WO2013029584A1 - Method for manufacturing, repairing and/or exchanging a rotor/stator combination system, and a rotor/stator combination system manufactured in accordance wih the method - Google Patents

Method for manufacturing, repairing and/or exchanging a rotor/stator combination system, and a rotor/stator combination system manufactured in accordance wih the method Download PDF

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Publication number
WO2013029584A1
WO2013029584A1 PCT/DE2012/000809 DE2012000809W WO2013029584A1 WO 2013029584 A1 WO2013029584 A1 WO 2013029584A1 DE 2012000809 W DE2012000809 W DE 2012000809W WO 2013029584 A1 WO2013029584 A1 WO 2013029584A1
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WO
WIPO (PCT)
Prior art keywords
rotor
stator
composite system
support structure
forming
Prior art date
Application number
PCT/DE2012/000809
Other languages
German (de)
French (fr)
Inventor
Edgar MERKL
Original Assignee
Mtu Aero Engines Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mtu Aero Engines Gmbh filed Critical Mtu Aero Engines Gmbh
Publication of WO2013029584A1 publication Critical patent/WO2013029584A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/02—Blade-carrying members, e.g. rotors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • 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
    • B23P15/006—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine wheels
    • 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
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • 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
    • F01D5/005—Repairing methods or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • 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
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency
    • 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

Definitions

  • the present invention relates to a method of manufacturing, repairing and / or replacing a rotor / stator composite system.
  • the rotor-stator composite system is here in particular a rotor / stator composite system of an aircraft engine.
  • a method for producing a high-pressure turbine rotor wherein the turbine rotor is designed as a blisk and a radially inwardly disposed disc and a plurality of projecting from this disc blades or blades forms.
  • the turbine rotor has an inner channel system for air cooling. At least the turbine rotor is generated by a generative manufacturing process.
  • the turbo-engine has a housing that encloses a flow passage in which a rotationally driven first fan rotor rotates. Behind the first fan rotor, a second fan rotor is arranged, which rotates in opposite directions to the first fan rotor. Between the fan rotors is a booster compressor, which has two booster rotors. The first fan rotor accelerates incoming air and drives it into a main flow path and a bypass path. Both flow paths are separated by a tubular spinner. The spinner is mounted in a bearing which is fixed relative to the housing and fixed to a stator with a variable angle of attack.
  • the invention is based on the object to provide a method for producing or forming, repairing and / or replacing an improved composite of rotor and stator, as well as such a rotor / stator composite.
  • a method for manufacturing, repairing and / or replacing a rotor / stator compound system, in particular a compressor or a turbine of an engine, with a rotor having at least one blade element and a stator, the method having the following step : Layer-wise building up of the rotor with the at least one blade element together with the stator by means of a generative manufacturing process.
  • a rotor / stator composite system in particular a compressor or a turbine of an engine, provided with a rotor having at least one blade element and a stator, wherein the rotor is formed with the at least one blade element together with the stator by means of a generative manufacturing process.
  • the method and the system have the advantage that the rotor and the stator can be manufactured in one step and thus can be dispensed with additional flanges or grooves, which were previously necessary for the assembly of the individual parts.
  • the step of constructing the rotor and the stator in layers further comprises the steps of building up a support structure by means of the additive manufacturing process, then forming the rotor-stator composite system on the support structure by means of the additive manufacturing process and removing the support structure Completion of the rotor / stator compound system.
  • the support structure has the advantage that the composite system does not have to be built directly on the base plate.
  • the fixing of the rotor and of the stator takes place by means of a holding device, the support structure subsequently being removed.
  • the support means By the support means, the rotor and stator can be held and fixed in a predetermined, in particular centered position, while the support structure is removed.
  • the step of laminating the rotor and the stator further comprises the step of forming the stator with at least one blade element.
  • the step of constructing the rotor and the stator in layers further comprises the step of forming the stator and the rotor with a plurality of blade elements, wherein the blade elements of the stator and the rotor are offset from one another.
  • the step of laminating the rotor and the stator further comprises the step of forming at least one end of the stator and / or the rotor with at least one mounting portion.
  • the integrally formed with the stator or rotor mounting portion allows a subsequent simplified assembly to other components.
  • the step of constructing the rotor and the stator in layers further comprises the step of forming at least a part of the rotor and the stator from the same material or material combination, or forming at least a part of the rotor and the stator from a different one Material or from a different combination of materials.
  • the blade elements of the rotor and the rotor housing may be made of a different material or combination of materials.
  • the blade elements of the stator and the stator housing may be made of a different material or combination of materials.
  • the blade elements of the rotor, the blade elements of the stator, the rotor housing and / or the stator housing can be made of a different material or material combination or of the same material or the same material combination, depending on the function and purpose.
  • FIG. 1 is a sectional view of a rotor / stator composite system according to an embodiment of the invention
  • Fig. 2 is a flow chart of the manufacture of a rotor / stator composite system according to the invention.
  • Fig. 1 is a sectional view of a rotor / stator composite system 1 according to an embodiment of the invention is shown.
  • the mountability must be taken into account by providing and appropriately positioning respective flanges, grooves and the like.
  • this has the disadvantage that it is a design-, weight and cost-optimized design of the composite considerably more difficult.
  • an integral rotor / stator composite system 1 is provided, which is produced by means of a generative manufacturing process.
  • This has the advantage that rotor 2 and stator 3 are not, as previously, later assembled and accordingly with this additional fastening devices, such as flanges, grooves, etc., must be provided for mounting the items.
  • additive manufacturing processes include so-called rapid manufacturing and so-called rapid prototyping.
  • generative manufacturing components are built up, in particular, in layers by material application.
  • material application for example, in the corresponding processes known as Laser Sintering, Selective Laser Sintering (SLS), Electron Beam Melting (EBM), LaserCusing, Selective Laser Melting (SLM) or 3D Printing, etc.
  • the material to be added or applied is Processed powder.
  • the powder is applied, for example, in layers on a base plate or a carrier.
  • the powder layer is solidified in a device region for forming the device by means of energy radiation, such as a laser beam and / or electron beam.
  • the component can be built layer by layer.
  • the solidification of the respective powder layer is usually carried out on the basis of geometric data, such as CAD data, of the component to be produced.
  • the area of the powder layer can be scanned, for example, and the component area of the powder layer can be solidified by means of energy radiation. By acting on the energy radiation, the powder is sintered or melted in this area.
  • the sectional view of an embodiment of the rotor / stator composite system 1 according to the invention shown in FIG. 1 is in this case for example a compressor, e.g. for an engine, in particular an aircraft engine.
  • the rotor / stator compound system may also include a turbine e.g. for an engine, in particular aircraft engine.
  • the rotor / stator composite system 1 in this case has the rotor 2, which has a rotor housing 4 with a plurality of blade elements 5.
  • the rotor / stator composite system 1 the stator 3, which has a stator 6, on which, as illustrated in the embodiment in Fig. 1, optionally additionally a plurality of blade elements 7 can be provided.
  • the blade elements 5, 7 of rotor 2 and stator 3 can be arranged to each other in such a way that they are arranged, for example offset from one another, as shown in the embodiment in Fig. 2.
  • the rotor 2 and / or the stator 3 can have at least one end of their housing 4, 6 least a mounting portion 8, for example at least one flange or a receptacle.
  • At least one powder which can be solidified by means of an energy radiation is applied as a powder layer to a support 9, here for example a base plate 10.
  • the powder is in particular a metal powder of at least one metal and / or one metal alloy.
  • the at least one powder may also be, for example, a ceramic powder or plastic powder, which can be solidified by means of energy radiation.
  • the powder layer is selectively solidified by means of energy radiation from an energy radiation source 11, eg a laser or an electron beam source.
  • the powder layer is solidified in its component region by means of the energy radiation of the energy radiation source 1 1.
  • the rotor / stator compound system 1 comprises, for example, the rotor housing 4 with a plurality of blade elements 5, the stator housing 6 with a plurality of blade elements 7, in each case a fastening section 8 at both ends of the rotor housing 4 and the stator housing 6 ,
  • a respective powder layer may also have areas with different powders.
  • a portion of the device area which is e.g. comprises the stator 3, can be formed from a first powder and a further portion of the component area, which e.g. comprises the rotor 2 may be formed of a second powder.
  • different metal powders may be chosen for the first and second powders, so that the rotor 2 and the stator 3 are made of different materials, here e.g. various metals or metal alloys are produced.
  • the blade elements 5, 7 of rotor 2 and / or stator 3 made of a different material or material combination than the rotor housing 4 and / or stator 6 are produced in the generative manufacturing process.
  • the invention is not limited to the examples mentioned.
  • the materials or material combinations for the rotor / stator composite system 1 can be varied as desired within the framework of the generative production of the rotor / stator composite system 1.
  • the rotor / stator composite system 1 is manufactured by means of a generative manufacturing process in one step or one piece.
  • the rotor 2 and the stator 3 normally form two separate parts, as shown in the exemplary embodiment in Fig. 1, wherein the rotor 2 and the stator 3, for example, each concentric with each other and have a common longitudinal axis 12.
  • a support structure 13 may optionally be initially formed on the carrier 9, here the base plate 10, before subsequently the actual component 1, ie the rotor / stator composite system 1, is formed.
  • the respective powder layer can be solidified somewhat coarser in the region of the support structure 13 by means of the energy radiation of the energy radiation source 11, so that the support structure 13 is formed, for example, similar to a needle bed, on which then the actual rotor / stator composite system 1 is formed becomes.
  • the rotor / stator composite system 1 does not have to be formed directly on the carrier 9 or the base plate 10.
  • the support structure 13 is removed again, as indicated by the dividing line in Fig. 1.
  • the support structure 13 can additionally be used to position the rotor 2 and the stator 3 relative to one another, for example when the rotor 2 is slightly raised or offset in height relative to the stator 3 or vice versa.
  • Additional fastening sections 8, for example in the form of at least one flange or a receptacle, on the exposed or open upper side 14 of the stator housing 6 or of the rotor housing 4 can, if necessary, be reworked very easily.
  • the rotor 2 and stator 3 can be fixed in a centric position if necessary by means of an additional holding device 15, before the support structure 13 is separated with the base plate 10. After separation of the support structure 13 and the base plate 10, the respective attachment portion 8 at the lower end 16 of the stator housing 6 or rotor housing 4 can also be reworked if necessary.
  • the rotor / stator composite system 1 as an overall system is easy to install.
  • the mounting device 15 can be removed, for example, before assembly or attachment of the rotor / stator composite system 1 to an engine or after attachment to the engine, depending on the function and purpose.
  • the invention also has the advantage that in the generative production of the rotor / stator composite system 1, the blade elements 5, 7 of rotor 2 and stator 3, for example, formed offset from each other. In this way, eliminates a complicated assembly of rotor 2 and stator 3 to each other.
  • Fig. 2 an embodiment of a flow chart for manufacturing a rotor / stator composite system according to the invention is shown.
  • a first step S1 an auxiliary structure or support structure of the component or rotor / stator composite system is first formed on the carrier or the base plate in advance by means of a generative manufacturing process.
  • the support structure will be removed later after completion of the rotor / stator composite system.
  • a powder layer is applied to the baseplate and then irradiated by a suitable energy beam of an energy radiation source, e.g. a laser, a support structure area of the powder layer solidifies. Subsequently, the base plate is moved by a layer thickness, e.g. lowered, and the next powder layer applied to the previous powder layer and in turn solidified the support structure region of this powder layer by means of energy radiation. Step S1 is repeated until the support structure is constructed.
  • an energy radiation source e.g. a laser
  • the actual component here the rotor / stator composite system, built.
  • the rotor / stator composite system is constructed with its rotor and its stator.
  • the rotor comprises a rotor housing having a plurality of vane elements.
  • the stator has a stator housing with a plurality of blade elements, which are arranged offset to the blade elements of the rotor.
  • a fastening portion for example a flange or a receptacle.
  • a new powder layer is applied to the last solidified powder layer and the new powder layer in the component area of the rotor / stator composite system solidified by a suitable energy radiation of an energy radiation source, such as a laser or electron beam source.
  • an energy radiation source such as a laser or electron beam source.
  • the base plate is moved by one layer thickness, for example lowered, and the next powder layer is applied to the previous powder layer and the component area of the rotor / stator composite system of this powder layer is solidified by means of the energy radiation.
  • the step S2 is repeated until the rotor / stator composite system is made entirely of the solidified component regions.
  • a step S3 the non-solidified powder is removed.
  • a subsequent step S4 the support structure of the rotor / stator composite system is removed.
  • the centric positioning of the stator and the rotor can be secured or fixed by means of a suitable mounting device.
  • the mounting device is fastened, for example, to the stator and the rotor, for example to their fastening sections. Subsequently, the support structure is removed.
  • Step S4 * a respective attachment portion of the rotor / stator compound system is machined on the open side of the rotor / stator compound system, if necessary. Step S4 * may take place before removal or after removal of the support structure in step S4.
  • step Sl of producing an additional support structure is optional and the associated step S4, in which the support structure after the completion of the rotor / stator composite system is removed again.
  • step S4 * of reworking a fastening section of the rotor / stator composite system is optional.
  • Blade element (rotor housing)
  • Blade element (stator housing)

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

A rotor/stator combination system and a method for manufacturing, repairing and/or exchanging a rotor/stator combination system, in particular a compressor or a turbine of an engine, having a rotor which has at least one blade element and having a stator, wherein the method has the following step: layered build-up of the rotor with the at least one blade element together with the stator by means of a generative production process.

Description

Verfahren zum Herstellen, Reparieren und/oder Austauschen eines Rotor/Stator- Verbundsystems, sowie ein gemäß dem Verfahren hergestelltes Rotor/Stator- Verbundsystem  A method of manufacturing, repairing and / or replacing a rotor / stator composite system, and a rotor / stator composite system made according to the method
Die vorliegende Erfindung betrifft ein Verfahren zum Herstellen bzw. Ausbilden, Reparieren und/oder Austauschen eines Rotor/Stator- Verbundsystems. Das Rotor-Stator- Verbundsystem ist hier insbesondere ein Rotor/Stator- Verbundsystem eines Flugzeugtriebwerks. The present invention relates to a method of manufacturing, repairing and / or replacing a rotor / stator composite system. The rotor-stator composite system is here in particular a rotor / stator composite system of an aircraft engine.
Aus der DE 10 2006 049 216 AI ist ein Verfahren zur Herstellung eines Hochdruckturbinen- Rotors bekannt, wobei der Turbinenrotor als Blisk gestaltet ist und eine radial innen angeordnete Scheibe sowie mehrere von dieser Scheibe abragende Schaufeln bzw. Schaufelblätter ausbildet. Der Turbinenrotor weist für eine Luftkühlung ein inneres Kanalsystem auf. Zumindest der Turbinenrotor wird dabei durch ein generatives Herstellungsverfahren erzeugt. From DE 10 2006 049 216 AI a method for producing a high-pressure turbine rotor is known, wherein the turbine rotor is designed as a blisk and a radially inwardly disposed disc and a plurality of projecting from this disc blades or blades forms. The turbine rotor has an inner channel system for air cooling. At least the turbine rotor is generated by a generative manufacturing process.
Des Weiteren ist aus der DE 10 2006 023 246 AI ein Turbotriebwerk bekannt. Das Turbotriebwerk weist ein Gehäuse auf, das einen Strömungskanal umschließt, in dem ein drehend angetriebener erster Fan-Rotor rotiert. Hinter dem ersten Fan-Rotor ist ein zweiter Fan-Rotor angeordnet, der gegenläufig zu dem ersten Fan-Rotor rotiert. Zwischen den Fan-Rotoren befindet sich ein Booster- Verdichter, welcher zwei Booster-Rotoren aufweist. Der erste Fan-Rotor beschleunigt einströmende Luft und treibt sie in einen Hauptstromweg und einen Bypassweg. Beide Strömungswege sind dabei durch einen rohrförmigen Spinner getrennt. Der Spinner ist in einem Lager gelagert, welches relativ zum Gehäuse ortsfest und an einem Stator mit variablem Anstellwinkel befestigt ist. Furthermore, from DE 10 2006 023 246 AI a turbo engine is known. The turbo-engine has a housing that encloses a flow passage in which a rotationally driven first fan rotor rotates. Behind the first fan rotor, a second fan rotor is arranged, which rotates in opposite directions to the first fan rotor. Between the fan rotors is a booster compressor, which has two booster rotors. The first fan rotor accelerates incoming air and drives it into a main flow path and a bypass path. Both flow paths are separated by a tubular spinner. The spinner is mounted in a bearing which is fixed relative to the housing and fixed to a stator with a variable angle of attack.
Bei einem Verbund aus einem Rotor und einem Stator sind konstruktive Vorkehrungen notwendig, um einen solchen Verbund montierbar zu gestalten. Diese konstruktiven Vorkehrungen beeinträchtigen jedoch eine design-, gewichts- und kostenoptimierte Gestaltung des Verbunds aus Rotor und Stator. In a composite of a rotor and a stator design precautions are necessary to make such a composite mountable. However, these design precautions affect design, weight and cost optimized design of the rotor and stator.
Dies ist ein Zustand den es zu verbessern gilt. Der Erfindung liegt nun die Aufgabe zugrunde, ein Verfahren bereitzustellen zum Herstellen bzw. Ausbilden, Reparieren und/oder Austauschen eines verbesserten Verbundes aus Rotor und Stator, sowie einen derartigen Rotor/Stator Verbund. This is a condition to be improved. The invention is based on the object to provide a method for producing or forming, repairing and / or replacing an improved composite of rotor and stator, as well as such a rotor / stator composite.
Gemäß der Erfindung wird nun ein Verfahren bereitgestellt zum Herstellen, Reparieren und/oder Austauschen eines Rotor/Stator- Verbundsystems, insbesondere eines Verdichters oder einer Turbine eines Triebwerks, mit einem wenigstens ein Schaufelelement aufweisenden Rotor und einem Stator, wobei das Verfahren den folgenden Schritt aufweist: Schichtweises Aufbauen des Rotors mit dem wenigstens einen Schaufelelement zusammen mit dem Stator mittels eines generativen Fertigungsverfahrens. According to the invention, a method is now provided for manufacturing, repairing and / or replacing a rotor / stator compound system, in particular a compressor or a turbine of an engine, with a rotor having at least one blade element and a stator, the method having the following step : Layer-wise building up of the rotor with the at least one blade element together with the stator by means of a generative manufacturing process.
Des Weiteren wird ein Rotor/Stator- Verbundsystem, insbesondere ein Verdichter oder eine Turbine eines Triebwerks, bereitgestellt mit einem wenigstens eine Schaufelelement aufweisenden Rotor und einem Stator, wobei der Rotor mit dem wenigstens einen Schaufelelement zusammen mit dem Stator mittels eines generativen Fertigungsverfahrens ausgebildet ist. Furthermore, a rotor / stator composite system, in particular a compressor or a turbine of an engine, provided with a rotor having at least one blade element and a stator, wherein the rotor is formed with the at least one blade element together with the stator by means of a generative manufacturing process.
Das Verfahren und das System haben den Vorteil, dass der Rotor und der Stator in einem Schritt hergestellt werden können und so auf zusätzliche Flansche oder Nuten verzichtet werden kann, welche bisher zur Montage der Einzelteile notwendig waren. The method and the system have the advantage that the rotor and the stator can be manufactured in one step and thus can be dispensed with additional flanges or grooves, which were previously necessary for the assembly of the individual parts.
Vorteilhafte Ausgestaltungen und Weiterbildungen der Erfindung ergeben sich aus den Unteransprüchen sowie der Beschreibung unter Bezugnahme auf die Zeichnungen. Advantageous embodiments and modifications of the invention will become apparent from the dependent claims and the description with reference to the drawings.
In einer Ausführungsform der Erfindung weist der Schritt des schichtweisen Aufbauens des Rotors und des Stators ferner die Schritte auf: Schichtweises Aufbauen einer Stützstruktur mittels des generativen Fertigungsverfahrens, anschließendes Ausbilden des Rotor-Stator- Verbundsystems mittels des generativen Fertigungsverfahrens auf der Stützstruktur und Entfernen der Stützstruktur nach Fertigstellung des Rotor/Stator- Verbundsystems. Die Stützstruktur hat den Vorteil, dass das Verbundsystem nicht direkt auf der Grundplatte aufgebaut werden muss. In one embodiment of the invention, the step of constructing the rotor and the stator in layers further comprises the steps of building up a support structure by means of the additive manufacturing process, then forming the rotor-stator composite system on the support structure by means of the additive manufacturing process and removing the support structure Completion of the rotor / stator compound system. The support structure has the advantage that the composite system does not have to be built directly on the base plate.
In einer weiteren erfindungsgemäßen Ausführungsform erfolgt das Fixieren des Rotors und des Stators mittels einer Halterungseinrichtung, wobei anschließend die Stützstruktur entfernt wird. Durch die Halterungseinrichtung können der Rotor und Stator in einer vorbestimmten, insbesondere zentrierten Position gehalten und fixiert werden, während die Stützstruktur entfernt wird. Gemäß einer weiteren erfindungsgemäßen Ausführungsform weist der Schritt des schichtweisen Aufbauens des Rotors und des Stators ferner den Schritt des Ausbildens des Stators mit wenigstens einem Schaufelelement auf. In a further embodiment according to the invention, the fixing of the rotor and of the stator takes place by means of a holding device, the support structure subsequently being removed. By the support means, the rotor and stator can be held and fixed in a predetermined, in particular centered position, while the support structure is removed. According to a further embodiment of the invention, the step of laminating the rotor and the stator further comprises the step of forming the stator with at least one blade element.
In einer anderen erfindungsgemäßen Ausführungsform weist der Schritt des schichtweisen Aufbauens des Rotors und des Stators ferner den Schritt des Ausbildens des Stators und des Rotors mit mehreren Schaufelelementen auf, wobei die Schaufelelemente des Stators und des Rotors zueinander versetzt angeordnet sind. Mittels des generativen Fertigens des Rotor/Stator- Verbundsystems lassen sich selbst komplizierte Strukturen herstellen, ohne dass solche Strukturen aus Einzelteilen, wie bisher gefertigt und montiert werden müssen. In another embodiment of the invention, the step of constructing the rotor and the stator in layers further comprises the step of forming the stator and the rotor with a plurality of blade elements, wherein the blade elements of the stator and the rotor are offset from one another. By means of the generative manufacturing of the rotor / stator composite system, even complicated structures can be produced without such structures having to be manufactured and assembled from individual parts, as hitherto.
In einer weiteren erfindungsgemäßen Ausführungsform weist der Schritt des schichtweisen Aufbauens des Rotors und des Stators ferner den Schritt des Ausbildens wenigstens eines Endes des Stators und/oder des Rotors mit wenigstens einem Befestigungsabschnitt auf. Der integral mit dem Stator bzw. Rotor ausgebildete Befestigungsabschnitt erlaubt eine anschließende vereinfachte Montage an weiteren Bauteilen. In a further embodiment of the invention, the step of laminating the rotor and the stator further comprises the step of forming at least one end of the stator and / or the rotor with at least one mounting portion. The integrally formed with the stator or rotor mounting portion allows a subsequent simplified assembly to other components.
Gemäß einer weiteren Ausführungsform weist der Schritt des schichtweisen Aufbauens des Rotors und des Stators ferner den Schritt des Ausbildens zumindest eines Teils des Rotors und des Stators aus demselben Material oder aus derselben Materialkombination, oder ein Ausbilden zumindest eines Teils des Rotors und des Stators aus einem unterschiedlichen Material oder aus einer unterschiedlichen Materialkombination auf. Beispielsweise können die Schaufelelemente des Rotors und das Rotorgehäuse aus einem unterschiedlichen Material oder Materialkombination hergestellt sein. Entsprechend können die Schaufelelemente des Stators und das Statorgehäuse aus einem unterschiedlichen Material oder Materialkombination hergestellt sein. Außerdem können die Schaufelelemente des Rotors, die Schaufelelemente des Stators, das Rotorgehäuse und/oder das Statorgehäuse aus einem unterschiedlichen Material oder Materialkombination hergestellt sein oder aus demselben Material oder derselben Materialkombination, je nach Funktion und Einsatzzweck. According to a further embodiment, the step of constructing the rotor and the stator in layers further comprises the step of forming at least a part of the rotor and the stator from the same material or material combination, or forming at least a part of the rotor and the stator from a different one Material or from a different combination of materials. For example, the blade elements of the rotor and the rotor housing may be made of a different material or combination of materials. Accordingly, the blade elements of the stator and the stator housing may be made of a different material or combination of materials. In addition, the blade elements of the rotor, the blade elements of the stator, the rotor housing and / or the stator housing can be made of a different material or material combination or of the same material or the same material combination, depending on the function and purpose.
Die Erfindung wird nachfolgend anhand der in den schematischen Figuren der Zeichnungen angegebenen Ausführungsbeispiele näher erläutert. Es zeigen: Fig. 1 eine Schnittansicht eines Rotor/Stator-Verbundsystems gemäß einer Ausfuhrungsform der Erfindung; The invention will be explained in more detail with reference to the exemplary embodiments indicated in the schematic figures of the drawings. Show it: 1 is a sectional view of a rotor / stator composite system according to an embodiment of the invention;
Fig. 2 ein Ablaufdiagramm der Herstellung eines Rotor/Stator- Verbundsystems gemäß der Erfindung. Fig. 2 is a flow chart of the manufacture of a rotor / stator composite system according to the invention.
In den Figuren sind gleiche Elemente oder ähnliche Elemente mit gleichen Bezugszeichen versehen, sofern nichts Gegenteiliges ausgeführt ist. In the figures, the same elements or similar elements are provided with the same reference numerals, unless otherwise stated.
In Fig. 1 ist eine Schnittansicht eines Rotor/Stator- Verbundsystems 1 gemäß einer Ausführungsform der Erfindung gezeigt. In Fig. 1 is a sectional view of a rotor / stator composite system 1 according to an embodiment of the invention is shown.
Ein Verbund aus einem Rotor und einem Stator, beispielsweise bei einem Verdichter oder einer Turbine eines Flugzeugtriebwerks, wird bisher aus Einzelteilen zusammengebaut. Bei der Gestaltung des Verbunds von Rotor und Stator muss daher die Montierbarkeit berücksichtigt werden, indem entsprechende Flansche, Nuten und dergleichen vorgesehen und geeignet angeordnet werden. Dies hat jedoch den Nachteil, dass es eine design-, gewichts- und kostenoptimierte Gestaltung des Verbunds erheblich erschwert wird. A composite of a rotor and a stator, for example in a compressor or a turbine of an aircraft engine, has so far been assembled from individual parts. In the design of the composite rotor and stator, therefore, the mountability must be taken into account by providing and appropriately positioning respective flanges, grooves and the like. However, this has the disadvantage that it is a design-, weight and cost-optimized design of the composite considerably more difficult.
Erfindungsgemäß wird daher ein integrales Rotor/Stator- Verbundsystem 1 bereitgestellt, welches mittels eines generativen Fertigungsverfahrens hergestellt ist. Dies hat den Vorteil, dass Rotor 2 und Stator 3 nicht, wie bisher, später zusammengebaut und dem entsprechend mit hierfür zusätzlichen Befestigungseinrichtungen, wie Flanschen, Nuten usw., versehen sein müssen zum Montieren der Einzelteile. According to the invention, therefore, an integral rotor / stator composite system 1 is provided, which is produced by means of a generative manufacturing process. This has the advantage that rotor 2 and stator 3 are not, as previously, later assembled and accordingly with this additional fastening devices, such as flanges, grooves, etc., must be provided for mounting the items.
Zu generativen Fertigungsverfahren gehören beispielsweise das sog. Rapid Manufacturing und das sog. Rapid Prototyping. Bei der generativen Fertigung werden Bauteile insbesondere schichtweise durch Materialauftrag aufgebaut. Bei den entsprechenden Verfahren, die z.B. als Lasersintern, Selective Laser Sintering (SLS), Elektronenstrahlsintera, Electron Beam Melting (EBM), LaserCusing, Selective Laser Melting (SLM) oder 3D-Printing usw. bekannt sind, wird der hinzuzufügende oder aufzutragende Werkstoff in Pulverform verarbeitet. Das Pulver wird dabei z.B. schichtweise auf eine Grundplatte oder einen Träger aufgetragen. Anschließend wird die Pulverschicht in einem Bauteilbereich zum Ausbilden des Bauteils mittels einer Energiestrahlung verfestigt, wie z.B. eines Laserstrahls und/oder Elektronenstrahls. Anschließend wird über dieser Pulverschicht die nächste Pulverschicht aufgetragen und mittels Energiestrahlung wiederum selektiv verfestigt. Auf diese Weise kann Schicht für Schicht das Bauteil aufgebaut werden. Die Verfestigung der jeweiligen Pulverschicht erfolgt dabei üblicherweise auf Basis von Geometriedaten, z.B. CAD-Daten, des herzustellenden Bauteils. Des Weiteren kann die Verfestigung des Pulvers mittels Energiestrahlung ohne Abschirmung oder abgeschirmt z.B. in einer Schutzgas- oder Edelgasatmosphäre, oder im Vakuum, erfolgen. Examples of additive manufacturing processes include so-called rapid manufacturing and so-called rapid prototyping. In generative manufacturing, components are built up, in particular, in layers by material application. For example, in the corresponding processes known as Laser Sintering, Selective Laser Sintering (SLS), Electron Beam Melting (EBM), LaserCusing, Selective Laser Melting (SLM) or 3D Printing, etc., the material to be added or applied is Processed powder. The powder is applied, for example, in layers on a base plate or a carrier. Subsequently, the powder layer is solidified in a device region for forming the device by means of energy radiation, such as a laser beam and / or electron beam. Subsequently, will applied the next powder layer over this powder layer and selectively solidified by energy radiation again. In this way, the component can be built layer by layer. The solidification of the respective powder layer is usually carried out on the basis of geometric data, such as CAD data, of the component to be produced. Furthermore, the solidification of the powder by means of energy radiation without shielding or shielded, for example, in a protective gas or inert gas atmosphere, or in a vacuum, take place.
Der Bereich der Pulverschicht kann beispielsweise abgescannt und der Bauteilbereich der Pulverschicht mittels Energiestrahlung verfestigt werden. Durch Einwirken der Energiestrahlung wird das Pulver in diesem Bereich gesintert oder aufgeschmolzen. The area of the powder layer can be scanned, for example, and the component area of the powder layer can be solidified by means of energy radiation. By acting on the energy radiation, the powder is sintered or melted in this area.
Die in Fig. 1 gezeigte Schnittansicht einer Ausführungsform des erfindungsgemäßen Rotor/Stator-Verbundsystems 1 ist hierbei beispielsweise ein Verdichter, z.B. für ein Triebwerk, insbesondere Flugzeugtriebwerk. Statt eines Verdichters kann das Rotor/Stator- Verbundsystem auch eine Turbine z.B. für ein Triebwerk, insbesondere Flugzeugtriebwerk, sein. The sectional view of an embodiment of the rotor / stator composite system 1 according to the invention shown in FIG. 1 is in this case for example a compressor, e.g. for an engine, in particular an aircraft engine. Instead of a compressor, the rotor / stator compound system may also include a turbine e.g. for an engine, in particular aircraft engine.
Das Rotor/Stator-Verbundsystem 1 weist dabei den Rotor 2 auf, welcher ein Rotorgehäuse 4 mit mehreren Schaufelelementen 5 aufweist. Außerdem weist das Rotor/Stator- Verbundsystem 1 den Stator 3 auf, welcher ein Statorgehäuse 6 aufweist, an welchem, wie in dem Ausführungsbeispiel in Fig. 1 illustriert ist, wahlweise zusätzlich mehrere Schaufelelemente 7 vorgesehen werden können. The rotor / stator composite system 1 in this case has the rotor 2, which has a rotor housing 4 with a plurality of blade elements 5. In addition, the rotor / stator composite system 1, the stator 3, which has a stator 6, on which, as illustrated in the embodiment in Fig. 1, optionally additionally a plurality of blade elements 7 can be provided.
Die Schaufelelemente 5, 7 von Rotor 2 und Stator 3 können dabei derart zueinander angeordnet sein, dass sie beispielweise zueinander versetzt angeordnet sind, wie in dem Ausführungsbeispiel in Fig. 2 gezeigt ist. Der Rotor 2 und/oder der Stator 3 können dabei an wenigstens einem Ende ihres Gehäuses 4, 6 wenigsten einen Befestigungsabschnitt 8 aufweisen, beispielweise wenigstens einen Flansche oder eine Aufnahme. The blade elements 5, 7 of rotor 2 and stator 3 can be arranged to each other in such a way that they are arranged, for example offset from one another, as shown in the embodiment in Fig. 2. The rotor 2 and / or the stator 3 can have at least one end of their housing 4, 6 least a mounting portion 8, for example at least one flange or a receptacle.
Wie in Fig. 1 gezeigt ist, wird auf einem Träger 9, hier z.B. einer Grundplatte 10, wenigstens ein mittels einer Energiestrahlung verfestigbares Pulver als Pulverschicht aufgebracht. Das Pulver ist hierbei insbesondere ein Metallpulver aus wenigstens einem Metall und/oder einer Metalllegierung. Je nach Funktion und Einsatzzweck kann das wenigstens eine Pulver auch beispielsweise ein mittels Energiestrahlung verfestigbares Keramikpulver oder Kunststoffpulver usw. sein. Nachdem eine Schicht aus wenigstens einem Pulver auf die Grundplatte 10 aufgebracht wurde, wird die Pulverschicht selektiv mittels Energiestrahlung einer Energiestrahlungsquelle 11, z.B. einem Laser oder einer Elektronenstrahlquelle, verfestigt. Die Pulverschicht wird dabei in ihrem Bauteilbereich mittels der Energiestrahlung der Energiestrahlungsquelle 1 1 verfestigt. As shown in FIG. 1, at least one powder which can be solidified by means of an energy radiation is applied as a powder layer to a support 9, here for example a base plate 10. In this case, the powder is in particular a metal powder of at least one metal and / or one metal alloy. Depending on the function and intended use, the at least one powder may also be, for example, a ceramic powder or plastic powder, which can be solidified by means of energy radiation. After a layer of at least one powder has been applied to the base plate 10, the powder layer is selectively solidified by means of energy radiation from an energy radiation source 11, eg a laser or an electron beam source. The powder layer is solidified in its component region by means of the energy radiation of the energy radiation source 1 1.
Anschließend wird die nächste Pulverschicht über die zuletzt selektiv verfestigte Pulverschicht aufgetragen und der Bauteilbereich dieser nächsten Pulverschicht wiederum mittels der Energiestrahlung der Energiestrahlungsquelle 11 verfestigt bis am Ende die verfestigten Bauteilbereiche das fertige Rotor/Stator-Verbundsystem 1 bilden. Wie in dem Ausfuhrungsbeispiel in Fig. 1 gezeigt ist, umfasst das Rotor/Stator-Verbundsystem 1 beispielsweise das Rotorgehäuses 4 mit mehreren Schaufelelementen 5, das Statorgehäuses 6 mit mehreren Schaufelelementen 7, jeweils einen Befestigungsabschnitt 8 an beiden Ende des Rotorgehäuses 4 und des Statorgehäuses 6. The next powder layer is subsequently applied over the last selectively solidified powder layer and the component region of this next powder layer in turn solidified by means of the energy radiation of the energy radiation source 11 until the solidified component regions form the finished rotor / stator composite system 1 at the end. As shown in the exemplary embodiment in FIG. 1, the rotor / stator compound system 1 comprises, for example, the rotor housing 4 with a plurality of blade elements 5, the stator housing 6 with a plurality of blade elements 7, in each case a fastening section 8 at both ends of the rotor housing 4 and the stator housing 6 ,
Statt einem Pulver kann eine jeweilige Pulverschicht auch Bereiche mit unterschiedlichen Pulvern aufweisen. Ein Bereich des Bauteilbereichs, welcher z.B. den Stator 3 umfasst, kann aus einem ersten Pulver gebildet werden und ein weiterer Bereich des Bauteilbereichs, welche z.B. den Rotor 2 umfasst, kann aus einem zweiten Pulver gebildet werden. Für das erste und zweite Pulver können hierbei beispielsweise verschiedene Metallpulver gewählt werden, so dass der Rotor 2 und der Stator 3 aus verschiedenen Materialien, hier z.B. verschiedenen Metallen oder Metalllegierungen hergestellt werden. Dabei können beispielsweise auch die Schaufelelemente 5, 7 von Rotor 2 und/oder Stator 3 aus einem anderen Material oder Materialkombination als das Rotorgehäuse 4 und/oder Statorgehäuse 6 im Rahmen des generativen Fertigungsverfahrens hergestellt werden. Entsprechendes gilt für Befestigungsabschnitte 8 von Rotor 2 und Stator 3. Die Erfindung ist auf die genannten Beispiele nicht beschränkt. Die Materialien oder Materialkombinationen für das Rotor/Stator- Verbundsystem 1 können beliebig variiert werden im Rahmen der generativen Fertigung des Rotor/Stator-Verbundsystems 1. Instead of a powder, a respective powder layer may also have areas with different powders. A portion of the device area which is e.g. comprises the stator 3, can be formed from a first powder and a further portion of the component area, which e.g. comprises the rotor 2 may be formed of a second powder. For example, different metal powders may be chosen for the first and second powders, so that the rotor 2 and the stator 3 are made of different materials, here e.g. various metals or metal alloys are produced. In this case, for example, the blade elements 5, 7 of rotor 2 and / or stator 3 made of a different material or material combination than the rotor housing 4 and / or stator 6 are produced in the generative manufacturing process. The same applies to fastening sections 8 of rotor 2 and stator 3. The invention is not limited to the examples mentioned. The materials or material combinations for the rotor / stator composite system 1 can be varied as desired within the framework of the generative production of the rotor / stator composite system 1.
Das Rotor/Stator- Verbundsystem 1 wird mittels eines generativen Fertigungsverfahrens in einem Schritt oder einem Stück gefertigt. Der Rotor 2 und der Stator 3 bilden dabei normalerweise zwei separate Teile, wie in dem Ausfuhrungsbeispiel in Fig. 1 gezeigt ist, wobei der Rotor 2 und der Stator 3 beispielsweise jeweils konzentrisch zueinander angeordnet sind und eine gemeinsame Längsachse 12 aufweisen. Dabei kann außerdem optional zunächst eine Stützstruktur 13 auf dem Träger 9, hier der Grundplatte 10 ausgebildet werden, bevor anschließend das eigentliche Bauteil 1, d.h. das Rotor/Stator- Verbundsystem 1, ausgebildet wird. Zur Ausbildung der Stützstruktur 13 kann die jeweilige Pulverschicht z.B. etwas gröber im Bereich der Stützstruktur 13 mittels der Energiestrahlung der Energiestrahlungsquelle 11 verfestigt werden, so dass die Stützstruktur 13 beispielsweise ähnlich einem Nadelbett ausgebildet ist, auf dem anschließend das eigentliche Rotor/Stator- Verbundsystem 1 ausgebildet wird. Hierdurch muss das Rotor/Stator-Verbundsystem 1 nicht direkt auf dem Träger 9 bzw. der Grundplatte 10 ausgebildet werden. Nach der Fertigstellung des Rotor/Stator-Verbundsystems 1 wird die Stützstruktur 13 wieder entfernt, wie durch die Trennlinie in Fig. 1 angedeutet ist. Die Stützstruktur 13 kann zusätzlich dazu genutzt werden, Rotor 2 und Stator 3 zueinander zu positionieren, wenn beispielsweise der Rotor 2 etwas erhöht oder in der Höhe versetzt gegenüber dem Stator 3 ist oder umgekehrt. The rotor / stator composite system 1 is manufactured by means of a generative manufacturing process in one step or one piece. The rotor 2 and the stator 3 normally form two separate parts, as shown in the exemplary embodiment in Fig. 1, wherein the rotor 2 and the stator 3, for example, each concentric with each other and have a common longitudinal axis 12. In addition, a support structure 13 may optionally be initially formed on the carrier 9, here the base plate 10, before subsequently the actual component 1, ie the rotor / stator composite system 1, is formed. To form the support structure 13, the respective powder layer can be solidified somewhat coarser in the region of the support structure 13 by means of the energy radiation of the energy radiation source 11, so that the support structure 13 is formed, for example, similar to a needle bed, on which then the actual rotor / stator composite system 1 is formed becomes. As a result, the rotor / stator composite system 1 does not have to be formed directly on the carrier 9 or the base plate 10. After the completion of the rotor / stator composite system 1, the support structure 13 is removed again, as indicated by the dividing line in Fig. 1. The support structure 13 can additionally be used to position the rotor 2 and the stator 3 relative to one another, for example when the rotor 2 is slightly raised or offset in height relative to the stator 3 or vice versa.
Zusätzliche Befestigungsabschnitte 8, beispielsweise in Form von wenigstens einem Flansch oder einer Aufnahmen, an der freiliegenden oder offenen oberen Seite 14 des Statorgehäuses 6 bzw. des Rotorgehäuses 4 können, falls erforderlich, sehr leicht nachbearbeitet werden. Additional fastening sections 8, for example in the form of at least one flange or a receptacle, on the exposed or open upper side 14 of the stator housing 6 or of the rotor housing 4 can, if necessary, be reworked very easily.
Des Weiteren können der Rotor 2 und Stator 3 in einer zentrischen Position bei Bedarf mittels einer zusätzlichen Halterungseinrichtung 15 fixiert werden, bevor die Stützstruktur 13 mit der Grundplatte 10 abgetrennt wird. Nach dem Abtrennen der Stützstruktur 13 und der Grundplatte 10 kann der jeweilige Befestigungsabschnitt 8 an dem unteren Ende 16 des Statorgehäuses 6 bzw. Rotorgehäuses 4 bei Bedarf ebenfalls nachbearbeitet werden. Somit ist das Rotor/Stator- Verbundsystem 1 als Gesamtsystem leicht montierbar. Furthermore, the rotor 2 and stator 3 can be fixed in a centric position if necessary by means of an additional holding device 15, before the support structure 13 is separated with the base plate 10. After separation of the support structure 13 and the base plate 10, the respective attachment portion 8 at the lower end 16 of the stator housing 6 or rotor housing 4 can also be reworked if necessary. Thus, the rotor / stator composite system 1 as an overall system is easy to install.
Die Halterungseinrichtung 15 kann dabei beispielsweise vor der Montage oder Befestigung des Rotor/Stator- Verbundsystems 1 an einem Triebwerk oder nach dem Anbringen an dem Triebwerk entfernt werden, je nach Funktion und Einsatzzweck. The mounting device 15 can be removed, for example, before assembly or attachment of the rotor / stator composite system 1 to an engine or after attachment to the engine, depending on the function and purpose.
Die Erfindung hat des Weiteren den Vorteil, dass bei der generativen Fertigung des Rotor/Stator- Verbundsystems 1 die Schaufelelemente 5, 7 von Rotor 2 und Stator 3 beispielsweise zueinander versetzt ausgebildet werden. Auf diese Weise entfällt eine komplizierte Montage von Rotor 2 und Stator 3 zueinander. In Fig. 2 ist ein Ausfuhrungsbeispiel eines Ablaufdiagramms zum Fertigen eines Rotor/Stator- Verbundsystems gemäß der Erfindung gezeigt. The invention also has the advantage that in the generative production of the rotor / stator composite system 1, the blade elements 5, 7 of rotor 2 and stator 3, for example, formed offset from each other. In this way, eliminates a complicated assembly of rotor 2 and stator 3 to each other. In Fig. 2 an embodiment of a flow chart for manufacturing a rotor / stator composite system according to the invention is shown.
In einem ersten Schritt Sl wird zunächst vorab mittels eines generativen Fertigungsverfahrens eine Hilfsstruktur oder Stützstruktur des Bauteils bzw. Rotor/Stator- Verbundsystems auf dem Träger bzw. der Grundplatte ausgebildet. Die Stützstruktur wird später nach Fertigstellung des Rotor/Stator- Verbundsystems wieder entfernt wird. In a first step S1, an auxiliary structure or support structure of the component or rotor / stator composite system is first formed on the carrier or the base plate in advance by means of a generative manufacturing process. The support structure will be removed later after completion of the rotor / stator composite system.
Zum Ausbilden der Stützstruktur wird eine Pulverschicht auf die Grundplatte aufgetragen und anschließend durch eine geeignete Energiestrahlung einer Energiestrahlungsquelle, z.B. einem Laser, ein Stützstrukturbereich der Pulverschicht verfestigt. Anschließend wird die Grundplatte um eine Schichtdicke verfahren, z.B. abgesenkt, und die nächste Pulverschicht auf die vorherige Pulverschicht aufgebracht und wiederum der Stützstrukturbereich dieser Pulverschicht mittels der Energiestrahlung verfestigt. Schritt Sl wird solange wiederholt bis die Stützstruktur aufgebaut ist. To form the support structure, a powder layer is applied to the baseplate and then irradiated by a suitable energy beam of an energy radiation source, e.g. a laser, a support structure area of the powder layer solidifies. Subsequently, the base plate is moved by a layer thickness, e.g. lowered, and the next powder layer applied to the previous powder layer and in turn solidified the support structure region of this powder layer by means of energy radiation. Step S1 is repeated until the support structure is constructed.
In einem darauf folgenden Schritt S2 wird das eigentliche Bauteil, hier das Rotor/Stator- Verbundsystem, aufgebaut. Dabei wird mittels des generativen Fertigungsverfahrens das Rotor/Stator-Verbundsystem mit seinem Rotor und seinem Stator aufgebaut. Wie zuvor in dem Ausführungsbeispiel in Fig. 1 illustriert ist, weist der Rotor ein Rotorgehäuse mit mehreren Schaufelelementen auf. Entsprechend weist in diesem Ausfuhrungsbeispiel der Stator ein Statorgehäuse mit mehreren Schaufelelementen auf, welche versetzt zu den Schaufelelementen des Rotors angeordnet sein. Des Weiteren ist an beiden Enden, d.h. am oberen und unteren Ende, des Rotorgehäuses und des Statorgehäuses jeweils ein Befestigungsabschnitt vorgesehen, beispielsweise ein Flansch oder eine Aufnahme. In a subsequent step S2, the actual component, here the rotor / stator composite system, built. In this case, by means of the generative manufacturing process, the rotor / stator composite system is constructed with its rotor and its stator. As previously illustrated in the embodiment of FIG. 1, the rotor comprises a rotor housing having a plurality of vane elements. Accordingly, in this exemplary embodiment, the stator has a stator housing with a plurality of blade elements, which are arranged offset to the blade elements of the rotor. Furthermore, at both ends, i. provided at the upper and lower ends of the rotor housing and the stator housing in each case a fastening portion, for example a flange or a receptacle.
Zum Fertigen des Rotor/Stator- Verbundsystems wird eine neue Pulverschicht auf die zuletzt verfestigte Pulverschicht aufgebracht und die neue Pulverschicht in dem Bauteilbereich des Rotor/Stator-Verbundsystems durch eine geeignete Energiestrahlung einer Energiestrahlungsquelle, z.B. einem Laser oder einer Elektronenstrahlquelle, verfestigt. Anschließend wird die Grundplatte um eine Schichtdicke verfahren, z.B. abgesenkt, und die nächste Pulverschicht auf die vorherige Pulverschicht aufgebracht und der Bauteilbereich des Rotor/Stator- Verbundsystems dieser Pulverschicht mittels der Energiestrahlung verfestigt. Der Schritt S2 wird solange wiederholt bis das Rotor/Stator- Verbundsystem vollständig aus den verfestigten Bauteilbereichen hergestellt ist. Im Anschluss daran wird in einem Schritt S3 das nicht verfestigte Pulver entfernt. In einem darauffolgenden Schritt S4 wird die Stützstruktur des Rotor/Stator-Verbundsystems entfernt. Dazu kann die beispielsweise zentrische Positionierung des Stators und des Rotors mittels einer geeigneten Halterungseinrichtung gesichert bzw. fixiert werden. Die Halterungseinrichtung wird dazu beispielsweise an dem Stator und dem Rotor befestigt, beispielsweise an deren Befestigungsabschnitten. Anschließend wird die Stützstruktur entfernt. To manufacture the rotor / stator composite system, a new powder layer is applied to the last solidified powder layer and the new powder layer in the component area of the rotor / stator composite system solidified by a suitable energy radiation of an energy radiation source, such as a laser or electron beam source. Subsequently, the base plate is moved by one layer thickness, for example lowered, and the next powder layer is applied to the previous powder layer and the component area of the rotor / stator composite system of this powder layer is solidified by means of the energy radiation. The step S2 is repeated until the rotor / stator composite system is made entirely of the solidified component regions. Subsequently, in a step S3, the non-solidified powder is removed. In a subsequent step S4, the support structure of the rotor / stator composite system is removed. For this purpose, for example, the centric positioning of the stator and the rotor can be secured or fixed by means of a suitable mounting device. For this purpose, the mounting device is fastened, for example, to the stator and the rotor, for example to their fastening sections. Subsequently, the support structure is removed.
In einem Schritt S4* wird ein jeweiliger Befestigungsabschnitt des Rotor/Stator- Verbundsystems an der offenen Seite des Rotor/Stator-Verbundsystems, falls erforderlich, bearbeitet. Schritt S4* kann hierbei vor dem Entfernen oder nach dem Entfernen der Stützstruktur in Schritt S4 erfolgen. In a step S4 *, a respective attachment portion of the rotor / stator compound system is machined on the open side of the rotor / stator compound system, if necessary. Step S4 * may take place before removal or after removal of the support structure in step S4.
Neben einer vollständigen Herstellung des Gehäuses gemäß der Schritte Sl bis S4 kann ebenso auch auf einem bereits vorhandenen Teil eines Rotor/Stator- Verbundsystems, z.B. im Rahmen einer Reparatur oder einer Ergänzung, der restliche Teil oder fehlende Teil des Rotor/Stator- Verbundsystems ergänzt werden mittels eines generativen Fertigungsverfahrens. In addition to a complete production of the housing according to the steps S1 to S4, it is also possible to use on an already existing part of a rotor / stator composite system, e.g. as part of a repair or a supplement, the remaining part or missing part of the rotor / stator composite system are supplemented by means of a generative manufacturing process.
Zudem ist der Schritt Sl des Herstellens einer zusätzlichen Stützstruktur optional und der damit verbundene Schritt S4, in welchem die Stützstruktur nach der Fertigstellung des Rotor/Stator- Verbundsystems wieder entfernt wird. Gleiches gilt für den Schritt S4* des Nachbearbeitens eines Befestigungsabschnitts des Rotor/Stator- Verbundsystems. In addition, the step Sl of producing an additional support structure is optional and the associated step S4, in which the support structure after the completion of the rotor / stator composite system is removed again. The same applies to step S4 * of reworking a fastening section of the rotor / stator composite system.
Obwohl die vorliegende Erfindung vorstehend anhand der bevorzugten Ausfuhrungsbeispiele beschrieben wurde, ist sie darauf nicht beschränkt, sondern auf vielfältige Art und Weise modifizierbar. Insbesondere sind die zuvor beschriebenen Ausfuhrungsbeispiele miteinander kombinierbar, insbesondere einzelne Merkmale davon. Bezugszeichenliste 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 exemplary embodiments described above can be combined with one another, in particular individual features thereof. LIST OF REFERENCE NUMBERS
Rotor/Stator- Verbundsystem Rotor / stator composite system
Rotor  rotor
Stator  stator
Rotorgehäuse  rotor housing
Schaufelelement (Rotorgehäuse)  Blade element (rotor housing)
Statorgehäuse  stator
Schaufelelement (Statorgehäuse)  Blade element (stator housing)
Befestigungsabschnitt  attachment section
Träger  carrier
Grundplatte  baseplate
Energiestrahlungsquelle  Energy radiation source
Längsachse  longitudinal axis
Stützstruktur  support structure
oberes Ende (Rotor-/Stator- Verbundsystem) Upper end (rotor / stator composite system)
Halterungseinrichtung  support means
unteres Ende (Rotor/Stator- Verbundsystem) lower end (rotor / stator composite system)

Claims

P a t e n t a n s p r ü c h e Patent claims
1. Verfahren zum Herstellen, Reparieren und/oder Austauschen eines Rotor Stator- Verbundsystems (1), insbesondere eines Verdichters oder einer Turbine eines Triebwerks, mit einem wenigstens ein Schaufelelement (5) aufweisenden Rotor (2) und einem Stator (3), wobei das Verfahren den folgenden Schritt aufweist: 1. A method for producing, repairing and / or replacing a rotor stator composite system (1), in particular a compressor or a turbine of an engine, with a at least one blade element (5) having rotor (2) and a stator (3), wherein the method comprises the following step:
Schichtweises Aufbauen des Rotors (2) mit dem wenigstens einen Schaufelelement (5) zusammen mit dem Stator (3) mittels eines generativen Fertigungsverfahrens.  Layer-wise building up of the rotor (2) with the at least one blade element (5) together with the stator (3) by means of a generative manufacturing process.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der Schritt des schichtweisen Aufbauens des Rotors und des Stators ferner die Schritte aufweist: 2. The method according to claim 1, characterized in that the step of laminating the rotor and the stator further comprises the steps of:
Schichtweises Aufbauen einer Stützstruktur (13) mittels des generativen Fertigungsverfahrens, anschließendes Ausbilden des Rotor/Stator- Verbundsystems (1) mittels des generativen Fertigungsverfahrens auf der Stützstruktur (13); und Entfernen der Stützstruktur (13) nach Fertigstellung des Rotor/Stator- Verbundsystems (1).  Layer-wise constructing a support structure (13) by means of the generative manufacturing process, then forming the rotor / stator compound system (1) by means of the additive manufacturing process on the support structure (13); and removing the support structure (13) after completion of the rotor / stator compound system (1).
3. Verfahren nach Anspruch 2, gekennzeichnet durch die Schritte des Fixierens des Rotors (2) und des Stators (3) mittels einer Halterungseinrichtung (15) und des anschließenden Entfernens der Stützstruktur (13). 3. The method according to claim 2, characterized by the steps of fixing the rotor (2) and the stator (3) by means of a holding device (15) and the subsequent removal of the support structure (13).
4. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass der4. The method according to any one of the preceding claims, characterized in that the
- Schritt des schichtweisen Aufbauens des Rotors (2) und des Stators (3) ferner den Schritt des Ausbildens des Stators (3) mit wenigstens einem Schaufelelement (7) aufweist. - Step of laminating the rotor (2) and the stator (3) further comprises the step of forming the stator (3) with at least one blade element (7).
5. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass der Schritt des schichtweisen Aufbauens des Rotors (2) und des Stators (3) ferner den Schritt des Ausbildens des Stators (3) und des Rotors (2) mit mehreren Schaufelelementen (7, 5) aufweist, wobei die Schaufelelemente (7, 5) des Stators (3) und des Rotors (2) zueinander versetzt angeordnet werden. 5. The method according to any one of the preceding claims, characterized in that the step of laminating the rotor (2) and the stator (3) further comprises the step of forming the stator (3) and the rotor (2) with a plurality of blade elements (7 , 5), wherein the blade elements (7, 5) of the stator (3) and the rotor (2) are arranged offset from one another.
6. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass der Schritt des schichtweisen Aufbauens des Rotors und des Stators ferner den Schritt des Ausbildens wenigstens eines Endes (14, 16) des Stators (3) und/oder des Rotors (2) mit wenigstens einem Befestigungsabschnitt (8) aufweist. 6. The method according to any one of the preceding claims, characterized in that the step of laminating the rotor and the stator further comprises the step of forming at least one end (14, 16) of the stator (3) and / or the rotor (2) has at least one attachment portion (8).
7. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass der Schritt des schichtweisen Aufbauens des Rotors und des Stators ferner den Schritt des Ausbildens zumindest eines Teils des Rotors (2) und des Stators (3) aus demselben Material oder aus derselben Materialkombination oder des A method according to any one of the preceding claims, characterized in that the step of laminating the rotor and the stator further comprises the step of forming at least a part of the rotor (2) and the stator (3) from the same or the same material combination of
Ausbildens zumindest eines Teils des Rotors (2) und des Stators (3) aus einem unterschiedlichen Material oder aus einer unterschiedlichen Materialkombination aufweist.  Forming at least a part of the rotor (2) and the stator (3) made of a different material or of a different combination of materials.
8. Rotor/Stator- Verbundsystem (1), insbesondere ein Verdichter oder eine Turbine eines Triebwerks, mit einem wenigstens ein Schaufelelement (5) aufweisenden Rotor (2) und einem Stator (3), wobei der Rotor (2) mit dem wenigstens einen Schaufelelement (5) zusammen mit dem Stator (3) mittels eines generativen Fertigungsverfahrens ausgebildet ist. 8. rotor / stator composite system (1), in particular a compressor or a turbine of an engine, with a at least one blade element (5) having rotor (2) and a stator (3), wherein the rotor (2) with the at least one Blade element (5) is formed together with the stator (3) by means of a generative manufacturing process.
9. Rotor/Stator- Verbundsystem nach Anspruch 8, dadurch gekennzeichnet, dass der Stator (3) und der Rotor (2) jeweils mit mehreren Schaufelementen (7, 5) ausgebildet sind, wobei die Schaufelelemente (7, 5) des Stators (3) und des Rotors (2) zueinander versetzt angeordnet sind. 9. rotor / stator composite system according to claim 8, characterized in that the stator (3) and the rotor (2) are each formed with a plurality of blade elements (7, 5), wherein the blade elements (7, 5) of the stator (3 ) and the rotor (2) are arranged offset from each other.
10. Rotor/Stator- Verbundsystem nach Anspruch 8 oder 9, dadurch gekennzeichnet, dass wenigstens ein Ende (14, 16) des Stators (3) und/oder des Rotors (2) wenigstens einen Befestigungsabschnitt (8) aufweist. 10. rotor / stator composite system according to claim 8 or 9, characterized in that at least one end (14, 16) of the stator (3) and / or the rotor (2) has at least one fastening portion (8).
11. Rotor/Stator- Verbundsystem nach Anspruch 8, 9 oder 10, dadurch gekennzeichnet, dass das Rotor/Stator-Verbundsystem (1) aus einem Material oder einer Materialkombination besteht oder wenigstens zwei Bereiche des Rotor/Stator- Verbundsystems (1) aus einem unterschiedlichen Material oder einer Materialkombination ausgebildet sind. 11. rotor / stator composite system according to claim 8, 9 or 10, characterized in that the rotor / stator composite system (1) consists of a material or a material combination or at least two areas of the rotor / stator composite system (1) of a different material or a combination of materials are formed.
12. Rotor/Stator- Verbundsystem nach einem der Ansprüche 8 bis 1 1, dadurch gekennzeichnet, dass das Rotor/Stator- Verbundsystem (1) als ein Verdichter oder eine Turbine eines Flugzeugtriebwerks ausgebildet ist. 12. rotor / stator composite system according to one of claims 8 to 1 1, characterized in that the rotor / stator composite system (1) is designed as a compressor or a turbine of an aircraft engine.
PCT/DE2012/000809 2011-08-27 2012-08-10 Method for manufacturing, repairing and/or exchanging a rotor/stator combination system, and a rotor/stator combination system manufactured in accordance wih the method WO2013029584A1 (en)

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