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
  • F01D5/12—Blades
  • F01D5/14—Form or construction
  • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
• • 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
  • F01D5/34—Rotor-blade aggregates of unitary construction, e.g. formed of sheet laminae
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
  • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
  • F01D5/12—Blades
  • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
• • 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
  • F01D5/30—Fixing blades to rotors; Blade roots ; Blade spacers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
  • F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
• • 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
  • F05D2230/40—Heat treatment
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49316—Impeller making
  • Y10T29/49336—Blade making
  • Y10T29/49339—Hollow blade

Definitions

• Cooled bladed rotors are commonly used in gas turbine engines to enable components to operate at higher gas path temperatures than would otherwise be possible with un-cooled configurations.
• Longstanding practice in the turbine engine art for cooled bladed rotors is having separate parts (i.e., a disk and blades) joined together by mechanical means to produce a rotor assembly.
• the use of separate parts is driven by the need for different superalloys for the disk and the blade due to one set of mechanical properties needed for a disk location and a significantly different set of mechanical properties needed for a blade airfoil location. If taken to the next level of technology development, the disk itself would ideally be thermally-mechanically- processed (TMP) to have different mechanical properties within its bore, web, and rim.
• TMP thermally-mechanically- processed
• IBR integrally bladed rotors
• IBRs are typically machined from a single forging having one chemistry. IBRs may also be produced by linear friction welding solid airfoils or hollow airfoils onto a disk (or hub if for the 1 st stage of a gas turbine engine's fan). The blades and the disk may be of same chemistry or of different chemistries. For these examples of prior art IBR's, there is no internal cooling. The ability to produce a cooled integrally bladed rotor (IBR) which can operate thousands of hours in a thermal environment that exceeds the rotor's blade's superalloy's melting temperature by several hundred degrees Fahrenheit is not so simple.
• IBR integrally bladed rotor
• the present invention provides for metallurgically bonding a forged disk portion of the IBR (which may be made of one or more superalloys) to uber-cooled, additive manufactured, thermally mechanically processed superalloy blades.
• IBR which may be made of one or more superalloys
• the end result is an Uber-cooled Multi-alloy IBR, which achieves the operating conditions currently needed in the industry.
• a disk is selected to have the uber-cooled blades attached and is machined to a configuration suitable for accepting an uber-cooled, additive manufactured blade or blade block of desired chemistry.
• the airfoil would be produced as taught in commonly owned patent application filed of even date herewith having the title Uber- Cooled Turbine Airfoil identified above.
• the airfoil would have its finished shape and could already contain a coating for oxidation protection if so desired.
• Metallurgical bonding is performed by applying pressure using conventional mechanical means and heat would be provided by resistance heating or induction heating, or other means.
• FIG. 1 is a perspective view of a rotor and a set of blades without a blade block prior to attachment.
• FIG. 2 is a perspective view of the rotor and set of blades of FIG. 1 after attachment of the blades to the rotor.
• FIG. 3 illustrates the assembly of the disk and a blade containing a blade block prior to bonding to show the relationship therebetween.
• FIG. 4 shows the blade and disk of FIG. 3 after bonding.
• FIG. 5 shows the bonded blade and disk after machining.
• the superalloy turbine airfoils that are bonded to the disk in this invention have internal passages through which cooling air passes to provide super-cooling or uber- cooling of the airfoils.
• the internal passages are formed in configurations as desired. Such configurations include ellipsoidal, serpentine, layered, stacked, labyrinth and the like.
• the airfoils with passages are formed from a superalloy powder of the desired composition wherein the superalloy powder is sintered or melted by direct metal laser sintering (DMLS hereinafter), electron beam melting (EBM hereinafter), or other similar additive manufacturing processing.
• DMLS direct metal laser sintering
• EBM electron beam melting
• Layers of the superalloy powder are placed in a vacuum chamber (for EBM) or an argon chamber (for DMLS) and each layer is subjected to laser or electron beam heat that melts the powder into the shape of a two dimensional layer, followed by the next layer and the next until the part is formed.
• the internal passages not being fused continue to be filled with un-fused powder particles.
• the airfoil Upon completion of the airfoil, it has to be vibrated and/or flushed with a fluid, such as, for example, a gas or a liquid to remove the powder particles that are in the internal passages. The part is then flow checked to verify the internal cavities are open and capable of meeting the internal flow conditions needed to meet the airfoil's design intent. A slurry with abrasive particles may be used to reduce internal surface roughness. The airfoil is then ready for bonding to the disk.
• a fluid such as, for example, a gas or a liquid
• FIGS show a few airfoils. In practice, a significantly greater number of airfoils would be bonded to a disk for a production part actually used in an engine.
• FIG. 1 illustrates rotor disk 20 with a plurality of protrusions 22 extending radially out from disk 20. Positioned proximate each protrusion 22 is a blade 10 that is to be attached to its respective protrusion 22.
• FIG. 2 illustrates the same disk 20 with blades 10 attached thereto as is explained below.
• FIG. 3 is a cross-section showing a portion of the disk assembly and one of a plurality of blades to be joined to the disk.
• blade 10 has a recess 12 that is adapted to fit over protrusion 22, which is an integral portion of disk 20.
• Protrusion 22 and recess 12 are shaped to be closely conforming, in that the cross section of cavity 16 and protrusion 22 are closely matched. Bonding is desired on matching surfaces labeled 14 and 24 while portions of cavity 16 of blade 10 are present only for bonding and are subsequently removed.
• Faying surfaces 14 and 24 are to be clean and free of any dirt, oil, oxide or the like that could impede either the flow of electrical current or bonding and should be cleaned by conventional or known techniques.
• Bonding is accomplished using a combination of heat and pressure. Bonding is performed in a vacuum or inert atmosphere to eliminate oxidation, and vacuum does not have the possibility of inert gas entrapment in the bond. Force is applied normal to faying surfaces 14 and 24, such as by application of hydraulic pressure means.
• Bonding forces on the order of 3-15 ksi (20.7 -103.4 mpa) are appropriate although the exact bonding force is related to the specific materials used and the bonding temperature.
• Localized heating of faying surfaces 14 and 24 is obtained by passing a high current between blade 10 and disk 20. Either AC or DC current sources are acceptable.
• the bonding temperature will depend on the specific alloys being bonded. A temperature range of 1700 °F to 2300 °F (927 °C to 1260 °C) are examples of temperatures used. The specific temperature selected is one at which the disk material softens but the blade material does not. A typical current flow to provide the necessary heating is about 3,600 to 4,000 amps for a time of about 0.5 to 4 hours. Induction heating is also within the scope of this invention. Use of a conventional furnace to heat the assembly to less than bonding temperature, followed by additional localized heating is also within the scope of this invention.
• FIG. 5 illustrates how side portions 16 are removed by conventional machining techniques after the bonding is complete since the cavity formed by element 16 is no longer needed.
• the bladed portion of the IBR includes a passageway in the side of the blade that feeds cooling air into the blade's internal passages.
• a cover plate fits up against either side of the disk with the mechanically attached turbine blades in place.
• a passageway is machined after diffusion bonding that links the internal cavity of the turbine blade. A hole could already be in place prior to diffusion bonding. Machining the hole after diffusion bonding takes advantage of a more rigid airfoil root from the diffusion bonding process.
• Uber-cooling technology made possible by the use of additive manufacturing technology enables the bladed portion of the IBR to (a) operate at significantly higher gas path temperatures than previously possible, or (b) operate at state-of-the-art temperatures with less cooling air, or (c) operate at state-of-the-art temperatures using the same cooling air, but using a lower cost superalloy. Vibratory and/or resonance issues associated with mechanically attached bladed rotors are reduced.
• a method of making an integrally bladed rotor having blades with internal cooling passages attached to a disk by forming a cavity in a root portion of at least one blade having internal cooling, forming a protrusion on the periphery of the disk for each at least one blade having internal cooling passages and forcing the blade and disk together with localized heating and pressure to bond the blade to the disk and removing any part of the blade that is excess on the disk.
• the method of the preceding paragraph can optionally include additionally and/or alternatively, any one or more of the following features, configurations and/or additional components.
• Bonding may take place at a temperature range of 1700 °F to 2300 °F (927 °C to 1260 °C).
• Local heating may be provided by flowing current between the blade and the protrusion on the disk.
• the current flow to provide the heating can be about 3,600 to 4,000 amps for a time of about 0.5 to 4 hours.
• the bonding force can range from 3-15 ksi (20.7 -103.4 mpa).
• An integrally bladed rotor having blades with internal cooling passages where the blades have a cavity in the root portion, the disk has a protrusion for each blade, and the blade or blades is bonded to the disk protrusion.
• the integrally bladed rotor of the preceding paragraph can optionally include additionally and/or alternatively, any one or more of the following features, configurations and/or additional components.
• the blade can be bonded to the protrusion bonding at a temperature range of 1700 °F to 2300 °F (927 °C to 1260 °C).
• Local heating to bond the blade to the protrusion may be provided by flowing current between the blade and the protrusion.
• the current flow to provide the necessary heating may be about 3,600 to 4,000 amps for a time of about 0.5 to 4 hours.
• a bonding force may range from 3-15 ksi (20.7 -103.4 mpa).
• the method of the preceding paragraph can optionally include additionally and/or alternatively, any one or more of the following features, configurations and/or additional components.
• Bonding may be performed at a temperature range of 1700 °F to 2300 °F (927 °C to 1260 °C).
• Bonding may use local heating provided by flowing current between the blade and the protrusion, wherein the current flow to provide the heating is about 3,600 to 4,000 amps for a time of about 0.5 to 4 hours.
• the bonding force may range from 3-15 ksi (20.7 -103.4 mpa).

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Combustion & Propulsion (AREA)
• Ceramic Engineering (AREA)
• Materials Engineering (AREA)
• Pressure Welding/Diffusion-Bonding (AREA)
• Turbine Rotor Nozzle Sealing (AREA)
• Structures Of Non-Positive Displacement Pumps (AREA)

Applications Claiming Priority (2)

Publications (2)

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Family Applications (1)

Country Status (3)

Families Citing this family (11)

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• 2012
  • 2012-09-28 US US13/630,120 patent/US20140140859A1/en not_active Abandoned
• 2013
  • 2013-09-24 EP EP13841587.2A patent/EP2900930A4/de not_active Withdrawn
  • 2013-09-24 WO PCT/US2013/061427 patent/WO2014052320A1/en not_active Ceased

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