WO2022123174A1

WO2022123174A1 - Hybrid manufacturing process for producing a turbomachine component comprising an internal cooling circuit

Info

Publication number: WO2022123174A1
Application number: PCT/FR2021/052238
Authority: WO
Inventors: Filippo PAGNONI; Romain Pierre CARIOU; Léandre OSTINO; Sylvain Paquin; Adrien Bernard Vincent ROLLINGER
Original assignee: Safran
Priority date: 2020-12-10
Filing date: 2021-12-08
Publication date: 2022-06-16
Also published as: FR3117533A1; FR3117533B1

Abstract

The invention relates to a manufacturing process for producing a turbomachine component (100) comprising an internal cooling circuit (60), wherein a cast intermediate workpiece (10) is provided and all or part of the remainder (50) of the component (100) is formed on the basis of the intermediate workpiece (10) by laser metal deposition, while forming all or part of the internal cooling circuit (60).

Description

Mixed method of manufacturing a turbomachine component comprising an internal cooling circuit

Technical area

[0001] This presentation relates to a manufacturing process for a turbomachine component comprising an internal cooling circuit, and more particularly a manufacturing process combining foundry manufacturing and additive manufacturing.

Prior technique

[0002] Certain turbomachine components, such as for example turbomachine blade platforms, can be subjected to significant thermal stresses. Also, such components can be equipped with one or more internal cooling circuits within which a cooling fluid, for example air, can circulate to reduce these thermal stresses undergone by said component.

[0003] However, providing an internal cooling circuit is particularly complex and the possibilities are limited if this component is manufactured by foundry. Alternatively, such a component can be manufactured by additive manufacturing, which notably makes it possible to obtain much more complex and efficient structures in terms of cooling for the internal cooling circuit. However, such a process is particularly long and costly. So there is a need for that.

Disclosure of Invention

[0004] One embodiment relates to a method of manufacturing a turbomachine component, comprising an internal cooling circuit, in which an intermediate part from a foundry is provided, and one forms, from the intermediate part, all or part of the rest of the component by metallic deposition by laser while forming all or part of the internal cooling circuit

[0005] Hereafter and unless otherwise indicated, the term “cooling circuit” means “internal cooling circuit”. Hereafter, and unless otherwise indicated, by “component” is meant “turbomachine component” and by “remainder” is meant “remainder of the turbomachine component”. Furthermore, in the present description, the axial direction corresponds to the direction of the axis of rotation of the turbomachine (or of the disk of the fan), and a radial direction is a direction perpendicular to this axis.

[0006] Within the meaning of the present presentation, the remainder corresponds to the entire part of the component which is not present in the intermediate part. The rest can be manufactured solely by metal deposition by laser, or else by metal deposition by laser (in one or more steps) and at least one other manufacturing/machining step different from the metal deposition by laser, this at least one other step possibly intervene before, after or be interposed with respect to the metal deposition step(s) by laser.

[0007] The intermediate part may comprise an internal cooling circuit, but not necessarily. This cooling circuit can be separate from, or be connected to, the cooling circuit of the rest. In other words, the intermediate part can comprise none, a single one, or several internal cooling circuits while the rest comprises at least one internal cooling circuit. In other words, the intermediate part can comprise at least one internal cooling circuit configured to cool the part of the component corresponding to the intermediate part, but not necessarily, while the rest comprises at least one internal cooling circuit configured to cool the part of the component corresponding to the rest. Hereafter and unless otherwise indicated, by "cooling circuit" is meant the cooling circuit of the remainder.

[0008] The manufacturing process that is the subject of this exhibit combines, via the supply of the intermediate part, manufacturing by foundry and manufacturing by additive manufacturing, for example by metal deposition by laser. Metal deposition by laser, or Laser Metal Deposition in English (also known as under the acronym "LMD") is an additive manufacturing process well known as such by those skilled in the art. In some embodiments, the method may include an initial step of manufacturing the intermediate part by foundry, but not necessarily. In other words, the process according to the present description can be limited to the simple supply of the intermediate part from foundry, this intermediate part being manufactured elsewhere (ie manufactured by foundry by a process distinct from the present process), and to the manufacture of all or part of the rest of the component by laser metal deposition.

[0009] Such a manufacturing process combining two stages of two distinct processes makes it possible to reduce manufacturing costs and lead times (thanks to the stage of supplying the intermediate part from the foundry), while making it possible to obtain a complex and improved structure in terms of cooling for the cooling circuit (thanks to the manufacturing step by metal deposition by laser).

[0010] In certain embodiments, the rest of the component is formed, including the internal cooling circuit, by laser metal deposition.

[0011] This allows great manufacturing flexibility and great structural complexity to manufacture the rest, in particular the cooling circuit. For example, the intermediate part can be a blade (fixed or moving) or an inter-blade platform foot, and the rest can be the entire inter-blade platform.

In some embodiments, at least a portion of a wall of the intermediate piece forms at least a bottom of at least one passage of the internal cooling circuit, and the rest of the component is formed, including the the other walls of at least one passage of the internal cooling circuit, by metal deposition by laser.

[0013] Thereafter, and unless otherwise indicated, the term “passage” means “at least one passage”.

[0014] In other words, it is based on the wall of the intermediate piece to manufacture the rest, and a wall of the passage is formed by a portion of the wall of the intermediate piece. For example, in the case where the passage would have a square section, one face of the square of the section is formed by a portion of the wall of the intermediate piece on which the rest is formed. According to another example, in the case where the passage would have a square section, the wall may have a groove resulting from foundry, during the manufacture of the intermediate part, and the groove may form a first face of the square of the section and any or part of the two faces contiguous to the first face. The last face (facing the first face) of the square section and any remaining portions of the two adjoining faces are formed when the rest is manufactured by metal deposition by laser. For example, the intermediate part can comprise an internal or external wall of an inter-blade platform (ie wall radially internal or external with respect to a radial direction of a rotor or of a stator within which the component is configured to be mounted, also known to those skilled in the art as the internal or external bottom of the platform), said wall being configured to extend between two adjacent blades, while the rest comprises the entire rest of the platform (ie the entire platform with the exception of said internal or external wall).

[0015] This facilitates the manufacture of the portion of the component manufactured by foundry, and limits the manufacturing time of the portion of the part manufactured by metal deposition by laser.

In certain embodiments, at least one groove defining a part of at least one passage of the internal cooling circuit is formed by shrinking material in a wall of the intermediate piece before manufacturing the remaining part of the rest of the component. , including the remaining part of the internal cooling circuit, by laser metal deposition.

In this example, it is understood that the rest includes the groove formed by removal of material (i.e. part of the rest) and all the portion manufactured by metallic deposition by laser (i.e. the remaining part of the rest)

[0018] In other words, we first machine the wall of the intermediate piece on which we rely to manufacture the rest, to form a groove. For example, the machining can be milling, electro-erosion, or any other suitable known process. For example, in the case where the passage would have a square section, the groove can form a first face of the square of the section and all or part of the two faces contiguous to the first face. The last face (facing the first face) of the square section and any remaining portions of the two adjoining faces are formed when the rest is manufactured by metal deposition by laser. For example, the intermediate part can comprise an internal or external wall of an inter-blade platform (ie wall radially internal or external with respect to a radial direction of a rotor or of a stator within which the component is configured to be mounted, also known to those skilled in the art as the internal or external bottom of the platform), said wall being configured to extend between two adjacent blades, this face being machined beforehand by removing material to then form the rest , the latter comprising all the rest of the platform (ie the entire platform with the exception of said internal or external machined wall).

[0019] This makes it possible to limit the portion of the component manufactured by metal deposition by laser.

[0020] In certain embodiments, disruptors configured to disrupt a cooling flow flow within the internal cooling circuit are formed, by metal deposition by laser.

Thanks to the method according to the present presentation, it becomes possible to form such disturbers to destabilize the boundary layer, intensify the convective mixing in the cooling flow and, consequently, increase the parietal heat exchanges.

In some embodiments, the internal cooling circuit comprises several passages together forming at least one winding channel.

In some embodiments, the sinuous channel forms at least one loop portion having a main dimension in a longitudinal direction, the loop portion being formed by two passages extending straight in the longitudinal direction and by a part of connection connecting the two passages. Optionally, the longitudinal direction corresponds to the axial direction.

Thanks to the method according to the present description, it becomes possible to form sinuous (or serpentine) channels to improve the parietal heat exchanges. In other words, the method according to the present disclosure makes it possible to manufacture complex internal cooling circuits to optimize parietal heat exchange.

[0025] In certain embodiments, the method comprises surface treatment of all or part of a portion manufactured by metal deposition by laser.

[0026] The surface treatment can be, for example, machining (eg deburring, sanding, etc.), electroerosion treatment, chemical treatment, etc.

[0027] In certain embodiments, the intermediate part comprises a turbine engine blade (fixed or mobile) or a turbomachine inter-blade platform foot, and the rest of the component comprises all or part of an inter-blade platform of turbomachine comprising an internal cooling circuit.

The remainder may comprise all or part of the platform, including all or part of the internal cooling circuit.

[0029] In some embodiments, the component is a high pressure turbine blade.

[0030] A blade is an assembly comprising one or more fixed or mobile blades in rotation around the axis of the turbomachine.

[0031] One embodiment relates to a high pressure turbine comprising a turbomachine component manufactured according to a method according to any one of the embodiments according to the present disclosure.

Brief description of the drawings

The object of this presentation and its advantages will be better understood on reading the detailed description given below of various embodiments given by way of non-limiting examples. This description refers to the pages of appended figures, on which:

[0033] [Fig. 1] FIG. 1 represents a step for supplying an intermediate part for a method of manufacturing a turbomachine component according to a first embodiment, [0034] [Fig. 2] FIG. 2 represents a metal deposition step by laser for the manufacturing method of a turbomachine component according to the first embodiment,

[0035] [Fig. 3] Figure 3 represents a turbomachine component,

[0036] [Fig. 4] FIG. 4 represents a step for supplying an intermediate part for a method of manufacturing a turbomachine component according to a second embodiment,

[0037] [Fig. 5] FIG. 5 represents a metal deposition step by laser for the manufacturing method of a turbomachine component according to the second embodiment,

[0038] [Fig. 6] FIG. 6 represents a step for supplying an intermediate part for a method of manufacturing a turbomachine component according to a first variant of the second embodiment,

[0039] [Fig. 7] FIG. 7 represents a metal deposition step by laser for the manufacturing method of a turbomachine component according to the first variant of the second embodiment,

[0040] [Fig. 8] FIG. 8 represents a step for supplying an intermediate part for a method of manufacturing a turbomachine component according to a second variant of the second embodiment,

[0041] [Fig. 9] FIG. 9 represents a metal deposition step by laser for the manufacturing method of a turbomachine component according to the second variant of the second embodiment,

[0042] [Fig. 10] FIG. 10 represents a step for supplying an intermediate part for a method of manufacturing a turbomachine component according to a third embodiment,

[0043] [Fig. 11] FIG. 11 represents a step of forming a groove by removing material for the method of manufacturing a turbomachine component according to the third embodiment, and

[0044] [Fig. 12] FIG. 12 represents a metal deposition step by laser for the method of manufacturing a turbomachine component according to the third embodiment. Description of embodiments

[0045] In all the following examples, the turbomachine component 100 is a high-pressure turbine blade comprising a single blade, for example a moving blade, equipped with an inter-blade platform 50, the platform comprising an internal cooling circuit 60. According to a variant, the component can be a platform fitted with a platform foot, or any other turbomachine component comprising an internal cooling circuit.

A first embodiment of the method for manufacturing a turbomachine component according to this presentation is described with reference to Figures 1 to 3.

[0047] FIG. 1 represents a step for supplying an intermediate part 10 from a foundry, in this example a turbomachine blade (or a blade without a platform, i.e. a blade comprising a root and an aerodynamic profile). The intermediate piece 10 is then fixed on a gripping tool (not shown) to ensure that it is held in position and to be able to proceed with the following steps.

Figure 2 shows the manufacture of all the rest of the component 100, in this example the entire platform 50, including the internal cooling circuit 60, by metal deposition by laser. To do this, a tool 200 is brought closer to the intermediate part 10 to carry out the metal deposition by laser. In this example, the tool 200 comprises a head provided with a laser beam emitter and nozzle(s) for emitting metal powder. It is noted that such a tool is well known to those skilled in the art and that it is represented schematically in FIG. 2. Successive layers of molten metal powder are deposited by virtue of the heat flux generated by the laser beam. The mobility of the tool 200 makes it possible to have adaptive scanning and thus to manufacture the platform 50, including the cooling circuit 60. FIG. 2 represents the platform 50 during manufacture, the portion represented in continuous lines representing the portion already manufactured by metal deposition by laser (as well as the intermediate piece 10), while the portion shown in broken lines represents the portion of the platform 50 which is not yet manufactured. Figure 2 is a schematic representation and principle of manufacturing by metal deposition by laser, which is not necessarily representative of the actual configuration of such manufacturing by metal deposition by laser, which is in itself well known to man of career.

Note that in this example, the internal cooling circuit 60 comprises several passages 60A together forming a winding channel 60B. Furthermore, as can be seen in the magnifying glass of FIG. 2, the internal cooling circuit 60 comprises disturbers 62 configured to intensify the parietal heat exchanges carried out by the cooling flow.

Figure 3 shows the finished turbomachine component 100. The internal cooling circuit 60 is represented by transparency in broken lines. In this example, the rest (in this example the platform 50) has received a surface treatment, for example deburring.

A second embodiment of the method of manufacturing a turbomachine component according to this presentation is described with reference to Figures 4 and 5. The common elements between the first and the second embodiment have the same reference signs . Unless otherwise indicated, the steps described with reference to the first embodiment are also carried out in the second embodiment and are not described again.

[0052] FIG. 4 represents a step for supplying an intermediate part 12 from a foundry, in this example a turbine engine blade comprising an internal wall 13 of an inter-blade platform. In this example, a portion 61 of the internal wall 13 forms a bottom 61 of the passages 60A of the internal cooling circuit 60 (in this example a bottom of the entire circuit 60).

[0053] Figure 5 shows the manufacture of the rest 52 of the component 100, including the other walls of at least one passage of the internal cooling circuit 60, by metal deposition by laser. In this example, the remainder 52 comprises only part of the platform 50, including only part of the cooling circuit 60. FIG. 5 represents the platform 50 during manufacture, the portion shown in solid lines representing the portion already manufactured by metal deposition by laser (as well as the intermediate part 12) while the portion shown in broken lines represents the portion which is not yet manufactured. The component 100 obtained at the end of the process is identical to that obtained by the process according to the first embodiment, and is represented in FIG. 3.

Figures 6 and 7 show a first variant of the method according to the second embodiment where the intermediate piece 12 'has an outer wall 14 of inter-blade platform instead of an inner wall 13 of inter-blade platform. A portion 61′ of the outer wall 14 of the inter-blade platform of the intermediate piece 12′ forms a bottom 61′ of the passages 60A of the internal cooling circuit 60 (in this example a bottom of the entire circuit 60). Also, the main difference with the example of Figures 4 and 5 is that the underside of the platform 50 (radially internal part) is manufactured by laser metal deposition rather than the top of the platform 50 (radially external part). The component 100 obtained at the end of this variant is identical to that obtained by the method according to the first embodiment, and is shown in Figure 3.

[0055] Figures 8 and 9 show a second variant of the method according to the second embodiment where the intermediate part 12" has an internal wall 13' of the inter-blade platform comprising a groove 16 from casting, this groove 16 forming a part of the walls of the internal cooling circuit 60, and in particular a bottom 61”. In this example, during manufacture of the remainder 52” of component 100, groove 16 is closed (of course while retaining the internal cavity of groove 16) so as to form an internal channel in platform 50 forming all or part of the internal circuit 60. According to a third variant, not shown, and similarly to the first variant, the intermediate part may comprise an outer wall of the inter-blade platform comprising a groove resulting from casting instead of an inner wall of the platform inter-blades. The component 100 obtained at the end of these variants is identical to that obtained by the method according to the first embodiment, and is represented in FIG. 3.

A third embodiment of the method for manufacturing a turbomachine component according to the present description is described with reference to FIGS. 10, 11 and 12. The common elements between the first, the second and the third embodiment present the same reference signs. Unless specified On the contrary, the steps described with reference to the first embodiment are also carried out in the second embodiment and are not described again.

FIG. 10 represents a step for supplying an intermediate part 18 from a foundry, in this example a turbine engine blade comprising an internal wall 20 of an inter-blade platform. FIG. 11 represents a step of forming at least one groove 22 defining part of at least one passage of the internal cooling circuit 60 by shrinking material in a wall of the intermediate piece. In this example, the material is removed by milling, using a milling cutter 210. The groove 22 forms in this example part of the rest 54 of the component 100, namely part of the circuit 60. FIG. 12 represents a step of manufacturing the remaining part of the rest 54 of the component 100, including the remaining part of the internal cooling circuit 60, by metal deposition by laser. FIG. 11 represents the platform 50 during manufacture, the portion represented in continuous lines representing the portion already manufactured by metal deposition by laser (as well as the intermediate part 18 having undergone the removal of material) while the portion represented in broken lines represents the portion that is not yet manufactured. The component 100 obtained at the end of the process is identical to that obtained by the process according to the first embodiment, and is shown in Figure 3.

Although the present invention has been described with reference to specific embodiments, it is obvious that modifications and changes can be made to these examples without departing from the general scope of the invention as defined by the revendications. In particular, individual features of the different illustrated/mentioned embodiments can be combined in additional embodiments. Accordingly, the description and the drawings should be considered in an illustrative rather than restrictive sense.

In particular, the figures represent a circuit having an output on a side edge of a platform (ie an edge which extends in a radial direction). Of course, there can be one or more outputs, each output being able to be arranged at any position, on a side edge and/or on a face. radially internal or external of the platform, on the upstream side or on the downstream side with respect to the direction of flow of the fluid within the blading.

It is also obvious that all the characteristics described with reference to a method can be transposed, alone or in combination, to a device, and conversely, all the characteristics described with reference to a device can be transposed, alone or in combination, to a method.

Claims

[Claim 1] Method of manufacturing a turbomachine component (100) comprising an internal cooling circuit (60), in which an intermediate part (10, 12, 12', 12", 18) from a foundry is provided, all or part of the rest (50, 52, 52", 54) of the component (100) is formed from the intermediate piece (10, 12, 12', 12", 18) by metal deposition by laser while forming all or part of the internal cooling circuit (60), characterized in that the internal cooling circuit (60) comprises several passages (60A) together forming at least one sinuous channel (60B).

[Claim 2] A method of manufacturing a turbomachine component (100) according to claim 1, in which all the rest (50) of the component, including the internal cooling circuit (60), is formed by metallic deposition by laser .

[Claim 3] A method of manufacturing a turbomachine component (100) according to claim 1, wherein at least a portion of a wall (13, 14, 13') of the intermediate piece (12, 12', 12 ") forms at least one bottom (61, 61', 61") of at least one passage (60A) of the internal cooling circuit (60), and in which the rest (52, 52") of the component ( 100), including the other wall(s) of at least one passage of the internal cooling circuit (60), by laser metal deposition.

[Claim 4] A method of manufacturing a turbomachine component (100) according to claim 1, in which at least one groove (22) is formed defining part of at least one passage (60A) of the internal cooling circuit ( 60) by removing material from a wall (20) of the intermediate part (18) before manufacturing the remaining part of the rest (54) of the component (100), including the remaining part of the internal cooling circuit (60), by laser metal deposition.

[Claim 5] A method of manufacturing a turbomachine component (100) according to any one of claims 1 to 4, wherein the sinuous channel (60B) forms at least one loop portion having a main dimension along a longitudinal direction, the loop portion being formed by two passages (60A) extending straight along the longitudinal direction and by a connecting part connecting the two passages (60A).

[Claim 6] A method of manufacturing a turbomachine component (100) according to claim 5, wherein the longitudinal direction corresponds to the axial direction.

[Claim 7] A method of manufacturing a turbomachine component (100) according to any one of claims 1 to 6, in which disturbers (62) configured to disturb a flow of cooling flux within the internal circuit are formed. cooling (60), by metal deposition by laser.

[Claim 8] A method of manufacturing a turbomachine component (100) according to any one of claims 1 to 7, comprising surface treatment of all or part of a portion manufactured by metal deposition by laser.

[Claim 9] A method of manufacturing a turbomachine component (100) according to any one of claims 1 to 8, wherein the intermediate piece comprises a turbomachine blade (10, 12, 12', 12", 18) or a turbomachine inter-blade platform foot, and the rest of the component comprises all or part of a turbomachine inter-blade platform (50) comprising an internal cooling circuit (60).

[Claim 10] A method of manufacturing a turbomachine component according to any one of claims 1 to 9, wherein the component is a high pressure turbine blade (100).

[Claim 11] A high pressure turbine comprising a turbine engine component (100) manufactured by a method according to any one of claims 1 to 10.