EP1923152A1 - Procédés de coulage de pale - Google Patents

Procédés de coulage de pale Download PDF

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Publication number
EP1923152A1
EP1923152A1 EP07254456A EP07254456A EP1923152A1 EP 1923152 A1 EP1923152 A1 EP 1923152A1 EP 07254456 A EP07254456 A EP 07254456A EP 07254456 A EP07254456 A EP 07254456A EP 1923152 A1 EP1923152 A1 EP 1923152A1
Authority
EP
European Patent Office
Prior art keywords
casting core
sheet casting
airfoil
feedcore
array
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.)
Granted
Application number
EP07254456A
Other languages
German (de)
English (en)
Other versions
EP1923152B1 (fr
Inventor
P. Brennan Reilly
Lea D. Kennard
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.)
Raytheon Technologies Corp
Original Assignee
United Technologies Corp
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 United Technologies Corp filed Critical United Technologies Corp
Publication of EP1923152A1 publication Critical patent/EP1923152A1/fr
Application granted granted Critical
Publication of EP1923152B1 publication Critical patent/EP1923152B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • 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
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/103—Multipart cores
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/187—Convection cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/21—Manufacture essentially without removing material by casting
    • F05D2230/211—Manufacture essentially without removing material by casting by precision casting, e.g. microfusing or investment casting
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49622—Vehicular structural member making

Definitions

  • This invention relates to gas turbine engines, and more particularly to cooled turbine elements (e.g., blades and vanes).
  • air from the engine's compressor bypasses the combustor and cools the elements, allowing them to be exposed to temperatures well in excess of the melting point of the element's alloy substrate. Trailing edge cooling of the element's airfoil is particularly significant.
  • the main passageways of a cooling network within the element airfoil are formed utilizing a sacrificial core (e.g., a molded ceramic core) during the element casting process.
  • the airfoil surface may be provided with holes communicating with the network. Some or all of these holes may be drilled. These holes may include film holes on pressure and suction side surfaces and holes along or near the trailing edge.
  • US patent 4601638 discloses the casting of trailing edge cooling passageways by a portion of the ceramic core.
  • US patent 7014424 discloses the casting of trailing edge cooling passageways by a refractory metal core assembled to a ceramic feedcore.
  • one aspect of the invention involves a method for casting a turbine element.
  • a sheet casting core is assembled to a feedcore.
  • the sheet casting core and feedcore are placed in a die.
  • a sacrificial pattern material is molded over the casting core and feedcore to form a pattern including an airfoil.
  • the sheet casting core extends from at or adjacent a trailing edge of the airfoil.
  • the sheet casting core has a first array of open areas and a second array of portions interspersed with the open areas.
  • a first portion of the die has a third array of projections contacting the second array.
  • FIG. 1 shows a turbine blade 20 having an airfoil 22 extending along a length from a proximal inboard end/root 24 at an inboard platform 26 to a distal end 28 defining a blade tip.
  • a convoluted "fir tree" attachment root 29 depends from the underside of the platform 26 for mounting the blade to a complementary slot in a disk (not shown).
  • a number of such blades may be assembled to the disk side by side with their respective platforms forming an inboard ring bounding an inboard portion of a flow path.
  • the blade is unitarily formed of a metal alloy.
  • the airfoil extends from a leading edge 30 to a trailing edge 32.
  • the leading and trailing edges separate pressure and suction sides or surfaces 34 and 36 ( FIG. 2 ).
  • the airfoil is provided with a cooling passageway network 40 ( FIG. 1 ) coupled to ports 42 in the root 29.
  • the exemplary passageway network includes a series of cavities extending generally lengthwise along the airfoil. An aftmost cavity is identified as a trailing edge cavity 44 extending generally parallel to the trailing edge 32. A penultimate cavity 46 is located ahead of the trailing edge cavity 32. In the illustrated embodiment, the cavities 44 and 46 are impingement cavities.
  • the penultimate cavity 46 receives air from a supply cavity 48 through an array of apertures 50 in the wall 52 separating the two.
  • the exemplary supply cavity 48 receives air from one or more of the ports 42.
  • the trailing edge cavity 44 receives air from the penultimate cavity 46 via apertures 56 in the wall 58 between the two.
  • FIG. 3 shows a trailing edge portion of the airfoil including a trailing edge cooling slot 70 extending from an inlet 72 at the cavity 44 to an outlet 74 at the trailing end of the airfoil pressure side 34.
  • the slot 70 has pressure and suction side wall surfaces 76 and 78 along pressure and suction side walls 80 and 82 of the airfoil.
  • An exemplary slot height H between the surfaces 76 and 78 is an essentially constant 2.5mm, more broadly 2-3mm or 1.2-7.6mm.
  • An exemplary slot streamwise length L s is 12.7mm, more broadly 10-15mm.
  • An exemplary outlet length L o (streamwise and parallel to the slot) is 2.54mm, more broadly 2-3mm.
  • FIG. 4 shows further details of the slot 70.
  • the exemplary slot 70 includes a number of posts spanning between the surfaces 76 and 78.
  • the exemplary slot includes a first/upstream/leading array of posts 90, a second array of posts 92, a third array of posts 94, a fourth array of posts 96, a fifth array of posts 98, and a sixth/downstream/trailing array of posts 100.
  • Each of the exemplary arrays 90-100 extends essentially spanwise along the airfoil.
  • the size and cross-sectional shape of the posts, the pitch or spacing within an array, the pitch or spacing between arrays, and the relative phases of the arrays may be selected to achieve desired airflow and heat transfer properties.
  • the exemplary trailing posts 100 are streamwise elongate of near teardrop planform.
  • the posts 100 have width W P and length L P .
  • the pressure side wall 80 has a small recess 120 ( FIG. 5 ) forming an upstream portion of the outlet 74.
  • the pressure side wall 80 has a trailing portion 122.
  • the exemplary trailing portion 122 is arcuate and downstream concave to merge with the adjacent posts 100.
  • the main passageways of the airfoil may be cast against a sacrificial ceramic feedcore.
  • the slot 70 may be cast against a refractory metal core (RMC) assembled to the feedcore.
  • the core assembly may be molded within sacrificial material (e.g., wax) of an investment casting pattern.
  • a ceramic shell may be formed over the pattern (e.g., in a multi-stage stuccoing process).
  • the sacrificial material may be removed (e.g., in an autoclave), leaving the core assembly within the ceramic shell.
  • the pattern may have surface features corresponding with or essentially identical to corresponding external surface features of the turbine element to be cast. These features form inverse surface features of the associated shell and are, themselves, molded against inverse features of an associated die.
  • FIG. 6 shows a refractory metal core 180 assembled to a ceramic feedcore 182.
  • FIG. 7 shows the core assembly mounted in a pattern molding die.
  • the exemplary RMC 180 is formed as a sheet of essentially constant thickness T s between first and second surfaces (faces) 184 and 186 generally along pressure and suction sides.
  • the faces 184 and 186 extend between a leading/upstream end 188 and a trailing/downstream end 190 ( FIG. 6 ).
  • the faces also extend between first (e.g., inboard) and second (e.g., outboard) spanwise ends 192 and 194.
  • a leading portion 196 ( FIG. 7 ) of the RMC is captured within a trailing slot 200 in a trailing leg 202 of the feedcore.
  • FIG. 6 further shows the RMC as including arrays of through-holes 204, 206, 208, 210, 212, and 214 complementary to and for casting the posts 90, 92, 94, 96, 98, and 100, respectively.
  • the exemplary RMC has a series of relief notches 216 each extending to a single one of several of the holes 214.
  • FIG. 7 shows the exemplary die as including a series of die elements 210, 212, and 214.
  • the elements combine to define a cavity 220 for receiving wax to be molded over the core assembly.
  • the die elements 210, 212, and 214 may be assembled over the core assembly by relative translations in associated pull directions 510, 512, and 514. After molding, separation of the die elements may be by a reverse translation.
  • the first element 210 falls generally along the pressure side of the airfoil portion of the cavity and pattern.
  • the second element 212 falls generally along the suction side.
  • the third element 214 has a relatively small extent along a cavity 220 just at the trailing edge thereof. In the exemplary die, a portion 230 of the RMC 200 extending beyond the trailing edge is captured between the first and third die elements 210 and 214.
  • the pattern preferably includes recesses corresponding to the recesses 120 in the wall 80.
  • the first element 210 includes a spanwise array of projections 240 (see also FIG. 8).
  • FIG. 8 also shows a surface portion 242 of the die element 210 for molding the pressure side surface of the pattern.
  • This surface portion 242 includes a trailing array of portions 244 alternatingly extending between the projections 240 for molding the exposed pressure side surfaces of the trailing array of pattern posts (corresponding to the airfoil posts 100).
  • FIG. 8 further shows a surface portion 250 for contacting the pressure side surface 184 of the RMC downstream of the surface portion 242 and projections 240.
  • the present teachings may be implemented to manufacture a reengineered turbine element as a replacement for an existing element (or element configuration).
  • An exemplary existing element may be manufactured using a molded ceramic core to provide both the feed passageways and the outlet passageways.
  • the present teachings may permit finer features to be formed in the outlet passageway (e.g., a passageway with a smaller height, more and differently shaped posts, and the like).
  • the projections 240 may provide similar ultimate features in the wax pattern to features molded by projections from the trailing portion of the baseline ceramic core. However, in the present implementation, the recesses formed by these projections would be filled during the shelling process rather than being formed over and remaining filled by the core projections.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP07254456A 2006-11-14 2007-11-14 Procédé de coulage d'aube de turbine Active EP1923152B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/600,416 US20080110024A1 (en) 2006-11-14 2006-11-14 Airfoil casting methods

Publications (2)

Publication Number Publication Date
EP1923152A1 true EP1923152A1 (fr) 2008-05-21
EP1923152B1 EP1923152B1 (fr) 2012-01-04

Family

ID=39081787

Family Applications (1)

Application Number Title Priority Date Filing Date
EP07254456A Active EP1923152B1 (fr) 2006-11-14 2007-11-14 Procédé de coulage d'aube de turbine

Country Status (2)

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US (2) US20080110024A1 (fr)
EP (1) EP1923152B1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2146052A2 (fr) 2008-07-14 2010-01-20 United Technologies Corporation Passage de bord de fuite de surface portante refroidissable
EP2340902A1 (fr) * 2009-12-15 2011-07-06 Rolls-Royce plc Moulage de caractéristiques internes dans un produit
FR2971440A1 (fr) * 2011-02-14 2012-08-17 Peugeot Citroen Automobiles Sa Outillage pour le moulage d'une piece de fonderie et un procede de moulage
EP3060363A4 (fr) * 2013-10-24 2017-07-26 United Technologies Corporation Noyaux de moulage à noyau perdu pour former des passages de refroidissement
EP3351731A1 (fr) * 2017-01-19 2018-07-25 United Technologies Corporation Configuration de bord de fuite comportant des rainures de fonderie et des trous de refroidissement par film percés
WO2019046036A1 (fr) * 2017-08-28 2019-03-07 Siemens Aktiengesellschaft Procédé pour réaliser un profil aérodynamique de turbine

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2933884B1 (fr) * 2008-07-16 2012-07-27 Snecma Procede de fabrication d'une piece d'aubage.
US8944141B2 (en) 2010-12-22 2015-02-03 United Technologies Corporation Drill to flow mini core
EP2956257B1 (fr) * 2013-02-12 2022-07-13 Raytheon Technologies Corporation Passage de refroidissement de composant de moteur à turbine à gaz et âme économe en espace
PL3086893T3 (pl) * 2013-12-23 2020-01-31 United Technologies Corporation Rama konstrukcyjna z traconym rdzeniem
US12031724B2 (en) 2022-05-05 2024-07-09 General Electric Company Turbine engine combustor having a combustion chamber heat shield

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EP1306147A1 (fr) * 2001-10-24 2003-05-02 United Technologies Corporation Noyau destiné au moulage de précision
EP1600230A1 (fr) * 2004-04-15 2005-11-30 United Technologies Corporation Procédé d'élaboration d'un moule de coulée de précision
EP1652601A2 (fr) * 2004-10-26 2006-05-03 United Technologies Corporation Revêtement non oxidable
EP1715139A2 (fr) * 2005-04-22 2006-10-25 United Technologies Corporation Refroidissement du bord de fuite d'une aube de turbine

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US4180373A (en) * 1977-12-28 1979-12-25 United Technologies Corporation Turbine blade
US4286924A (en) * 1978-01-14 1981-09-01 Rolls-Royce Limited Rotor blade or stator vane for a gas turbine engine
US4303374A (en) * 1978-12-15 1981-12-01 General Electric Company Film cooled airfoil body
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US5599166A (en) * 1994-11-01 1997-02-04 United Technologies Corporation Core for fabrication of gas turbine engine airfoils
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US5947181A (en) * 1996-07-10 1999-09-07 General Electric Co. Composite, internal reinforced ceramic cores and related methods
US6062817A (en) * 1998-11-06 2000-05-16 General Electric Company Apparatus and methods for cooling slot step elimination
US6176678B1 (en) * 1998-11-06 2001-01-23 General Electric Company Apparatus and methods for turbine blade cooling
US6179565B1 (en) * 1999-08-09 2001-01-30 United Technologies Corporation Coolable airfoil structure
EP1245785B1 (fr) * 2001-03-26 2005-06-01 Siemens Aktiengesellschaft Méthode de fabrication d' une aube de turbine
US6672836B2 (en) * 2001-12-11 2004-01-06 United Technologies Corporation Coolable rotor blade for an industrial gas turbine engine
US7014424B2 (en) * 2003-04-08 2006-03-21 United Technologies Corporation Turbine element
US7097425B2 (en) * 2003-08-08 2006-08-29 United Technologies Corporation Microcircuit cooling for a turbine airfoil
US7216689B2 (en) * 2004-06-14 2007-05-15 United Technologies Corporation Investment casting
US7172012B1 (en) * 2004-07-14 2007-02-06 United Technologies Corporation Investment casting
US7364405B2 (en) * 2005-11-23 2008-04-29 United Technologies Corporation Microcircuit cooling for vanes
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Publication number Priority date Publication date Assignee Title
EP1306147A1 (fr) * 2001-10-24 2003-05-02 United Technologies Corporation Noyau destiné au moulage de précision
EP1600230A1 (fr) * 2004-04-15 2005-11-30 United Technologies Corporation Procédé d'élaboration d'un moule de coulée de précision
EP1652601A2 (fr) * 2004-10-26 2006-05-03 United Technologies Corporation Revêtement non oxidable
EP1715139A2 (fr) * 2005-04-22 2006-10-25 United Technologies Corporation Refroidissement du bord de fuite d'une aube de turbine

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2146052A2 (fr) 2008-07-14 2010-01-20 United Technologies Corporation Passage de bord de fuite de surface portante refroidissable
EP2146052A3 (fr) * 2008-07-14 2013-01-23 United Technologies Corporation Passage de bord de fuite de surface portante refroidissable
EP2340902A1 (fr) * 2009-12-15 2011-07-06 Rolls-Royce plc Moulage de caractéristiques internes dans un produit
US9038706B2 (en) 2009-12-15 2015-05-26 Rolls-Royce Plc Casting of internal features within a product
FR2971440A1 (fr) * 2011-02-14 2012-08-17 Peugeot Citroen Automobiles Sa Outillage pour le moulage d'une piece de fonderie et un procede de moulage
EP3060363A4 (fr) * 2013-10-24 2017-07-26 United Technologies Corporation Noyaux de moulage à noyau perdu pour former des passages de refroidissement
US10005123B2 (en) 2013-10-24 2018-06-26 United Technologies Corporation Lost core molding cores for forming cooling passages
US10821500B2 (en) 2013-10-24 2020-11-03 Raytheon Technologies Corporation Lost core molding cores for forming cooling passages
EP3351731A1 (fr) * 2017-01-19 2018-07-25 United Technologies Corporation Configuration de bord de fuite comportant des rainures de fonderie et des trous de refroidissement par film percés
US10641103B2 (en) 2017-01-19 2020-05-05 United Technologies Corporation Trailing edge configuration with cast slots and drilled filmholes
WO2019046036A1 (fr) * 2017-08-28 2019-03-07 Siemens Aktiengesellschaft Procédé pour réaliser un profil aérodynamique de turbine

Also Published As

Publication number Publication date
EP1923152B1 (fr) 2012-01-04
US20120055647A1 (en) 2012-03-08
US20080110024A1 (en) 2008-05-15

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