WO2020032964A1 - Fabrication additive par friction-malaxage et réparation de composants de turbine - Google Patents

Fabrication additive par friction-malaxage et réparation de composants de turbine Download PDF

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Publication number
WO2020032964A1
WO2020032964A1 PCT/US2018/046155 US2018046155W WO2020032964A1 WO 2020032964 A1 WO2020032964 A1 WO 2020032964A1 US 2018046155 W US2018046155 W US 2018046155W WO 2020032964 A1 WO2020032964 A1 WO 2020032964A1
Authority
WO
WIPO (PCT)
Prior art keywords
grain size
average grain
turbine blade
airfoil portion
alloy
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/US2018/046155
Other languages
English (en)
Inventor
Kazim Ozbaysal
Ahmed Kamel
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 Energy Inc
Original Assignee
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 Energy Inc filed Critical Siemens Energy Inc
Priority to PCT/US2018/046155 priority Critical patent/WO2020032964A1/fr
Publication of WO2020032964A1 publication Critical patent/WO2020032964A1/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
    • F01D5/005—Repairing methods or devices
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950°C
    • B23K35/284—Mg as the principal constituent
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/3033—Ni as the principal constituent
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/32—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550°C
    • B23K35/325—Ti as the principal constituent
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • 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
    • F05D2230/239—Inertia or friction 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
    • F05D2230/30—Manufacture with deposition of material
    • 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods
    • 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
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/609—Grain size

Definitions

  • the present disclosure is directed, in general, to additive manufacturing and more specifically to additive manufacturing or repair of turbine components in the solid state.
  • Additive manufacturing allows for the manufacture of a component by adding material rather than removing material from a raw material, a casting, or a forging.
  • a turbine blade airfoil portion having a total length and fixedly attached to a base includes a first portion extending from the base to a repair line such that the first portion has a first length that is shorter than the total length, the first portion having a microstructure with a first average grain size, and a second portion extending from the repair line and having a second length equal to the difference between the total length and the first length, the second portion having a microstructure with a second average grain size, wherein the second average grain size is smaller than the first average grain size.
  • a bladed disk in another construction, includes a disk portion formed from a first material and having a microstructure with a first average grain size, the disk portion having an annular shape that extends around a central axis, and a plurality of blades each extending from the disk portion substantially along a radial line with respect to the central axis, each blade including an airfoil portion formed from a second material and having a microstructure with a second average grain size, wherein the second average grain size is different than the first average grain size.
  • a turbine blade includes a platform formed from a first alloy material and a airfoil portion formed onto the platform in a plurality of layers each added in the solid state, the airfoil portion formed from a second alloy.
  • FIG. 1 is a perspective view of a turbine blade including damaged portions.
  • FIG. 2 is a perspective view of the turbine blade of Fig. 1 with the damaged portions removed to define a platform.
  • FIG. 3 is a perspective view of a portion of a disk portion of a bladed disk or blisk without a blade.
  • Fig. 4 is a perspective view of the disk portion of Fig. 3 with a blade added.
  • Fig. 5 is a schematic illustration of a friction stir additive manufacturing process (FSAM).
  • Fig. 6 is a schematic illustration of a layer deposition pattern that can be followed using the process of Fig. 5.
  • FSAM friction stir additive manufacturing process
  • Fig. 7 is an image of the microstructure between a cast first portion and a repaired portion formed using the friction stir additive manufacturing process (FSAM).
  • FSAM friction stir additive manufacturing process
  • Fig. 8 illustrates a turbine blade including directionally solidified grains illustrating a potential crack location.
  • Fig. 9 illustrates the grain structure in the cracked portion of the blade of Fig. 8 following a repair using the FSAM process.
  • Fig. 10 illustrates the microstructure between a forged disk portion of a blisk and a repaired airfoil portion formed using the FSAM process.
  • Fig. 11 illustrates the grain microstructure of a forged blisk showing the location of potential creep damage.
  • Fig. 12 illustrates the grain microstructure of a blisk having a forged disk portion and FSAM formed airfoils.
  • first, second, third and so forth may be used herein to refer to various elements, information, functions, or acts, these elements, information, functions, or acts should not be limited by these terms. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act could be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act could be termed a first element, information, function, or act, without departing from the scope of the present disclosure.
  • the term “adjacent to” may mean: that an element is relatively near to but not in contact with a further element; or that the element is in contact with the further portion, unless the context clearly indicates otherwise.
  • the phrase“based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Terms“about” or“substantially” or like terms are intended to cover variations in a value that are within normal industry manufacturing tolerances for that dimension. If no industry standard as available a variation of 20 percent would fall within the meaning of these terms unless otherwise stated.
  • Turbines gas and steam are often used in power generation applications as a prime mover that drives a generator.
  • the drive for higher efficiencies has led to the use of different materials and higher operating temperatures.
  • repair is often preferable to replacement from a cost standpoint.
  • Fig. 1 illustrates an example of a damaged turbine blade 10. Damage can occur due to many factors including fatigue, erosion, or impacts from foreign objects. While repairs using welding or other high temperature techniques are known, they are sometimes not applicable to the newer materials and they often result in a grain microstructure that is sometimes undesirable.
  • blade and“airfoil” used herein are meant to be broad terms that encompass other terms for the same or similar features on both rotating and stationary components.
  • rotating blades include an aerodynamic section often referred to as an airfoil section.
  • a similar feature on a stationary blade is often referred to as a vane or vane portion.
  • the components and methods described herein should not be limited by the terms used to describe the features.
  • Fig. 2 illustrates the first step in the repair process of the turbine blade 10 of Fig. 1.
  • the damaged portion is first removed to define a repair surface 15 or a platform. It is preferable that the repair surface 15 be planar and normal to a long axis 20 of the blade 10.
  • Fig. 5 illustrates an apparatus 25 for adding material to the repair surface 15 to rebuild the removed portion of the blade 10.
  • the repair surface 15 defines a substrate or platform onto which layers of material will be applied.
  • a consumable rod 30 is moved into engagement with the repair surface 15, an axial force 35 is applied along the rod, and the rod 30 is rotated 40 while also moving along a path 45 parallel to the repair surface 15.
  • the consumable rod 30 is made from a material or alloy that matches the blade material or the desired material of the airfoil portion of the blade 10. As the consumable rod 30 moves, it mixes with the material of the repair surface 30 in the solid state with some of the material from the consumable rod 30 is deposited on the repair surface 15.
  • powdered metal is placed between the consumable rod 30 and the repair surface 15 to enhance the quantity of material deposited. Because there is no material melting, the microstructure of the deposited material is in a form of the forged base metal of the airfoil portion. Powdered metal can be selected to chemically match the existing base material or could be selected to produce a desired alloy in the deposited material.
  • Fig. 5 The process illustrated in Fig. 5 is particularly useful with materials such as titanium and titanium alloys.
  • materials such as titanium and titanium alloys.
  • Ti6Al4V or TI6Al2Sn4Zr2Mo is used to repair the turbine blade 10.
  • nickel -based superalloys or other alloys are used as the rod 30 and the powder if employed.
  • nickel-based blades can be manufactured or repaired using a sintered consumable feed generated from the blade base material and a braze powder made of Ni-Cr-X alloy where X is either Ti, Zr, Hf, or some combination thereof.
  • Fig. 1 illustrates the turbine blade 10 with operational damage.
  • portions of the leading and trailing edges and the blade tip are damaged.
  • the first step in the process is to remove the damaged areas. Due to the axial force 35 required for the process described herein, a substantially planar surface 15 oriented in a way that will allow for the axial force 35 should first be established.
  • Fig. 2 illustrates the blade 10 of Fig. 1 with the damaged portions removed to define the repair surface 15 onto which repair material can be deposited.
  • the repair surface 15 is substantially normal to the long axis 20 of the turbine blade 10 such that the downward axial force 35 is directed along the same long axis 20.
  • the repair surface 15 is substantially normal to the axis 20 but could be angled with respect to the axis 20 if necessary.
  • a planar repair surface 15 is preferred, a slightly curved surface could be employed if desired.
  • the removed portion is then replaced using the additive process described with regard to Fig. 5.
  • the process adds material as illustrated in Fig. 6. Specifically, rows 50 are added in a side-by-side fashion as necessary to complete a layer 55. Subsequent layers 55 are then applied on top of the prior layers 55. Once the layers 55 are completed the repaired portion can be machined or otherwise finished to return the blade to a usable condition.
  • the damaged portions could be removed to define two or more separate planar (or slightly curved) surfaces that are obliquely angled with respect to the long axis 20 of the blade 10.
  • a fixture then supports the blade 10 with one of the planar surfaces in the desired orientation to allow for the addition of the necessary material. Once one of the surfaces is completed, the blade 10 is repositioned to allow material to be added to the other repair locations. The blade 10 is then machined or otherwise finished as required.
  • a repaired blade 10 that is repaired according to the aforementioned process is structurally different from the original blade. Often, blades 10 of this type are cast which produces a cast microstructure 11 with an average grain size of about 1 mm or more.
  • one cast blade includes a columnar grain structure with grains near 300 mm long and about 10 mm wide.
  • Investment casting typically produces grain sizes in the range of 1 -20 mm.
  • the repaired portion will be more similar to a forged component and will have a repaired microstructure 12 that has a smaller average grain size (e.g., 0.1 mm or less) than the original material.
  • Optimal poly crystalline grain size for blade applications is about 0.040 mm.
  • the smaller grain size illustrated in Fig. 7 provides superior fatigue life (e.g., high-cycle fatigue) when compared to the original material which can be of benefit during future operation.
  • the repaired portion includes a microstructure with an average grain size that is about 50 percent the average grain size of the base material.
  • the average grain size of the repaired microstructure is about 10 percent of the average grain size of the base material. In a more preferred construction, the average grain size of the repaired microstructure is about 1 percent of the average grain size of the base material. It should be understood that measuring an average grain size can be difficult.
  • the term“about” as used herein is meant to include the potential errors in this process and cover the tolerances as well as the normal deviation in such measurements when performed by different individuals or using different techniques.
  • Figs. 8 and 9 illustrate another blade 56 that includes a crack 57 formed as a result of high cycle fatigue.
  • the blade 56 is a directionally solidified blade having elongated grains 58 that extend the length of the blade 56. These grains 58 are still susceptible to high cycle fatigue in the transverse direction to elongated grains, particularly in the region where the airfoil extends from the platform as illustrated in Fig. 8.
  • the damaged material is removed, and new material is added using the FSAM process described above.
  • the newly added material includes a repaired
  • microstructure 12 having a polycrystalline small grain size as illustrated in Fig. 9 that is much less susceptible to high cycle fatigue.
  • This repair technique can also be used to repair a blade 59 on a bladed disk or blisk 65 as illustrated in Fig. 10.
  • the damaged portion of the airfoil is removed, and new material is added using the FSAM process discussed above.
  • the result is a repaired blisk 65 wherein the microstructure of the disk portion is a forged microstructure 61 and the added material has the smaller repair microstructure 12 that exhibits superior mechanical properties.
  • a disk portion 70 of the blisk 65 is first formed.
  • Substantially planar portions 75 can be formed on an outer surface 80 of the disk portion 70 to define platforms 85 for the addition of blades 60.
  • the blades 60 can simply be added to the curved surface of the disk portion 70.
  • blades 60 are formed using the process described with regard to Fig. 5 using the pattern illustrated in Fig. 6. Once sufficient material is added, the blades 60 can be finish machined as may be required to complete the blisk 65.
  • the disk portion 70 of the blisk 65 of Figs. 3 and 4 is typically a forged component and as such has a forged microstructure 61 with an average grain size smaller than that of a cast component. As illustrated in Fig. 11, the micro structure of the forged airfoils is still susceptible to creep damage 62.
  • Each of the blades 60 could be added using the aforementioned process and would have the repair microstructure 12, shown in Fig. 12 that includes an average grain size that is still smaller than that of the disk portion 70.
  • the smaller repair microstructure 12 would give the blades 60 different mechanical properties than the disk portion 70 including superior creep resistance if a creep resistant composition is selected for the build-up.
  • the blades 60 could also be added to the disk portion 70 using a dissimilar material that provides other advantages over the disk material (e.g. superior corrosion resistance, fatigue resistance, creep resistance, etc.).
  • a blade root 90 and platform 95 are manufactured using any desired technique.
  • the platform 95 defines a substantially planar surface on which the airfoil portion of the blade can be formed.
  • the airfoil portion is formed using the process described with regard to Fig. 5 by adding layers as illustrated in Fig. 6.
  • the airfoil portion is then machined, or further process as required to complete the airfoil portion of the blade.
  • the new blade could include dissimilar materials throughout its construction that provide the desired mechanical properties for the different areas of the blade.
  • FSAM FSAM

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

Dans la présente invention, une partie de profil aérodynamique d'aube de turbine ayant une longueur totale et fixée à demeure à une base comprend une première partie s'étendant de la base à une ligne de réparation de telle sorte que la première partie comporte une première longueur qui est plus courte que la longueur totale, la première partie ayant une microstructure ayant une première taille de grain moyenne, et une seconde partie s'étendant à partir de la ligne de réparation et ayant une seconde longueur égale à la différence entre la longueur totale et la première longueur, la seconde partie ayant une microstructure ayant une seconde taille de grain moyenne, la seconde taille de grain moyenne étant inférieure à la première taille de grain moyenne.
PCT/US2018/046155 2018-08-10 2018-08-10 Fabrication additive par friction-malaxage et réparation de composants de turbine Ceased WO2020032964A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2018/046155 WO2020032964A1 (fr) 2018-08-10 2018-08-10 Fabrication additive par friction-malaxage et réparation de composants de turbine

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2018/046155 WO2020032964A1 (fr) 2018-08-10 2018-08-10 Fabrication additive par friction-malaxage et réparation de composants de turbine

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20230173576A1 (en) * 2021-12-07 2023-06-08 Lockheed Martin Corporation Housing and method of preparing same using a hybrid casting-additive manufacturing process
EP4234129A1 (fr) * 2022-02-23 2023-08-30 Goodrich Corporation Procédés et appareil de fabrication de composants
US20250187073A1 (en) * 2023-12-11 2025-06-12 Lockheed Martin Corporation Housing and method of preparing same using a hybrid casting-additive manufacturing process

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2920007A (en) * 1958-01-16 1960-01-05 Gen Electric Elastic fluid blade with a finegrained surface
EP0575685A1 (fr) * 1992-06-23 1993-12-29 Sulzer Innotec Ag Moulage de précision ayant des surfaces d'usure
DE102008056741A1 (de) * 2008-11-11 2010-05-12 Mtu Aero Engines Gmbh Verschleissschutzschicht für Tial
EP2947266A1 (fr) * 2014-05-19 2015-11-25 United Technologies Corporation Procédés de réparation d'un rotor à aubes intégré
US20160096234A1 (en) * 2014-10-07 2016-04-07 Siemens Energy, Inc. Laser deposition and repair of reactive metals

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2920007A (en) * 1958-01-16 1960-01-05 Gen Electric Elastic fluid blade with a finegrained surface
EP0575685A1 (fr) * 1992-06-23 1993-12-29 Sulzer Innotec Ag Moulage de précision ayant des surfaces d'usure
DE102008056741A1 (de) * 2008-11-11 2010-05-12 Mtu Aero Engines Gmbh Verschleissschutzschicht für Tial
EP2947266A1 (fr) * 2014-05-19 2015-11-25 United Technologies Corporation Procédés de réparation d'un rotor à aubes intégré
US20160096234A1 (en) * 2014-10-07 2016-04-07 Siemens Energy, Inc. Laser deposition and repair of reactive metals

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20230173576A1 (en) * 2021-12-07 2023-06-08 Lockheed Martin Corporation Housing and method of preparing same using a hybrid casting-additive manufacturing process
US11878343B2 (en) * 2021-12-07 2024-01-23 Lockheed Martin Corporation Housing and method of preparing same using a hybrid casting-additive manufacturing process
EP4234129A1 (fr) * 2022-02-23 2023-08-30 Goodrich Corporation Procédés et appareil de fabrication de composants
US12138708B2 (en) 2022-02-23 2024-11-12 Goodrich Corporation Methods, systems, and apparatus for component manufacturing
US20250187073A1 (en) * 2023-12-11 2025-06-12 Lockheed Martin Corporation Housing and method of preparing same using a hybrid casting-additive manufacturing process

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