WO2020038318A1

WO2020038318A1 - Preparation method for tesla turbine disc, and tesla turbine disc

Info

Publication number: WO2020038318A1
Application number: PCT/CN2019/101318
Authority: WO
Inventors: 靳普; 陈宗良
Original assignee: 至玥腾风科技集团有限公司
Priority date: 2018-08-22
Filing date: 2019-08-19
Publication date: 2020-02-27
Also published as: CN109020591B; CN109020591A

Abstract

A preparation method for a Tesla turbine disc, and a Tesla turbine prepared with the method. The preparation method comprises: placing a carbon fiber in an electroplating pool of a nickel-containing electrolyte for electroplating; winding the electroplated carbon fiber on a core shaft to form a disc-shaped carbon fiber; heating the disc-shaped carbon fiber and the core shaft together to reach a melting point of nickel, so that the metal nickel is molten and adhered and then cooled to room temperature, thereby obtaining a nickel-based carbon fiber composite material of a Tesla turbine disc; removing the core shaft, and machining an exhaust hole on the nickel-based carbon fiber composite material of the Tesla turbine disc by means of mechanical machining; performing anodic oxidation on the surface of the nickel-based carbon fiber composite material; sintering a ceramic on the surface of the nickel-based carbon fiber composite material subjected to anodic oxidation to obtain a ceramic material of the Tesla turbine disc; and polishing by using a diamond grinding liquid, thereby obtaining the Tesla turbine disc.

Description

Preparation method of Tesla turbine disk and Tesla turbine disk

Technical field

The invention relates to the field of composite material preparation, in particular to a method for preparing a Tesla turbine disk and a Tesla turbine disk prepared by the method.

Background technique

A Tesla turbine is also called a bladeless turbine. Its shape is that a number of smooth and thin disks are fixed on a shaft at a certain distance. The air stream hits the disks from the tangential direction. The boundary layer effect is used to drive these disks and shafts. Turn them together. Although the turbine has the advantages of simple structure, compact size, high efficiency, and low cost, it has not been widely used because of the shortcomings of large discs, such as insufficient rigidity and easy deformation, resulting in large eddy currents between discs and large vibrations.

Metal-based carbon fiber composites have broad application prospects in the fields of aerospace, biomaterials and civil industry due to their excellent properties such as high specific strength, high specific modulus and good toughness. Compared with metal materials, it has a high specific modulus. Amount and specific strength; Compared with ceramics, it has high toughness and impact resistance. However, due to the large inertness and low surface energy of the carbon fiber, the lack of chemically active chemical bonds, the low reactivity, the poor binding force with the matrix, and the presence of many defects on the surface directly affect the mechanical properties of the composite material and limit the high performance of the carbon fiber. Play. During the manufacture of composite materials, metal carbonization, carburization, and electrochemical corrosion occur when carbon fibers and metals are compounded. Many effective attempts and explorations of carbon fiber metallization methods have been made in the prior art, but the existing methods have certain defects. The quality of metallized carbon fibers is uneven and universally reinforced. A preparation method that maximizes the interface bonding strength between the carbon fiber and the substrate is necessary.

In addition, ceramic materials are a class of inorganic non-metallic materials made from natural or synthetic compounds through shaping and high-temperature sintering. It has the advantages of high melting point, high hardness, high abrasion resistance and oxidation resistance. It can be used as structural material and tool material. Since ceramic also has some special properties, it can also be used as a functional material. Ceramic material is the material with the best stiffness and the highest hardness among engineering materials, and its hardness is mostly above 1500HV. Ceramics have higher compressive strength, but lower tensile strength, poor plasticity and toughness. Ceramic materials generally have a high melting point (mostly above 2000 ° C) and have excellent chemical stability at high temperatures; the thermal conductivity of ceramics is lower than that of metal materials, and ceramics are also good thermal insulation materials. At the same time, the linear expansion coefficient of ceramics is lower than that of metals. When temperature changes, ceramics have good dimensional stability. Ceramic materials are not easily oxidized at high temperatures, and have good corrosion resistance to acids, alkalis, and salts. In order to improve the abrasion resistance of the metal, a ceramic coating is applied on the metal substrate. However, due to the large physical and chemical properties of ceramic and metal, it is difficult to directly connect them, mainly because the thermal expansion coefficients of the two differ greatly. The joint is prone to generate large residual thermal stress.

Summary of the Invention

In order to solve the above problems, the present invention provides a method for preparing a Tesla turbine disk and a Tesla turbine disk prepared by the method. A nickel-based carbon fiber composite material is used to prepare a ceramic material, and the ceramic material is further used for the ceramic material. The Tesla turbine disc is produced, and the obtained Tesla turbine disc has the characteristics of high hardness, good compression resistance and strong heat resistance.

It is implemented by the following technical solutions:

A first aspect of the present invention provides a method for preparing a Tesla turbine disk, including the following steps:

The carbon fiber is electroplated in a plating bath containing a nickel electrolyte;

Winding the electroplated carbon fiber on a mandrel to form a disc-shaped carbon fiber;

Heating the disc-shaped carbon fiber and the mandrel to the melting point of nickel, melting the metal nickel and adhering to the room temperature, and preparing the nickel-based carbon fiber composite material of the Tesla turbine disk;

Removing the mandrel and machining exhaust holes on the nickel-based carbon fiber composite material of the Tesla turbine disk by machining;

Anodizing the surface of the nickel-based carbon fiber composite material of the Tesla turbine disk;

Ceramics are sintered on the surface of the nickel-based carbon fiber composite material of the Tesla turbine disc that has been anodized to obtain a ceramic material of the Tesla turbine disc;

The Tesla turbine disc was prepared by polishing with a diamond abrasive.

In a specific embodiment, the metal is nickel; the metal-based carbon fiber composite material is a nickel-based carbon fiber composite material.

In a specific embodiment, the step of placing carbon fibers in a plating bath containing a nickel-containing electrolytic solution includes: the mass percentage of nickel in the nickel-containing electrolytic solution is greater than 25%.

In a specific embodiment, the diameter of the carbon fiber is 0.1-0.3 mm.

In a specific embodiment, the mandrel is made of ceramic.

In a specific embodiment, the ceramic made of the mandrel is one or more combinations of alumina, zirconium carbide and boron nitride.

In a specific embodiment, the ceramic is yttria-stabilized zirconia.

In a specific embodiment, the step of sintering ceramics on the surface of the nickel-based carbon fiber composite material of the Tesla turbine disk subjected to anodization includes spraying yttria-stabilized zirconia powder onto the nickel-based carbon fiber composite material. The surface is sintered by hot isostatic pressing.

In a specific embodiment, the step of hot isostatic pressing sintering includes: increasing the temperature from room temperature 25 ° C to 1400-1800 ° C at a speed of 1-5 ° C / min at 1-3Mpa; Pressure, heat preservation time is 0.5-3 hours, heat preservation pressure is 3-6Mpa; after heat preservation and pressure preservation, under the pressure of 1-3Mpa, the temperature is reduced to room temperature 25 ° C at a speed of 3-7 ° C / min.

In a specific embodiment, the hot isostatic pressing sintering step includes: increasing the temperature from room temperature 25 ° C to 1600 ° C at a rate of 3 ° C / min at 1-3Mpa; maintaining the temperature for 1 hour, and maintaining the pressure After 3-6Mpa; under the pressure of 1-3Mpa, the temperature is lowered to a room temperature of 25 ° C at a rate of 5 ° C / min.

According to a second aspect of the present invention, a Tesla turbine disk is prepared by the above-mentioned preparation method. The Tesla turbine disk is made of a ceramic material made of a nickel-based carbon fiber composite material, and has a center in the center. A hole, the positioning hole is provided with at least one exhaust hole.

In summary, the present invention provides a method for preparing a Tesla turbine disk and a Tesla turbine prepared by the method. The preparation method includes: placing carbon fibers in a plating bath containing a nickel-containing electrolyte Electroplating; winding the electroplated carbon fiber on a mandrel to form a disc-shaped carbon fiber; heating the disc-shaped carbon fiber and the mandrel together to the melting point of nickel, melting and adhering the metallic nickel, and cooling to room temperature to obtain the Tesla turbine Nickel-based carbon fiber composite material of the disc; removing the mandrel, machining exhaust holes on the nickel-based carbon fiber composite material of the Tesla turbine disc by machining; anodizing the surface of the nickel-based carbon fiber composite material; Ceramics are sintered on the surface of the nickel-based carbon fiber composite material subjected to anodization to obtain a ceramic material of a Tesla turbine disk; the diamond polishing liquid is used to polish the Tesla turbine disk. The Tesla turbine disk produced by the above method has extremely high hardness and compressive strength, and good heat resistance.

(Three) beneficial effects

The above technical solution of the present invention has the following beneficial technical effects:

1. The step of heating the electroplated metallic nickel-carbon fiber to a temperature above the melting point of the metal achieves an effective combination of metallic nickel and carbon fiber. The nickel-based carbon fiber composite material prepared by the method of the present invention causes carbon fiber and metallic nickel substrate to occur Effective fusion, forming an organic whole, and improving the bonding strength of carbon fiber and metal nickel matrix;

2. Sintering the ceramic on the surface of the anodized nickel-based carbon fiber composite material to achieve the connection between the metallic material nickel and the ceramic. The nickel-based carbon fiber composite material has a ceramic with extremely high hardness and compressive strength and good heat resistance. It can keep the shape and size unchanged at high temperature, and can resist the erosion of high temperature jet;

3. The Tesla turbine disc made of the ceramic material made of the nickel-based carbon fiber composite material has extremely high hardness and compressive strength, good heat resistance, and can maintain the same shape and size at high temperatures, which can resist The erosion of high-temperature jets makes it difficult to deform when the disk is large in size, which has achieved the widespread application of Tesla turbine disks.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic structural diagram of a Tesla turbine disk in the present invention;

2 is a flowchart of a method for preparing a metal-based carbon fiber composite material according to the present invention;

3 is a flowchart of a method for preparing a metal-based carbon fiber composite ceramic according to the present invention;

FIG. 4 is a flowchart of a method for preparing a Tesla turbine disk according to the present invention.

detailed description

In order to make the objectives, technical solutions, and advantages of the present invention clearer, the following further describes the present invention in detail with reference to specific embodiments and the accompanying drawings. It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the invention. In addition, in the following description, descriptions of well-known structures and techniques are omitted to avoid unnecessarily obscuring the concept of the present invention.

FIG. 1 is a schematic structural diagram of a Tesla turbine disk according to the present invention; a positioning hole 110 and an exhaust hole 120 are provided on the Tesla turbine disk 100, and the rotating shaft passes through the positioning holes 110 of the same Tesla turbine disk 100. And the Tesla turbine discs 100 with the same structure are fixedly connected.

Preferably, the exhaust hole 120 is disposed near the positioning block 110. Further preferably, there are several, preferably three, exhaust holes 120, which are all distributed on the surface of the Tesla turbine disk 100.

The Tesla turbine disk is made of a ceramic material made of a metal-based carbon fiber composite material. The following describes the preparation method of the metal-based carbon fiber composite material and ceramics, and a method of preparing a Tesla turbine disk from the ceramic material.

A method 200 for preparing a metal-based carbon fiber composite material, as shown in FIG. 2, includes the following steps:

Step 210: The carbon fiber is electroplated in an electrolyte;

Step 220: Shape the electroplated carbon fibers to obtain carbon fibers of a predetermined shape;

Step 230: The shaped carbon fiber is heated to the melting point of the metal, and after the metal is melted and mixed, it is cooled to room temperature and discharged, and the metal-based carbon fiber composite material is prepared.

The metal-based carbon fiber composite material is a nickel-based carbon fiber composite material.

Specifically, the step 210 includes placing carbon fibers into an electroplating bath containing a nickel-containing electrolyte, wherein the nickel-containing electrolyte has a mass percentage content of nickel greater than 25%, and the diameter of the carbon fibers is 0.1- 0.3mm, preferably 0.2mm.

Specifically, the step 220 includes:

Shape the carbon fiber after plating; use the tooling to shape the carbon fiber after plating, the meaning of the shape is to shape the carbon fiber into a predetermined shape. The tooling material needs to be resistant to high temperatures, difficult to deform, and difficult to react with metals, and is preferably made of ceramics selected from one or more combinations of alumina, zirconium carbide, and boron nitride;

Preferably, the method further comprises the step of using a non-plated metal carbon fiber to reinforce the shaped carbon fiber.

Specifically, the step 230 includes: after the metal is melted (when the metal-based carbon fiber composite material is a nickel-based carbon fiber composite material, the heating temperature is greater than 1000 ° C.), all carbon fiber surfaces have metal and the metal is stuck together, and cooled to After room temperature, the metal solidified.

The metal-based carbon fiber composite material prepared by the above method realizes the effective combination of metal nickel and carbon fiber, effectively fuses the carbon fiber and the metal substrate, forms an organic whole, and improves the bonding strength of the carbon fiber and the metal matrix.

A second aspect of the present invention provides a method 300 for preparing ceramics using a metal-based carbon fiber composite material, as shown in FIG. 3, including the following steps:

Step 310: Put the carbon fiber into the electrolyte for electroplating;

Step 320: Shape the electroplated carbon fibers to obtain carbon fibers of a predetermined shape;

Step 330: heating the shaped carbon fiber to the melting point of the metal, cooling to room temperature after the metal is melted and mixed, and discharging, to obtain the metal-based carbon fiber composite material;

Step 340: Perform anodization on the surface of the metal-based carbon fiber composite material. The effect of the anodization can make the interface between the metal (nickel) and the high-temperature ceramic better fused, and form a transition surface. An oxide layer is formed on the surface;

Step 350: Sinter a high-temperature-resistant ceramic on the surface of the metal-based carbon fiber composite material subjected to anodization to obtain the ceramic.

Specifically, the metal-based carbon fiber composite material is a nickel-based carbon fiber composite material, and the ceramic is yttria-stabilized zirconia YSZ. The steps 310-330 are the same as the method for preparing the aforementioned metal-based carbon fiber composite material.

The step 350 includes: spraying YSZ powder on the surface of the metal-based carbon fiber composite material, and then performing hot isostatic sintering. The specific process is: increasing the temperature from room temperature 25 ° C at a speed of 1-5 ° C / min (preferably 3 ° C / min) to 1400-1800 ° C (preferably 1600 ° C) at 1-3Mpa; The holding time is 0.5-3 hours (preferably 1 hour) and the holding pressure is 3-6Mpa. After the holding and holding pressure, the temperature is reduced at a speed of 3-7 ° C / minute (preferably 5 ° C / minute) under the pressure of 1-3Mpa. To room temperature 25 ° C. If the heating or cooling rate is too fast, it will cause the components to shrink and phase change unevenly, resulting in a large amount of internal stress, which will cause the ceramic to crack; if the insulation pressure and time are not enough, it will also cause the components to shrink and phase change unevenly, resulting A large amount of internal stress causes the ceramic to crack.

The method for preparing ceramics by using the metal-based carbon fiber composite material realizes the connection between the metal material and the ceramic. The metal-based carbon fiber composite material has extremely high hardness and compressive strength, good heat resistance, and can be used at high temperatures. Keeping the shape and size unchanged, it can resist the erosion of high-temperature jets.

A third aspect of the present invention provides a method 400 for preparing a Tesla turbine disk. As shown in FIG. 4, the method includes the following steps:

Step 410, the carbon fiber is electroplated in a nickel-containing electrolyte;

Step 420: The electroplated carbon fiber is wound on a mandrel to form a disc-shaped carbon fiber. The mandrel needs to be resistant to high temperatures, difficult to deform, and difficult to react with a metal. The ceramic is one or more combinations of alumina, zirconium carbide and boron nitride;

Step 430: The disc-shaped carbon fiber and the mandrel are heated together to the melting point of nickel, the metallic nickel is melted and adhered, and then cooled to room temperature to obtain a nickel-based carbon fiber composite material of the Tesla turbine disc;

Step 440: Remove the mandrel and machine an exhaust hole on the nickel-based carbon fiber composite material of the Tesla turbine disc by machining. The exhaust hole is disposed near the positioning hole of the turbine disc, and the exhaust There may be several holes, preferably three, evenly distributed on the surface of the turbine disk;

Step 450: Anodize the surface of the nickel-based carbon fiber composite material of the Tesla turbine disk;

Step 460: Sinter ceramics on the surface of the nickel-based carbon fiber composite material of the Tesla turbine disc that has been anodized to obtain a ceramic material of the Tesla turbine disc. The ceramic is yttria stabilized zirconia YSZ.

Step 470: Polish using a diamond abrasive to obtain the Tesla turbine disk.

The Tesla turbine disk prepared by the above-mentioned method for preparing a Tesla turbine disk has extremely high hardness and compressive strength, good heat resistance, can maintain the shape and size unchanged at high temperatures, and can resist the erosion of high-temperature jets. When the disc size is large, it is not easy to deform, which realizes the universal application of Tesla turbine discs.

The present invention is further described below through specific examples.

Example 1:

Method for preparing Tesla turbine disc using nickel-based carbon fiber composite ceramics:

First, carbon fibers are put into a nickel-containing electrolyte for electroplating; the electrolyte contains 500 g / L of nickel sulfate; 70 g / L of nickel chloride; 40 g / L of boric acid; and 0.1 g / L of sodium lauryl sulfate. The nickel sulfate is a main salt, boric acid is a buffering agent, nickel chloride is an anti-passivation agent, and sodium lauryl sulfate is a dispersant. Experimental conditions: pH value is 3 ～ 4; temperature is 25 ℃; plating time is 1 ～ 12min; current density is 0.1 ～ 0.5A / dm2. The diameter of the carbon fiber was 0.2 mm. After electroplating, nickel-based carbon fibers were obtained.

The electroplated nickel-based carbon fiber is wound on a mandrel to form a disc-shaped carbon fiber; the mandrel is selected from one or more combinations of alumina, zirconium carbide, and boron nitride.

The disc-shaped carbon fiber and the mandrel are heated together to a temperature above the melting point of nickel, and the heating temperature is 1500 ° C, and the temperature is maintained for 10-45 minutes, preferably 30 minutes. After the metal nickel is melted and adhered, it is cooled to room temperature to obtain the Tesla turbine Plate of nickel-based carbon fiber composite material.

The mandrel is removed, and three uniformly distributed exhaust holes are machined on the nickel-based carbon fiber composite material of the Tesla turbine disk.

Anodizing is performed on the surface of the nickel-based carbon fiber composite material of the Tesla turbine disk. The specific process is: anodizing the nickel-based carbon fiber composite material in an external magnetic field, and the strength of the external magnetic field is 20-60mT. The cathode and electrolyte are ammonium salts, the concentration of the electrolyte is 1-15%, the temperature of the electrolyte is 0-50 ° C, the applied current density is 0.5-10mA / cm2, and the residence time of the nickel-based carbon fiber composite material in the electrolyte It is 1-2 minutes; then it is taken out for washing and drying to obtain an anodized nickel-based carbon fiber composite material.

After spraying YSZ powder on the surface of the nickel-based carbon fiber composite material, hot isostatic pressing is performed for sintering. The specific process is: at 1-3Mpa, the temperature is increased from room temperature 25 ° C to 1600 ° C at a rate of 3 ° C / min. After maintaining the temperature for 1 hour, the temperature is 3-6Mpa, and under the pressure of 1-3Mpa, Cool down to 25 ℃ at room temperature at a rate of 5 ℃ / min;

The nickel-based carbon fiber composite material was polished using a diamond polishing solution to prepare the Tesla turbine disk.

The nickel-based carbon fiber composite material obtained through the above method has a tensile strength of 4 to 7 Gpa and a tensile modulus of 400 to 700 Gpa.

It should be understood that, the foregoing specific implementation manners of the present invention are only used to exemplarily illustrate or explain the principle of the present invention, and do not constitute a limitation to the present invention. Therefore, any modification, equivalent replacement, improvement, etc. made without departing from the spirit and scope of the present invention should be included in the protection scope of the present invention. Further, the appended claims of the present invention are intended to cover all changes and modifications that fall within the scope and boundary of the appended claims, or equivalents of such ranges and boundaries.

Claims

A method for preparing a Tesla turbine disk, comprising the following steps:

The carbon fiber is electroplated in a plating bath of a metal electrolyte;

Winding the electroplated carbon fiber on a mandrel to form a disc-shaped carbon fiber;

Heating the disc-shaped carbon fiber and the mandrel to the melting point of the metal, melting the metal and adhering to the room temperature, and preparing the metal-based carbon fiber composite material of the Tesla turbine disk;

Removing the mandrel and machining exhaust holes on the metal-based carbon fiber composite material of the Tesla turbine disk by machining;

Performing anodizing on the surface of the metal-based carbon fiber composite material of the Tesla turbine disk;

Ceramics are sintered on the surface of the metal-based carbon fiber composite material of the Tesla turbine disk subjected to anodization to obtain a ceramic material of the Tesla turbine disk;

The Tesla turbine disc was prepared by polishing with a diamond abrasive.
The method of claim 1, wherein the metal is nickel; and the metal-based carbon fiber composite material is a nickel-based carbon fiber composite material.
The method for preparing a Tesla turbine disk according to claim 2, wherein the step of placing carbon fibers in a plating bath containing a nickel-containing electrolytic solution comprises: mass percentage of nickel in the nickel-containing electrolytic solution Greater than 25%.
The method for preparing a Tesla turbine disk according to claim 1, wherein the diameter of the carbon fiber is 0.1-0.3 mm.
The method for manufacturing a Tesla turbine disk according to claim 1, wherein the mandrel is made of ceramic.
The method for preparing a Tesla turbine disk according to claim 5, wherein the ceramic made of the mandrel is one or more combinations of alumina, zirconium carbide and boron nitride.
The method of claim 1, wherein the ceramic is yttria-stabilized zirconia.
The method for preparing a Tesla turbine disk according to claim 7, wherein the step of sintering ceramics on the surface of the nickel-based carbon fiber composite material of the Tesla turbine disk subjected to anodization comprises: yttria After spraying the stabilized zirconia powder on the surface of the nickel-based carbon fiber composite material, hot isostatic sintering is performed.
The method for preparing a Tesla turbine disk according to claim 8, wherein the step of hot isostatic sintering comprises: at a temperature of 1-3 MPa, starting from a room temperature of 25 ° C and a temperature of 1-5 ° C / The speed of the minute is increased to 1400-1800 ℃; then the temperature is maintained at a pressure of 0.5-3 hours and the temperature is 3-6Mpa; after the temperature is maintained at a pressure of 1-3Mpa, the temperature is 3-7 ℃ / min The temperature was reduced to room temperature of 25 ° C.
A Tesla turbine disk, which is prepared by the preparation method according to any one of claims 1-9, wherein the Tesla turbine disk is made of a ceramic material made of a nickel-based carbon fiber composite material, wherein A positioning hole is provided in the center, and at least one exhaust hole is provided around the positioning hole.