EP3980201A1 - Improved method for forming a wax model for a turbine blade - Google Patents

Improved method for forming a wax model for a turbine blade

Info

Publication number
EP3980201A1
EP3980201A1 EP20740373.4A EP20740373A EP3980201A1 EP 3980201 A1 EP3980201 A1 EP 3980201A1 EP 20740373 A EP20740373 A EP 20740373A EP 3980201 A1 EP3980201 A1 EP 3980201A1
Authority
EP
European Patent Office
Prior art keywords
shell
core
wax
surface shell
intrados
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.)
Pending
Application number
EP20740373.4A
Other languages
German (de)
French (fr)
Inventor
Ramzi BOHLI
Mirna Bechelany
Didier DANGEUL
Didier Maurice Marceau GUERCHE
Alain Armel LE HEGARAT
Ngadia Taha NIANE
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.)
Safran SA
Original Assignee
Safran SA
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 Safran SA filed Critical Safran SA
Publication of EP3980201A1 publication Critical patent/EP3980201A1/en
Pending legal-status Critical Current

Links

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
    • B22C7/023—Patterns made from expanded plastic materials
    • B22C7/026—Patterns made from expanded plastic materials by assembling preformed parts
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing

Definitions

  • This presentation relates to the field of turbomachines, and more specifically relates to the techniques of manufacturing wax models for the production of turbomachine blades by lost wax casting.
  • turbomachine blades are commonly carried out by lost wax casting, in particular because of the advantages of this process in terms of tolerances and precision.
  • the present disclosure thus aims to propose a solution making it possible to at least partially respond to this problem.
  • the present invention provides a method of forming a wax model for the production of turbine blades by lost wax casting, in which: a core is provided, defining ducts extending between a foot and a top, we provide an intrados shell and an extrados shell, we position the intrados shell and the extrados shell on either side of ducts of the core adjacent to the foot, we secure the intrados shell and the extrados shell around the core , the core provided with the lower surface shell and the upper surface shell is positioned in an injection mold, wax is injected around said core provided with the lower surface shell and the upper surface shell, so as to form a wax model comprising a blade blade and a blade root comprising a tree, the shell intrados and the extrados shell being positioned around the core so as to form part of the tree of the wax model.
  • the intrados shell and the extrados shell are made of wax or of polymer.
  • the intrados shell and the extrados shell are positioned around the core and are each in contact with said core, and in which the intrados shell and the extrados shell are positioned so as to define a clearance of between 0.05 and 0.2 mm between them.
  • the lower surface shell and the upper surface shell are positioned around the core and are in contact with each other, the lower surface shell and the upper surface shell being dimensioned so as to allow a clearance of between 0.05 and 0.2 mm relative to the core prior to their joining around the core.
  • the core comprises at least 3 conduits extending between a foot and a top, and in which the intrados shell and / or the extrados shell comprises bosses adapted to be inserted between said conduits, so as to indexing said shell relative to the ducts.
  • the lower surface shell and the upper surface shell are positioned around the core in a region of the core in which the wax model comprises walls having a thickness between 1 and 10 times the thickness of the ducts of the core.
  • said method comprises a preliminary step of manufacturing the lower surface shell and the upper surface shell by additive manufacturing.
  • FIG. 1 shows an example of a kernel for a method according to one aspect of the invention.
  • Figure 2 shows another view of an example of a core provided with a shell a method according to one aspect of the invention.
  • Figure 3 shows another view of an exemplary core provided with a shell for a method according to one aspect of the invention.
  • Figure 4 is a view of a shell according to one aspect of the invention.
  • Figure 5 is another view of a shell according to one aspect of the invention.
  • Figure 6 shows a sectional view of a ceramic core around which a wax model has been cast.
  • FIG. 1 shows an example of a core 1 typically made of ceramic for a method according to one aspect of the invention.
  • the core 1 as shown comprises a foot 2 and a top 3 between which extend a plurality of conduits 4.
  • the core 1 comprises 4 conduits. It is well understood that this example is not limiting, and that the present description is directly transposable to a core 1 comprising any number of conduits.
  • a longitudinal direction DL which corresponds to the direction going from the foot 2 to the top 3
  • a transverse direction DT extending in the plane of Figure 1, and perpendicular to the longitudinal direction DL
  • a thickness E measured in a direction perpendicular to a plane defined by the transverse direction DT and by the longitudinal direction DL.
  • the longitudinal direction DL defines the length of the core 1
  • the transverse direction DT defines its width
  • the thickness E its thickness.
  • the core 1 is intended to be positioned in a wax injection mold, with a view to forming a wax model of a turbine blade, in order to define the internal ducts of the blade.
  • This zone Z1 in fact corresponds to a zone of the blade root which is qualified as “fir” or “fir root” having walls having a significant thickness, thus being able for example to be 10 times greater than the thickness of the walls of the blade. dawn in the other dawn regions.
  • the proposed method thus aims to position a shell around the zone Z1, this shell having a dual function of protecting the core 1 and preventing the formation of deformations or cracks in the wax model.
  • FIGs 2 and 3 thus illustrate the core 1 as shown in Figure 1 which is here provided with a shell 5.
  • the shell 5 as presented comprises an intrados shell 6 and an extrados shell 7, which are positioned respectively on the intrados face and on the extrados face of the core 1, the intrados and extrados designations being defined as a function of the geometry of the desired blade.
  • the shell 5 can comprise more than two components, since it makes it possible to at least partially envelop a region of the core 1 as will be seen below, the geometry of the shell 5 being adapted as a function of the core geometry 1.
  • the intrados shell 6 and the extrados shell 7 are defined so as to come at least partially envelop the ducts 4 at their junction with the foot 2 of the core 1. More specifically, the intrados shell 6 and the extrados shell 7 are positioned so as to at least partially envelop the ducts 4 over part of their length (the length being measured in a direction going u foot 2 to the top 3 of core 1), and typically to cover part of foot 2 of core 1 from which the ducts 4 extend.
  • Figures 4 and 5 show an example of a portion of the shell 5, these figures can equally well represent a lower surface shell 6 or an upper surface shell 7.
  • the intrados shell 6 as shown comprises a body 61 generally forming a plate of variable thickness, and dimensioned so as to be able to extend over all of the ducts 4 of the core 1 in the transverse direction DT (c ' i.e. according to the width) of the core 1.
  • the body 61 has two ends in the transverse direction DT provided with ribs 62 each extending in the longitudinal direction DL.
  • the body 61 is also typically provided with bosses 63 extending along the thickness of the lower surface shell 6, and adapted to be inserted between two adjacent ducts 4 of the core 1.
  • the ribs 62 are for their part typically dimensioned so as to cover partially the ends of the conduits 4 in the tangential direction DT.
  • the intrados shell 6 and the extrados shell 7 positioned around the core 1 are typically secured around the core 1, for example by means of an adhesive, which may be a suitable wax.
  • the core 1 thus provided with the shell 5 is then positioned in a wax injection mold for the production of a wax model of a turbine blade.
  • This partial envelopment of the core 1 protects it against the forces generated by the injection of wax during the formation of the associated wax model, which thus makes it possible to prevent the risk of rupture of the core 1 during the injection. of wax.
  • FIG. 6 shows an example of a sectional view of a wax model 8 formed around a core 1 provided with an intrados shell 6 and an extrados shell 7.
  • the intrados shell 6 and the extrados shell 7 positioned around the core 1 make it possible to reduce the quantity of wax necessary for the formation of the wax model, insofar as the shells 6 and 7 will here directly form part of the wax model.
  • this region has a significant thickness compared to the other regions of the wax model 8.
  • the shells 6 and 7 form part of this thickness, which thus makes it possible to reduce the amount of wax required to the production of this region, and therefore limits the risk of cracks forming resulting from the removal of the wax during its cooling.
  • the intrados shell 6 and the extrados shell 7 are typically sized so that the thickness of wax injected around the shells 6 and 7 for the formation of the wax model is constant or substantially constant.
  • the intrados shell 6 and the extrados shell 7 are typically made of wax or of polymer, the choice of material being made in particular according to its compatibility with the wax used during the injection for the production of the wax model 8 of dawn.
  • the material used must also be able to be removed during an operation to remove the wax model or firing a ceramic shell around the wax model.
  • the intrados shell 6 and the extrados shell 7 are typically produced by additive manufacturing, for example by polymerization of a resin under the action of a laser or a UV lamp, by projection of drops of material, by projection of a binder on a bed of powder, for example solidification of powder under the action of an energy source (laser or electron beam), by fusion of wire through a heating nozzle, or by any other suitable process, in particular any other suitable additive manufacturing process .
  • the intrados shell 6 and the extrados shell 7 can also for example be produced by simultaneous injection with the wax model, during an injection operation, the intrados shell and the extrados shell produced during such an operation then being used for the production of a wax model during a subsequent injection operation.
  • the intrados shell 6 and the extrados shell 7 are then produced during an N injection step, which can then be used for an N + 1 injection step.
  • the intrados shell 6 and the extrados shell 7 are typically configured so as to define a spacing either between the intrados shell 6 and the extrados shell 7, or between said shells 6 and 7 and the core 1.
  • the intrados shell 6 and extrados shell 7 are dimensioned so that when they are each positioned resting against the core 1, a spacing typically between 0.05 and 0.2 mm or typically equal to 0.1 mm is formed between said intrados 6 and extrados hulls 7. This embodiment is illustrated in FIG. 3, where a non-zero spacing e is maintained between the intrados shell 6 and the extrados shell 7.
  • the lower surface shell 6 and the upper surface shell 7 can be dimensioned so that when they are positioned around the core 1, said shells 6 and 7 are in contact with one another, but then define a clearance of between 0.05 and 0.2 mm or typically equal to 1 mm relative to the core 1.
  • the intrados shell 6 and the extrados shell 7 are then typically positioned so as to each be spaced by an identical distance with respect to core 1.
  • the invention as described therefore proposes to associate a shell with a core for the formation of a wax model of a turbomachine blade.
  • the hull is made up of two elements; an intrados shell and an extrados shell.
  • the shell will be integrated into the wax model, in order to reduce the volume of wax necessary for the formation of specific areas of the wax model, in this case the fir tree at the root of the vane, which prevents the formation of cracks in the core due to the shrinkage of the wax model material, and also the risk of core breakage due to the large amount of wax in this specific area.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

Method for forming a wax model for the manufacture of turbine blades by lost wax casting, wherein a core (1) is provided, a lower surface shell (6) and an upper surface shell (7) are positioned and secured on either side of ducts (4) of the core which are adjacent to the foot (2), the core (1) provided with the lower surface shell (6) and the upper surface shell (7) is positioned in an injection mould, wax is injected around the core (1) provided with the lower surface shell (6) and the upper surface shell (7), so as to form a wax model (8) comprising an aerofoil and a blade root comprising a fir tree (81), the lower surface shell (6) and the upper surface shell (7) being positioned around the core (1) so as to form part of the fir tree (81) of the wax model (8).

Description

Procédé amélioré de formation d'un modèle cire pour une aube de turbine. Improved method of forming a wax model for a turbine blade.
Domaine Technique Technical area
[0001 ] Le présent exposé concerne le domaine des turbomachines, et concerne plus précisément les techniques de fabrication de modèles en cire pour la réalisation d’aubes de turbomachine par voie de fonderie à cire perdue. [0001] This presentation relates to the field of turbomachines, and more specifically relates to the techniques of manufacturing wax models for the production of turbomachine blades by lost wax casting.
Technique antérieure Prior art
[0002] La réalisation d’aubes de turbomachine est communément réalisée par voie de fonderie à cire perdue en raison notamment des avantages de ce procédé en termes de tolérances et de précision. [0002] The production of turbomachine blades is commonly carried out by lost wax casting, in particular because of the advantages of this process in terms of tolerances and precision.
[0003] Cependant, l’évolution des circuits de refroidissement au sein des aubes impose des cavités d’alimentation de plus en plus fines, ce qui entraine une diminution de l’épaisseur des noyaux employés pour la réalisation des modèles en cire, jusqu’à des épaisseurs de l’ordre de 0,06 mm. Du fait de ces épaisseurs très faibles, on observe un taux très élevé de rupture du noyau lors de l’injection de cire pour la formation du modèle, en particulier pour la formation du sapin du modèle cire de l’aube. However, the evolution of cooling circuits within the blades requires increasingly thin supply cavities, which leads to a reduction in the thickness of the cores used for the production of wax models, up to to thicknesses of the order of 0.06 mm. Due to these very low thicknesses, a very high rate of core breakage is observed during the injection of wax for the formation of the model, in particular for the formation of the tree of the wax model of the dawn.
[0004] Le présent exposé vise ainsi à proposer une solution permettant de répondre au moins partiellement à cette problématique. [0004] The present disclosure thus aims to propose a solution making it possible to at least partially respond to this problem.
Exposé de l’invention Disclosure of the invention
[0005] A cet effet, la présente invention propose un procédé de formation d’un modèle cire pour la réalisation d’aubes de turbine par fonderie à cire perdue, dans lequel : on fournit un noyau, définissant des conduits s’étendant entre un pied et un sommet, on fournit une coque intrados et une coque extrados, on positionne la coque intrados et la coque extrados de part et d’autre de conduits du noyau adjacents au pied, on solidarise la coque intrados et la coque extrados autour du noyau, on positionne le noyau muni de la coque intrados et de la coque extrados dans un moule d’injection, on injecte de la cire autour dudit noyau muni de la coque intrados et de la coque extrados, de manière à former un modèle cire comprenant une pale d’aube et un pied d’aube comprenant un sapin, la coque intrados et la coque extrados étant positionnées autour du noyau de manière à former une partie du sapin du modèle cire. To this end, the present invention provides a method of forming a wax model for the production of turbine blades by lost wax casting, in which: a core is provided, defining ducts extending between a foot and a top, we provide an intrados shell and an extrados shell, we position the intrados shell and the extrados shell on either side of ducts of the core adjacent to the foot, we secure the intrados shell and the extrados shell around the core , the core provided with the lower surface shell and the upper surface shell is positioned in an injection mold, wax is injected around said core provided with the lower surface shell and the upper surface shell, so as to form a wax model comprising a blade blade and a blade root comprising a tree, the shell intrados and the extrados shell being positioned around the core so as to form part of the tree of the wax model.
[0006] Selon un exemple, la coque intrados et la coque extrados sont réalisées en cire ou en polymère. [0006] According to one example, the intrados shell and the extrados shell are made of wax or of polymer.
[0007] Selon un exemple, la coque intrados et la coque extrados sont positionnées autour du noyau et sont chacune au contact dudit noyau, et dans lequel la coque intrados et la coque extrados sont positionnées de manière à définir un jeu compris entre 0,05 et 0,2 mm entre elles. [0007] According to one example, the intrados shell and the extrados shell are positioned around the core and are each in contact with said core, and in which the intrados shell and the extrados shell are positioned so as to define a clearance of between 0.05 and 0.2 mm between them.
[0008] En variante, la coque intrados et la coque extrados sont positionnées autour du noyau et sont au contact l’une de l’autre, la coque intrados et la coque extrados étant dimensionnées de manière à permettre un débattement compris entre 0, 05 et 0,2 mm par rapport au noyau préalablement à leur solidarisation autour du noyau. [0008] As a variant, the lower surface shell and the upper surface shell are positioned around the core and are in contact with each other, the lower surface shell and the upper surface shell being dimensioned so as to allow a clearance of between 0.05 and 0.2 mm relative to the core prior to their joining around the core.
[0009] Selon un exemple, le noyau comprend au moins 3 conduits s’étendant entre un pied et un sommet, et dans lequel la coque intrados et/ou la coque extrados comprend des bossages adaptés pour être insérés entre lesdits conduits, de manière à indexer ladite coque par rapport aux conduits. [0009] According to one example, the core comprises at least 3 conduits extending between a foot and a top, and in which the intrados shell and / or the extrados shell comprises bosses adapted to be inserted between said conduits, so as to indexing said shell relative to the ducts.
[0010] Selon un exemple, la coque intrados et la coque extrados sont positionnées autour du noyau dans une région du noyau dans laquelle le modèle en cire comprend des parois présentant une épaisseur comprise entre 1 et 10 fois l’épaisseur des conduits du noyau. [0010] According to one example, the lower surface shell and the upper surface shell are positioned around the core in a region of the core in which the wax model comprises walls having a thickness between 1 and 10 times the thickness of the ducts of the core.
[0011 ] Selon un exemple, ledit procédé comprend une étape préalable de fabrication de la coque intrados et la coque extrados par fabrication additive. [0011] According to one example, said method comprises a preliminary step of manufacturing the lower surface shell and the upper surface shell by additive manufacturing.
Brève description des dessins Brief description of the drawings
[0012] L’invention et ses avantages seront mieux compris à la lecture de la description détaillée faite ci-après de différents modes de réalisation de l’invention donnés à titre d’exemples non limitatifs. Cette description fait référence aux pages de figures annexées, sur lesquelles : [0013] [Fig. 1 ] La figure 1 présente un exemple de noyau pour un procédé selon un aspect de l’invention. The invention and its advantages will be better understood on reading the detailed description given below of various embodiments of the invention given by way of non-limiting examples. This description refers to the pages of appended figures, on which: [0013] [Fig. 1] FIG. 1 shows an example of a kernel for a method according to one aspect of the invention.
[0014] [Fig. 2] La figure 2 présente une autre vue d’un exemple de noyau muni d’une coque un procédé selon un aspect de l’invention. [0014] [Fig. 2] Figure 2 shows another view of an example of a core provided with a shell a method according to one aspect of the invention.
[0015] [Fig. 3] La figure 3 présente une autre vue d’un exemple de noyau muni d’une coque pour un procédé selon un aspect de l’invention. [0015] [Fig. 3] Figure 3 shows another view of an exemplary core provided with a shell for a method according to one aspect of the invention.
[0016] [Fig. 4] La figure 4 est une vue d’une coque selon un aspect de l’invention. [0016] [Fig. 4] Figure 4 is a view of a shell according to one aspect of the invention.
[0017] [Fig. 5] La figure 5 est une autre vue d’une coque selon un aspect de l’invention. [0017] [Fig. 5] Figure 5 is another view of a shell according to one aspect of the invention.
[0018] [Fig. 6] La figure 6 présente une vue en coupe d’un noyau en céramique autour duquel a été coulé un modèle en cire. [0018] [Fig. 6] Figure 6 shows a sectional view of a ceramic core around which a wax model has been cast.
[0019] Sur l’ensemble des figures, les éléments en commun sont repérés par des références numériques identiques. [0019] In all of the figures, the elements in common are identified by identical reference numerals.
Description des modes de réalisation Description of embodiments
[0020] La figure 1 présente un exemple de noyau 1 typiquement réalisé en céramique pour un procédé selon un aspect de l’invention. [0020] FIG. 1 shows an example of a core 1 typically made of ceramic for a method according to one aspect of the invention.
[0021 ] Le noyau 1 tel que présenté comprend un pied 2 et un sommet 3 entre lesquels s’étendent une pluralité de conduits 4. Dans l’exemple illustré, le noyau 1 comprend 4 conduits. On comprend bien que cet exemple n’est pas limitatif, et que le présent exposé est directement transposable à un noyau 1 comprenant un nombre quelconque de conduits. On définit pour le noyau 1 une direction longitudinale DL, qui correspond à la direction allant du pied 2 au sommet 3, une direction transversale DT, s’étendant dans le plan de la figure 1 , et perpendiculaire à la direction longitudinale DL, et une épaisseur E, mesurée selon une direction perpendiculaire à un plan défini par la direction transversale DT et par la direction longitudinale DL. Plus généralement, la direction longitudinale DL est définit la longueur du noyau 1 , la direction transversale DT définit sa largeur, et l’épaisseur E son épaisseur. [0022] Le noyau 1 est destiné à être positionné dans un moule d’injection de cire, en vue de la formation d’un modèle cire d’une aube de turbine, afin de définir les conduits internes de l’aube. The core 1 as shown comprises a foot 2 and a top 3 between which extend a plurality of conduits 4. In the example illustrated, the core 1 comprises 4 conduits. It is well understood that this example is not limiting, and that the present description is directly transposable to a core 1 comprising any number of conduits. We define for the core 1 a longitudinal direction DL, which corresponds to the direction going from the foot 2 to the top 3, a transverse direction DT, extending in the plane of Figure 1, and perpendicular to the longitudinal direction DL, and a thickness E, measured in a direction perpendicular to a plane defined by the transverse direction DT and by the longitudinal direction DL. More generally, the longitudinal direction DL defines the length of the core 1, the transverse direction DT defines its width, and the thickness E its thickness. The core 1 is intended to be positioned in a wax injection mold, with a view to forming a wax model of a turbine blade, in order to define the internal ducts of the blade.
[0023] Lors de la formation du modèle cire, la zone repérée par la référence Z1 sur la figure 1 pose des problématiques pour une bonne formation du modèle. Cette zone Z1 correspond en effet à une zone du pied d’aube qui est qualifiée de « sapin » ou « pied de sapin » ayant des parois présentant une épaisseur importante, pouvant ainsi par exemple être 10 fois supérieure à l’épaisseur des parois de l’aube dans les autres régions de l’aube. During the formation of the wax model, the area identified by the reference Z1 in Figure 1 poses problems for a good formation of the model. This zone Z1 in fact corresponds to a zone of the blade root which is qualified as “fir” or “fir root” having walls having a significant thickness, thus being able for example to be 10 times greater than the thickness of the walls of the blade. dawn in the other dawn regions.
[0024] De telles variations d’épaisseur entraînent des problématiques de retrait de matière importante lors du refroidissement, ce qui génère des contraintes élevées sur le noyau réalisé à l’aide du modèle cire, et tend donc à générer des criques dans le noyau. De plus, la quantité de matière plus élevée dans cette région va entraîner des contraintes plus élevées sur le noyau 1 lors de l’injection, ce qui peut entraîner sa rupture. [0024] Such variations in thickness lead to problems of significant material shrinkage during cooling, which generates high stresses on the core made using the wax model, and therefore tends to generate cracks in the core. In addition, the higher amount of material in this region will cause higher stresses on core 1 during injection, which can cause it to break.
[0025] Le procédé proposé vise ainsi à positionner une coque autour de la zone Z1 , cette coque ayant une double fonction de protection du noyau 1 et de prévention de la formation de malformations ou de criques dans le modèle cire. The proposed method thus aims to position a shell around the zone Z1, this shell having a dual function of protecting the core 1 and preventing the formation of deformations or cracks in the wax model.
[0026] Les figures 2 et 3 illustrent ainsi le noyau 1 tel que présenté sur la figure 1 qui est ici muni d’une coque 5. La coque 5 telle que présentée comprend une coque intrados 6 et une coque extrados 7, qui sont positionnées respectivement sur la face intrados et sur la face extrados du noyau 1 , les désignations intrados et extrados étant définies en fonction de la géométrie de l’aube souhaitée. En variante, la coque 5 peut comprendre plus de deux composants, dès lors qu’elle permet d’envelopper au moins partiellement une région du noyau 1 comme on le verra par la suite, la géométrie de la coque 5 étant adaptée en fonction de la géométrie du noyau 1. Figures 2 and 3 thus illustrate the core 1 as shown in Figure 1 which is here provided with a shell 5. The shell 5 as presented comprises an intrados shell 6 and an extrados shell 7, which are positioned respectively on the intrados face and on the extrados face of the core 1, the intrados and extrados designations being defined as a function of the geometry of the desired blade. As a variant, the shell 5 can comprise more than two components, since it makes it possible to at least partially envelop a region of the core 1 as will be seen below, the geometry of the shell 5 being adapted as a function of the core geometry 1.
[0027] La coque intrados 6 et la coque extrados 7 sont définies de manière à venir au moins partiellement envelopper les conduits 4 au niveau de leur jonction avec le pied 2 du noyau 1. Plus précisément, la coque intrados 6 et la coque extrados 7 sont positionnées de manière à envelopper au moins partiellement les conduits 4 sur une partie de leur longueur (la longueur étant mesurée selon une direction allant u pied 2 au sommet 3 du noyau 1 ), et typiquement à recouvrir une partie du pied 2 du noyau 1 à partir de laquelle s’étendent les conduits 4. The intrados shell 6 and the extrados shell 7 are defined so as to come at least partially envelop the ducts 4 at their junction with the foot 2 of the core 1. More specifically, the intrados shell 6 and the extrados shell 7 are positioned so as to at least partially envelop the ducts 4 over part of their length (the length being measured in a direction going u foot 2 to the top 3 of core 1), and typically to cover part of foot 2 of core 1 from which the ducts 4 extend.
[0028] Les figures 4 et 5 représentent un exemple de portion de coque 5, ces figures pouvant indifféremment représenter une coque intrados 6 ou une coque extrados 7. A des fins de description, on considérera ici qu’il s’agit de la coque intrados 6, la coque extrados 7 associée pouvant alors être identique ou distincte, les éléments en commun étant désignés par la même référence numérique incrémentée de 10. Figures 4 and 5 show an example of a portion of the shell 5, these figures can equally well represent a lower surface shell 6 or an upper surface shell 7. For the purposes of description, it will be considered here that it is the shell intrados 6, the associated extrados shell 7 then being able to be identical or distinct, the elements in common being designated by the same numerical reference incremented by 10.
[0029] La coque intrados 6 telle que représentée comprend un corps 61 formant généralement une plaque d’épaisseur variable, et dimensionné de manière à pouvoir s’étendre sur l’ensemble des conduits 4 du noyau 1 dans la direction transverse DT (c’est-à-dire selon la largeur) du noyau 1. The intrados shell 6 as shown comprises a body 61 generally forming a plate of variable thickness, and dimensioned so as to be able to extend over all of the ducts 4 of the core 1 in the transverse direction DT (c ' i.e. according to the width) of the core 1.
[0030] Le corps 61 présente deux extrémités selon la direction transversale DT munies de nervures 62 s’étendant chacune selon la direction longitudinale DL. Le corps 61 est également typiquement muni de bossages 63 s’étendant selon l’épaisseur de la coque intrados 6, et adaptés pour être insérés entre deux conduits 4 adjacents du noyau 1. Les nervures 62 sont quant à elles typiquement dimensionnées de manière à recouvrir partiellement les extrémités des conduits 4 selon la direction tangentielle DT. The body 61 has two ends in the transverse direction DT provided with ribs 62 each extending in the longitudinal direction DL. The body 61 is also typically provided with bosses 63 extending along the thickness of the lower surface shell 6, and adapted to be inserted between two adjacent ducts 4 of the core 1. The ribs 62 are for their part typically dimensioned so as to cover partially the ends of the conduits 4 in the tangential direction DT.
[0031 ] En positionnant deux coques 6 et 7 autour du noyau 1 , on obtient ainsi une configuration telle que représentée sur les figures 2 et 3. Comme on le voit sur ces figures, la face supérieure et la face inférieure de la région Z1 du noyau 1 sont recouvertes par les coques 6 et 7. Les faces latérales des extrémités du noyau 1 sont recouvertes par les nervures 62 et 72 des coques 6 et 7. La région Z1 du noyau 1 est ainsi partiellement enveloppée par la coque intrados 6 et la coque extrados 7. By positioning two shells 6 and 7 around the core 1, there is thus obtained a configuration as shown in Figures 2 and 3. As seen in these figures, the upper face and the lower face of the region Z1 of the core 1 are covered by shells 6 and 7. The side faces of the ends of core 1 are covered by ribs 62 and 72 of shells 6 and 7. Region Z1 of core 1 is thus partially enveloped by lower surface shell 6 and extrados hull 7.
[0032] Une fois la coque intrados 6 et la coque extrados 7 positionnée autour du noyau 1 , ces dernières sont typiquement solidarisées autour du noyau 1 , par exemple au moyen d’une colle, pouvant être une cire adaptée. Once the intrados shell 6 and the extrados shell 7 positioned around the core 1, the latter are typically secured around the core 1, for example by means of an adhesive, which may be a suitable wax.
[0033] Le noyau 1 ainsi muni de la coque 5 est ensuite positionné dans un moule d’injection de cire pour la réalisation d’un modèle cire d’une aube de turbine. [0034] Cet enveloppement partiel du noyau 1 permet de le protéger contre les efforts générés par l’injection de cire lors de la formation du modèle cire associé, ce qui permet ainsi de prévenir les risques de rupture du noyau 1 lors de l’injection de cire. [0033] The core 1 thus provided with the shell 5 is then positioned in a wax injection mold for the production of a wax model of a turbine blade. This partial envelopment of the core 1 protects it against the forces generated by the injection of wax during the formation of the associated wax model, which thus makes it possible to prevent the risk of rupture of the core 1 during the injection. of wax.
[0035] Par ailleurs, la coque intrados 6 et la coque extrados 7 ainsi positionnées autour du noyau 1 vont être intégrées au modèle cire lorsque celui-ci est réalisé. On représente sur la figure 6 un exemple de vue en coupe d’un modèle cire 8 formé autour d’un noyau 1 muni d’une coque intrados 6 et d’une coque extrados 7. Comme on le comprend à la vue de cette figure, la coque intrados 6 et la coque extrados 7 positionnées autour du noyau 1 permettent de réduire la quantité de cire nécessaire à la formation du modèle cire, dans la mesure où les coques 6 et 7 vont ici former directement une partie du modèle cire. On identifie par la référence 81 la zone du modèle cire qui forme le sapin ou pied de sapin de l’aube dont on forme le modèle cire 8, cette zone se prolongeant par une zone du modèle cire formant une lame de l’aube dont on forme le modèle cire 8. La coque intrados 6 et la coque extrados 7 forment ainsi une partie du sapin 81 du modèle cire 8. Furthermore, the intrados shell 6 and the extrados shell 7 thus positioned around the core 1 will be integrated into the wax model when the latter is produced. FIG. 6 shows an example of a sectional view of a wax model 8 formed around a core 1 provided with an intrados shell 6 and an extrados shell 7. As can be understood from the view of this figure , the intrados shell 6 and the extrados shell 7 positioned around the core 1 make it possible to reduce the quantity of wax necessary for the formation of the wax model, insofar as the shells 6 and 7 will here directly form part of the wax model. We identify by the reference 81 the area of the wax model which forms the tree or fir tree base of the dawn of which the wax model 8 is formed, this area being extended by a zone of the wax model forming a blade of the blade of which we forms the wax model 8. The lower surface shell 6 and the upper surface shell 7 thus form part of the tree 81 of the wax model 8.
[0036] Comme on le voit sur cette figure, cette région présente une épaisseur importante par rapport aux autres régions du modèle cire 8. Les coques 6 et 7 forment une partie de cette épaisseur, ce qui permet ainsi de réduire la quantité de cire nécessaire à la réalisation de cette région, et limite donc les risques de formation de criques résultant du retrait de la cire lors de son refroidissement. En variante, la coque intrados 6 et la coque extrados 7 sont typiquement dimensionnées de manière à ce que l’épaisseur de cire injectée autour des coques 6 et 7 pour la formation du modèle cire soit constante ou sensiblement constante. As seen in this figure, this region has a significant thickness compared to the other regions of the wax model 8. The shells 6 and 7 form part of this thickness, which thus makes it possible to reduce the amount of wax required to the production of this region, and therefore limits the risk of cracks forming resulting from the removal of the wax during its cooling. As a variant, the intrados shell 6 and the extrados shell 7 are typically sized so that the thickness of wax injected around the shells 6 and 7 for the formation of the wax model is constant or substantially constant.
[0037] La coque intrados 6 et la coque extrados 7 sont typiquement réalisées en cire ou en polymère, le choix de la matière étant notamment réalisé en fonction de sa compatibilité avec la cire utilisée lors de l’injection pour la réalisation du modèle cire 8 de l’aube. Le matériau employé doit également pouvoir être éliminé lors d’une opération de retrait du modèle cire ou de cuisson d’une carapace céramique autour du modèle cire. La coque intrados 6 et la coque extrados 7 sont typiquement réalisées par fabrication additive, par exemple par polymérisation d’une résine sous l’action d’un laser ou d’une lampe UV, par projection de gouttes de matériau, par projection d’un liant sur un lit de poudre, par solidification de poudre sous l’action d’une source d’énergie (laser ou faisceau d’électrons), par fusion de fil au travers d’une buse chauffante, ou par tout autre procédé adapté, notamment tout autre procédé de fabrication additive adapté. La coque intrados 6 et la coque extrados 7 peuvent également par exemple être réalisées par injection simultanée avec le modèle cire, lors d’une opération d’injection, la coque intrados et la coque extrados réalisées lors d’une telle opération étant alors employées pour la réalisation d’un modèle cire lors d’une opération ultérieure d’injection. On réalise alors lors d’une étape d’injection N la coque intrados 6 et la coque extrados 7 qui peuvent ensuite être utilisées pour une étape d’injection N+1. The intrados shell 6 and the extrados shell 7 are typically made of wax or of polymer, the choice of material being made in particular according to its compatibility with the wax used during the injection for the production of the wax model 8 of dawn. The material used must also be able to be removed during an operation to remove the wax model or firing a ceramic shell around the wax model. The intrados shell 6 and the extrados shell 7 are typically produced by additive manufacturing, for example by polymerization of a resin under the action of a laser or a UV lamp, by projection of drops of material, by projection of a binder on a bed of powder, for example solidification of powder under the action of an energy source (laser or electron beam), by fusion of wire through a heating nozzle, or by any other suitable process, in particular any other suitable additive manufacturing process . The intrados shell 6 and the extrados shell 7 can also for example be produced by simultaneous injection with the wax model, during an injection operation, the intrados shell and the extrados shell produced during such an operation then being used for the production of a wax model during a subsequent injection operation. The intrados shell 6 and the extrados shell 7 are then produced during an N injection step, which can then be used for an N + 1 injection step.
[0038] La coque intrados 6 et la coque extrados 7 sont typiquement configurées de manière à définir un espacement soit entre la coque intrados 6 et la coque extrados 7, soit entre lesdites coques 6 et 7 et le noyau 1. Selon un exemple, la coque intrados 6 et la coque extrados 7 sont dimensionnées de manière à ce que lorsqu’elles sont chacune positionnées en appui contre le noyau 1 , un espacement typiquement compris entre 0,05 et 0,2 mm ou typiquement égal à 0,1 mm soit formé entre lesdites coques intrados 6 et extrados 7. Ce mode de réalisation est illustré sur la figure 3, où un espacement e non nul est maintenu entre la coque intrados 6 et la coque extrados 7. The intrados shell 6 and the extrados shell 7 are typically configured so as to define a spacing either between the intrados shell 6 and the extrados shell 7, or between said shells 6 and 7 and the core 1. According to one example, the intrados shell 6 and extrados shell 7 are dimensioned so that when they are each positioned resting against the core 1, a spacing typically between 0.05 and 0.2 mm or typically equal to 0.1 mm is formed between said intrados 6 and extrados hulls 7. This embodiment is illustrated in FIG. 3, where a non-zero spacing e is maintained between the intrados shell 6 and the extrados shell 7.
[0039] En variante, la coque intrados 6 et la coque extrados 7 peuvent être dimensionnées de manière à ce que lorsqu’elles sont positionnées autour du noyau 1 , lesdites coques 6 et 7 sont au contact l’une de l’autre, mais définissent alors un débattement compris entre 0, 05 et 0,2 mm ou typiquement égal à 1 mm par rapport au noyau 1. La coque intrados 6 et la coque extrados 7 sont alors typiquement positionnées de manière à être chacune espacée d’un écart identique par rapport au noyau 1. [0039] As a variant, the lower surface shell 6 and the upper surface shell 7 can be dimensioned so that when they are positioned around the core 1, said shells 6 and 7 are in contact with one another, but then define a clearance of between 0.05 and 0.2 mm or typically equal to 1 mm relative to the core 1. The intrados shell 6 and the extrados shell 7 are then typically positioned so as to each be spaced by an identical distance with respect to core 1.
[0040] L’invention telle que décrite propose donc d’associer une coque à un noyau pour la formation d’un modèle cire d’aube de turbomachine. La coque est composé de deux éléments ; une coque intrados et une coque extrados. La coque va être intégrée au modèle cire, afin de réduire le volume de cire nécessaire pour la formation de zones spécifiques du modèle cire, en l’occurrence le sapin du pied de l’aube, ce qui permet d’éviter les formations de criques dans le noyau du fait du retrait de la matière du modèle cire, et également les risques de rupture du noyau du fait de la quantité importante de cire dans cette zone spécifique. The invention as described therefore proposes to associate a shell with a core for the formation of a wax model of a turbomachine blade. The hull is made up of two elements; an intrados shell and an extrados shell. The shell will be integrated into the wax model, in order to reduce the volume of wax necessary for the formation of specific areas of the wax model, in this case the fir tree at the root of the vane, which prevents the formation of cracks in the core due to the shrinkage of the wax model material, and also the risk of core breakage due to the large amount of wax in this specific area.

Claims

Revendications Claims
[Revendication 1] Procédé de formation d'un modèle cire pour la réalisation d'aubes de turbine par fonderie à cire perdue, dans lequel [Claim 1] A method of forming a wax model for making turbine blades by lost wax casting, in which
- on fournit un noyau (1), définissant des conduits (4) s'étendant entre un pied (2) et un sommet (3), - a core (1) is provided, defining conduits (4) extending between a foot (2) and a top (3),
- on fournit une coque intrados (6) et une coque extrados (7), - we provide an intrados shell (6) and an extrados shell (7),
- on positionne la coque intrados (6) et la coque extrados (7) de part et d'autre de conduits (4) du noyau adjacents au pied (2), - the intrados shell (6) and the extrados shell (7) are positioned on either side of ducts (4) of the core adjacent to the foot (2),
- on solidarise la coque intrados (6) et la coque extrados (7) autour du noyau (1), - the intrados shell (6) and the extrados shell (7) are secured around the core (1),
- on positionne le noyau (1) muni de la coque intrados (6) et de la coque extrados (7) dans un moule d'injection, - the core (1) provided with the lower surface shell (6) and the upper surface shell (7) is positioned in an injection mold,
- on injecte de la cire autour dudit noyau (1) muni de la coque intrados (6) et de la coque extrados (7), de manière à former un modèle cire (8) comprenant une pale d'aube et un pied d'aube comprenant un sapin (81), la coque intrados (6) et la coque extrados (7) étant positionnées autour du noyau (1) de manière à former une partie du sapin (81) du modèle cire (8). - Wax is injected around said core (1) provided with the intrados shell (6) and the extrados shell (7), so as to form a wax model (8) comprising a blade blade and a root blade comprising a tree (81), the lower surface shell (6) and the upper surface shell (7) being positioned around the core (1) so as to form part of the tree (81) of the wax model (8).
[Revendication 2] Procédé selon la revendication 1, dans lequel la coque intrados (6) et la coque extrados (7) sont réalisées en cire ou en polymère. [Claim 2] The method of claim 1, wherein the lower surface shell (6) and the upper surface shell (7) are made of wax or polymer.
[Revendication 3] Procédé selon l'une des revendications 1 ou 2, dans lequel la coque intrados (6) et la coque extrados (7) sont positionnées autour du noyau (1) et sont chacune au contact dudit noyau (1), et dans lequel la coque intrados (6) et la coque extrados (7) sont positionnées de manière à définir un jeu compris entre 0,05 et 0,2 mm entre elles. [Claim 3] Method according to one of claims 1 or 2, wherein the lower surface shell (6) and the upper surface shell (7) are positioned around the core (1) and are each in contact with said core (1), and wherein the lower surface shell (6) and the upper surface shell (7) are positioned so as to define a clearance of between 0.05 and 0.2 mm between them.
[Revendication 4] Procédé selon l'une des revendications 1 ou 2, dans lequel la coque intrados (6) et la coque extrados (7) sont positionnées autour du noyau (1) et sont au contact l'une de l'autre, la coque intrados (6) et la coque extrados (7) étant dimensionnées de manière à permettre un débattement compris entre 0, 05 et 0,2 mm par rapport au noyau (1) préalablement à leur solidarisation autour du noyau (1). [Claim 4] Method according to one of claims 1 or 2, wherein the lower surface shell (6) and the upper surface shell (7) are positioned around the core (1) and are in contact with each other, the intrados shell (6) and the extrados shell (7) being dimensioned so as to allow a clearance between 0.05 and 0.2 mm relative to the core (1) prior to their joining around the core (1).
[Revendication 5] Procédé selon l'une des revendications 1 à 4, dans lequel le noyau (1) comprend au moins 3 conduits s'étendant entre un pied (2) et un sommet (3), et dans lequel la coque intrados (6) et/ou la coque extrados (7) comprend des bossages (63, 73) adaptés pour être insérés entre lesdits conduits (4), de manière à indexer ladite coque (6, 7) par rapport aux conduits (4). [Claim 5] Method according to one of claims 1 to 4, in which the core (1) comprises at least 3 conduits extending between a foot (2) and a top (3), and in which the intrados shell ( 6) and / or the extrados shell (7) comprises bosses (63, 73) adapted to be inserted between said ducts (4), so as to index said shell (6, 7) with respect to the ducts (4).
[Revendication 6] Procédé selon l'une des revendications 1 à 5, dans lequel la coque intrados (6) et la coque extrados (7) sont positionnées autour du noyau (1) dans une région du noyau (1) dans laquelle le modèle en cire (8) comprend des parois présentant une épaisseur comprise entre 1 et 10 fois l'épaisseur des conduits du noyau (1). [Claim 6] A method according to one of claims 1 to 5, wherein the lower surface shell (6) and the upper surface shell (7) are positioned around the core (1) in a region of the core (1) in which the model wax (8) comprises walls having a thickness between 1 and 10 times the thickness of the conduits of the core (1).
[Revendication 7] Procédé selon l'une des revendications 1 à 6, comprenant une étape préalable de fabrication de la coque intrados (6) et la coque extrados (7) par fabrication additive. [Claim 7] Method according to one of claims 1 to 6, comprising a preliminary step of manufacturing the lower surface shell (6) and the upper surface shell (7) by additive manufacturing.
EP20740373.4A 2019-06-05 2020-06-03 Improved method for forming a wax model for a turbine blade Pending EP3980201A1 (en)

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FR1905967A FR3096910B1 (en) 2019-06-05 2019-06-05 Improved method of forming a wax model for a turbine blade.
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JPH035040A (en) * 1989-05-30 1991-01-10 Mitsubishi Materials Corp Casting method into wax pattern
FR2688326A1 (en) * 1992-03-06 1993-09-10 Moviluty CONTROL DEVICE.
KR100217895B1 (en) * 1996-11-06 1999-09-01 장세풍 Method and device for manufacturing wax pattern
JP2902379B2 (en) * 1997-04-25 1999-06-07 三菱製鋼株式会社 How to make a wax pattern
US10307816B2 (en) * 2015-10-26 2019-06-04 United Technologies Corporation Additively manufactured core for use in casting an internal cooling circuit of a gas turbine engine component
CN205270753U (en) * 2015-11-17 2016-06-01 沈阳明禾石英制品有限责任公司 Ceramic core of plastics chaplet with play location support effect
CN106734885B (en) 2017-01-18 2018-10-12 江苏永瀚特种合金技术有限公司 A method of cold wax stone and ceramic core are used for wax-pattern simultaneously and suppressed
CN107052260B (en) * 2017-05-27 2018-11-13 鹰普航空零部件（无锡）有限公司 Application of the ceramic core packet wax positioning process in model casting
CN108080576B (en) * 2017-12-01 2020-11-10 东方电气集团东方汽轮机有限公司 Ceramic core pretreatment method for precision casting of medium-temperature wax investment
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WO2020245539A1 (en) 2020-12-10
US11717880B2 (en) 2023-08-08

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