:

Removing at least one damaged and / or wear-prone area (14, 16) of the component (10); and

at least layered building of the remote area (14, 16) by means of a kinetic cold gas compacting.

Method according to claim 1 or 2, characterized in that the method further comprises the following steps:

Removing at least one damaged or worn portion (14, 16) of the component (10); and

Inserting a part (18) in the remote area (16) and connecting the part (18) with the blade element (10) by means of a kinetic cold gas compacting.

Method according to at least one of the preceding claims, characterized in that the step of cold gas compacting further comprises the following step: processing or reworking at least one layer applied by the kinetic cold gas compacting layer to produce a predetermined component contour and / or to provide improved adhesion conditions for the subsequent layer wherein the processing or post-processing of an associated layer is performed electrochemically and / or by milling.

Method according to at least one of the preceding claims, characterized in that the step of removing additionally comprises the following step: Activation or cleaning of the parting surfaces or separating edges (20) on which the damaged or wear-prone area (14) of the component (10) has been removed, in particular by means of a plasma cleaning or by means of a mechanical blasting process.

Method according to at least one of the preceding claims, characterized in that the method further comprises the following steps:

Forming at least one bump or protrusion on a component (22) on which a component (10), in particular a complete or complete blade element (10), is to be constructed or supplemented; and

Forming the component (10) on the bump or projection by means of a kinetic cold gas compacting.

Forming a component (10), in particular a complete or complete blade element, on a component (22) by means of a kinetic cold gas compacting with allowance; and

Lowering of the component (22) and thinning of the component (10) to a specified size.

Component (10), in particular blade element, housing element and / or disc, wherein at least a partial region (16) of the component (10) is formed by means of a kinetic cold gas compacting or the component (10) and a part (10) inserted in the part (18 ) is connected by means of a kinetic cold gas compacting.

Component according to Claim 8, characterized in that at least one layer of the component (10) applied by the kinetic cold gas compacting is processed or finished to produce a predetermined component contour and / or to provide improved adhesion conditions for the subsequent layer, the associated layer being electrochemical and / or machined by milling.

Component according to claim 8 or 9, characterized in that the component (10), in particular a blade element, on at least one bump or a projection of an associated part (22) can be applied by a kinetic cold gas compacting.

11. Component according to at least one of claims 8 to 10, characterized in that component (10) is a blade element, wherein the blade element is designed as a BLISK blade element or as a BLING blade element.