US20150239062A1 - Inertia friction disk welding - Google Patents
Inertia friction disk welding Download PDFInfo
- Publication number
- US20150239062A1 US20150239062A1 US14/185,997 US201414185997A US2015239062A1 US 20150239062 A1 US20150239062 A1 US 20150239062A1 US 201414185997 A US201414185997 A US 201414185997A US 2015239062 A1 US2015239062 A1 US 2015239062A1
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- United States
- Prior art keywords
- disk
- cutout
- forming
- component
- circumference
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1225—Particular aspects of welding with a non-consumable tool
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/129—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding specially adapted for particular articles or workpieces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
- B23K28/02—Combined welding or cutting procedures or apparatus
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
- B23P6/005—Repairing turbine components, e.g. moving or stationary blades, rotors using only replacement pieces of a particular form
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- 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
- F01D5/02—Blade-carrying members, e.g. rotors
- F01D5/06—Rotors for more than one axial stage, e.g. of drum or multiple disc type; Details thereof, e.g. shafts, shaft connections
-
- 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
- F01D5/02—Blade-carrying members, e.g. rotors
- F01D5/06—Rotors for more than one axial stage, e.g. of drum or multiple disc type; Details thereof, e.g. shafts, shaft connections
- F01D5/063—Welded rotors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/001—Turbines
-
- 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
- F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
- F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
- F05D2230/239—Inertia or friction welding
Definitions
- the invention relates generally to inertia friction disk welding, and in one embodiment, to the repair and restoration of high-temperature superalloy gas turbine components
- Gas turbine blades are designed with platform structures that are subject to degradation from thermo-mechanical fatigue and resulting cracks. Cracking of such elements ranges from crazing (superficial or shallow cracks) to through-wall cracks.
- crazing superficial or shallow cracks
- through-wall cracks The use of high-temperature superalloy metals in these structures increases the difficulty of repair, often requiring hotbox welding with a low yield of successful repairs Often degraded components are considered irreparable and must be scrapped A need exists to improve the success in repairing such components.
- FIG. 1 is a perspective side/front view of a conventional gas turbine blade assembly
- FIG. 2 is a front sectional view taken along line 2 - 2 of FIG. 1
- FIG. 3 is a top view of a blade and a cracked platform.
- FIG. 4 is a view as in FIG. 3 after removal of cracked area of platform
- FIG. 5 is a view as in FIG. 3 during inertia welding with an additive disk
- FIG. 6 is a view as in FIG. 3 after removal of excess disk and shaft
- FIG. 7 is a perspective view of an additive cylindrical disk with dual shafts
- FIG. 8 is a perspective view of an additive conical disk with dual shafts.
- FIG. 9 is a top view of a turbine blade and platform planned for simultaneous repair on opposite edges of the platform with balanced disk forces
- FIG. 10 is a top partial sectional view of an inertia friction repair in progress with rotary oscillation of the disk.
- FIG. 11 is a view as in FIG. 10 using a partial disk to reduce excess metal to be trimmed.
- FIG. 12 is a view as in FIG. 11 showing a nut mounting a partial disk to a shaft.
- FIG. 13 is a top sectional view of a partial disk mounted on a shaft with flats indexing the disk to the shaft.
- FIG. 14 is a top view of a platform with a hollow turbine blade in section with a supporting material in the blade chamber to reduce strain from disk pressure
- FIG. 15 is a top view of a platform with a turbine blade in section showing a deep, narrow repair using overlapping disk additions
- FIGS. 1 and 2 illustrate a conventional gas turbine blade assembly 20 , including a blade 22 , a platform 24 and a root 26
- the blade has a hollow airfoil sectional shape with cooling chambers 28 supplied by coolant flow channels 30 from the bottom of the root
- FIG. 3 is a top view of a blade 22 on a platform 24 having cracks 32 near a first edge 34 thereof, with the blade 22 staged for repair in accordance with an embodiment of the present invention
- the cracks may be surface cracks or through cracks
- FIG. 4 shows the platform after removal of cracks by milling or cutting from the edge 34 to form a cutout 35
- the cutout 35 may have a concave cylindrical surface with diameter D.
- other surfaces of rotation may be used, such a conical or spherical Milling with the side of a mechanical milling bit is suggested, but other cutting technologies may be used, such as water jet, plasma cutting, and laser cutting
- FIG. 5 shows an inertia welding disk 36 rotated by a shaft 38 .
- the shaft may have a smaller diameter than the disk, but this is not a requirement
- the circumference 40 of the disk is pressed radially 42 into the cutout 35 as the disk rotates, creating frictional heat that plastically fuses the surface of the disk onto the surface of the cutout.
- An opposing force 43 is needed to oppose the inward force 42 of the disk into the cutout 35
- the disk 40 may be made of the same material as the platform, although different materials may be fused in some embodiments Variations in pressure across the cutout surface are largely self-correcting as hot areas plasticize and relieve local pressure. This results in uniform heating and a consistent fusion interface.
- the disk cutout may have less depth than the disk radius. Alternately or additionally, the disk may be reciprocated radially laterally 44 against alternate sides of the cutout to normalize pressure over the extent of the cutout.
- FIG. 6 shows a repaired platform after removal of excess disk and shaft material flush with the edges of the cutout and flush with the surfaces of the platform
- the inventors have recognized that prior art friction welding with a rod end generates no rotary motion at the center of the rod end, so the weld receives no friction centrally, while the periphery of the weld receives maximum friction This contributes to a thermal gradient and solidification stress and possibly incomplete fusion at the center of the rod end.
- the present method lacks a frictionless center because the circumference of the disk has the same speed over the whole cutout surface (with a cylindrical disk) or has a non-zero speed within a desired range (spherical, conic, and other disk shapes).
- FIGS. 7 and 8 show examples of a cylindrical disk 36 A and a conical disk 36 B in disk/shaft assemblies 47 , 53
- a two-ended shaft 38 A and 38 B may extend from opposite ends of each disk. This allows the shaft to be supported by a drive chuck on one end and a bearing on the other end, making it a doubly supported beam, rather than a cantilever, which improves pressure control and reduces vibrations.
- a two-ended shaft is not a requirement
- the disk 36 A, 36 B may be formed integrally with the shaft or mounted thereon, for example by a nut and an opposed flange against opposite ends of the disk. The disk may be indexed to the shaft for example by flats on the shaft and disk
- FIG. 9 shows a platform 24 in which degradation is present on opposite edges 34 A, 34 B.
- Opposed cutouts 35 A, 35 B can be made, and two disks can be pressed into the cutouts from opposite directions 42 A, 42 B allowing the two opposed edges of the platform to be repaired at once with minimal fixturing because the disk pressure forces are balanced.
- FIG. 10 shows a disk pressed radially 42 into cutout 35 in a platform 24 .
- the disk is not rotating constantly, but uses rotary oscillation 56 to create the friction. This generates a plasticized interface 58 , 60 between the respective surfaces of the cutout 35 and the disk 36 Using rotary oscillation avoids maintaining a plastic zone 60 around the whole disk circumference 40 subject to environmental cooling. It also avoids dragging extruded plasticized material of the platform around the disk. It also avoids creating a subduction trench at the inward-moving side of the disk. Rotary oscillation beneficially extrudes a small amount of material 62 from both sides of the interface. This provides material for flush trimming, and avoids a trench on either end.
- the rotary oscillation may be less than 20 degrees total, such as plus and minus 5 or 3 degrees, minimizing exposure of the heated zone 60 to the air during welding
- the oscillations may be rapid such as 10 to 50,000 cycles per second Rotary oscillation mechanisms are known, and are not detailed here
- FIG. 11 shows an embodiment of a disk 36 C for rotary oscillation using a partial disk 36 C with less than 360 degrees of circumference. Using a partial disk leaves less scrap metal to trim For example, the disk may have less than 220 degrees of circumference, or less than 180 or 150 degrees for shallower cutouts.
- FIG. 12 shows an embodiment as in FIG. 11 using mounting means such as a nut 64 and opposed flange (not visible) to fasten the disk 36 C onto the shaft 38
- FIG. 13 shows a partial disk 36 C mounted on a shaft 38 C against a shaft flange 65 The disk has internal flats 66 for indexing it to external flats 68 on the shaft 38 C. Other attachment means may be used.
- FIG. 14 is a top sectional view of a hollow turbine blade 22 on a platform 24 Cracks extend from an edge 34 A of the platform to close proximity with the blade.
- the cutout 35 may allow strain in the blade wall to deform the platform and blade under pressure by the disk
- the blade chamber 28 may be filled with sand or fluid 70 to internally support the wall of the blade and the adjoining reduced platform
- incompressible fugitive cement may be inserted into the relevant chamber(s), and then removed by chemical means after the repair is complete
- Great Stuff TM from Dow Chemical Company. That product expands to fill gaps but may be dissolved by certain solvents such as acetone
- FIG. 15 shows a deep narrow repair made with overlapping disk additions 36 D, 36 E, 36 F
- a second cutout is formed into the first disk in order to receive the second disk 36 E.
- the first disk 36 D may be formed to have less than a circumference of 360 degrees such that the second cutout is at least partially preformed. This process may be repeated for disk 36 F.
- Extrudate 62 from rotary oscillation fills the gaps in the cutouts between successive disks.
- the present invention may have particular application to the repair of superalloy components such as gas turbine vanes and blades, but it is not necessarily limited to any particular type of material While various embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only Numerous variations, changes and substitutions may be made without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims
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- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Abstract
Description
- The invention relates generally to inertia friction disk welding, and in one embodiment, to the repair and restoration of high-temperature superalloy gas turbine components
- Gas turbine blades are designed with platform structures that are subject to degradation from thermo-mechanical fatigue and resulting cracks. Cracking of such elements ranges from crazing (superficial or shallow cracks) to through-wall cracks The use of high-temperature superalloy metals in these structures increases the difficulty of repair, often requiring hotbox welding with a low yield of successful repairs Often degraded components are considered irreparable and must be scrapped A need exists to improve the success in repairing such components.
- United States patent application publication number US 2012/0205014 A1 discusses prior art problems with inertia friction welding, including strain on the workpiece causing solidification stress.
FIG. 2 of that application illustrates separation of the fusion interface from such stress. That application describes a stress relief regiment to address that problem. Further improvements in such technology are desired - The invention is explained in the following description in view of the drawings that show.
-
FIG. 1 is a perspective side/front view of a conventional gas turbine blade assembly -
FIG. 2 is a front sectional view taken along line 2-2 ofFIG. 1 -
FIG. 3 is a top view of a blade and a cracked platform. -
FIG. 4 is a view as inFIG. 3 after removal of cracked area of platform -
FIG. 5 is a view as inFIG. 3 during inertia welding with an additive disk -
FIG. 6 is a view as inFIG. 3 after removal of excess disk and shaft -
FIG. 7 is a perspective view of an additive cylindrical disk with dual shafts -
FIG. 8 is a perspective view of an additive conical disk with dual shafts. -
FIG. 9 is a top view of a turbine blade and platform planned for simultaneous repair on opposite edges of the platform with balanced disk forces -
FIG. 10 is a top partial sectional view of an inertia friction repair in progress with rotary oscillation of the disk. -
FIG. 11 is a view as inFIG. 10 using a partial disk to reduce excess metal to be trimmed. -
FIG. 12 is a view as inFIG. 11 showing a nut mounting a partial disk to a shaft. -
FIG. 13 is a top sectional view of a partial disk mounted on a shaft with flats indexing the disk to the shaft. -
FIG. 14 is a top view of a platform with a hollow turbine blade in section with a supporting material in the blade chamber to reduce strain from disk pressure -
FIG. 15 is a top view of a platform with a turbine blade in section showing a deep, narrow repair using overlapping disk additions -
FIGS. 1 and 2 illustrate a conventional gasturbine blade assembly 20, including ablade 22, aplatform 24 and aroot 26 The blade has a hollow airfoil sectional shape withcooling chambers 28 supplied bycoolant flow channels 30 from the bottom of the root -
FIG. 3 is a top view of ablade 22 on aplatform 24 havingcracks 32 near afirst edge 34 thereof, with theblade 22 staged for repair in accordance with an embodiment of the present invention The cracks may be surface cracks or through cracksFIG. 4 shows the platform after removal of cracks by milling or cutting from theedge 34 to form acutout 35 In one embodiment, thecutout 35 may have a concave cylindrical surface with diameter D. However, other surfaces of rotation may be used, such a conical or spherical Milling with the side of a mechanical milling bit is suggested, but other cutting technologies may be used, such as water jet, plasma cutting, and laser cutting -
FIG. 5 shows aninertia welding disk 36 rotated by ashaft 38. The shaft may have a smaller diameter than the disk, but this is not a requirement Thecircumference 40 of the disk is pressed radially 42 into thecutout 35 as the disk rotates, creating frictional heat that plastically fuses the surface of the disk onto the surface of the cutout. Anopposing force 43 is needed to oppose theinward force 42 of the disk into thecutout 35 Thedisk 40 may be made of the same material as the platform, although different materials may be fused in some embodiments Variations in pressure across the cutout surface are largely self-correcting as hot areas plasticize and relieve local pressure. This results in uniform heating and a consistent fusion interface. The disk cutout may have less depth than the disk radius. Alternately or additionally, the disk may be reciprocated radially laterally 44 against alternate sides of the cutout to normalize pressure over the extent of the cutout. -
FIG. 6 shows a repaired platform after removal of excess disk and shaft material flush with the edges of the cutout and flush with the surfaces of the platform The remaining disk material, now fused with the platform, becomes an integral part of the platform, restoring it. The inventors have recognized that prior art friction welding with a rod end generates no rotary motion at the center of the rod end, so the weld receives no friction centrally, while the periphery of the weld receives maximum friction This contributes to a thermal gradient and solidification stress and possibly incomplete fusion at the center of the rod end. The present method lacks a frictionless center because the circumference of the disk has the same speed over the whole cutout surface (with a cylindrical disk) or has a non-zero speed within a desired range (spherical, conic, and other disk shapes). -
FIGS. 7 and 8 show examples of acylindrical disk 36A and aconical disk 36B in disk/shaft assemblies 47, 53 A two-ended shaft disk -
FIG. 9 shows aplatform 24 in which degradation is present onopposite edges cutouts opposite directions -
FIG. 10 shows a disk pressed radially 42 intocutout 35 in aplatform 24. The disk is not rotating constantly, but usesrotary oscillation 56 to create the friction. This generates aplasticized interface cutout 35 and thedisk 36 Using rotary oscillation avoids maintaining aplastic zone 60 around thewhole disk circumference 40 subject to environmental cooling. It also avoids dragging extruded plasticized material of the platform around the disk. It also avoids creating a subduction trench at the inward-moving side of the disk. Rotary oscillation beneficially extrudes a small amount ofmaterial 62 from both sides of the interface. This provides material for flush trimming, and avoids a trench on either end. The rotary oscillation may be less than 20 degrees total, such as plus and minus 5 or 3 degrees, minimizing exposure of theheated zone 60 to the air during welding The oscillations may be rapid such as 10 to 50,000 cycles per second Rotary oscillation mechanisms are known, and are not detailed here -
FIG. 11 shows an embodiment of adisk 36C for rotary oscillation using apartial disk 36C with less than 360 degrees of circumference. Using a partial disk leaves less scrap metal to trim For example, the disk may have less than 220 degrees of circumference, or less than 180 or 150 degrees for shallower cutouts.FIG. 12 shows an embodiment as inFIG. 11 using mounting means such as anut 64 and opposed flange (not visible) to fasten thedisk 36C onto theshaft 38FIG. 13 shows apartial disk 36C mounted on ashaft 38C against ashaft flange 65 The disk hasinternal flats 66 for indexing it toexternal flats 68 on theshaft 38C. Other attachment means may be used. -
FIG. 14 is a top sectional view of ahollow turbine blade 22 on aplatform 24 Cracks extend from anedge 34A of the platform to close proximity with the blade. Thecutout 35 may allow strain in the blade wall to deform the platform and blade under pressure by the disk In this situation theblade chamber 28 may be filled with sand orfluid 70 to internally support the wall of the blade and the adjoining reduced platform Alternately, incompressible fugitive cement may be inserted into the relevant chamber(s), and then removed by chemical means after the repair is complete An example of such a routinely fugitive cement is widely recognized as Great Stuff ™ from Dow Chemical Company. That product expands to fill gaps but may be dissolved by certain solvents such as acetone -
FIG. 15 shows a deep narrow repair made with overlappingdisk additions first disk 36D into a first cutout, a second cutout is formed into the first disk in order to receive thesecond disk 36E. Thefirst disk 36D may be formed to have less than a circumference of 360 degrees such that the second cutout is at least partially preformed. This process may be repeated fordisk 36F. Extrudate 62 from rotary oscillation fills the gaps in the cutouts between successive disks. - The present invention may have particular application to the repair of superalloy components such as gas turbine vanes and blades, but it is not necessarily limited to any particular type of material While various embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only Numerous variations, changes and substitutions may be made without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims
Claims (20)
Priority Applications (1)
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US14/185,997 US9114481B1 (en) | 2014-02-21 | 2014-02-21 | Inertia friction disk welding |
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US14/185,997 US9114481B1 (en) | 2014-02-21 | 2014-02-21 | Inertia friction disk welding |
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US9114481B1 US9114481B1 (en) | 2015-08-25 |
US20150239062A1 true US20150239062A1 (en) | 2015-08-27 |
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JP6252747B2 (en) * | 2013-11-22 | 2017-12-27 | ポップリベット・ファスナー株式会社 | Joining apparatus and joining method |
US10610944B2 (en) * | 2017-07-18 | 2020-04-07 | General Electric Company | Method for closing a plurality of holes in a metal article |
CN113977067A (en) * | 2021-11-22 | 2022-01-28 | 中国兵器工业第五九研究所 | Friction material increase blank manufacturing method |
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