WO2019046036A1 - Procédé pour réaliser un profil aérodynamique de turbine - Google Patents

Procédé pour réaliser un profil aérodynamique de turbine Download PDF

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Publication number
WO2019046036A1
WO2019046036A1 PCT/US2018/047191 US2018047191W WO2019046036A1 WO 2019046036 A1 WO2019046036 A1 WO 2019046036A1 US 2018047191 W US2018047191 W US 2018047191W WO 2019046036 A1 WO2019046036 A1 WO 2019046036A1
Authority
WO
WIPO (PCT)
Prior art keywords
airfoil
core
trailing edge
extended portion
along
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/US2018/047191
Other languages
English (en)
Inventor
Scott Michael Widrig
Michael Stemmler
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.)
Siemens AG
Siemens Corp
Siemens Energy Inc
Original Assignee
Siemens AG
Siemens Corp
Siemens Energy Inc
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 Siemens AG, Siemens Corp, Siemens Energy Inc filed Critical Siemens AG
Priority to US16/642,100 priority Critical patent/US20200208530A1/en
Publication of WO2019046036A1 publication Critical patent/WO2019046036A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

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
    • F01D5/187—Convection cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • 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
    • F05D2230/21—Manufacture essentially without removing material by casting
    • F05D2230/211—Manufacture essentially without removing material by casting by precision casting, e.g. microfusing or investment casting

Definitions

  • the present invention relates to turbine blades for a gas turbine and, more particularly, to a three dimensional (3D) curved trailing edge core float.
  • Effective cooling of turbine airfoils requires delivering the relatively cool air to critical regions such as along a trailing edge of a turbine blade or a stationary vane.
  • Associated cooling apertures may, for example, extend between an upstream, relatively high pressure cavity within the airfoil and one of the exterior surfaces of the turbine blade.
  • Blade cavities typically extend in a radial direction with respect to the rotor and stator of the machine,
  • Airfoils also commonly include internal cooling channels which remove heat from the pressure sidewall arid the suction sidewall in order to minimize thermal stresses. Achieving a high cooling efficiency based on the rate of heat transfer is a significant design consideration in order to minimize the volume of coolant air diverted from the compressor for cooling.
  • the relatively narrow trailing edge portion of a gas turbine airfoil may include, for example, up to about one third of the total airfoil external surface area.
  • the trailing edge is made relatively thin with high detail for aerodynamic efficiency. Consequently, manufacturing of the airfoil and especially the trailing edge area are of great concern.
  • a method for making a turbine airfoil comprises; generating a mold shell; generating an airfoil core comprising a pressure side and suction side that are connected by a trailing edge and a leading edge, a radially outward tip end and a radially inward root end, and a core exit along an extended portion of the trailing edge outside of the airfoil part geometry; and positioning float points along the extended portion of the airfoil core, wherein each float point includes a float feature that includes a localized radially straight surface extending out and creating a gap between the airfoil core and the mold shell.
  • a method for making a turbine airfoil comprises: generating a mold shell; generating an airfoil core comprising a pressure side and suction side that are connected by the trailing edge and a leading edge, a radially outward tip end and a radially inward root end, and a core exit along an extended portion of the trailing edge outside of the airfoil part geometry; positioning float points along the extended portion of the airfoil core, wherein each float point includes a float feature that includes localized radially straight surface extending out and creating a gap between the airfoil core and the mold shell; introducing molten metal alloy into the gap and surrounding the floats points; solidifying the alloy to form an airfoil casting having a plurality of float point openings at the extended portion location; removing the mold shell so as to expose the airfoil; and sealing the plurality of float point openings in the airfoil.
  • FIG 1 is a trailing edge view of a blade core and mold shell of a conventional technique
  • FIG 2 is a trailing edge view of a curved airfoil blade core and mold shell of the conventional technique
  • FIG 3 is a trailing edge view of an airfoil blade core and mold shell of the exemplary embodiment of the present invention.
  • FIG 4 is a perspective trailing edge view of the airfoil blade core
  • FIG 5 is a side view of a portion of a core including a core printout
  • FIG 6 is a side view of a portion of an airfoil prior to completion of manufacturing.
  • a method of making a turbine airfoil comprising generating an airfoil core includes a core exit along an extended portion of the trailing edge outside of the airfoil part geometry.
  • Float points are positioned along the extended portion of the airfoil core.
  • Each float point includes a float feature that includes a localized radially straight surface extending out and creating a gap between the airfoil core (14) and the mold shell.
  • gas turbine engines are required to provide movement to produce electricity in a generator.
  • compressed air discharged from a compressor section and fuel introduced from a source of fuel are mixed together and burned in a combustion section, creating combustion products defining a high temperature working gas.
  • the working gas is directed through a hot gas path in a turbine section of the engine, where the working gas expands to provide rotation of a turbine rotor.
  • the turbine rotor may be linked to an electric generator, wherein the rotation of the turbine rotor can be used to produce electricity in the generator,
  • Modem engines and certain components such as airfoils, e.g. stationary vanes and rotating blades within the turbine section, implement high pressure ratios and high engine firing temperatures. As advancements are made, components are seeing higher and higher temperatures and require more and more expensive materials to produce these components.
  • Embodiments of the present invention provide a method of manufacturing that may allow for the reduction of cost in manufacturing a master tooling assembly as well as the master tooling assembly itself.
  • the turbine blade and airfoil are used below as an example of the method and tooling assembly; however, the method and tooling assembly may be used for any component requiring detailed features along a core for casting purposes.
  • the turbine blade can be within the power generation industry.
  • materials of construction can be specifically selected to work in cooperation with the casting and firing processes to provide a core that overcomes known problems with prior art cores.
  • the materials and processes of embodiments of the present invention may result in a ceramic body which is suitable for use in a conventional metal alloy casting process.
  • the investment casting of the blade or vane includes an initial wax pattern.
  • the wax pattern is then coated with the ceramic material. Once the ceramic material is hardened, the internal geometry takes the shape of the casting.
  • the wax is then melted out and molten metal, or similar material, is poured into the cavity where the wax pattern was located. The metal solidifies within the ceramic mold and then the metal casting is broken out.
  • the hardened metal becomes the part such as a blade or vane, or a portion of either.
  • the process can be used to form a plurality of trailing edge passages along the airfoil, for example.
  • Several wax patterns can be combined for a single casting or connecting multiple wax patterns and poured together producing many castings in a single process.
  • pre-formed ceramics can be used instead of the soluble wax cores.
  • the core For a core to be cast for any extended length of time, the core needs to be supported at points along the core.
  • the core is extended in length to provide an area outside of the detailed portion of the part for the location of these supports. This extended area of the core is called the core printout, or tie bar.
  • These supports, or floats ensure the core stays in the correct position within the casting and also facilitates the removal of the ceramic from the part after it has been cast.
  • the floats are typically approximately 0.1 mm in thickness and extend out from the core printout.
  • the overall core can typically be fixed in at one end, such as a root end or tip end.
  • FIG. 5 shows the location of an extended portion 28 along a trailing edge 32 of an airfoil core 14.
  • the floats 12 can be tie bars that are placed along the trailing edge extended portion 28 of the airfoil core 14.
  • the tie bars can run through this trailing edge extended portion 28 so that there is no distortion of the actual airfoil core 14.
  • Possible tie bar locations are pointed out in FIG. 5. These locations can have the tie bars extend out from the page.
  • the direction X denotes an axial direction parallel to an axis of the turbine engine which the airfoil will be a part of eventually, while the direction R denotes a radial direction with respect to said axis of the turbine engine.
  • a master tooling assembly 10 may be put together in order to create a blade or vane.
  • the master tooling assembly 10 provides a mold shell 16.
  • a ceramic core 14, or a core 34 of similar material, is placed within the mold shell 16 for a period of tirae.
  • the core 34 provides the details for the eventual blade or vane by being a negative of the blade or vane.
  • the core 14 can provide advanced details along a trailing edge of an airfoil blade or vane.
  • the gap 18 is maintained through the use of floats 12.
  • FIG. 1 illustrates the change in geometry when there is a radial expansion.
  • the core 14 has an original pre expansion location 24. Expansion occurs and then there is the post expansion location 26 of the core that extends radially outward.
  • the gap 18, or distance between the core 14 and mold shell 16 can remain relative! ⁇ ' the same along the axial direction X.
  • the core i 4 needs to be able to float relative to the moid shell 16 only enough to prevent excess wall thickness variation without causing contact between the core and the mold shell 16 that causes cores to crack.
  • the conventional tooling assembly 10 works appropriately to hold the core 14 in place without causing contact between the core 14 and the mold shell 16.
  • a plurality of float points 12 resides along axial sides of the core 14 to help keep the core 14 in place or checked. These floats 12 are shown as a set of triangles in the FIGS and are positioned radially along each axial side of the core 14. With straight airfoil core 14 there is only a radial expansion that is a concern, assuming no torsion. Contact between the core 14 and mold shell 16 causes cores 14 to crack, so the goal is to keep a separation between the mold shell 16 and core 14 in order to allow the core 14 to grow freely due to expansion. Without the floats 12, there would likely be thickness variations along the core 14 which again can cause breakage.
  • advanced detailed trailing edges are being designed to be produced.
  • One aspect of the advanced trailing edges is to have a curved aspect to the radial length, which causes issues with the manufacturing process shown in FIG. 1 .
  • FIG. 4 displays an airfoil core 14 with a curved trailing edge 32.
  • the airfoil core 14 includes a pressure side 38 and suction side 40 that are connected by the trailing edge 32 and a leading edge 30.
  • the airfoil core 14 includes a radially outward tip end 22 and a radially inward root end 20.
  • FIG. 2 The same conventional technique in FIG. I is shown in FIG. 2 with the curved airfoil core 14. Having a curved airfoil core 14 provides an additional issue of axial expansion as shown since the airfoil core 14 has radial and axial features.
  • the core 14 expands in both the radial direction R, and in the axial direction X. Expanding in the axial direction X, the gap 1 8 between the core 14 and the moid shell 16 now become locked 36 in contact.
  • the expansion in the axial direction X removes the gap 18 between the float points 12 of the core 14 and mold shell 16.
  • the only way to help with this issue is to increase the gap 18 area between the core 14 and the mold shell 1 6. This increase in gap 18 length, however, only increases the variation in thickness along this trailing edge portion of the eventual blade or vane.
  • FIG. 3 illustrates an embodiment that includes a plurality of additional float features 34 located in the core 14 near the trailing edge 32 outside of the part geometry in the expanded portion 28.
  • a local radially parallel surface 42 is used in a tie bar of the trailing edge extended portion 28 of the core 14 that ties core exits together.
  • the gaps 1 8 are not impacted by the curved three-dimensional trailing edges with these float features 34 included.
  • the floats 12 are located along the radially flat surfaces 42 of the core 14 so there is no axial expansion effect at these localized places along the airfoil core 14.
  • the radially flat surfaces 42 can vary in radial length based on the geometry of the part and core exit being made.
  • each float 12 can be positioned only along one side in certain embodiments. Further, the shape of each float 12 can vary as well along the radially flat surface 42. FIG. 6 shows a circular shape while FIG. 3 suggests a square shape. As long as the localized radially flat surface 42 provides a surface for the axial expansion, the float feature 34 and the float points 12 allow for a reduction in variation in wall thickness while maintaining a proper distance between the core 14 and mold shell 16 in a master tooling.
  • the manufacturing of the airfoil includes the airfoil core 14 surrounded by the mold shell 16. Molten metal alloy or similar material is introduced into the gap 18 and surrounding the floats points 12. The alloy or similar material is solidified to form an airfoil casting having a plurality of float point openings 44 at the extended portion location. The mold shell is removed at this point to expose the airfoil 46. The float point openings in the airfoil are then sealed. FIG. 6 illustrates the float point openings 44.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un profil aérodynamique de turbine, lequel procédé comprend la génération d'une enveloppe de moule et la génération d'un noyau de profil aérodynamique (14) qui comprend une sortie de noyau le long d'une partie étendue du bord de fuite (32) à l'extérieur de la géométrie de partie de profil aérodynamique. Des points de flottement (12) sont positionnés le long de la partie étendue (28) du noyau de profil aérodynamique (14). Chaque point de flottement (12) comprend un élément de flottement (34) qui comprend une surface localisée radialement droite (42) s'étendant vers l'extérieur et créant un intervalle (18) entre le noyau de profil aérodynamique (14) et l'enveloppe de moule (16).
PCT/US2018/047191 2017-08-28 2018-08-21 Procédé pour réaliser un profil aérodynamique de turbine Ceased WO2019046036A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US16/642,100 US20200208530A1 (en) 2017-08-28 2018-08-21 Method for making a turbine airfoil

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201762550762P 2017-08-28 2017-08-28
US62/550,762 2017-08-28

Publications (1)

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WO2019046036A1 true WO2019046036A1 (fr) 2019-03-07

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN121061090A (zh) * 2025-11-04 2025-12-05 中国航发沈阳黎明航空发动机有限责任公司 一种双联导向叶片用悬浮双层壁型芯的旋转连接成型方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1923152A1 (fr) * 2006-11-14 2008-05-21 United Technologies Corporation Procédés de coulage de pale
US20090165988A1 (en) * 2007-12-31 2009-07-02 General Electric Company Turbine airfoil casting method
EP2191910A1 (fr) * 2008-11-21 2010-06-02 United Technologies Corporation Moulages, noyaux de moulage et procédés
US20130174998A1 (en) * 2010-10-19 2013-07-11 Snecma Injection mold for a wax model of a turbine blade having an isostatic core holder
EP2636466A1 (fr) * 2012-03-07 2013-09-11 Siemens Aktiengesellschaft Noyau de moulage d'un composant creux

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1923152A1 (fr) * 2006-11-14 2008-05-21 United Technologies Corporation Procédés de coulage de pale
US20090165988A1 (en) * 2007-12-31 2009-07-02 General Electric Company Turbine airfoil casting method
EP2191910A1 (fr) * 2008-11-21 2010-06-02 United Technologies Corporation Moulages, noyaux de moulage et procédés
US20130174998A1 (en) * 2010-10-19 2013-07-11 Snecma Injection mold for a wax model of a turbine blade having an isostatic core holder
EP2636466A1 (fr) * 2012-03-07 2013-09-11 Siemens Aktiengesellschaft Noyau de moulage d'un composant creux

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN121061090A (zh) * 2025-11-04 2025-12-05 中国航发沈阳黎明航空发动机有限责任公司 一种双联导向叶片用悬浮双层壁型芯的旋转连接成型方法

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