EP1398098B1 - Method for fabrication of turbine blades with cooling channels - Google Patents

Method for fabrication of turbine blades with cooling channels Download PDF

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Publication number
EP1398098B1
EP1398098B1 EP03015950A EP03015950A EP1398098B1 EP 1398098 B1 EP1398098 B1 EP 1398098B1 EP 03015950 A EP03015950 A EP 03015950A EP 03015950 A EP03015950 A EP 03015950A EP 1398098 B1 EP1398098 B1 EP 1398098B1
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EP
European Patent Office
Prior art keywords
pin
core
wax
turbine blade
mould shell
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.)
Expired - Lifetime
Application number
EP03015950A
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German (de)
French (fr)
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EP1398098A1 (en
Inventor
Wilfried Dr. Schneiders
Jörn Dr. Grossmann
Theodor Schmitte
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.)
Doncasters Precision Castings Bochum GmbH
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Doncasters Precision Castings Bochum GmbH
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Publication date
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Publication of EP1398098A1 publication Critical patent/EP1398098A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars

Definitions

  • the invention relates to a method for producing turbine blades with cooling channels arranged therein, wherein a ceramic core is produced, which is overmolded with a wax, wherein over the core coated with wax by repeated dipping and Besanden a ceramic shell mold is produced after removal the wax is fired, wherein the space formed by the removal of the wax to form the turbine blade is poured with molten metal, thereby preventing movements of the core in the shell mold by starting from the core, extending into the shell mold positioning aids, and wherein after the Hardening of the metal, the mold shell and the core are removed and the metallic turbine blade is machined.
  • the core is provided with projections (bumpers), which serve as spacers. It has also been proposed to remove the wax layer of the core regions, so that corresponding projections or spacers are formed by the mold shell (US 6,364,001 B1). Again, this is technically complex and does not guarantee the desired wall thickness of the turbine blade.
  • the object of the invention is to provide a method of the type described above, are reliably prevented in the movements of the core during the casting and impairments of the material properties or surfaces of the turbine blade are excluded.
  • a pin is embedded in the free end face of the core, which projects beyond the end face and is also embedded in the mold shell, and that the projecting end of the pin is removed during mechanical processing.
  • the pen can be embedded in the ceramic core without additional effort. Being over the so-called crown bottom of the turbine blade protruding end can be easily removed. The end of the pin under the crown floor need not be removed, because it does not bother. It is understood that the dimensions of the pin are chosen so that on the one hand a solid embedding in the core material is possible and that on the other hand, the pin has a sufficient stability during casting.
  • the pin should consist of a nickel-based alloy, in particular NiCr 82.
  • NiCr 82 is substantially resistant to oxidation and has a sufficient mechanical strength in the high temperature range above 1400 ° C.
  • other materials known per se for the pencil for example platinum, Palladium-based or tungsten-based noble metal alloys, or optionally also pins of ceramic materials.
  • a pin is used whose material oxidizes upon firing of the mold shell, then an embodiment is recommended in which the pin is provided with an abutment for the metal of the turbine blade. This may be a circumferential groove in the simplest case. The pin should then be embedded in the core so that the circumferential groove is located in the area of the later crown bottom.
  • the core represented schematically in FIGS. 1 and 2 consists of a ceramic material. His lower in the figures 1 and 2 section 2 is adapted for connection to a holder, not shown. From the lower portion go out two upper sections 3, 4, which extend substantially parallel to each other. At least the upper section 4 has profilings 5 which serve to form the cooling channels in the turbine blade.
  • pins 7 are embedded in the upper end faces, which protrude beyond the upper end faces 6.
  • the pins consist in the illustrated embodiment of a nickel-based alloy, namely NiCr 82.
  • the thus prepared core is overmolded with a wax layer 8 (FIG. 3).
  • This wax layer 8 defines a space which is later poured with molten metal to form the turbine blade.
  • the projecting beyond the core 1 end 10 of the pin 7 and the pins 7 also protrudes beyond the wax layer 8 and has a circumferential groove 11 in the region of the wax layer 8.
  • a ceramic shell 9 is produced over the wax layer 8 by repeated dipping and sanding. After removal of the wax layer 8, the mold shell 9 is fired (FIG. 5).
  • the released from the wax layer 8 space can be poured with molten metal 12, which forms the turbine blade after cooling and hardening.
  • the molten metal 12 also flows into the circumferential groove 11 of the pin or pins 7, so that a positive connection is formed, which is necessary at least when the pin material tends to surface oxidation during firing of the shell mold 9 ( Figure 6).
  • the core 1 and the mold shell 9 are removed (FIG. 7) and the resulting turbine blade 13 can be machined.
  • the extending into the interior of the turbine blade 13 end of the pin or 7 is not removed, because it does not bother.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Casting Devices For Molds (AREA)

Description

Die Erfindung betrifft ein Verfahren zum Herstellen von Turbinenschaufeln mit darin angeordneten Kühlkanälen, wobei ein keramischer Kern hergestellt wird, der mit einem Wachs umspritzt wird, wobei über dem mit Wachs umspritzten Kern durch wiederholtes Tauchen und Besanden eine keramische Formschale erzeugt wird, die nach dem Entfernen des Wachses gebrannt wird, wobei der durch das Entfernen des Wachses entstandene Raum zur Bildung der Turbinenschaufel mit geschmolzenem Metall ausgegossen wird und dabei Bewegungen des Kerns in der Formschale durch vom Kern ausgehende, sich bis in die Formschale erstreckende Positionierungshilfen verhindert werden, und wobei nach dem Erhärten des Metalls die Formschale und der Kern entfernt werden sowie die metallische Turbinenschaufel mechanisch bearbeitet wird.The invention relates to a method for producing turbine blades with cooling channels arranged therein, wherein a ceramic core is produced, which is overmolded with a wax, wherein over the core coated with wax by repeated dipping and Besanden a ceramic shell mold is produced after removal the wax is fired, wherein the space formed by the removal of the wax to form the turbine blade is poured with molten metal, thereby preventing movements of the core in the shell mold by starting from the core, extending into the shell mold positioning aids, and wherein after the Hardening of the metal, the mold shell and the core are removed and the metallic turbine blade is machined.

Derartige Verfahren sind in verschiedenen Ausführungen bekannt. In der Regel ist das untere Ende des Kerns beim Abguß fest angeordnet, sein oberes Ende kann aber unter dem Einfluß des einströmenden geschmolzenen Metalls Bewegungen ausführen, die verhindert werden müssen, damit die Wandungen der Turbinenschaufel in allen Bereichen die gewünschte Wandstärke aufweisen.Such methods are known in various designs. As a rule, the lower end of the core is fixed in the casting, but its upper end can under the influence of the inflowing molten metal perform movements that must be prevented so that the walls of the turbine blade in all areas have the desired wall thickness.

Dazu ist es bekannt, in diejenigen Bereiche der den Kern umgebenden Wachsschicht, die später die Wandungen der Turbinenschaufel begrenzen, Stifte einzudrücken, die gegen den Kern stoßen und etwas über die Wachsschicht vorstehen (DE 38 13 287 C2; EP 0 324 229 B1). Die überstehenden Enden der Stifte werden in die Formschale eingebettet und verhindern nach dem Entfernen des Wachses beim Abguß Bewegungen des Kerns. Das ist fertigungstechnisch aufwendig und kann in Abhängigkeit vom Stiftmaterial auch zu lokalen Veränderungen der Materialeigenschaften der Turbinenschaufel sowie zu Problemen bei einer gegebenenfalls nachfolgenden Beschichtung der Turbinenschaufel führen .For this purpose, it is known to push into those regions of the wax layer surrounding the core, which later limit the walls of the turbine blade, pins which abut against the core and protrude slightly beyond the wax layer (DE 38 13 287 C2, EP 0 324 229 B1). The protruding ends of the pins are embedded in the mold shell and prevent after removal of the wax during casting movements of the core. This is technically complex and can also lead to local changes in the material properties of the turbine blade as well as problems in an optionally subsequent coating of the turbine blade depending on the pin material.

Bei einem anderen bekannten Verfahren (EP 0 585 183 A1) wird der Kern mit Vorsprüngen (Bumper) versehen, die als Abstandshalter dienen. Es ist auch schon vorgeschlagen worden, die Wachsschicht des Kerns bereichsweise zu entfernen, so daß entsprechende Vorsprünge bzw. Abstandshalter von der Formschale gebildet werden (US 6 364 001 B1). Auch das ist fertigungstechnisch aufwendig und garantiert nicht die gewünschte Wandstärke der Turbinenschaufel.In another known method (EP 0 585 183 A1), the core is provided with projections (bumpers), which serve as spacers. It has also been proposed to remove the wax layer of the core regions, so that corresponding projections or spacers are formed by the mold shell (US 6,364,001 B1). Again, this is technically complex and does not guarantee the desired wall thickness of the turbine blade.

Aufgabe der Erfindung ist es, ein Verfahren der eingangs beschriebenen Gattung anzugeben, bei dem Bewegungen des Kerns während des Abgusses zuverlässig verhindert werden und Beeinträchtigungen der Materialeigenschaften oder Oberflächen der Turbinenschaufel ausgeschlossen sind.The object of the invention is to provide a method of the type described above, are reliably prevented in the movements of the core during the casting and impairments of the material properties or surfaces of the turbine blade are excluded.

Diese Aufgabe wird dadurch gelöst, daß als Positionierungshilfe ein Stift in die freie Stirnseite des Kerns eingebettet wird, der über die Stirnseite vorsteht und auch in die Formschale eingebettet wird, und daß das vorstehende Ende des Stiftes bei der mechanischen Bearbeitung entfernt wird. Damit bleiben die Materialeigenschaften, die Wandstärken und die Oberflächen aller funktionswichtigen Bereiche der Turbinenschaufel von der Anordnung des Stiftes unberührt. Der Stift läßt sich ohne zusätzlichen Aufwand in den keramischen Kern einbetten. Sein über die vom sogenannten Kronenboden der Turbinenschaufel vorstehendes Ende kann leicht entfernt werden. Das unter dem Kronenboden befindliche Ende des Stiftes braucht nicht entfernt zu werden, denn es stört nicht. Es versteht sich, daß die Abmessungen des Stiftes so gewählt werden, daß einerseits eine feste Einbettung in das Kernmaterial möglich ist und daß andererseits der Stift eine hinreichende Stabilität beim Abguß aufweist.This object is achieved in that as a positioning aid, a pin is embedded in the free end face of the core, which projects beyond the end face and is also embedded in the mold shell, and that the projecting end of the pin is removed during mechanical processing. Thus, the material properties, the wall thicknesses and the surfaces of all functionally important areas of the turbine blade remain unaffected by the arrangement of the pin. The pen can be embedded in the ceramic core without additional effort. Being over the so-called crown bottom of the turbine blade protruding end can be easily removed. The end of the pin under the crown floor need not be removed, because it does not bother. It is understood that the dimensions of the pin are chosen so that on the one hand a solid embedding in the core material is possible and that on the other hand, the pin has a sufficient stability during casting.

Vorzugsweise sollte der Stift aus einer Nickelbasis-Legierung bestehen, insbesondere aus NiCr 82. Eine solche Legierung ist im wesentlichen oxydationsbeständig und weist eine hinreichende mechanische Festigkeit im Hochtemperaturbereich oberhalb 1.400°C auf. Es können aber auch andere an sich bekannte Materialien für den Stift verwendet werden, z.B. Platin, Edelmetall-Legierungen auf Palladiumbasis oder auf Wolframbasis, oder gegebenenfalls auch Stifte aus keramischen Materialien.Preferably, the pin should consist of a nickel-based alloy, in particular NiCr 82. Such an alloy is substantially resistant to oxidation and has a sufficient mechanical strength in the high temperature range above 1400 ° C. However, it is also possible to use other materials known per se for the pencil, for example platinum, Palladium-based or tungsten-based noble metal alloys, or optionally also pins of ceramic materials.

Wird ein Stift verwendet, dessen Material beim Brennen der Formschale oxydiert, dann empfiehlt sich eine Ausführung, bei der der Stift mit einem Widerlager für das Metall der Turbinenschaufel versehen wird. Dabei kann es sich im einfachsten Fall um eine Umfangsnut handeln. Der Stift sollte dann so in den Kern eingebettet werden, daß die Umfangsnut sich im Bereich des späteren Kronenbodens befindet.If a pin is used whose material oxidizes upon firing of the mold shell, then an embodiment is recommended in which the pin is provided with an abutment for the metal of the turbine blade. This may be a circumferential groove in the simplest case. The pin should then be embedded in the core so that the circumferential groove is located in the area of the later crown bottom.

lm folgenden wird ein Ausführungsbeispiel der Erfindung erläutert; es zeigen:

Figur 1
schematisch eine Draufsicht auf eine Breitseite eines Kerns, der für die Herstellung einer Turbinenschaufel mit Kühlkanälen eingesetzt wird,
Figur 2
einen Schnitt in Richtung II-II durch den Gegenstand nach Figur 1,
Figur 3
den Gegenstand nach Figur 2 nach dem Umspritzen mit Wachs,
Figur 4
den Gegenstand nach Figur 3 mit einer keramischen Formschale über der Wachsschicht,
Figur 5
den Gegenstand nach Figur 4 nach dem Ausschmelzen der Wachsschicht,
Figur 6
den Gegenstand nach Figur 5 nach dem Abguß,
Figur 7
den Gegenstand nach Figur 6 nach dem Entfernen des Kerns und der Formschale,
Figur 8
den Gegenstand nach Figur 7 nach dem Entfernen des über den Kronenboden vorstehenden Endes des Stiftes.
In the following an embodiment of the invention will be explained; show it:
FIG. 1
2 is a schematic plan view of a broad side of a core used for the manufacture of a turbine blade with cooling channels.
FIG. 2
a section in the direction II-II through the article of Figure 1,
FIG. 3
the article according to FIG. 2 after injection molding with wax,
FIG. 4
the article according to FIG. 3 with a ceramic shell mold over the wax layer,
FIG. 5
the article according to FIG. 4 after the wax layer has melted out,
FIG. 6
the article according to FIG. 5 after the casting,
FIG. 7
the article according to FIG. 6 after removal of the core and the shell mold,
FIG. 8
the article of Figure 7 after removing the over the crown bottom protruding end of the pin.

Der in den Figuren 1 und 2 schematisch wiedergegebene Kern besteht aus einem keramischen Material. Sein in den Figuren 1 und 2 unterer Abschnitt 2 ist für den Anschluß an eine nicht dargestellte Halterung eingerichtet. Vom unteren Abschnitt gehen zwei obere Abschnitte 3, 4 aus, die sich im wesentlichen parallel zueinander erstrecken. Wenigstens der obere Abschnitt 4 weist Profilierungen 5 auf, die zur Bildung der Kühlkanäle in der Turbinenschaufel dienen. Bei der Herstellung des Kerns 1 werden in die oberen Stirnseiten 6 Stifte 7 eingebettet, die über die oberen Stirnseiten 6 vorstehen. Die Stifte bestehen bei der dargestellten Ausführung aus einer Nickelbasis-Legierung, nämlich aus NiCr 82.The core represented schematically in FIGS. 1 and 2 consists of a ceramic material. His lower in the figures 1 and 2 section 2 is adapted for connection to a holder, not shown. From the lower portion go out two upper sections 3, 4, which extend substantially parallel to each other. At least the upper section 4 has profilings 5 which serve to form the cooling channels in the turbine blade. In the manufacture of the core 1 6 pins 7 are embedded in the upper end faces, which protrude beyond the upper end faces 6. The pins consist in the illustrated embodiment of a nickel-based alloy, namely NiCr 82.

Der so vorbereitete Kern wird mit einer Wachsschicht 8 umspritzt (Figur 3). Diese Wachsschicht 8 definiert einen Raum, der später zur Bildung der Turbinenschaufel mit geschmolzenem Metall ausgegossen wird. Das über den Kern 1 vorstehende Ende 10 des Stiftes 7 bzw. der Stifte 7 steht auch über die Wachsschicht 8 vor und weist im Bereich der Wachsschicht 8 eine Umfangsnut 11 auf.The thus prepared core is overmolded with a wax layer 8 (FIG. 3). This wax layer 8 defines a space which is later poured with molten metal to form the turbine blade. The projecting beyond the core 1 end 10 of the pin 7 and the pins 7 also protrudes beyond the wax layer 8 and has a circumferential groove 11 in the region of the wax layer 8.

In einem weiteren Verfahrensschritt (Figur 4) wird über der Wachsschicht 8 durch mehrfaches Tauchen und Besanden eine keramische Formschale 9 erzeugt. Nach dem Entfernen der Wachsschicht 8 wird die Formschale 9 gebrannt (Figur 5).In a further method step (FIG. 4), a ceramic shell 9 is produced over the wax layer 8 by repeated dipping and sanding. After removal of the wax layer 8, the mold shell 9 is fired (FIG. 5).

Nun kann der von der Wachsschicht 8 freigegebene Raum mit geschmolzenem Metall 12 ausgegossen werden, welches nach dem Abkühlen und Erhärten die Turbinenschaufel bildet. Das geschmolzene Metall 12 fließt auch in die Umfangsnut 11 des oder der Stifte 7, so daß ein Formschluß entsteht, der zumindest dann notwendig ist, wenn das Stiftmaterial beim Brennen der Formschale 9 zu Oberflächenoxydation neigt (Figur 6).Now, the released from the wax layer 8 space can be poured with molten metal 12, which forms the turbine blade after cooling and hardening. The molten metal 12 also flows into the circumferential groove 11 of the pin or pins 7, so that a positive connection is formed, which is necessary at least when the pin material tends to surface oxidation during firing of the shell mold 9 (Figure 6).

Nach dem Abkühlen und Erhärten des Metalls 12 werden der Kern 1 und die Formschale 9 entfernt (Figur 7) und die so entstandene Turbinenschaufel 13 kann mechanisch bearbeitet werden. Im Zuge der mechanischen Bearbeitung wird auch das ursprünglich in die Formschale 9 eingebettete Ende 10 des oder der Stifte 7, welches über den Kronenboden 14 der Turbinenschaufel 13 vorsteht, entfernt. Das sich in das Innere der Turbinenschaufel 13 erstreckende Ende des oder der Stifte 7 wird nicht entfernt, denn es stört nicht.After cooling and hardening of the metal 12, the core 1 and the mold shell 9 are removed (FIG. 7) and the resulting turbine blade 13 can be machined. In the course of mechanical processing is also the originally embedded in the shell 9 end 10 of the pin or 7, which projects beyond the crown bottom 14 of the turbine blade 13, removed. The extending into the interior of the turbine blade 13 end of the pin or 7 is not removed, because it does not bother.

Claims (6)

  1. Method of producing turbine blades (13) with cooling channels arranged therein, wherein a ceramic core (2, 3, 4) is produced, which is injection-moulded around by a wax (8), wherein a ceramic mould shell (9) is produced over the core, which is injection-moulded around by wax, by repeated dipping and sanding and is fired after removal of the wax, wherein the space created by removal of the wax is filled by casting with molten metal (12) for formation of the turbine blade and in that case movements of the core in the mould shell are prevented by positioning aids going out from the core and extending into the mould shell and wherein after hardening of the metal the mould shell and the core are removed and the metallic turbine blade mechanically processed, characterised in that as positioning aid a pin (7) is embedded in the free end face (6) of the core (1), which pin protrudes beyond the end face (6) and is also embedded in the mould shell (9), and that the protruding end (10) of the pin (7) is removed in the mechanical processing.
  2. Method according to claim 1, characterised in that the pin (7) consists of a nickel-based alloy.
  3. Method according to claim 1 or 2, characterised in that the pin (7) consists of NiCr 82.
  4. Method according to one of claims 1 to 3, characterised in that a pin (7) with a counter-bearing for the material of the turbine blade (13) is used.
  5. Method according to claim 4, characterised in that the pin (7) has a circumferential groove (11).
  6. Method according to one of claims 4 and 5, characterised in that the pin (7) is so embedded in the core (1) that the circumferential groove (11) is arranged in the region of the later crown base (14).
EP03015950A 2002-08-08 2003-07-14 Method for fabrication of turbine blades with cooling channels Expired - Lifetime EP1398098B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10236339 2002-08-08
DE10236339A DE10236339B3 (en) 2002-08-08 2002-08-08 Method for manufacturing turbine blades with cooling ducts involves making ceramic core with positioning pins embedded in free end to protrude into surrounding moulding shell for removal during mechanical finishing of hardened blades

Publications (2)

Publication Number Publication Date
EP1398098A1 EP1398098A1 (en) 2004-03-17
EP1398098B1 true EP1398098B1 (en) 2006-09-13

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US (1) US6896036B2 (en)
EP (1) EP1398098B1 (en)
JP (1) JP2004076731A (en)
DE (2) DE10236339B3 (en)
ES (1) ES2272858T3 (en)

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US20040055736A1 (en) 2004-03-25
ES2272858T3 (en) 2007-05-01
EP1398098A1 (en) 2004-03-17
DE10236339B3 (en) 2004-02-19
DE50305016D1 (en) 2006-10-26
JP2004076731A (en) 2004-03-11
US6896036B2 (en) 2005-05-24

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