EP2792434A1 - Method for manufacturing a component having a damping structure - Google Patents
Method for manufacturing a component having a damping structure Download PDFInfo
- Publication number
- EP2792434A1 EP2792434A1 EP13164577.2A EP13164577A EP2792434A1 EP 2792434 A1 EP2792434 A1 EP 2792434A1 EP 13164577 A EP13164577 A EP 13164577A EP 2792434 A1 EP2792434 A1 EP 2792434A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- component
- base material
- core parts
- damping structure
- manufacturing
- 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.)
- Withdrawn
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Classifications
-
- 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
-
- 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
- B22C9/108—Installation of cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
-
- 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
- F01D5/16—Form or construction for counteracting blade vibration
-
- 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
Definitions
- the present disclosure relates to a method for manufacturing a component having a damping structure.
- the component can be a part of a large machine such as a gas or steam turbine, for example a blade, a vane, a casing or also parts thereof, or parts of a large electric generator such as a hydro generator or a turbo generator, but in different application the component can also be a part of a different device that requires damping to improve service lifetime.
- a blade or vane of a turbine such as a gas turbine will be made, the scope of the disclosure is anyhow not limited to such an application.
- the blade length of the last turbine stage has a major impact on engine performance.
- the engine efficiency can be increased.
- damping elements include for example under-platform dampers, but these under-platform dampers do not provide enough damping for very long blades and they can be used only for the vibration modes with significant relative movement at the platforms.
- damping elements are the so called impact dampers (described in US 6,827,551 ) or particle dampers (described in US 6,224,341 ).
- Particle dampers include a cavity in the component whose vibrations need to be damped; the cavity is fully or partly filled with particle material. Particle dampers proved to be quite effective in damping vibrations, but their manufacturing is not easy. For example, the cavities must be cast and after casting the cavities have to be filled with particle material. Finally the cavities must be closed e.g. by a threaded plug. However, the requirements for the location, size and geometry of the cavities must accept compromises (e.g. in design or use of non-optimal solutions). In addition, filling the cavities after they have been realised can be troublesome and costly, because of the need to handle an already casted component that shall not be damaged and to introduce the particle material in the cavities that can be small or whose opening are small or difficult to access.
- the method according to clam 1 of that mentioned application can be used preferably for manufacturing components having a thin thickness.
- the method comprising the following steps:
- An aspect of the disclosure includes providing a method for manufacturing components having a damping structure that allows great flexibility for the location, size and geometry of the damping structures, at the same time, counteracts the drawbacks of the known state of the art solutions.
- the component according to the invention is cast in a known usual way, but using cores, made of ceramic or of other high melting materials, for example high melting metallic alloys using as damping means. Those additional cores are not removed after casting.
- Damping into a part can be introduced by having one material fully confined by another material, if the two materials have got reasonable different physical properties, e.g. Young's modulus and/or thermal expansion. Due to the differences in properties relative movement during service and especially during vibrational excitation between the contact surfaces are induced. Those cause dissipation of energy due to friction effects. Thus, vibrational response of the part is reduced.
- Young's modulus and/or thermal expansion Due to the differences in properties relative movement during service and especially during vibrational excitation between the contact surfaces are induced. Those cause dissipation of energy due to friction effects. Thus, vibrational response of the part is reduced.
- the method can be used to manufacture blades or vanes of turbines, compressors, etc, but also other structure for power generation, automotive, small appliances or devices such as PCs, fans, etc requiring damping to improve service lifetime.
- the method for manufacturing a component 1 having an internal damping structure 2 comprising the following steps:
- the component can be any kind of component that requires damping.
- said first material is a ceramic material or a high melting metallic material. It is essential that the first material (for the core parts) and the second material (base material) have got reasonable for present application different physical properties, at least different melting points.
- the base material 4 is preferable a metallic material, for example a Nickel base superalloy or a Co base superalloy or a high temperature resistant steel. The melting point of the base material is lower than the melting point of the core part material.
- Fig. 1a, 1 b shows a cross section of a schematic airfoil of a gas turbine blade according to one embodiment of the invention.
- the component 1 can be a blade or a vane of a turbo machine.
- the cross section in Fig. 1 a is done after step f) of the described method.
- the main inner core 3 is connected via webs 5 with the additional core parts 3'.
- the cores parts 3, 3' are made of a first material, for example of ceramic material or of a high melting metallic material.
- the core parts 3, 3' can also be made of different material dependent on the desired damping requirements.
- the core parts 3, 3' are surrounded by a base material, for example a Nickel base superalloy.
- the inner core 3 is then removed in this embodiment, so that according to Fig. 1 b an internal cavity 6 is located in the component 1, which is here used as a cooling channel for guiding a cooling medium during operation of the turbo machine.
- the additional core parts 3' are not removed, they build the desired damping structure 2 in the airfoil 1.
- Fig. 2 shows a second embodiment.
- the component 1 is an insert to be connected to a complex element.
- the component 1 (insert) has damping structures 2 with several core parts 3'.
- the core parts 3' have different shape and location to better counteract the oscillations.
- the insert can for example be used for manufacturing new turbine part or for repairing or reconditioning of already used parts in service.
- the method can be used to manufacture components that are:
- the method can be used to manufacture blades or vanes of turbines, compressors, etc, but also other structure for power generation, automotive, small appliances or devices such as PCs, fans, etc requiring damping to improve service lifetime.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
Abstract
A method for manufacturing a component (1) having an internal damping structure (2) is disclosed. The method comprising the following steps:
a) providing core parts (3, 3'), made of a first material with a melting point higher than the manufacturing process temperature,
b) arranging the core parts (3,3') in a cast mould in a pattern for receiving a desired internal damping structure (2),
c) providing and melting a base material (4), the base material (4) having different physical properties, at least a lower melting point then the first material, then
d) casting the component (1) by using the molten base material (4), the base material surrounding the core parts (3,3'), then
e) solidification of the base material (4), then
f) removing the cast mould, then
g) optionally removing a part (3) of the core parts.
a) providing core parts (3, 3'), made of a first material with a melting point higher than the manufacturing process temperature,
b) arranging the core parts (3,3') in a cast mould in a pattern for receiving a desired internal damping structure (2),
c) providing and melting a base material (4), the base material (4) having different physical properties, at least a lower melting point then the first material, then
d) casting the component (1) by using the molten base material (4), the base material surrounding the core parts (3,3'), then
e) solidification of the base material (4), then
f) removing the cast mould, then
g) optionally removing a part (3) of the core parts.
Description
- The present disclosure relates to a method for manufacturing a component having a damping structure.
- The component can be a part of a large machine such as a gas or steam turbine, for example a blade, a vane, a casing or also parts thereof, or parts of a large electric generator such as a hydro generator or a turbo generator, but in different application the component can also be a part of a different device that requires damping to improve service lifetime. In the following particular reference to a blade or vane of a turbine such as a gas turbine will be made, the scope of the disclosure is anyhow not limited to such an application.
- The blade length of the last turbine stage has a major impact on engine performance. In particular, by increasing the last turbine blade length, the engine efficiency can be increased. As longer the blade is as lower is the Ma number and in turn flow losses decrease.
- However, longer blades suffer vibration problems (e.g. flutter) and thus require damping elements to reduce vibration stresses (e. g. shroud, snubber).
- State of the art of damping elements include for example under-platform dampers, but these under-platform dampers do not provide enough damping for very long blades and they can be used only for the vibration modes with significant relative movement at the platforms.
- Other damping elements are the so called impact dampers (described in
US 6,827,551 ) or particle dampers (described inUS 6,224,341 ). - Particle dampers include a cavity in the component whose vibrations need to be damped; the cavity is fully or partly filled with particle material. Particle dampers proved to be quite effective in damping vibrations, but their manufacturing is not easy. For example, the cavities must be cast and after casting the cavities have to be filled with particle material. Finally the cavities must be closed e.g. by a threaded plug. However, the requirements for the location, size and geometry of the cavities must accept compromises (e.g. in design or use of non-optimal solutions). In addition, filling the cavities after they have been realised can be troublesome and costly, because of the need to handle an already casted component that shall not be damaged and to introduce the particle material in the cavities that can be small or whose opening are small or difficult to access.
- The applicant has filed a so far unpublished application in which a method for manufacturing components having a damping structure is disclosed that allows great flexibility for the location, size and geometry of the cavities and at the same time, counteracts the drawbacks caused by needs of introducing particle material into the cavities.
- The method according to clam 1 of that mentioned application can be used preferably for manufacturing components having a thin thickness. The method comprising the following steps:
- a) providing a substrate base, then
- b) providing a layer of particle material on the substrate base, then
- c) welding and/or sintering at least a part of the particle material of the layer of particle material according to a defined pattern, then
- d) providing an additional layer of particle material on top of the layer of particle material whose particle material has already been welded and/or sintered, then
- e) welding and/or sintering at least a part of the particle material of the additional layer of particle material according to a defined pattern, then
- f) repeating steps d) and e) and define the component, and wherein
- Although this method has the above mentioned advantages it has the disadvantage that it is time consuming because of the layer wise built up of the component.
- An aspect of the disclosure includes providing a method for manufacturing components having a damping structure that allows great flexibility for the location, size and geometry of the damping structures, at the same time, counteracts the drawbacks of the known state of the art solutions.
- These and further aspects are attained by providing a method in accordance with the accompanying claims.
- The component according to the invention is cast in a known usual way, but using cores, made of ceramic or of other high melting materials, for example high melting metallic alloys using as damping means. Those additional cores are not removed after casting.
- Damping into a part can be introduced by having one material fully confined by another material, if the two materials have got reasonable different physical properties, e.g. Young's modulus and/or thermal expansion. Due to the differences in properties relative movement during service and especially during vibrational excitation between the contact surfaces are induced. Those cause dissipation of energy due to friction effects. Thus, vibrational response of the part is reduced.
- For example the method can be used to manufacture blades or vanes of turbines, compressors, etc, but also other structure for power generation, automotive, small appliances or devices such as PCs, fans, etc requiring damping to improve service lifetime.
- Further characteristics and advantages will be more apparent from the description of a preferred but non-exclusive embodiment of the method, illustrated by way of non-limiting example in the accompanying drawings, in which:
-
Fig. 1a,1b shows each a cross section of a schematic airfoil of a turbine blade according to an embodiment of the invention, whereinFig. 1 a shows the cross section after step f) andFig. 1b shows the cross section after step g) of the disclosed method according to claim 1; and -
Fig. 2 shows a part of a component, for example an insert for a gas turbine blade. - With reference to the figures the invention is now described in detail.
- According to claim 1 the method for manufacturing a component 1 having an
internal damping structure 2 comprising the following steps: - a) providing
core parts 3, 3', made of a first material with a melting point higher than the manufacturing process temperature, - b) arranging said
core parts 3, 3' in a cast mould (not shown) in a pattern for receiving a desiredinternal damping structure 2, - c) providing and melting a
base material 4, thebase material 4 having different physical properties, at least a lower melting point then the first material, then - d) casting the component 1 by using the
molten base material 4, the base material surrounding thecore parts 3,3', then - e) solidification of the
base material 4, then - f) removing the cast mould, then
- g) optionally removing a
part 3 of the core parts for building an internal cavity (6). - The component can be any kind of component that requires damping.
- Preferably, said first material is a ceramic material or a high melting metallic material. It is essential that the first material (for the core parts) and the second material (base material) have got reasonable for present application different physical properties, at least different melting points. The
base material 4 is preferable a metallic material, for example a Nickel base superalloy or a Co base superalloy or a high temperature resistant steel. The melting point of the base material is lower than the melting point of the core part material. -
Fig. 1a, 1 b shows a cross section of a schematic airfoil of a gas turbine blade according to one embodiment of the invention. - The component 1 can be a blade or a vane of a turbo machine. The cross section in
Fig. 1 a is done after step f) of the described method. The maininner core 3 is connected viawebs 5 with the additional core parts 3'. There can be a plurality ofwebs 5 located on thecore parts 3, 3' over the entire height to give a good stability. Thecores parts 3, 3' are made of a first material, for example of ceramic material or of a high melting metallic material. Thecore parts 3, 3' can also be made of different material dependent on the desired damping requirements. Thecore parts 3, 3' are surrounded by a base material, for example a Nickel base superalloy. - After finishing the casting (after step f)) the
inner core 3 is then removed in this embodiment, so that according toFig. 1 b an internal cavity 6 is located in the component 1, which is here used as a cooling channel for guiding a cooling medium during operation of the turbo machine. The additional core parts 3' are not removed, they build the desired dampingstructure 2 in the airfoil 1. -
Fig. 2 shows a second embodiment. The component 1 is an insert to be connected to a complex element. The component 1 (insert) has dampingstructures 2 with several core parts 3'. The core parts 3' have different shape and location to better counteract the oscillations. The insert can for example be used for manufacturing new turbine part or for repairing or reconditioning of already used parts in service. - The method can be used to manufacture components that are:
- an whole complex element, such as a whole blade or vane, including a root and an airfoil extending from the root, or
- a part of a more complex element, such as an airfoil of a blade having an airfoil connected to a root; or
- an insert to be connected to a complex element.
- For example the method can be used to manufacture blades or vanes of turbines, compressors, etc, but also other structure for power generation, automotive, small appliances or devices such as PCs, fans, etc requiring damping to improve service lifetime.
REFERENCE NUMBERS 1 component 2 damping structure 3, 3' core parts 4 base material 5 web 6 internal cavity
closing the at least one cavity without removing at least a part of the particle material from it. Preferably, the particle material is metallic material and the welding and/or sintering include laser or electron beam welding and/or sintering.
Claims (7)
- A method for manufacturing a component (1) having an internal damping structure (2), the method comprisinga) providing core parts (3, 3'), made of a first material with a melting point higher than the manufacturing process temperature,b) arranging the core parts (3,3') in a cast mould in a pattern for receiving a desired internal damping structure (2),c) providing and melting a base material (4), the base material (4) having different physical properties, at least a lower melting point then the first material, thend) casting the component (1) by using the molten base material (4), the base material surrounding the core parts (3,3'), thene) solidification of the base material (4), thenf) removing the cast mould, theng) optionally removing a part (3) of the core parts.
- The method according to claim 1, characterized in that said first material is ceramic or a high melting metallic material.
- The method according to claim 1, characterized in that said core parts (3, 3') are connected via at least one web (5).
- The method according to claim 3, characterized in that there is a plurality of webs (5) located on the core parts (3, 3').
- The method according to claim 1, characterized in that said base material is metallic material, preferable a Nickel base superalloy.
- The method according to one of claims 1 to 5, characterized in that said component (1) is a blade or a vane of a turbo machine and that the main inner core (3) is removed after casting for cooling purposes of the component (1).
- The method according to one of claims 1 to 5, characterized in that said component (1) is an insert to be connected to a complex element.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP13164577.2A EP2792434A1 (en) | 2013-04-19 | 2013-04-19 | Method for manufacturing a component having a damping structure |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP13164577.2A EP2792434A1 (en) | 2013-04-19 | 2013-04-19 | Method for manufacturing a component having a damping structure |
Publications (1)
Publication Number | Publication Date |
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EP2792434A1 true EP2792434A1 (en) | 2014-10-22 |
Family
ID=48143501
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP13164577.2A Withdrawn EP2792434A1 (en) | 2013-04-19 | 2013-04-19 | Method for manufacturing a component having a damping structure |
Country Status (1)
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EP (1) | EP2792434A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10577940B2 (en) | 2017-01-31 | 2020-03-03 | General Electric Company | Turbomachine rotor blade |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5915452A (en) * | 1995-06-07 | 1999-06-29 | Howmet Research Corporation | Apparatus for removing cores from castings |
US6224341B1 (en) | 1996-09-17 | 2001-05-01 | Edge Innovations & Technology, Llc | Damping systems for vibrating members |
US6827551B1 (en) | 2000-02-01 | 2004-12-07 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Self-tuning impact damper for rotating blades |
US20090020256A1 (en) * | 2007-07-20 | 2009-01-22 | Gm Global Technology Operations, Inc. | Method of casting damped part with insert |
EP2161411A1 (en) * | 2008-09-05 | 2010-03-10 | Siemens Aktiengesellschaft | Turbine blade with customised natural frequency by means of an inlay |
EP2441542A1 (en) * | 2010-10-12 | 2012-04-18 | Siemens Aktiengesellschaft | Method for producing a cast component with internal frame and component |
-
2013
- 2013-04-19 EP EP13164577.2A patent/EP2792434A1/en not_active Withdrawn
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5915452A (en) * | 1995-06-07 | 1999-06-29 | Howmet Research Corporation | Apparatus for removing cores from castings |
US6224341B1 (en) | 1996-09-17 | 2001-05-01 | Edge Innovations & Technology, Llc | Damping systems for vibrating members |
US6827551B1 (en) | 2000-02-01 | 2004-12-07 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Self-tuning impact damper for rotating blades |
US20090020256A1 (en) * | 2007-07-20 | 2009-01-22 | Gm Global Technology Operations, Inc. | Method of casting damped part with insert |
EP2161411A1 (en) * | 2008-09-05 | 2010-03-10 | Siemens Aktiengesellschaft | Turbine blade with customised natural frequency by means of an inlay |
EP2441542A1 (en) * | 2010-10-12 | 2012-04-18 | Siemens Aktiengesellschaft | Method for producing a cast component with internal frame and component |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10577940B2 (en) | 2017-01-31 | 2020-03-03 | General Electric Company | Turbomachine rotor blade |
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