US20120031579A1 - Method for producing a negative mold for casting a turbine blade and mold for producing a wax model of a gas turbine - Google Patents

Method for producing a negative mold for casting a turbine blade and mold for producing a wax model of a gas turbine Download PDF

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Publication number
US20120031579A1
US20120031579A1 US13/263,871 US201013263871A US2012031579A1 US 20120031579 A1 US20120031579 A1 US 20120031579A1 US 201013263871 A US201013263871 A US 201013263871A US 2012031579 A1 US2012031579 A1 US 2012031579A1
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United States
Prior art keywords
vane
blade
wax model
spacer
platform
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Abandoned
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US13/263,871
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English (en)
Inventor
Fathi Ahmad
Winfried Esser
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Siemens AG
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Siemens AG
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Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: AHMAD, FATHI, ESSER, WINFRIED
Publication of US20120031579A1 publication Critical patent/US20120031579A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00

Definitions

  • the present invention relates to a method for producing a negative mold for casting a turbine blade or vane, in which method a wax model of the turbine blade or vane is produced and the negative mold is created on the basis of the wax model.
  • the invention relates to an aid used in the method and to a mold for producing a wax model of a turbine blade or vane.
  • DE 197 26 111 C1 discloses a method for producing a turbine rotor blade by casting, in which method a wax model of the blade is produced, the blade root being produced by filling a permanent mold having the blade contour. This is followed by the production of a mold shell for casting the turbine blade, the permanent mold remaining on the blade root. Once the wax model has been melted out, the inner contour of the permanent mold defines the outer contour of the turbine blade to be cast. In other words, the permanent mold represents part of the casting mold for producing the turbine blade by casting. Within the context of this method, the permanent mold should improve the surface accuracy for shaping the blade root, such that complex reworking of the blade root once the turbine blade has been cast is not necessary.
  • the permanent mold is either produced from an alloy material which is resistant to high temperatures and has sufficient oxidation resistance, such that it can be reused, or it is produced as a disposable permanent mold made of a low-alloy steel.
  • the first object is achieved by a method for producing a negative mold for casting a turbine blade or vane as claimed in the claims
  • the second object is achieved by a method for producing a turbine blade or vane as claimed in the claims
  • the third object is achieved by a spacer for a wax mold as claimed in the claims.
  • the turbine blade or vane to be cast has a blade or vane platform and a fastening element for fastening the blade or vane to a blade or vane mount, wherein at least one surface of the fastening element is located opposite a platform surface of the blade or vane platform at a distance.
  • a wax model of the turbine blade or vane to be produced is produced, and a negative mold of the turbine blade or vane is created on the basis of the wax model once the wax model has hardened. The wax model is melted out once the negative mold has been completed.
  • at least one spacer is arranged between the platform surface of the blade or vane platform and the at least one opposite surface of the fastening element of the wax model.
  • the invention is based on the knowledge that deviations in the shaping in particular of the fastening elements of turbine blades or vanes occur on account of deformations of the wax model during hardening and/or storage up to the production of the negative mold and/or transport.
  • deformations can be particularly serious in the region of the blade or vane suspension, which is generally formed by hook-shaped elements spaced apart from the blade or vane platform.
  • these hooks are particularly critical with respect to the dimensioning of the distance between the hooks and the blade or vane platform. Specifically, this distance defines the position of the platform in the hot gas path of the turbine.
  • the spacer By using the spacer, it is possible for the particularly critical distance between the hooks and the blade or vane platform to be kept constant very effectively, and therefore reworking of a cast turbine blade or vane is generally no longer necessary. Since the spacer is removed from the wax model before the negative mold is produced, it does not need to consist of a material which withstands the casting process for casting the turbine blade or vane. Compared to the permanent mold mentioned in the introduction, it is therefore possible to use a material which is very much less resistant to high temperatures and therefore a less expensive material.
  • the spacer is arranged between the platform surface of the blade or vane platform and the at least one opposite surface of the fastening element as early as during the hardening of the wax model, but also remains in the wax model until immediately before the negative mold is produced. It is thereby possible for deformations of the wax model which influence the distance between the blade or vane platform and the fastening element to be avoided without interruption from production up to the use thereof.
  • the at least one spacer completely fills the space between the platform surface of the blade or vane platform and the at least one opposite surface of the fastening element.
  • the spacer can rest against at least one further surface of the fastening element.
  • a spacer which has a receptacle, matched to the shape of the fastening element, for receiving at least part of the fastening element.
  • the fastening element can thereby be secured against deformations in all relevant directions.
  • the spacer can also be part of a mold for producing the wax model of the turbine blade or vane.
  • the spacer used can be produced, in particular, from metal or ceramic. If the spacer is produced from metal, steel or aluminum are suitable, for example, in which case aluminum involves advantages on account of its low weight.
  • a turbine blade or vane having a blade or vane platform and a fastening element for fastening the blade or vane to a blade or vane mount is produced, wherein at least one surface of the fastening element is located opposite a platform surface of the blade or vane platform at a distance.
  • the turbine blade or vane is cast with the aid of a negative mold of the turbine blade or vane.
  • the negative mold is created according to the method according to the invention for producing a negative mold.
  • the method according to the invention for producing a turbine blade or vane makes it possible to produce the turbine blade or vane with surfaces and dimensions which are readily controllable in the particularly relevant regions of the suspension, without this requiring the use of a permanent mold.
  • the invention also provides a spacer for a wax mold of a turbine blade or vane having a blade or vane platform and a fastening element for fastening the blade or vane to a blade or vane mount, wherein at least one surface of the fastening element is located opposite a platform surface of the blade or vane platform at a distance.
  • the spacer according to the invention has a receptacle, matched to the shape of the fastening element, for receiving at least part of the fastening element.
  • such a spacer can advantageously be used for the production of a turbine blade or vane. It can be produced, in particular, from metal, for example from steel or aluminum. It can also be produced from ceramic.
  • a further aspect of the invention provides a mold for producing a wax model of a turbine blade or vane.
  • the mold comprises a removable or detachable part which remains on the wax model as the wax model is being removed from the mold and forms a spacer according to the invention.
  • FIG. 1 shows a partial longitudinal section through a gas turbine.
  • FIG. 2 shows a perspective view of an example of a turbine blade or vane.
  • FIG. 3 shows an example of a combustion chamber of a gas turbine.
  • FIG. 4 shows a highly diagrammatic view of the suspension of a turbine blade or vane.
  • FIG. 5 shows the sequence of a method for producing a turbine blade or vane by casting.
  • FIG. 6 shows a section of a wax model of a turbine blade or vane.
  • FIG. 1 shows, by way of example, a partial longitudinal section through a gas turbine 100 .
  • the gas turbine 100 has a rotor 103 with a shaft 101 which is mounted such that it can rotate about an axis of rotation 102 and is also referred to as the turbine rotor.
  • the annular combustion chamber 110 is in communication with a, for example, annular hot-gas passage 111 , where, by way of example, four successive turbine stages 112 form the turbine 108 .
  • Each turbine stage 112 is formed, for example, from two blade or vane rings. As seen in the direction of flow of a working medium 113 , in the hot-gas passage 111 a row of guide vanes 115 is followed by a row 125 formed from rotor blades 120 .
  • the guide vanes 130 are secured to an inner housing 138 of a stator 143 , whereas the rotor blades 120 of a row 125 are fitted to the rotor 103 for example by means of a turbine disk 133 .
  • a generator (not shown) is coupled to the rotor 103 .
  • the compressor 105 While the gas turbine 100 is operating, the compressor 105 sucks in air 135 through the intake housing 104 and compresses it. The compressed air provided at the turbine-side end of the compressor 105 is passed to the burners 107 , where it is mixed with a fuel. The mix is then burnt in the combustion chamber 110 , forming the working medium 113 . From there, the working medium 113 flows along the hot-gas passage 111 past the guide vanes 130 and the rotor blades 120 . The working medium 113 is expanded at the rotor blades 120 , transferring its momentum, so that the rotor blades 120 drive the rotor 103 and the latter in turn drives the generator coupled to it.
  • Substrates of the components may likewise have a directional structure, i.e. they are in single-crystal form (SX structure) or have only longitudinally oriented grains (DS structure).
  • SX structure single-crystal form
  • DS structure longitudinally oriented grains
  • iron-based, nickel-based or cobalt-based superalloys are used as material for the components, in particular for the turbine blade or vane 120 , 130 and components of the combustion chamber 110 .
  • the blades or vanes 120 , 130 may likewise have coatings protecting against corrosion (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon, scandium (Sc) and/or at least one rare earth element, or hafnium). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1.
  • thermal barrier coating to be present on the MCrAlX, consisting for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
  • Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
  • EB-PVD electron beam physical vapor deposition
  • the guide vane 130 has a guide vane root (not shown here), which faces the inner housing 138 of the turbine 108 , and a guide vane head which is at the opposite end from the guide vane root.
  • the guide vane head faces the rotor 103 and is fixed to a securing ring 140 of the stator 143 .
  • FIG. 2 shows a perspective view of a rotor blade 120 or guide vane 130 of a turbomachine, which extends along a longitudinal axis 121 .
  • the turbomachine may be a gas turbine of an aircraft or of a power plant for generating electricity, a steam turbine or a compressor.
  • the blade or vane 120 , 130 has, in succession along the longitudinal axis 121 , a securing region 400 , an adjoining blade or vane platform 403 and a main blade or vane part 406 and a blade or vane tip 415 .
  • the vane 130 may have a further platform (not shown) at its vane tip 415 .
  • a blade or vane root 183 which is used to secure the rotor blades 120 , 130 to a shaft or a disk (not shown), is formed in the securing region 400 .
  • the blade or vane root 183 is designed, for example, in hammerhead form. Other configurations, such as a fir-tree or dovetail root, are possible.
  • the blade or vane 120 , 130 has a leading edge 409 and a trailing edge 412 for a medium which flows past the main blade or vane part 406 .
  • the blade or vane 120 , 130 may in this case be produced by a casting process, by means of directional solidification, by a forging process, by a milling process or combinations thereof.
  • Workpieces with a single-crystal structure or structures are used as components for machines which, in operation, are exposed to high mechanical, thermal and/or chemical stresses.
  • Single-crystal workpieces of this type are produced, for example, by directional solidification from the melt. This involves casting processes in which the liquid metallic alloy solidifies to form the single-crystal structure, i.e. the single-crystal workpiece, or solidifies directionally.
  • dendritic crystals are oriented along the direction of heat flow and form either a columnar crystalline grain structure (i.e. grains which run over the entire length of the workpiece and are referred to here, in accordance with the language customarily used, as directionally solidified) or a single-crystal structure, i.e. the entire workpiece consists of one single crystal.
  • a transition to globular (polycrystalline) solidification needs to be avoided, since non-directional growth inevitably forms transverse and longitudinal grain boundaries, which negate the favorable properties of the directionally solidified or single-crystal component.
  • directionally solidified microstructures refers in general terms to directionally solidified microstructures, this is to be understood as meaning both single crystals, which do not have any grain boundaries or at most have small-angle grain boundaries, and columnar crystal structures, which do have grain boundaries running in the longitudinal direction but do not have any transverse grain boundaries.
  • This second form of crystalline structures is also described as directionally solidified microstructures (directionally solidified structures).
  • the blades or vanes 120 , 130 may likewise have coatings protecting against corrosion or oxidation e.g. (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon and/or at least one rare earth element, or hafnium (Hf)). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1, which are intended to form part of this disclosure with respect to the chemical composition of the alloy.
  • MrAlX M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni)
  • X is an active element and stands for yttrium (Y) and/or silicon and/or at least one rare earth element, or hafnium (Hf)). Alloys of
  • the density is preferably 95% of the theoretical density.
  • the layer preferably has a composition Co-30Ni-28Cr-8Al-0.6Y-0.7Si or Co-28Ni-24Cr-10Al-0.6Y.
  • nickel-based protective layers such as Ni-10Cr-12Al-0.6Y-3Re or Ni-12Co-21Cr-11Al-0.4Y-2Re or Ni-25Co-17Cr-10Al-0.4Y-1.5Re.
  • thermal barrier coating which is preferably the outermost layer and consists for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide, to be present on the MCrAlX.
  • the thermal barrier coating covers the entire MCrAlX layer.
  • Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
  • EB-PVD electron beam physical vapor deposition
  • the thermal barrier coating may include grains that are porous or have micro-cracks or macro-cracks, in order to improve the resistance to thermal shocks.
  • the thermal barrier coating is therefore preferably more porous than the MCrAlX layer.
  • Refurbishment means that after they have been used, protective layers may have to be removed from components 120 , 130 (e.g. by sand-blasting). Then, the corrosion and/or oxidation layers and products are removed. If appropriate, cracks in the component 120 , 130 are also repaired. This is followed by recoating of the component 120 , 130 , after which the component 120 , 130 can be reused.
  • the blade or vane 120 , 130 may be hollow or solid in form. If the blade or vane 120 , 130 is to be cooled, it is hollow and may also have film-cooling holes 418 (indicated by dashed lines).
  • FIG. 3 shows a combustion chamber 110 of a gas turbine.
  • the combustion chamber 110 is configured, for example, as what is known as an annular combustion chamber, in which a multiplicity of burners 107 , which generate flames 156 , arranged circumferentially around an axis of rotation 102 open out into a common combustion chamber space 154 .
  • the combustion chamber 110 overall is of annular configuration positioned around the axis of rotation 102 .
  • the combustion chamber 110 is designed for a relatively high temperature of the working medium M of approximately 1000° C. to 1600° C.
  • the combustion chamber wall 153 is provided, on its side which faces the working medium M, with an inner lining formed from heat shield elements 155 .
  • each heat shield element 155 made from an alloy is equipped with a particularly heat-resistant protective layer (MCrAlX layer and/or ceramic coating) or is made from material that is able to withstand high temperatures (solid ceramic bricks).
  • M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon and/or at least one rare earth element or hafnium (Hf). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1.
  • a, for example, ceramic thermal barrier coating to be present on the MCrAlX, consisting for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
  • Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
  • EB-PVD electron beam physical vapor deposition
  • the thermal barrier coating may include grains that are porous or have micro-cracks or macro-cracks, in order to improve the resistance to thermal shocks.
  • Refurbishment means that after they have been used, protective layers may have to be removed from heat shield elements 155 (e.g. by sand-blasting).
  • a cooling system may be provided for the heat shield elements 155 and/or their holding elements, on account of the high temperatures in the interior of the combustion chamber 110 .
  • the heat shield elements 155 are then, for example, hollow and may also have cooling holes (not shown) opening out into the combustion chamber space 154 .
  • FIG. 4 shows a highly diagrammatic illustration of the suspension of a guide vane 1 on a holding ring 3 , which extends in the circumferential direction of the turbine at least around part of the circumference.
  • the holding element 3 has holding projections 5 , on which the turbine blade or vane 1 is fastened.
  • the turbine blade or vane 1 has a main blade or vane part 9 and at least one blade or vane platform 11 arranged at the radially outer end of the main blade or vane part 9 .
  • a corresponding blade or vane platform can also be arranged at the radially inner end of the main blade or vane part 9 (not shown in FIG. 4 ).
  • the blade or vane platform 11 has a radially inner platform surface 13 , which forms part of the wall of the flow path for the hot combustion gases in the gas turbine.
  • Holding hooks 7 are foamed on the radially outer platform surface 15 located opposite the radially inner platform surface 13 and can be used to suspend the turbine blade or vane on the holding projections 5 of the holding element 3 . Corresponding holding hooks can also be present on the radially inner platform.
  • the distance d between the radially outer platform surface 15 and a hook surface 17 located opposite this platform surface determines the positioning of the radially inner platform surface 13 in the hot gas path of the gas turbine, and is therefore of great importance for the formation of a hot gas path which is optimized in terms of flow.
  • it is therefore of great importance to ensure a defined distance d between the radially outer platform surface and the hook surface 7 .
  • a method for producing the turbine blade or vane shown in FIG. 4 by casting is described below with reference to FIG. 5 .
  • a casting mold is created for a wax model of the turbine blade or vane 9 to be produced. Since no particularly high temperatures prevail during casting of the wax model, the material for the wax model casting mold can be selected so that it is optimized in terms of processability, such that the contour of the wax model can be produced precisely as a negative mold.
  • a casting mold once produced for the wax model can also be reused, and therefore the step of producing a casting mold for a wax model does not necessarily have to be present in each method for producing a negative model for a turbine blade or vane. Only when a turbine blade or vane with a new geometry is to be produced for the first time is it necessary to produce a new casting mold for the corresponding wax model.
  • step 21 the wax model of the turbine blade or vane is cast by means of the casting mold for the wax model.
  • spacer elements are inserted into the region of the holding hooks 7 in step 23 .
  • Such a spacer element 219 is shown schematically in FIG. 6 .
  • the figure shows a section of a wax model 201 of the turbine blade or vane 1 shown in FIG. 4 .
  • the wax model has a model main blade or vane part 209 , a model platform 211 with a radially inner model platform surface 213 and a radially outer model platform surface 215 .
  • a model holding hook 207 extends from the model platform 211 and has a model hook surface 217 which faces toward the outer model platform surface 215 and is spaced apart therefrom.
  • spacer elements 219 are pushed into the intermediate space between the radially outer model platform surface 215 and the opposite model hook surface 217 .
  • the spacer 219 is produced from a dimensionally stable material, for example metal or ceramic.
  • Metallic materials in particular, for instance steel or aluminum, can be produced with precise dimensions, such that the thickness of the spacer can be matched very accurately to the distance d to be observed between the radially outer model platform surface 215 and the opposite model hook surface 217 .
  • the spacer 219 As soon as the spacer 219 has been pushed into the intermediate space between the radially outer platform surface 215 and the opposite model hook surface 217 , the distance between these two surfaces is secured against a change on account of deformations in the wax model during further hardening and/or during transport and/or storage of the wax model.
  • the spacer 219 additionally has a thickened portion 221 , which serves as an edge located opposite the end face 223 of the model hook 207 . It is thereby also possible to reliably counteract displacement of the end face 223 by deformation, in particular, of the model hook 207 .
  • the spacer 219 in the present exemplary embodiment, is inserted after the wax model has been removed from the casting mold, the spacer can also be designed such that, during the casting process, it forms part of the casting mold which can subsequently be taken from the casting mold together with the wax model or can be separated from the casting mold. Since, in this alternative configuration of the method, the spacer is already located in its position during casting, in the region of the model hook 207 the wax model is also secured against deformations which might occur as the model is being removed from the mold.
  • the spacer 229 advantageously remains in the wax model 201 of the turbine blade or vane 1 until a negative mold is created for the turbine blade or vane 1 on the basis of the wax model 201 .
  • the negative mold is formed around the wax model, for example by means of a ceramic material (step 27 ). Once the negative mold has set, the wax is melted out of the negative mold, and therefore the cavity thereby created is available for casting the turbine blade or vane in step 29 . Once the turbine blade or vane has been cast with the aid of the negative mold, the negative mold is removed and the method for producing the turbine blade or vane is complete.
  • the present invention provides a simple means with which it is possible to counteract deformation of the wax model used during a casting process for producing a turbine blade or vane. It is thereby possible to achieve improvements in the observance of a precise geometry of the wax model, as a result of which it is possible to reduce the number of erroneously cast turbine blades or vanes, which are to be reworked or, in the worst case, represent rejects.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
US13/263,871 2009-04-14 2010-03-31 Method for producing a negative mold for casting a turbine blade and mold for producing a wax model of a gas turbine Abandoned US20120031579A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP09005327A EP2241391A1 (fr) 2009-04-14 2009-04-14 Procédé de fabrication d'un moule négatif destiné à couler une aube de turbine et moule de fabrication d'un modèle en cire d'une aube de turbine
EP09005327.3 2009-04-14
PCT/EP2010/054327 WO2010118960A1 (fr) 2009-04-14 2010-03-31 Procédé de fabrication d'un moule négatif pour la coulée d'une aube de turbine et moule pour la fabrication d'un modèle à la cire d'aube de turbine

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US20120031579A1 true US20120031579A1 (en) 2012-02-09

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US (1) US20120031579A1 (fr)
EP (2) EP2241391A1 (fr)
WO (1) WO2010118960A1 (fr)

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EP2623252A1 (fr) * 2012-02-06 2013-08-07 Siemens Aktiengesellschaft Procédé de liaison interposée de deux composants utilisant des formes en vu de manipuler les composants
CN117000947B (zh) * 2023-09-21 2026-02-17 河北钢研德凯科技有限公司 涡轮转子蜡模拼接工装

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GB2326363A (en) * 1997-06-20 1998-12-23 Mtu Muenchen Gmbh Casting using a wax model produced with an auxiliary casting die

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DE3926479A1 (de) 1989-08-10 1991-02-14 Siemens Ag Rheniumhaltige schutzbeschichtung, mit grosser korrosions- und/oder oxidationsbestaendigkeit
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WO1999067435A1 (fr) 1998-06-23 1999-12-29 Siemens Aktiengesellschaft Alliage a solidification directionnelle a resistance transversale a la rupture amelioree
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GB2326363A (en) * 1997-06-20 1998-12-23 Mtu Muenchen Gmbh Casting using a wax model produced with an auxiliary casting die

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EP2419229A1 (fr) 2012-02-22
WO2010118960A1 (fr) 2010-10-21
EP2241391A1 (fr) 2010-10-20

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