WO2012173512A1 - Procédé de fabrication d'une ailette de ventilateur creuse. - Google Patents

Procédé de fabrication d'une ailette de ventilateur creuse. Download PDF

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Publication number
WO2012173512A1
WO2012173512A1 PCT/RU2011/000984 RU2011000984W WO2012173512A1 WO 2012173512 A1 WO2012173512 A1 WO 2012173512A1 RU 2011000984 W RU2011000984 W RU 2011000984W WO 2012173512 A1 WO2012173512 A1 WO 2012173512A1
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WO
WIPO (PCT)
Prior art keywords
blanks
blank
aggregate
blade
skin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/RU2011/000984
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English (en)
Russian (ru)
Inventor
Радик Рафикович МУЛЮКОВ
Александр Александрович ИНОЗЕМЦЕВ
Ринат Владикович САФИУЛЛИН
Сергей Александрович ХАРИН
Александр Николаевич КОЗЛОВ
Николай Леонидович КОКШАРОВ
Владимир Алексеевич КРОПОТОВ
Алексей Анатольевич КРУГЛОВ
Игорь Васильевич ЛЕВИН
Ирек Усманович МАНАПОВ
Михаил Александрович МОРОЗОВ
Сергей Петрович ПАВЛИНИЧ
Сергей Илларионович ПЕРЕПЕЛИЦА
Вадим Геннадьевич ТРИФОНОВ
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AVIADVIGATEL OPEN JOINT STOCK Co
INSTITUTE FOR METALS SUPERPLASTICITY PROBLEMS OF RUSSIAN ACADEMY OF SCIENCES (IMSP RAS)
UFA ENGINE INDUSTRIAL ASSOCIATION OJSC
VSMPO Avisma Corp PSC
Original Assignee
AVIADVIGATEL OPEN JOINT STOCK Co
INSTITUTE FOR METALS SUPERPLASTICITY PROBLEMS OF RUSSIAN ACADEMY OF SCIENCES (IMSP RAS)
UFA ENGINE INDUSTRIAL ASSOCIATION OJSC
VSMPO Avisma Corp PSC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AVIADVIGATEL OPEN JOINT STOCK Co, INSTITUTE FOR METALS SUPERPLASTICITY PROBLEMS OF RUSSIAN ACADEMY OF SCIENCES (IMSP RAS), UFA ENGINE INDUSTRIAL ASSOCIATION OJSC, VSMPO Avisma Corp PSC filed Critical AVIADVIGATEL OPEN JOINT STOCK Co
Publication of WO2012173512A1 publication Critical patent/WO2012173512A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
    • B23K20/023—Thermo-compression bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/78—Making other particular articles propeller blades; turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/18—Zonal welding by interposing weld-preventing substances between zones not to be welded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
    • B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
    • 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
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/001—Turbines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/14—Titanium or alloys thereof
    • 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
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
    • 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
    • F05D2230/50—Building or constructing in particular ways
    • F05D2230/54—Building or constructing in particular ways by sheet metal manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Definitions

  • the invention relates to the field of metal forming, more specifically, to methods for manufacturing a hollow fan blade of a gas turbine engine (GTE), consisting of casing and aggregate made of a titanium alloy.
  • GTE gas turbine engine
  • the method involves the use of diffusion welding to connect the skin and aggregate and superplastic molding to form a hollow pen and stiffeners.
  • the inventive method can find application in aircraft engine manufacturing.
  • the inventive method can be successfully used for the manufacture of a hollow blade of a high-speed axial fan having a complex aerodynamic profile, an idea of which is given by the description given in [1].
  • the profiles of the cross sections of the scapula are located along its height in such a way that the centers of gravity of the profiles in the meridional plane are on a curved line that has a forward extension in the peripheral part and a bulge in the middle part.
  • the leading edge of the blade has a reverse sweep in the peripheral part and balancing its bulge in the middle part of the leading edge of the blade, eliminating the appearance of bending-twisting flutter at the calculated rotational speed of the impeller.
  • the shape of the curve of the position of the centers of gravity of the profiles of the cross sections of the scapula in the meridional plane is determined by the cubic polynomial:
  • C] is a constant for a member of the third degree and is in the range equal to -2.08 -1, 78;
  • C 2 is a constant for a term of the second degree and is in the range equal to 2.95 + 3.05;
  • Sz is a constant for a term of the second degree and is in the range equal to - 1, 2 K -1, 1 1;
  • g W - radius of the sleeve of the working blades;
  • g lane is the radius of the periphery of the working blades;
  • g CT - the radius of the center of gravity of the profile of the current flat section of the working blades;
  • X ct is the coordinate of the center of gravity of the current profile of the flat section of the scapula;
  • X W is the coordinate of the center of gravity of the sleeve profile of the working blade, and the aerodynamic profile of the cross section of the working blade is formed by a rarefaction line and a pressure line covering the middle line of the
  • the rarefaction line of one blade and the pressure line of the adjacent blade form the flow path of the interscapular channel, which ensures smooth braking of the supersonic flow in the system of weak oblique shock waves with the formation of a closing shock wave in the output part of the interscapular channel.
  • pressure loss during braking of the supersonic flow is reduced, the efficiency of the fan and the margin of its gas-dynamic stability are increased.
  • the line of rarefaction and the line of pressure lie on the surfaces, called, respectively, the back and trough of the scapula.
  • the blade in question has a number of undeniable advantages regarding aerodynamic performance. But when trying to manufacture a hollow blade with such a complex aerodynamic profile, problems arise that are discussed in detail below, which can be solved using the present invention.
  • an object of the present invention is a method for manufacturing a hollow fan blade having a complex aerodynamic profile, characterized by relations of type (1) and (2). Further, for brevity, we will call such a blade an improved hollow blade.
  • Another object of the invention is a method for manufacturing a hollow blade, including an improved hollow blade, using a filler blank with a QMS or NK structure.
  • One of the main technological operations in the manufacture of a hollow blade is diffusion welding.
  • the blanks of the casing are connected to the pre-shaped part intended for fastening the blades on the disk of the impeller, in particular in the form of a lock, and a sheet blank of the filler.
  • the blanks are connected in strictly defined areas so that during molding a given configuration of stiffeners is obtained.
  • a protective coating is applied to other sections of the workpieces, which prevents the connection of the workpieces during diffusion welding.
  • Another main operation of the method for manufacturing a hollow blade is superplastic molding, as a result of which stiffening ribs and the final profile of the hollow feather of the blade are formed. Equally important is the under conditions of hot plastic deformation, the operation of giving the blanks an aerodynamic profile, including the formation of the back and trough of the blade and the twist of the feather blade [4, 5, 6].
  • a method of manufacturing a hollow fan blade of a gas turbine engine [4] includes the following operations:
  • the combination of these operations entails the complexity of the method, in particular the application of a protective coating on the curved surfaces of the blanks of the skin, despite the presence of grooves, is a rather time-consuming operation.
  • the time-consuming is also the mechanical processing of the curved surfaces of the blanks of the skin to form grooves and protrusions on them.
  • a method of manufacturing a hollow fan blade [5] allows to a certain extent to eliminate the disadvantages inherent in the method [4], since in the method [5] the aerodynamic profile is already attached to a solid structural workpiece.
  • the method [5] includes the following basic operations: machining by cutting blanks of cladding with a pre-formed lock and a feather, in which sections to be joined are formed on their flat surface in the form of protrusions with a surface that is flat in cross section and sections not subjected to connection, in the form of grooves, while at least a part of the surface of the grooves opposite the protrusions in the bag assembled for diffusion welding is performed in a flat cross section;
  • a known method of manufacturing a hollow product [6], at least two workpieces, while at least one of the workpieces must be made of metal or alloy having the ability to superplastic deformation also involves the use of diffusion welding to connect the workpieces and superplastic forming to form stiffeners.
  • the blanks of two skins and a filler are made of a titanium alloy.
  • a protective coating is applied to the surface of sections of the skin blanks and / or aggregate blanks that are not subjected to bonding during diffusion welding. Collect the blanks of skin and aggregate in a bag, seal the bag at the edges, excluding the installation location of at least one tube, then connect the tube to obtain a sealed bag.
  • the cavity of the package is successively evacuated and filled with an inert gas to remove oxygen from them.
  • the binder of the protective coating is removed (evaporated) from its cavities by continuously evacuating the cavities of the packet.
  • the whole structural workpiece obtained after welding is given an aerodynamic profile, including the formation of a trough and a back of a blade and twisting of a feather of a blade by means of hot deformation.
  • a working medium is fed into its cavity for the operation of breaking the adhesive bond between the preforms of the skin and the filler and the protective coating, which is formed during diffusion welding in areas that are not subjected to connection, by creating a pressure in the cavity sufficient for elastic deformation of the preforms .
  • the whole structural billet is heated and a working medium is fed into its cavity to create the pressure necessary for superplastic molding to obtain a hollow feather of the blade and the formation of stiffeners.
  • the blanks are also successively evacuated and filled with an inert gas to remove oxygen from them.
  • the sequential evacuation and filling with inert gas of the cavities of the package or of the integral structural preform is intended for their purification from oxygen.
  • Inert gas is filled in the cavities of the bag and the integral structural blanks under pressure, which reaches atmospheric pressure.
  • At least one tube mounted on the edge of the bag is used to perform evacuation and supply of inert gas in the cavity of the bag and the integral structural blank. More than one tube may be required. In particular, two tubes can be installed for each pair of adjacent surfaces of the workpieces to be joined. In addition, various tubes may be required to supply the inert gas used as the working medium in the cavity of the whole structural preform during superplastic molding or to break the adhesive bond between the preforms and the protective coating, as well as to clean the cavities. At the end of the manufacturing process of the blade, all tubes are dismantled, and the holes remaining after this are sealed.
  • diffusion welding is carried out under conditions when the surfaces of the skin blanks adjacent to the surface of the aggregate blank are flat over the entire area.
  • the absence of the need to perform protrusions on the surface of the blanks of the skin significantly increases the efficiency of the method [6].
  • diffusion welding can be freely carried out under isostatic pressure conditions, for which it is most expedient to use a gas thermostat, which also increases the efficiency of the method [6].
  • a special device can be used, which is presented in the description of the patent [7]. In some cases, it may be necessary to complete the spinning process with correcting the shape of the bent solid structural blank in accordance with the given shape of the stamp used in the superplastic molding process.
  • a stamp of a hot plastic deformation press which contacts a solid structural workpiece only in technological zones, that is, in those zones that will be removed in the future.
  • the final spinning step can be carried out using a die intended for superplastic forming.
  • the protective coating will be less fragile, so that the assembled package can be transferred to the gas thermostat without violating the integrity of the coating.
  • the initial uniformity of the thickness of the protective coating may be violated due to the possibility of movement of the coating particles.
  • the assembled package in the gas bath the assembled package can be placed in a vertical position.
  • the adhesion bond is broken in the prototype method under the influence of a fixed pressure of the working medium, argon, supplied to the internal cavities of the whole structural billet at room temperature after giving it an aerodynamic profile.
  • argon is carefully introduced from one end of the integral structural billet into those zones where there is a protective coating. Argon seeping through the protective coating reaches the opposite end of the solid structural billet. You can skip argon first between the blanks of one sheathing and aggregate, then he, having reached the opposite end of the integral structural blanks, will return to the input, passing between the blanks of another shelling and aggregate. This operation is performed at room temperature, since the deformation of the preforms taking place does not extend beyond the elastic region.
  • a fixed value of the argon pressure supplied to the internal cavities of the integral structural billet is also selected. Since the cladding preform in part undergoing an elastic deformation, have a variable thickness, decreasing from the lock to the periphery of the pen pressure value of m is selected taking into account the maximum thickness of the skin workpieces.
  • the skin blanks When using both argon transmission schemes, the skin blanks, elastically deformed, diverge to the sides relative to each other, being released from the adhesive bond with the protective coating. In this case, the thin filler blank is subjected to elastic bending and stretching. It should be noted here that the elastic deformation of the sections of the sheathing preform that forms the trough, where the convexity is opposite to the direction of the acting forces, turns out to be noticeably smaller in size than the deformation of the corresponding sections of the sheathing preform that forms the back of the scapula.
  • the stability of the marked sections of the sheathing blank forming the trough of the blade under the influence of argon pressure can be considered as the stability of a shallow shell under the influence of an external uniformly distributed load [8]. Due to the stability of the marked sections of the sheathing blank forming the trough of the scapula, the elastic deformation may not be sufficient to break the adhesive bond, and there is a need to increase argon pressure. Under such conditions, it is more expedient to use the second scheme for passing argon through the cavities of the whole structural billet, which makes it possible to more objectively judge how fully the fracture process goes and to more accurately determine the amount by which it is necessary to increase the argon pressure.
  • the first section characterized by small degrees of deformation (relative deformation up to 10%), reflects an increase in the density of dislocations and the formation of the substructure necessary for further deformation.
  • the third section characterized by degrees of deformation of more than 50%, corresponds to stabilization of the structure.
  • the transitional second section is characterized by voltage fluctuations [15].
  • the protective coating may include powder yttrium distributed in the binder and solvent. After removing the binder, as already noted, the particles of the protective coating can move even before diffusion welding, which is prevented by careful handling of the package of blanks.
  • the particles of the protective coating moving along the surface of areas that are not subjected to diffusion welding, can group and form local clusters, which is not greatly facilitated by the location of the workpiece during the gap.
  • the whole structural workpiece is positioned vertically when the adhesive bond is broken, this is the most unfavorable case, such accumulations of particles of the protective coating become inevitable.
  • accumulations of particles of harder yttrium will be introduced into plastic preforms, primarily into the aggregate preform.
  • a sharp local thinning of the aggregate blank and accordingly stiffeners will develop in this place, which can lead to its rupture, that is, to the violation of the structural integrity of the finished product noted in the description of the prototype method.
  • the powder of the protective coating is somewhat compacted and is sandwiched between the blanks of the skin and the aggregate, which makes the conditions for the swirling favorable.
  • the subsequent breakdown of the adhesive bond due to the fact that the protective coating is on surfaces that already have an aerodynamic profile, some movement of its particles occurs, despite the careful introduction of argon into the cavity of the whole structural blank. But this displacement, due to its insignificance, which is due to the rather simple shape of the feather of the scapula, in the prototype method turns out to be uncritical in the subsequent superplastic molding, accompanied by the disclosure of the cavities of the integral structural blanks.
  • the particles of the protective coating due to the presence of pronounced kink of the pen at any location of the whole structural workpiece and, despite the careful introduction of argon in its cavity, are actively moving, falling asleep, into the corresponding sections, like in a bowl blanks of skin and aggregate. Having coalesced in this way, the particles of the protective coating form a large accumulation in volume, which, after relieving the argon pressure necessary to break the adhesive bond, bulges the skin and aggregate blanks in the elastic region. Such buckling in the elastic region before the superplastic forming operation is now becoming very critical, especially for the filler blank.
  • the objective of the invention is to expand the technological capabilities of the method of manufacturing a hollow fan blade, which allows to produce both a blade having a fairly simple aerodynamic profile, and an improved blade characterized by a complex aerodynamic profile.
  • the objective of the invention is also to improve the quality of the hollow blade by using at least a filler blank with a submicrocrystalline or nanocrystalline structure.
  • the problem is solved in the case when the method of manufacturing a hollow fan blade of a gas turbine engine, consisting of casing made of titanium alloy and a filler, using diffusion welding to connect the casing and filler and superplastic molding to form a hollow pen and stiffeners, according to which the surface sections of skin blanks and / or aggregate blanks not subjected to diffusion welding are coated with a protective coating that impedes bonding collect the blanks of skin and aggregate into a bag, seal the bag at the edges, excluding the installation site of at least one tube, connect the tube to the bag, the cavity of the bag is successively evacuated and filled with an inert gas to remove from the cavities of the oxygen packet, the packet is heated to remove the binder of the protective coating, the packet is heated and diffusion welding of the workpieces is carried out, the aerodynamic profile, including the formation of the trough and back of the blade and the spinning of the blade feather by hot deformation, is applied to the whole structural workpiece obtained after diffusion welding, the operation of breaking the adhesive bond between the blanks of the
  • the task is also solved in the following cases when: - sequential evacuation and filling with inert gas the cavities of the whole structural billet to remove oxygen from them before the operation of giving the integral structural billet an aerodynamic profile is carried out repeatedly;
  • - diffusion welding is carried out in two stages, while at the first stage pressure is applied at a temperature below the temperature of the second stage, close to the lower boundary of the temperature range, providing a deformation rate corresponding to the conditions of superplasticity of the aggregate preform, for a time sufficient to form a physical contact between the joined preforms lining and aggregate, and the second stage is carried out at a temperature and for the time necessary for development between the connected workpieces about lazy interaction;
  • the first stage of diffusion welding is carried out at a temperature of 650 ... 700 ° C for 30 minutes
  • the second stage of diffusion welding is carried out at a temperature of 900 ... 950 ° C for 2 hours;
  • the sections to be bonded are formed in the form of protrusions, the flat surface of which is adjacent to the surface of the filler blank, and the sections not to be bonded in the form of grooves, in addition, when removing the binder of the protective coating, the package of blanks is placed in such a way so that the adjacent surfaces of the blanks of the skin and the filler are in the horizontal plane, maintaining this position of the package before and during diffusion welding; - pressure during diffusion welding is applied from the side of the skin forming the back of the blade;
  • the product obtained by this method is a hollow fan blade.
  • the combination of the above essential features of the invention provides a solution to the problem and obtain a technical result, which consists in expanding the technological capabilities of the method of manufacturing a hollow fan blade, which allows to produce both a blade having a fairly simple aerodynamic profile, and an improved blade characterized by a complex aerodynamic profile described by type relationships (12).
  • the method also allows the manufacture of a blade using at least a filler blank with a QMS or NK structure.
  • the methods of the proposed method can completely prevent the manifestation of physical effects, such as the Bausinger effect or the growth of shear stresses when bending a thin preform aggregate, as well as the movement and sprinkling of particles of the protective coating with the formation of clusters when the adhesive bond is broken.
  • the particles of the protective coating may move somewhat, however, after depressurization, they will again be distributed fairly evenly, without pronounced accumulations, on the surface of the sections of the workpieces that are not subject to bonding.
  • argon in the cavity of an integral structural blank When performing the operation of breaking the adhesive bond, argon in the cavity of an integral structural blank must be entered very carefully. The last condition is observed in the prototype method. It is possible, as in the prototype method, the use of two schemes for transmitting argon through the cavity of a solid structural billet. According to the first scheme, argon is simultaneously introduced into all areas where there is a protective coating. According to the second scheme, argon can be skipped first between the blanks of one sheathing and aggregate, and then between the blanks of another sheathing and aggregate.
  • the operation of breaking the adhesive bond is performed at room temperature, since the deformation of the preforms taking place does not extend beyond the elastic region. From the same considerations, the value of the fixed argon pressure supplied to the internal cavities of the integral structural billet is also selected. It should be noted that in the inventive method, the pressure value can be selected significantly less than in the prototype method, in view of the absence of a counter in relation to the direction of the existing efforts of the deflection of the workpieces, which is also a factor preventing the growth of shear stresses when bending a thin workpiece aggregate.
  • the protective coating is again sandwiched between the blanks of the skin and the aggregate.
  • the conditions for the operation of imparting a one-piece structural blank to the aerodynamic profile actually become the same as in the prototype method.
  • the protective coating particles are not able to move and crumble to areas where there is a pen bend, which eliminates the inhomogeneous deformation of the filler blank during the formation of stiffeners in the process of superplastic molding.
  • the indicated operations are also carried out before the operation of imparting an aerodynamic profile to the integral structural blank.
  • the latter circumstance lengthens the manufacturing cycle of the product, but it is necessary in order to prevent oxidation of the surfaces of the workpieces during their hot deformation, that is, in general, to solve the task set before the invention.
  • the cavities of the whole structural billet when filling with inert gas are no longer revealed, since the inert gas pressure does not exceed atmospheric pressure. Therefore, the particles of the protective coating are not able to move.
  • the methods of the proposed method due to preventing the manifestation of the Bausinger effect will allow the use of a filler blank with QMS and NK structure. This will significantly improve the quality of the connection obtained by diffusion welding, due to a significant difference in the yield strength of the skin and filler blanks.
  • diffusion welding be carried out in two stages. At the same time, at the first stage of welding, it is recommended to apply pressure at a temperature close to the lower boundary of the temperature range of the superplasticity of the filler preform, for a time sufficient to form physical contact between the joined surfaces of the casing and filler preforms.
  • the second stage is carried out at a temperature and for the time necessary for development when connecting volumetric interaction between the blanks of the skin and the aggregate.
  • the time of the second stage should be sufficient for the relaxation processes to occur in the workpieces and in the junction zone: recrystallization, equilibration of grain boundaries, formation of common grains in the junction zone, and removal of internal stresses [19].
  • the surfaces of the skin blanks mating with the surface of the core blank, as in the prototype method be flat over the entire area.
  • the package of blanks be positioned so that the surfaces of the protrusions are in a horizontal plane, maintaining this position of the bag before and during diffusion welding.
  • This technique is designed so as not to damage the protective coating before the operation of breaking the adhesive bond between the protective coating and the workpieces.
  • a finished product made by the claimed method can be any hollow fan blade even of a fairly simple shape, such as, for example, the blade shown in the description of the prototype method [6, FIG. one].
  • FIG. 1 is a schematic illustration of a package of preforms during assembly prior to diffusion welding
  • FIG. 2 shows a cross-section of a package of blanks in the case where protrusions and grooves are made on the surface of the blank of the skin;
  • FIG. 3 schematically shows the feather of a scapula after twisting it
  • FIG. 4 shows a cross section of a feather of a blade after performing an operation of superplastic molding and machining
  • FIG. 5 is a photo of a simulator of a hollow scapula with a cross section in cross section.
  • FIG. 1 shows an image of a package of preforms during assembly before the diffusion welding operation in the case when the surfaces of the preforms of the casing 1, 2 are adjacent to the surface of the preform of the filler 3 over the entire area, that is, the surfaces of the preforms of the casing 1, 2 are flat.
  • protrusions 4, 5 under the lock of the blade.
  • technological protrusions 6, 7 from the side opposite to the one where the protrusions 4, 5 for the paddle lock are formed.
  • Technological protrusions 6, 7 are intended for fixing an integral structural blank, obtained after diffusion welding, during bending to obtain the trough and back of the scapula and twist its feather.
  • Holes 8 for mounting pins 9, 10 are made in the blanks of the casing and the filler.
  • Grooves 1 1, 12 are made in the blanks of the casing in the part where the padlock will be locked. 12.
  • the slot 13 In the blank of the filler, also in the part where the paddle lock is made, the slot 13. Grooves and the slot serve to install the tube 14. Sections 15 of the surface of the blank of filler 3 and the corresponding surface sections (not shown in Fig. 1) of the blanks 1, as well as sections 16 of the surface of the blanks 2 and their corresponding surface areas (in Fig. 1 not shown) for otovki filler 3 to be joined by diffusion welding. A protective coating is applied to the sections 17, 18 of the surfaces of the blanks of the casing 2 and the aggregate 3 by means of silk-screen printing. The protective coating prevents the marked areas from joining during diffusion welding. The grooves 1 1, 12 and the slot 13 are made in such a way that they connect the areas that are not exposed to the connection on the surfaces of the blanks of both skins and aggregate.
  • FIG. 2 shows a cross-section of a package of blanks of casing 19, 20 and aggregate 21 in the case when adjacent to the surface of the workpiece of the aggregate are only the surfaces of the protrusions 22, 23 made on the surfaces of the cladding 19, 20.
  • a protective coating is applied to the grooves 24, 25. The rest of the package of blanks does not differ from the package of blanks shown in figure 1.
  • the initial blanks of cladding are taken, which are used as plates or sheets of sufficient thickness to form the castle part.
  • the initial blank for the aggregate is a thin sheet.
  • the initial blanks of the skin and the aggregate are subjected to machining in order to obtain a predefined shape in the meridional plane, in particular, determined by the cubic polynomial (1). Also, by machining, protrusions 4, 5 are obtained for locking the blades and technological protrusions 6, 7.
  • the surfaces of the blanks of the skin and the filler are prepared for diffusion welding by grinding and polishing. Immediately before welding, the surfaces to be welded are chemically cleaned.
  • a protective coating is applied to predetermined sections 17, 18 of the blanks.
  • the protective coating may include yttrium powder dispersed in the binder and a solvent.
  • the protective coating is applied by screen printing.
  • the blanks 1, 2, 3 are collected in a bag and fixed relative to each other using the mounting pins 9, 10.
  • the tube 14 is connected to the bag.
  • the tube 14 is installed so that the sections of all the blanks that are not subject to connection are interconnected.
  • the tube 14 is mounted so that it protrudes beyond the contour of the bag, since then a conduit (not shown in FIG. 1) will be connected to the protruding end of the tube to connect the tube 14 to either a vacuum pump or an inert gas supply system.
  • All three workpieces 1, 2, 3 at the edges are interconnected by argon arc welding.
  • the tube 14 is also fixed by means of argon-arc welding.
  • a sealed assembly unit is created with the exception of the inlet of the tube 14.
  • the cavities of the bag are evacuated.
  • an inert gas, argon is supplied into the cavity of the packet.
  • the bag cavities are again evacuated, then argon is again fed into the bag cavity.
  • Argon is served in the cavity of the package under pressure, reaching the level of atmospheric pressure. It is recommended to control the oxygen level in the argon removed during the vacuum process. Repeated sequential evacuation and supply of argon must be carried out until the complete removal of oxygen from the cavities of the package.
  • the specific number of evacuation and argon filling operations depends on the size of the product.
  • the package is installed in an oven, where it is heated to a temperature of 250 ... 350 ° C to evaporate the binder from the protective coating with continuous evacuation of the cavity of the package.
  • the bag is removed from the oven and cooled, continuing continuous evacuation. The presence of binder residues is detected by monitoring its level in the gas removed during evacuation.
  • the tube 14 is sealed. The bag is carefully transferred to a gas bath. Also, as in the prototype, it is possible to carry out the final removal of the binder and sealing the tube 14 when the package is already in the gas bath. In any case, the binder is removed at the temperature indicated above.
  • diffusion welding of the workpieces is carried out, choosing the necessary temperature and pressure.
  • the temperature can increase stepwise for the implementation of stepwise diffusion welding.
  • the obtained integral structural blank is set so that the adjacent surfaces of the skin and aggregate blanks are located strictly in the horizontal plane.
  • Argon is carefully introduced into the cavity of the integral structural preform to effect elastic deformation of the blanks of the skin and aggregate and to break the adhesive bond between the protective coating and the preforms.
  • the operation of breaking the adhesive bond is carried out at room temperature.
  • the cavities of the whole structural billet are evacuated and sealed.
  • its cavities are subjected to repeated successive evacuation and filling with argon to remove oxygen from them. After removing oxygen from the cavities of the integral structural preform, the cavities are evacuated and sealed.
  • the integral structural blank is installed in a device similar to that described in [7] and subjected to bending and twisting by means of hot deformation.
  • the shape of the bent solid structural billet is corrected in accordance with the given shape of the stamp used for superplastic molding.
  • a stamp directly intended for superplastic molding can be used.
  • the split halves of the stamp are in contact with the integral structural blank along the edge portion, which will then be removed. It is advisable to perform the operation of imparting an aerodynamic profile to a solid structural workpiece in an inert gas environment in order to avoid intensive oxidation of the external surfaces of the workpiece.
  • FIG. 3 shows a blade feather 26 having a complex aerodynamic profile in accordance with relation (2).
  • an integral structural preform is installed between the already mentioned split die halves having the desired shape.
  • the workpiece is heated and subjected to superplastic deformation. It is advisable to also carry out this operation in an inert gas environment in order to avoid intensive oxidation of the outer surface of the whole structural billet.
  • the deformation is carried out due to the argon pressure supplied to the cavity of the integral structural billet so as to ensure the strain rate in the superplastic range of the billet placeholder.
  • the blank of the skin they take the form of a working cavity of the stamp, and the blank of the filler forms inclined stiffeners.
  • two parabolas having an inflection point at the location of the maximum thickness of the profile are formed on the sheath blank forming the trough of the scapula [1].
  • FIG. 4 shows the cross section of the blade, where pos. 27, sheathing forming the back of the scapula is indicated; pos. 28, the casing forming the trough of the scapula is indicated. Pos. 29, said inflection point is indicated. Pos. 30 marked stiffeners.
  • the semifinished product of the blade is machined by cutting, in which the process zones are removed, the edges of the blade feather, the peripheral part of the feather and the blade lock are finally formed.
  • all tubes are dismantled, and the holes remaining after them are sealed.
  • the protrusions and grooves are formed by machining (Fig. 2).
  • the protective coating is applied in the grooves 24, 25, after which the blanks of the skin and aggregate are collected in a bag.
  • the package of blanks is positioned so that adjacent surfaces are in a horizontal plane, maintaining this position of the package before and during diffusion welding.
  • the pressure during welding is applied from the side of the sheathing blank forming the blade back.
  • the method is carried out in the same way as described above for the case when the surfaces of the skin blanks are flat over the entire area.
  • the hollow fan blade is made of titanium alloy.
  • the most common titanium alloy used for the manufacture of such products is in Russia and abroad alloy VT6 (Ti-6A1-4V). However, this does not exclude the use of other titanium alloys for manufacturing the blades.
  • As a working medium argon is usually used.
  • a hollow fan blade was made having a complex aerodynamic profile designed in accordance with its description presented in [1].
  • Plates with an average grain size of 6 ⁇ m were used as the initial blanks of the skin.
  • As the initial filler blank a sheet 1 mm thick with an average grain size of 2 ⁇ m was used. The surfaces of the sheathing and filler blanks were flat over the entire area.
  • the operation of imparting a structural blank to the aerodynamic profile was performed at a temperature of 800 ° C.
  • Superplastic molding was carried out at a temperature of 920 ° C, argon was supplied under pressure according to a special schedule, ensuring the rate of deformation of the aggregate preform in the superplasticity mode.
  • Example 2 According to the claimed method were made simulators of the blades having an aerodynamic profile close to the profile of the working blades. In the manufacture of several simulators used blanks of skin with flat surfaces. In the manufacture of several other simulators, protrusions and grooves were performed on the surfaces of the skin blanks.
  • Sheets with an average grain size of 6 ⁇ m were used as the initial blanks of the skin.
  • a sheet with a thickness of 0.8 mm with an average grain size of 0.6 ⁇ m was used as the initial filler blank. Diffusion welding was carried out in two stages:
  • the first stage was carried out at a temperature of 650 ... 700 ° C for 30 minutes
  • the second stage was carried out at a temperature of 900 ... 950 ° C for 2 hours.
  • Three simulators two of which were also manufactured by the claimed method (one with protrusions on the surface of the skin blanks, the other with a flat surface of the skin blanks) and one - according to the prototype method, were subjected to destructive testing after the superplastic molding operation.
  • FIG. 5 is a photo of a simulator of a hollow shoulder blade with a cross section in cross section

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • General Engineering & Computer Science (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

L'invention concerne la fabrication d'une ailette creuse d'un ventilateur pour moteur à turbine à gaz. On applique à la surface des régions des ébauches non soumises au soudage un revêtement empêchant la liaison. On assemble les ébauches en un bloc et on le étanchéifie sur les bords. Les cavités du bloc sous soumis au vide et remplies de gaz inerte. On enlève par réchauffement la substance de liaison. On effectue le soudage par diffusion des ébauches. L'ébauche est disposée de manière à ce que les surfaces adjacentes des ébauches des revêtements et de la charge se trouvent dans un plan horizontal et on coupe les liaisons d'adhérence entre les ébauches et le revêtement dans les zones non connectées de manière à générer dans les cavités de l'ébauche une pression nécessaire à la déformation élastique des ébauches des revêtements et de la charge. On effectue une mise sous vide en plusieurs étapes et le remplissage avec un gaz inerte des cavités de l'ébauche pour en évacuer l'oxygène, une étachéification s'effectuant après la mise sous vide. La déformation à chaud de l'ébauche permet de former un auget, un dos d'ailette et une lame d'ailette. On chauffe l'ébauche et on remplit les cavités avec un fluide de travail de manière à assurer le formage ultraplastique et obtenir un lame d'ailette creuse et des nervures de rigidité. L'invention permet d'élargir les capacités techniques en termes de fabrication de l'ailette de ventilateur creuse.
PCT/RU2011/000984 2011-06-15 2011-12-14 Procédé de fabrication d'une ailette de ventilateur creuse. Ceased WO2012173512A1 (fr)

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RU2011124220/02A RU2477191C2 (ru) 2011-06-15 2011-06-15 Способ изготовления полой вентиляторной лопатки

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CN105980082A (zh) * 2013-12-12 2016-09-28 俄罗斯科学院金属超塑性课题研究所 制造中空风扇叶片的方法
CN111763809A (zh) * 2020-06-10 2020-10-13 中国航发北京航空材料研究院 一种空心叶片内腔禁喷区的保护装置及装配方法
CN113290086A (zh) * 2021-04-27 2021-08-24 南京航空航天大学 一种空心叶片电辅助分区拉扭成形装置及成形方法
CN113751570A (zh) * 2021-09-15 2021-12-07 北京航星机器制造有限公司 一种钛合金四层结构成形模具、模具组件及制备方法
CN113857346A (zh) * 2021-09-26 2021-12-31 北京航空航天大学 一种空心叶片热成型方法及空心叶片充气装置
CN114289594A (zh) * 2021-12-21 2022-04-08 北京星航机电装备有限公司 一种具有夹层的结构部件的超塑成形方法
US20220388090A1 (en) * 2021-06-04 2022-12-08 The Boeing Company Fabrication of thick stock via diffusion bonding of titanium alloys
CN115608838A (zh) * 2022-12-19 2023-01-17 天津伍玥航空科技有限公司 一种多通管件的成形工艺
CN116000195A (zh) * 2023-01-12 2023-04-25 上海交通大学 叶片前缘钛合金加强边热蠕变与扩散连接复合制造方法
CN116586524A (zh) * 2023-05-29 2023-08-15 哈尔滨工业大学 一种能实现模具自锁的超塑扩散连接方法
CN117548528A (zh) * 2023-11-15 2024-02-13 中国航发沈阳黎明航空发动机有限责任公司 一种导向叶片排气边局部感应加热校形修理的方法
CN119456793A (zh) * 2024-11-15 2025-02-18 哈尔滨工业大学 一种型面预分散超塑成形/扩散连接方法

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RU2569614C1 (ru) * 2014-07-08 2015-11-27 Аскар Джамилевич Мингажев Способ изготовления полой металлической лопатки турбомашины
WO2017086822A1 (fr) * 2015-11-17 2017-05-26 Аскар Джамилевич МИНГАЖЕВ Procédé de fabrication d'une ailette creuse de turbomachine

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EP1459818B1 (fr) * 2003-03-21 2006-08-16 Snecma Ensemble permettant la fabrication d'une pièce mécanique creuse par soudage-diffusion et formage superplastique, utilisation d'un tel ensemble et procédé de fabrication d'une telle pièce mécanique
EP2223767A1 (fr) * 2009-02-27 2010-09-01 Rolls-Royce plc Procédé de fabrication d'une aube

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EP3081319A4 (fr) * 2013-12-12 2017-08-23 Institute For Metals Superplasticity Problems Of The Russian Academy Of Sciences Procédé de fabrication de pale de ventilateur creuse
CN105980082A (zh) * 2013-12-12 2016-09-28 俄罗斯科学院金属超塑性课题研究所 制造中空风扇叶片的方法
CN111763809B (zh) * 2020-06-10 2021-10-15 中国航发北京航空材料研究院 一种空心叶片内腔禁喷区的保护装置及装配方法
CN111763809A (zh) * 2020-06-10 2020-10-13 中国航发北京航空材料研究院 一种空心叶片内腔禁喷区的保护装置及装配方法
CN113290086B (zh) * 2021-04-27 2022-06-17 南京航空航天大学 一种空心叶片电辅助分区拉扭成形装置及成形方法
CN113290086A (zh) * 2021-04-27 2021-08-24 南京航空航天大学 一种空心叶片电辅助分区拉扭成形装置及成形方法
US20220388090A1 (en) * 2021-06-04 2022-12-08 The Boeing Company Fabrication of thick stock via diffusion bonding of titanium alloys
CN113751570B (zh) * 2021-09-15 2022-09-02 北京航星机器制造有限公司 一种钛合金四层结构成形模具、模具组件及制备方法
CN113751570A (zh) * 2021-09-15 2021-12-07 北京航星机器制造有限公司 一种钛合金四层结构成形模具、模具组件及制备方法
CN113857346B (zh) * 2021-09-26 2024-01-09 北京航空航天大学 一种空心叶片热成型方法及空心叶片充气装置
CN113857346A (zh) * 2021-09-26 2021-12-31 北京航空航天大学 一种空心叶片热成型方法及空心叶片充气装置
CN114289594A (zh) * 2021-12-21 2022-04-08 北京星航机电装备有限公司 一种具有夹层的结构部件的超塑成形方法
CN114289594B (zh) * 2021-12-21 2024-04-19 北京星航机电装备有限公司 一种具有夹层的结构部件的超塑成形方法
CN115608838A (zh) * 2022-12-19 2023-01-17 天津伍玥航空科技有限公司 一种多通管件的成形工艺
CN116000195A (zh) * 2023-01-12 2023-04-25 上海交通大学 叶片前缘钛合金加强边热蠕变与扩散连接复合制造方法
CN116586524A (zh) * 2023-05-29 2023-08-15 哈尔滨工业大学 一种能实现模具自锁的超塑扩散连接方法
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CN119456793A (zh) * 2024-11-15 2025-02-18 哈尔滨工业大学 一种型面预分散超塑成形/扩散连接方法

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