CA2643568A1 - Method for the production of a sealing segment, and sealing segment to be used in compressor and turbine components - Google Patents
Method for the production of a sealing segment, and sealing segment to be used in compressor and turbine components Download PDFInfo
- Publication number
- CA2643568A1 CA2643568A1 CA002643568A CA2643568A CA2643568A1 CA 2643568 A1 CA2643568 A1 CA 2643568A1 CA 002643568 A CA002643568 A CA 002643568A CA 2643568 A CA2643568 A CA 2643568A CA 2643568 A1 CA2643568 A1 CA 2643568A1
- Authority
- CA
- Canada
- Prior art keywords
- mixture
- recited
- molded article
- powder
- sealing segment
- 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.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
- B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/638—Removal thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
- C04B37/02—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles
- C04B37/021—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles in a direct manner, e.g. direct copper bonding [DCB]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/002—Producing shaped prefabricated articles from the material assembled from preformed elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/24—Producing shaped prefabricated articles from the material by injection moulding
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/602—Making the green bodies or pre-forms by moulding
- C04B2235/6027—Slip casting
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
- C04B2237/34—Oxidic
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
- C04B2237/34—Oxidic
- C04B2237/341—Silica or silicates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
- C04B2237/36—Non-oxidic
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
- C04B2237/36—Non-oxidic
- C04B2237/361—Boron nitride
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
- C04B2237/36—Non-oxidic
- C04B2237/363—Carbon
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/40—Metallic
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
- F23R2900/00—Special features of, or arrangements for continuous combustion chambers; Combustion processes therefor
- F23R2900/00018—Manufacturing combustion chamber liners or subparts
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Composite Materials (AREA)
- Inorganic Chemistry (AREA)
- Structures Of Non-Positive Displacement Pumps (AREA)
- Powder Metallurgy (AREA)
- Sealing Using Fluids, Sealing Without Contact, And Removal Of Oil (AREA)
- Sealing Devices (AREA)
Abstract
The invention relates to a method for producing a sealing segment to be used in compressor and turbine components by means of a powder injection molding process. Said method encompasses the following steps: a) a first homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binder is produced; b) a first molded article is produced by injection-molding the first mixture; c) a second homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binder is produced, said second mixture being chosen so as to be provided with less abrasion resistance than the first mixture following a subsequent joint sintering process; d) a second molded article is produced as a brush layer by injection-molding the second mixture; and e) the first and second molded article are joined so as to obtain the sealing segment. The invention further relates to a sealing segment which is to be used in compressor and turbine components and comprises at least one first molded article as a basic element and at least one second molded article as a brush layer, which has less abrasion resistance than the first molded article, the first and the second molded article each being produced using a powder injection molding process.
Description
METHOD FOR THE PRODUCTION OF A SEALING SEGMENT, AND SEALING
SEGMENT TO BE USED IN COMPRESSOR AND TURBINE COMPONENTS' [METHOD FOR PRODUCING A SEALING SEGMENT AND SEALING
SEGMENT FOR USE IN COMPRESSOR AND TURBINE COMPONENTS]
[0001] The present invention relates to a method for producing a sealing segment for use in compressor and turbine components, by powder injection molding, as well as to a sealing segment for use in compressor and turbine components composed of at least one first molded article as a base element and of at least one second molded article exhibiting a higher abrasive wear rate than the first molded article, as a grazing-contact layer.
SEGMENT TO BE USED IN COMPRESSOR AND TURBINE COMPONENTS' [METHOD FOR PRODUCING A SEALING SEGMENT AND SEALING
SEGMENT FOR USE IN COMPRESSOR AND TURBINE COMPONENTS]
[0001] The present invention relates to a method for producing a sealing segment for use in compressor and turbine components, by powder injection molding, as well as to a sealing segment for use in compressor and turbine components composed of at least one first molded article as a base element and of at least one second molded article exhibiting a higher abrasive wear rate than the first molded article, as a grazing-contact layer.
[0002] Sealing segments of this kind are used, in particular, when working with what are generally known as gap-maintaining systems in the compressor and turbine components. Sealing segments, respectively sealing systems of this kind have the function of maintaining a minimal sealing gap between rotating blading [a blade assembly, blading system or blade row] and a housing, as well as between stationary blading and the rotating rotor hubs, and of thereby ensuring stable operating characteristics in the context of a highest possible efficiency. The rotating components of the turbine typically have sealing fins which run in against honeycomb seals in a manner known per se. A
honeycomb seal of this kind is described by World Patent Application WO 2004/061340 Al. This known honeycomb seal is made of an individual molded article fabricated by powder-metallurgical injection molding.
honeycomb seal of this kind is described by World Patent Application WO 2004/061340 Al. This known honeycomb seal is made of an individual molded article fabricated by powder-metallurgical injection molding.
[0003] The known running-in process can easily lead to overheating of the sealing fins when the contact with the honeycomb material lasts too long or the resistance generated by the rubbing away [abrading] of the honeycomb structures becomes too great.
Therefore, damage to the sealing fins cannot be ruled out in the case of the known sealing segments, respectively corresponding run-in coatings.
Therefore, damage to the sealing fins cannot be ruled out in the case of the known sealing segments, respectively corresponding run-in coatings.
[0004] It is, therefore, an object of the present invention to devise a method for ~ Transiator's note: This is the English title provided on the published PCT
cover page of the WO
document.
..a producing a sealing segment and a sealing segment produced accordingly for use in compressor and turbine components, which, on the one hand, make it possible to inexpensively manufacture a broad array of sealing segment geometries and, on the other hand, to reduce the load that the compressor and turbine components are subject to when running in against the sealing segments.
cover page of the WO
document.
..a producing a sealing segment and a sealing segment produced accordingly for use in compressor and turbine components, which, on the one hand, make it possible to inexpensively manufacture a broad array of sealing segment geometries and, on the other hand, to reduce the load that the compressor and turbine components are subject to when running in against the sealing segments.
[0005] These objectives are achieved by a method having the features set forth in claim 1, as well as by a sealing segment having the features set forth in claim 16.
[0006] Advantageous embodiments of the present invention are described in the respective dependent claims.
[0007] A method according to the present invention for producing a sealing segment for use in compressor and turbine components by powder injection molding includes the following method steps in accordance with the present invention: a) preparing a first homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent; b) producing a first molded article by injection molding the first mixture; c) preparing a second homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent, the second mixture being selected to have a higher abrasive wear rate than the first mixture following a subsequent joint [shared] sintering process; d) producing a second molded article as a grazing-contact layer by injection molding the second mixture; and e) joining the first and second molded articles to produce the sealing segment.
[0008] A cost-effective and also individual [targeted] production of the requisite sealing segments is ensured by using the powder injection molding method. In this context, all injection-moldable and sinterable metals, metal alloys, as well as ceramics may be used for the powder injection molding of the first and second molded articles.
Mixtures of the metal powder or ceramic powder are also conceivable. The sinterable ceramics may include nitride ceramics, oxide ceramics and silicate ceramics, as well as carbides, for example.
When manufacturing the sealing system according to the present invention, it is critical that the grazing-contact layer composed of the second molded article have a higher abrasive wear rate than the first molded article used as a base element and/or fastening element for the sealing segment. Therefore, the present invention makes it possible to satisfy a broad array of material requirements for a sealing segment of this kind in compressor and turbine components. On the one hand, this concerns the simple production of complicated geometries using the powder injection molding method, and, on the other hand, the targeted adaptation of the material selection for producing the first and second molded articles, which may be carried out in conformance with the actual technical conditions.
It is thus possible to adjust the properties of the second molded article that pertain to the abrasion characteristics, such as the generation of only low frictional energies and resistances, the effective chip formation and removability of the abraded material, or also that relate to preventing an ignition of the abraded material during grazing contact, in a targeted manner, to the turbine components making grazing contact, such as sealing fins, for example. This clearly lowers the loading of [stress to] the sealing fins by the grazing contact, for example, thereby making it possible to advantageously reduce the size of the corresponding sealing gap. Moreover, there is no need to use conventional geometries when producing honeycomb seals or honeycomb-structured run-in coatings. Geometries may be developed that are more aerodynamically effective and more cost-effective from a standpoint of production engineering. In addition, the honeycomb structure may be entirely eliminated and, accordingly, planar layers may be produced economically. Furthermore, the present invention makes it possible for the first formed element, which is used as a base element or fastening element of the sealing segment, to be adjusted to the relevant technical and material engineering conditions. This relates, in particular, to temperature resistance and erosion resistance.
Mixtures of the metal powder or ceramic powder are also conceivable. The sinterable ceramics may include nitride ceramics, oxide ceramics and silicate ceramics, as well as carbides, for example.
When manufacturing the sealing system according to the present invention, it is critical that the grazing-contact layer composed of the second molded article have a higher abrasive wear rate than the first molded article used as a base element and/or fastening element for the sealing segment. Therefore, the present invention makes it possible to satisfy a broad array of material requirements for a sealing segment of this kind in compressor and turbine components. On the one hand, this concerns the simple production of complicated geometries using the powder injection molding method, and, on the other hand, the targeted adaptation of the material selection for producing the first and second molded articles, which may be carried out in conformance with the actual technical conditions.
It is thus possible to adjust the properties of the second molded article that pertain to the abrasion characteristics, such as the generation of only low frictional energies and resistances, the effective chip formation and removability of the abraded material, or also that relate to preventing an ignition of the abraded material during grazing contact, in a targeted manner, to the turbine components making grazing contact, such as sealing fins, for example. This clearly lowers the loading of [stress to] the sealing fins by the grazing contact, for example, thereby making it possible to advantageously reduce the size of the corresponding sealing gap. Moreover, there is no need to use conventional geometries when producing honeycomb seals or honeycomb-structured run-in coatings. Geometries may be developed that are more aerodynamically effective and more cost-effective from a standpoint of production engineering. In addition, the honeycomb structure may be entirely eliminated and, accordingly, planar layers may be produced economically. Furthermore, the present invention makes it possible for the first formed element, which is used as a base element or fastening element of the sealing segment, to be adjusted to the relevant technical and material engineering conditions. This relates, in particular, to temperature resistance and erosion resistance.
[0009] In various specific embodiments of the method according to the present invention, the first and second molded articles may be joined immediately following the production thereof and prior to releasing [expelling] of the same in a joint process.
However, it is also possible for the first and second molded articles to be joined following a separate release process and prior to a subsequent joint sintering process that the molded articles undergo. Finally, it is also possible for the first and second molded articles to be joined following a separate release and sintering process that they undergo.
In the latter case, mechanical, as well as chemical joining processes are possible.
However, it is also possible for the first and second molded articles to be joined following a separate release process and prior to a subsequent joint sintering process that the molded articles undergo. Finally, it is also possible for the first and second molded articles to be joined following a separate release and sintering process that they undergo.
In the latter case, mechanical, as well as chemical joining processes are possible.
[0010] In other advantageous embodiments of the method according to the present invention, the higher abrasive wear rate of the second molded article is achieved by reducing the metal powder or ceramic powder content in the second mixture.
Thus, in the second mixture, for example, the metal powder or ceramic powder content is only approximately 15 - 30 % by volume. As a result, the sintering process yields a porous structure due to a reduction in intergranular contact. Advantageously, no separation effects ensue in the second mixture, and a homogeneous porosity distribution is obtained. There is also no need for any change in the process parameters.
Thus, in the second mixture, for example, the metal powder or ceramic powder content is only approximately 15 - 30 % by volume. As a result, the sintering process yields a porous structure due to a reduction in intergranular contact. Advantageously, no separation effects ensue in the second mixture, and a homogeneous porosity distribution is obtained. There is also no need for any change in the process parameters.
[0011] In another advantageous embodiment of the present invention, the higher abrasive wear rate of the second molded article is achieved by using metal powders and ceramic powders having reduced sintering activity. In this context, metal powders having a lower degree of purity, i.e., higher C- and 0-concentration may be used, for example. The use of air-atomized, instead of inert gas-atomized metal powder, leads to a higher C- and 0-coverage of the surfaces and thus to a reduced sintering activity. Here, the advantage of a very porous structure is derived due to a reduction in the intergranular contact, respectively in the sintering neck formation. Moreover, inexpensive metal powders or ceramic powders may be used. A homogeneous porosity distribution, as well as a reduction in separation effects are achieved. There is again no need for any changes in the process parameters.
[0012] In another advantageous embodiment of the method according to the present invention, the higher abrasive wear rate of the second molded article is achieved by admixing binder polymers, which do not entirely decompose during release and/or sintering processes, into the second mixture. In this context, the binder polymers may be selected from the group including the phenolic resins or novolak. Admixing binder polymers advantageously reduces the sintering activity. Carbon residues are produced in the grain interstices of the metal or ceramic powder particles in the sintered product, making it possible to achieve good abrasive wear properties. Advantageously in this case as well, no separation effects occur in the context of a homogeneous porosity distribution.
[0013] In another advantageous embodiment of the method according to the present invention, the higher abrasive wear rate of the second molded article is achieved by admixing fillers into the second mixture. In this context, the fillers may be formed from easily cleavable inert materials, such as graphite, bentonite or hexagonal boron nitride and/or from materials which at least partially decompose during the release and/or sintering and contribute to pore formation in the second molded article. Evaporation advantageously takes place during sintering, for example, thereby resulting in a pore formation in the scraping layer [grazing-contact layer],2 respectively in the second molded article.
However, it is also possible that the fillers do not decompose, and that they remain in the sintered product, i.e., in the scraping layer [grazing-contact layer],3 respectively in the second molded article, in the grain interstices of the metal or ceramic powder particles.
Overall, therefore, the result is a quite readily cleavable, respectively abradable grazing-contact layer. In addition, the pore formation is optionally effected by surface oxidation in the later use of the sealing segment, for example when graphite is selected as a filler.
However, it is also possible that the fillers do not decompose, and that they remain in the sintered product, i.e., in the scraping layer [grazing-contact layer],3 respectively in the second molded article, in the grain interstices of the metal or ceramic powder particles.
Overall, therefore, the result is a quite readily cleavable, respectively abradable grazing-contact layer. In addition, the pore formation is optionally effected by surface oxidation in the later use of the sealing segment, for example when graphite is selected as a filler.
[0014] In another advantageous embodiment of the method according to the present invention, a multiplicity of homogeneous mixtures of metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent are prepared in accordance with method steps a) through d) to produce a corresponding multiplicity of molded articles and a sealing segment resulting therefrom.
Thus, even multilayer sealing segments may be produced cost-effectively in virtually any given geometries.
Thus, even multilayer sealing segments may be produced cost-effectively in virtually any given geometries.
[0015] A sealing segment according to the present invention for use in compressor and turbine components composed of at least one first molded article as a base element and/or fastening element and at least one second molded article having a higher abrasive wear rate than the first molded article, as a grazing-contact layer, the first and the second molded articles each being produced by powder injection molding. The at least two-layered design of the sealing segment according to the present invention makes it possible, on the one hand, to adapt the base and/or fastening element, namely the first molded article, as well as the scraping layer [grazing-contact layer],4 namely the second molded article, both in the geometries thereof, as well as in the material compositions, in a targeted manner to the technical and material engineering requirements. In this context, the sealing segment may be a run-in coating for sealing a radial gap between a rotating rotor blade and a housing of a gas turbine, for example. Moreover, the sealing segment may have a 2 Translator's note: Here, and at two other places in the Specification, the author switches from "Anstreifschicht" or "grazing-contact layer" to "Abstreifschicht" or "scraping.layer." Both terms describe the "second molded article." It seems the author made this change inadvertently, perhaps thinking of the layer from a different perspective. To be consistent, it would seem to be preferable to use "grazing-contact layer" throughout, especially as this is how it is referred to in the claims.
3 Translator's note: See Footnote 2.
4 Translator's note: See Footnote 2.
honeycomb design.
3 Translator's note: See Footnote 2.
4 Translator's note: See Footnote 2.
honeycomb design.
[0016] In this context, the sealing segment according to the present invention is produced in accordance with a method as described in detail in the preceding.
[0017] In another advantageous embodiment of the sealing segment according to the present invention, the sealing segment is made of a multiplicity of molded articles, at least two molded articles being produced by powder injection molding.
Claims (14)
1. A method for producing a sealing segment for use in compressor and turbine components, by powder injection molding, the method comprising the following steps:
a) preparing a first homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent;
b) producing a first molded article by injection molding the first mixture;
c) preparing a second homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent, the second mixture being selected to exhibit a lower abrasion resistance than the first mixture following a subsequent joint [shared] sintering process;
d) producing a second molded article as a grazing-contact layer by injection molding the second mixture; and e) joining the first and second molded articles to produce the sealing segment, the lower abrasion resistance of the second molded article being achieved by reducing the metal powder or ceramic powder content in the second mixture.
a) preparing a first homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent;
b) producing a first molded article by injection molding the first mixture;
c) preparing a second homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent, the second mixture being selected to exhibit a lower abrasion resistance than the first mixture following a subsequent joint [shared] sintering process;
d) producing a second molded article as a grazing-contact layer by injection molding the second mixture; and e) joining the first and second molded articles to produce the sealing segment, the lower abrasion resistance of the second molded article being achieved by reducing the metal powder or ceramic powder content in the second mixture.
2. The method as recited in claim 1, wherein the first and second molded articles are joined immediately following the production thereof and prior to releasing [expelling] of the same in a joint process.
3. The method as recited in claim 1, wherein the first and second molded articles are joined following a separate release process and prior to a subsequent joint sintering process that they undergo.
4. The method as recited in claim 1, wherein the first and second molded articles are joined following a separate release and sintering process that they undergo.
5. The method as recited in one of the preceding claims, wherein the sealing segment is a run-in coating for sealing a radial gap between a rotating rotor blade and a housing of a gas turbine.
6. The method as recited in one of the preceding claims, wherein the sealing segment has a honeycomb design.
7. The method as recited in one of the preceding claims, wherein the metal powder or mixtures of metal powders or ceramic powder or mixtures of ceramic powders include all sinterable metals and metal alloys, as well as all sinterable ceramics, such as nitride ceramics, oxide ceramics and silicate ceramics, as well as carbides, for example.
8. The method as recited in one of the preceding claims, wherein the metal powder or ceramic powder content is 15 - 30 % by volume in the second mixture.
9. The method as recited in one of the preceding claims, wherein the lower abrasion resistance of the second molded article is achieved by using metal or ceramic powders having reduced sintering activity.
10. The method as recited in one of the preceding claims, wherein the lower abrasion resistance of the second molded article is achieved by admixing binder polymers, which do not entirely decompose during release and/or sintering processes, into the second mixture.
11. The method as recited in claim 10, wherein the binder polymers are selected from the group including the phenolic resins or novolak.
12. The method as recited in one of the preceding claims, wherein the higher abrasive wear rate of the second molded article is achieved by admixing fillers into the second mixture.
13. The method as recited in claim 12, wherein the fillers [are formed] from easily cleavable inert materials, such as graphite, bentonite or hexagonal boron nitride and/or from materials which at least partially decompose during the release and/or sintering [process] and contribute to the pore formation in the second molded article.
14. The method as recited in one of the preceding claims, wherein a multiplicity of homogeneous mixtures of metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent are prepared in accordance with the method steps a) through d) to produce a corresponding multiplicity of molded articles and a sealing segment resulting therefrom.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102006009860.9 | 2006-03-03 | ||
DE102006009860A DE102006009860A1 (en) | 2006-03-03 | 2006-03-03 | Method for producing a sealing segment and sealing segment for use in compressor and turbine components |
PCT/DE2007/000360 WO2007098739A1 (en) | 2006-03-03 | 2007-02-27 | Method for the production of a sealing segment, and sealing segment to be used in compressor and turbine components |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2643568A1 true CA2643568A1 (en) | 2007-09-07 |
Family
ID=38226598
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002643568A Abandoned CA2643568A1 (en) | 2006-03-03 | 2007-02-27 | Method for the production of a sealing segment, and sealing segment to be used in compressor and turbine components |
Country Status (5)
Country | Link |
---|---|
US (1) | US20090041607A1 (en) |
EP (1) | EP1991380A1 (en) |
CA (1) | CA2643568A1 (en) |
DE (1) | DE102006009860A1 (en) |
WO (1) | WO2007098739A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9517507B2 (en) | 2014-07-17 | 2016-12-13 | Pratt & Whitney Canada Corp. | Method of shaping green part and manufacturing method using same |
US9903275B2 (en) | 2014-02-27 | 2018-02-27 | Pratt & Whitney Canada Corp. | Aircraft components with porous portion and methods of making |
US11097343B2 (en) | 2015-03-12 | 2021-08-24 | Pratt & Whitney Canada Corp. | Method of forming a component from a green part |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102008019331A1 (en) * | 2008-04-16 | 2009-10-22 | Rolls-Royce Deutschland Ltd & Co Kg | Inlet seal for compressor of gas-turbine engine, has open-porous metallic sponge with filling material made of heat resistant duroplastic synthetic resin infiltrated in open-porous cavities of metallic sponge |
US10226818B2 (en) * | 2009-03-20 | 2019-03-12 | Pratt & Whitney Canada Corp. | Process for joining powder injection molded parts |
CA2797746C (en) * | 2009-04-29 | 2021-12-07 | Maetta Sciences Inc. | A method for co-processing components in a metal injection molding process, and components made via the same |
DE102009055914A1 (en) * | 2009-11-27 | 2011-06-09 | Rolls-Royce Deutschland Ltd & Co Kg | Sealing rings for a labyrinth seal |
US9970318B2 (en) * | 2014-06-25 | 2018-05-15 | Pratt & Whitney Canada Corp. | Shroud segment and method of manufacturing |
CN104841940A (en) * | 2015-04-01 | 2015-08-19 | 宝得粉末注射成形(常熟)有限公司 | Method for manufacturing small turbine engine blade |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3844011A (en) * | 1970-12-21 | 1974-10-29 | Gould Inc | Powder metal honeycomb |
CA963497A (en) * | 1970-12-21 | 1975-02-25 | Gould Inc. | Powder metal honeycomb |
US5024695A (en) * | 1984-07-26 | 1991-06-18 | Ultrafine Powder Technology, Inc. | Fine hollow particles of metals and metal alloys and their production |
US4639388A (en) * | 1985-02-12 | 1987-01-27 | Chromalloy American Corporation | Ceramic-metal composites |
US6547522B2 (en) * | 2001-06-18 | 2003-04-15 | General Electric Company | Spring-backed abradable seal for turbomachinery |
FR2840839B1 (en) * | 2002-06-14 | 2005-01-14 | Snecma Moteurs | METALLIC MATERIAL WHICH MAY BE USED BY ABRASION; PIECES, CARTER; PROCESS FOR PRODUCING SAID MATERIAL |
DE10259963B4 (en) * | 2002-12-20 | 2010-04-01 | Mtu Aero Engines Gmbh | honeycomb seal |
US6969231B2 (en) * | 2002-12-31 | 2005-11-29 | General Electric Company | Rotary machine sealing assembly |
DE10331397A1 (en) * | 2003-07-11 | 2005-01-27 | Mtu Aero Engines Gmbh | Production of blade segments for gas turbines comprises using a powder metallurgical injection molding |
DE10343782A1 (en) * | 2003-09-22 | 2005-04-14 | Mtu Aero Engines Gmbh | Process for the production of components |
-
2006
- 2006-03-03 DE DE102006009860A patent/DE102006009860A1/en not_active Withdrawn
-
2007
- 2007-02-27 CA CA002643568A patent/CA2643568A1/en not_active Abandoned
- 2007-02-27 EP EP07721961A patent/EP1991380A1/en not_active Withdrawn
- 2007-02-27 US US12/224,681 patent/US20090041607A1/en not_active Abandoned
- 2007-02-27 WO PCT/DE2007/000360 patent/WO2007098739A1/en active Application Filing
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9903275B2 (en) | 2014-02-27 | 2018-02-27 | Pratt & Whitney Canada Corp. | Aircraft components with porous portion and methods of making |
US9517507B2 (en) | 2014-07-17 | 2016-12-13 | Pratt & Whitney Canada Corp. | Method of shaping green part and manufacturing method using same |
US11097343B2 (en) | 2015-03-12 | 2021-08-24 | Pratt & Whitney Canada Corp. | Method of forming a component from a green part |
US11883882B2 (en) | 2015-03-12 | 2024-01-30 | Pratt & Whitney Canada Corp. | Method of forming a component from a green part |
Also Published As
Publication number | Publication date |
---|---|
WO2007098739A1 (en) | 2007-09-07 |
DE102006009860A1 (en) | 2007-09-06 |
US20090041607A1 (en) | 2009-02-12 |
EP1991380A1 (en) | 2008-11-19 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2643568A1 (en) | Method for the production of a sealing segment, and sealing segment to be used in compressor and turbine components | |
JP5199871B2 (en) | Polycrystalline diamond polishing element and method for manufacturing the same | |
AU737706B2 (en) | Abrasive tool | |
EP0254667B1 (en) | Improved method for adhesion of grit to blade tips | |
EP1583850B1 (en) | Thermal spray composition and method of deposition for abradable seals | |
RU2666199C2 (en) | Method for producing spray powders containing chromium nitride | |
EP1908925B1 (en) | Ternary carbide and nitrate abradable seal by thermal vaporisation | |
EP2952690B1 (en) | A turbine engine abradable outer air seal and a corresponding manufacturing process | |
US7128962B2 (en) | Metallic material that can be worn away by abrasion; parts, casings, and a process for producing said material | |
EP2372104B1 (en) | Blade outer air seal with improved efficiency | |
EP3093097B1 (en) | Near net shape abradable seal manufacturing method | |
EP2375002B1 (en) | Abradable seal for a gas turbine engine, corresponding gas turbine engine and manufacturing method | |
CN103231064B (en) | Manufacturing method for novel nickel base solder brazing monolayer diamond grinding wheel | |
JP4997561B2 (en) | Tool or mold material in which a hard film is formed on a hard alloy for forming a high-hardness film, and a method for producing the same | |
JP2007522339A5 (en) | ||
CN104032153A (en) | Production method of high-toughness microcrystal hard alloys | |
CA2647473A1 (en) | Method for production of a honeycomb seal | |
EP3647390B1 (en) | Sintered friction material and production method for sintered friction material | |
JP2001214869A (en) | Oil pump | |
CN105198435B (en) | Silicon carbide-carbon composite material and preparation method thereof | |
JP5358968B2 (en) | Metal bond grinding wheel | |
WO2001044533A1 (en) | Abradable coatings | |
CN114807724A (en) | Wear-resistant composite material prepared by laser 3D printing technology and method | |
CN107574349A (en) | A kind of clutch disc of cermet composite | |
JP2005139021A (en) | Lubricating ceramic material, method of manufacturing the same and sliding member |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
FZDE | Discontinued |
Effective date: 20130227 |