WO2007095902A1 - Method for producing and repairing an integrally bladed rotor - Google Patents

Method for producing and repairing an integrally bladed rotor Download PDF

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Publication number
WO2007095902A1
WO2007095902A1 PCT/DE2007/000282 DE2007000282W WO2007095902A1 WO 2007095902 A1 WO2007095902 A1 WO 2007095902A1 DE 2007000282 W DE2007000282 W DE 2007000282W WO 2007095902 A1 WO2007095902 A1 WO 2007095902A1
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WO
WIPO (PCT)
Prior art keywords
rotor
projection
stool
blade
integrally bladed
Prior art date
Application number
PCT/DE2007/000282
Other languages
German (de)
French (fr)
Other versions
WO2007095902A8 (en
Inventor
Reinhold Meier
Wilfried SCHÜTTE
Original Assignee
Mtu Aero Engines Gmbh
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Publication date
Application filed by Mtu Aero Engines Gmbh filed Critical Mtu Aero Engines Gmbh
Publication of WO2007095902A1 publication Critical patent/WO2007095902A1/en
Publication of WO2007095902A8 publication Critical patent/WO2007095902A8/en

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Classifications

    • 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
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/006—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine wheels
    • 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
    • B23K13/00—Welding by high-frequency current heating
    • B23K13/01—Welding by high-frequency current heating by induction heating
    • B23K13/02—Seam welding
    • 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
    • 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
    • F01D5/005—Repairing methods or devices
    • 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
    • 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
    • F05D2230/25—Manufacture essentially without removing material by forging
    • 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Definitions

  • the invention relates to a method for producing and / or repairing an integrally bladed rotor, in particular an integrally bladed gas turbine rotor.
  • titanium alloys The most important materials used today for aircraft engines or other gas turbines are titanium alloys, nickel alloys and high strength steels.
  • the high-strength steels are used for shaft parts, gear parts, compressor housing and turbine housing.
  • Titanium alloys are typical materials for compressor parts.
  • Nickel alloys are suitable for the hot turbine parts of the aircraft engine.
  • As a manufacturing method for gas turbine components made of titanium alloys, nickel alloy or other alloys are known from the prior art m primarily investment casting and forging. All highly stressed gas turbine components, such as the blades for a compressor, are forgings. Components for a turbine, however, m usually performed as precision castings.
  • Integrally bladed rotors are also referred to as blisk (b_laded disk) or blmg (bled ring), depending on whether there is a disk-shaped rotor body or a ring-shaped rotor body. All previously known from the prior art method for the production of integrally bladed rotors require a high production cost and are therefore expensive. Furthermore, the repair of integrally bladed rotors presents difficulties.
  • the present invention is based on the problem to provide a novel method for producing and / or repairing an integrally bladed rotor. This problem is solved by a method for manufacturing and / or repairing an integrally bladed rotor according to claim 1.
  • the method comprises at least the following steps: a) providing a Rotorgroundkorpers, wherein the Rotorgroundkorper has at least one stool-like projection for the connection of a respective blade to the Rotorgroundkorper; b) providing at least one rotor blade, wherein the or each Laufs ⁇ haufel has a stool-like projection for connecting the same to a stool-like projection of the Rotorgroundkorpers; c) jointing the or each blade to the Rotorgroundkorper by inductive high frequency pressure welding, wherein the or each rotor blade is connected at its stool-like projection with a stool-like projection of the Rotorgroundkorpers; d) contouring of the or each of the Rotorgroundkorper grooved Laufschaufei.
  • the present invention proposes a sequence of process steps for producing and / or repairing an integrally bladed rotor, which is equally suitable for the manufacture and repair of integrally bladed rotors and which furthermore has high reproducibility.
  • the steps used for producing and / or repairing integrally bladed rotors in combination, in particular inductive high-frequency pressure welding, are highly automatable process steps, so that integrally bladed rotors can be manufactured and repaired effectively and inexpensively.
  • a heat treatment of the or each Fugestelle, namely the or each weld in particular in a repair of an integrally bladed rotor after the joints in step c) and prior to contouring according to step d) performed.
  • Fig. 1 is a schematic representation of an integrally bladed rotor
  • FIG. 2 is a schematic axial section through a stool-like projection of Rotorcampuskorper or Laufschaufei.
  • Figure 3 is a schematic radial section through the stool-like projection of Rotorgroundkorper or blade before the joints.
  • Fig. 4 is a schematic radial section through the hump-like projection of the rotor body or rotor blade after joining.
  • FIG. 1 shows in a highly schematic perspective view an integrally bladed gas turbine rotor 10 to be produced or repaired with the aid of the method according to the invention, the integrally bladed gas turbine rotor 10 having a rotor main body 11 and a plurality of rotor blades 12.
  • the blades 12 are permanently attached to an outer hub 13 of the rotor base body 11 and therefore an integral part thereof.
  • the rotor blades 12 are arranged equidistantly or equidistant from each other over the circumference of the rotor base body 11 or its hub 13.
  • the present invention now relates to a method for producing and repairing the integrally bladed gas turbine rotor 10 shown in FIG.
  • the procedure is such that a preferably forged rotor base body 11 is first provided.
  • the forged rotor base body 11 has hump-like projections for connecting a respective rotor blade to the rotor base body 11, wherein the number of hump-like projections corresponds to the number of blades to be connected.
  • such a hump-like projection 14 for connecting a rotor blade 12 is located at a circumferential position. At the other circumferential positions, corresponding rotor blades 12 are already joined to hump-like projections 14.
  • At least one preferably forged rotor blade 12 is further provided, wherein the or each forged blade 12 also has a hump-like projection 15 for connecting the same to a hump-like projection 14 of the rotor base body 11.
  • a blade 12 are added with their hump-like projection 15 to a corresponding hump-like projection 14 of the rotor body 11, so the corresponding blade 12 is first aligned relative to the rotor body 11 (see Fig. 3), in which case the two stool-like protrusions 14 and 15 of blade 12 and rotor main body 11 come to rest against each other, and then wherein the blade 12 is connected to the Rotorgroundkorper 11 by inductive high frequency pressure welding to form a weld zone 16.
  • the stool-like projection 14 of the rotor base body 11 and the stool-like projection 15 of the rotor blade 12 to be bonded to the rotor base body 11 have a uniform profile thickness (see FIG. 2), so that can be ensured over the entire profile of the blade 12 a good weld to Rotorgroundkorper 11. If one works with such uniform profile thicknesses of the stool-like projections 14, 15 of rotor blade 12 and rotor base body 11, an optimum selection of the welding parameters of the inductive high-frequency pressure welding is possible.
  • the inductive high frequency pressure welding works with low compression forces, so that the forged Rotorgroundkorper 11 is preferably provided with a final contour.
  • a final contour machining or of each rotor blade 12 attached to the rotor body 11 is preferably carried out by PECM, ie by Precise Elektro Chemical Machimng.
  • PECM material is removed from the rotor blades 12 by means of electrodes, with the geometric contour of the electrodes used corresponding to the geometric contour to be produced. This blade edge contours can be produced with high accuracy, so that post-processing after the PECM is not required.
  • the final contour machining of the blades can take place over the entire radial extension of the same between a radially outer blade tip and a radially inner Anbmdungs Suite same to the Rotorgroundkorper 11 and over the entire axial extent Endkontearbeitearbeitung between a flow inlet edge and a flow exit edge.
  • 2 and 4 show dashed lines in the final contour machining to be produced desired contours 17th
  • the stool-like projections 14 and 15 in the region of the rotor base body 11 and of the rotor blades 12 ensure a constructive decoupling of the rotor base body 11 and the blade of the rotor blades 12.
  • the stool-like projections 14, 15 can between the Ro- torgroundkorper 11 and the blade 12 a targeted transition ms aerodynamic profile of the blade of the blades are provided.
  • the stool-like projections 14, 15 with their gleichrichigen profile thickness continue to allow the inductive high frequency pressure welding, the formation of high-precision weld, so that the connection between Rotorgrundkorper 11 and blades 12 is characterized by a high strength. In case of repair, repeated blade changes are possible.
  • a heat treatment of the weld takes place after the joint has been formed by inductive high-frequency compression welding and before the PECM machining of the rotor blades.
  • the inventive method enables economical production and repair of integrally bladed rotors, wherein the forging processes for Rotorgroundkorper and the blades are optimally matched to the desired component strength of these components.
  • the inventive method is safe, easy to test and well reproducible.
  • the blades can be forged from a different material as the Rotorgroundskorper.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

The invention relates to a method for producing and/or repairing an integrally bladed rotor (10). Said method comprises the following steps: a) providing a rotor base (11), said rotor base having at least one dome-shaped projection (14) for connecting one rotor blade (12) each to the rotor base; b) providing at least one rotor blade, the one or more rotor blades having respective dome-shaped projections (15) for connection to a dome-shaped projection of the rotor base; c) joining the one or more rotor blades to the rotor base by inductive HF pressure welding, the dome-shaped projections of the one or more rotor blades being connected to the dome-shaped projections of the rotor base; d) precise machining of the one or more rotor blades that are joined to the rotor base.

Description

VERFAHREN ZUR HERSTELLUNG UND REPARATUR EINES INTEGRAL BESCHAUFELTEN ROTORSMETHOD FOR PRODUCING AND REPAIRING AN INTEGRAL SHAKED ROTOR
Die Erfindung betrifft ein Verfahren zur Herstellung und/oder Reparatur eines integral beschaufelten Rotors, insbesondere eines integral beschaufelten Gasturbinenrotors .The invention relates to a method for producing and / or repairing an integrally bladed rotor, in particular an integrally bladed gas turbine rotor.
Moderne Gasturbinen, insbesondere Flugtriebwerke, müssen höchsten Ansprüchen im Hinblick auf Zuverlässigkeit, Gewicht, Leistung, Wirtschaftlichkeit und Lebensdauer gerecht werden. Bei der Entwicklung von Gasturbinen spielt unter anderem die Werkstoffauswahl, die Suche nach neuen, geeigneten Werkstoffen sowie die Suche nach neuen Fertigungsverfahren eine entscheidende Rolle.Modern gas turbines, in particular aircraft engines, must meet the highest demands in terms of reliability, weight, performance, economy and service life. In the development of gas turbines, among other things, the selection of materials, the search for new, suitable materials and the search for new manufacturing processes play a decisive role.
Die wichtigsten, heutzutage für Flugtriebwerke oder sonstige Gasturbinen verwendeten Werkstoffe sind Titanlegierungen, Nickellegierungen und hochfeste Stahle. Die hochfesten Stahle werden für Wellenteile, Getriebeteile, Verdichtergehause und Turbinengehause verwendet. Titanlegierungen sind typische Werkstoffe für Verdichterteile . Nickellegierungen sind für die heißen Turbinenteile des Flugtriebwerks geeignet. Als Fertigungsverfahren für Gasturbinenbauteile aus Titanlegierungen, Nickellegierung oder sonstigen Legierungen sind aus dem Stand der Technik m erster Linie das Feingießen sowie Schmieden bekannt. Alle hochbeanspruchten Gasturbinenbauteile, wie zum Beispiel die Schaufeln für einen Verdichter, sind Schmiedeteile . Bauteile für eine Turbine werden hingegen m der Regel als Feingussteile ausgeführt.The most important materials used today for aircraft engines or other gas turbines are titanium alloys, nickel alloys and high strength steels. The high-strength steels are used for shaft parts, gear parts, compressor housing and turbine housing. Titanium alloys are typical materials for compressor parts. Nickel alloys are suitable for the hot turbine parts of the aircraft engine. As a manufacturing method for gas turbine components made of titanium alloys, nickel alloy or other alloys are known from the prior art m primarily investment casting and forging. All highly stressed gas turbine components, such as the blades for a compressor, are forgings. Components for a turbine, however, m usually performed as precision castings.
Zur Steigerung des Wirkungsgrads von Gasturbinen werden die Rotoren derselben zunehmend als integral beschaufelte Rotoren ausgeführt. Integral beschaufelte Rotoren werden auch als Blisk (b_laded disk) oder Blmg (bla- ded ring) bezeichnet, und zwar abhangig davon, ob ein scheibenförmiger Rotorgrundkorper oder ein ringförmiger Rotorgrundkorper vorliegt . Alle bislang aus dem Stand der Technik bekannten Verfahren zur Herstellung von integral beschaufelten Rotoren erfordern einen hohen Fertigungsaufwand und sind daher teuer. Des Weiteren bereitet die Reparatur integral be- schaufelter Rotoren Schwierigkeiten.To increase the efficiency of gas turbines, the rotors of the same are increasingly designed as integrally bladed rotors. Integrally bladed rotors are also referred to as blisk (b_laded disk) or blmg (bled ring), depending on whether there is a disk-shaped rotor body or a ring-shaped rotor body. All previously known from the prior art method for the production of integrally bladed rotors require a high production cost and are therefore expensive. Furthermore, the repair of integrally bladed rotors presents difficulties.
Hiervon ausgehend liegt der vorliegenden Erfindung das Problem zu Grunde, ein neuartiges Verfahren zur Herstellung und/oder Reparatur eines integral beschaufelten Rotors zu schaffen. Dieses Problem wird durch ein Verfahren zur Herstellung und/oder Reparatur eines integral beschaufelten Rotors gemäß Patentanspruch 1 gelost. Erfmdungsgemaß umfasst das Verfahren zumindest die folgenden Schritte: a) Bereitstellen eines Rotorgrundkorpers, wobei der Rotorgrundkorper mindestens einen hockerartigen Vorsprung zur Αnbindung jeweils einer Laufschaufel an den Rotorgrundkorper aufweist; b) Bereitstellen mindestens einer Laufschaufei, wobei die oder jede Laufsσhaufel einen hockerartigen Vorsprung zur Anbindung derselben an einen hockerartigen Vorsprung des Rotorgrundkorpers aufweist; c) Fugen der oder jeder Laufschaufel an den Rotorgrundkorper durch induktives Hochfrequenzpressschweißen, wobei die oder jede Laufschaufei an ihrem hockerartigen Vorsprung mit einem hockerartigen Vorsprung des Rotorgrundkorpers verbunden wird; d) Konturbearbeiten der oder jeder an den Rotorgrundkorper gefugten Laufschaufei .On this basis, the present invention is based on the problem to provide a novel method for producing and / or repairing an integrally bladed rotor. This problem is solved by a method for manufacturing and / or repairing an integrally bladed rotor according to claim 1. Erfmdungsgemaß the method comprises at least the following steps: a) providing a Rotorgrundkorpers, wherein the Rotorgrundkorper has at least one stool-like projection for the connection of a respective blade to the Rotorgrundkorper; b) providing at least one rotor blade, wherein the or each Laufsσhaufel has a stool-like projection for connecting the same to a stool-like projection of the Rotorgrundkorpers; c) jointing the or each blade to the Rotorgrundkorper by inductive high frequency pressure welding, wherein the or each rotor blade is connected at its stool-like projection with a stool-like projection of the Rotorgrundkorpers; d) contouring of the or each of the Rotorgrundkorper grooved Laufschaufei.
Mit der hier vorliegenden Erfindung wird eine Abfolge von Prozessschritten zur Herstellung und/oder Reparatur eines integral beschaufelten Rotors vorgeschlagen, die xn ihrer Gesamtheit gleichermaßen für die Herstellung sowie Reparatur von integral beschaufelten Rotoren geeignet ist und die sich des Weiteren über eine hohe Reproduzierbarkeit auszeichnet. Bei den zur Herstellung und/oder Reparatur von integral beschaufelten Rotoren in Kombination verwendeten Schritten, insbesondere beim induktiven Hochfrequenzpressschweißen, handelt es sich um m hohem Maße automati- sierbare Prozessschritte, so dass integral beschaufelte Rotoren effektiv und kostengünstig hergestellt sowie repartiert werden können.The present invention proposes a sequence of process steps for producing and / or repairing an integrally bladed rotor, which is equally suitable for the manufacture and repair of integrally bladed rotors and which furthermore has high reproducibility. The steps used for producing and / or repairing integrally bladed rotors in combination, in particular inductive high-frequency pressure welding, are highly automatable process steps, so that integrally bladed rotors can be manufactured and repaired effectively and inexpensively.
Nach einer vorteilhaften Weiterbildung der Erfindung wird insbesondere bei einer Reparatur eines integral beschaufelten Rotors nach dem Fugen gemäß Schritt c) und vor der Konturbearbeitung gemäß Schritt d) eine Warmbehandlung der oder jeder Fugestelle, nämlich der oder jeder Schweißstelle, durchgeführt.According to an advantageous development of the invention, a heat treatment of the or each Fugestelle, namely the or each weld, in particular in a repair of an integrally bladed rotor after the joints in step c) and prior to contouring according to step d) performed.
Bevorzugte Weiterbildungen der Erfindung ergeben sich aus den Unteran- spruchen und der nachfolgenden Beschreibung. Ausfuhrungsbeispiele der Erfindung werden, ohne hierauf beschrankt zu sein, an Hand der Zeichnung naher erläutert. Dabei zeigt:Preferred developments of the invention emerge from the subclaims and the following description. Exemplary embodiments of the invention will be explained in more detail with reference to the drawing, without being limited thereto. Showing:
Fig. 1 eine schematisierte Darstellung eines integral beschaufelten Rotors;Fig. 1 is a schematic representation of an integrally bladed rotor;
Fig. 2 einen schematisierten Axialschnitt durch einen hockerartigen Vorsprung von Rotorgrundkorper bzw. Laufschaufei;2 is a schematic axial section through a stool-like projection of Rotorgrundkorper or Laufschaufei.
Fig. 3 einen schematisierten Radialschnitt durch den hockerartigen Vorsprung von Rotorgrundkorper bzw. Laufschaufel vor dem Fugen; und Fig. 4 einen schematisierten Radialschnitt durch den höckerartigen Vorsprung von Rotorgrundkörper bzw. Laufschaufei nach dem Fügen.Figure 3 is a schematic radial section through the stool-like projection of Rotorgrundkorper or blade before the joints. and Fig. 4 is a schematic radial section through the hump-like projection of the rotor body or rotor blade after joining.
Fig. 1 zeigt in perspektivischer Ansicht stark schematisiert ein mit Hilfe des erfindungsgemäßen Verfahrens herzustellenden bzw. zu reparierenden integral beschaufelten Gasturbinenrotor 10, wobei der integral beschaufelte Gasturbinenrotor 10 einen Rotorgrundkörper 11 sowie mehrere Laufschaufeln 12 aufweist.FIG. 1 shows in a highly schematic perspective view an integrally bladed gas turbine rotor 10 to be produced or repaired with the aid of the method according to the invention, the integrally bladed gas turbine rotor 10 having a rotor main body 11 and a plurality of rotor blades 12.
Die Laufschaufeln 12 sind unlösbar an einer äußeren Nabe 13 des Rotorgrundkörpers 11 befestigt und demnach integraler Bestandteil desselben. Die Laufschaufeln 12 sind über den Umfang des Rotorgrundkörpers 11 bzw. dessen Nabe 13 äquidistant bzw. mit gleichem Abstand zueinander angeordnet.The blades 12 are permanently attached to an outer hub 13 of the rotor base body 11 and therefore an integral part thereof. The rotor blades 12 are arranged equidistantly or equidistant from each other over the circumference of the rotor base body 11 or its hub 13.
Die hier vorliegende Erfindung betrifft nun ein Verfahren zur Herstellung sowie Reparatur des in Fig. 1 dargestellten, integral beschaufelten Gasturbinenrotors 10.The present invention now relates to a method for producing and repairing the integrally bladed gas turbine rotor 10 shown in FIG.
Zur Herstellung eines integral beschaufelten Gasturbinenrotors wird so vorgegangen, dass zuerst ein vorzugsweise geschmiedeter Rotorgrundkörper 11 bereitgestellt wird. Der geschmiedete Rotorgrundkörper 11 verfügt über höckerartige Vorsprünge zur Anbindung jeweils einer Laufschaufei an den Rotorgrundkörper 11, wobei die Anzahl der höckerartigen Vorsprünge der Anzahl der anzubindenden Laufschaufeln entspricht.To produce an integrally bladed gas turbine rotor, the procedure is such that a preferably forged rotor base body 11 is first provided. The forged rotor base body 11 has hump-like projections for connecting a respective rotor blade to the rotor base body 11, wherein the number of hump-like projections corresponds to the number of blades to be connected.
Bei dem in Fig. 1 dargestellten Gasturbinenrotor 10 befindet sich an einer Umfangsposition ein solcher höckerartiger Vorsprung 14 zur Anbindung einer Laufschaufei 12. An den anderen Umfangspositionen sind bereits entsprechende Laufschaufeln 12 an höckerartige Vorsprünge 14 gefügt.In the gas turbine rotor 10 shown in FIG. 1, such a hump-like projection 14 for connecting a rotor blade 12 is located at a circumferential position. At the other circumferential positions, corresponding rotor blades 12 are already joined to hump-like projections 14.
Neben dem vorzugsweise geschmiedeten Rotorgrundkörper 11 wird im Sinne des erfindungsgemäßen Verfahrens weiterhin mindestens eine ebenfalls vorzugsweise geschmiedete Laufschaufei 12 bereitgestellt, wobei die oder jede geschmiedete Laufschaufel 12 ebenfalls einen höckerartigen Vorsprung 15 zur Anbindung derselben an einen höckerartigen Vorsprung 14 des Rotorgrundkörpers 11 aufweist.In addition to the preferably forged rotor base body 11, at least one preferably forged rotor blade 12 is further provided, wherein the or each forged blade 12 also has a hump-like projection 15 for connecting the same to a hump-like projection 14 of the rotor base body 11.
Soll nun eine Laufschaufel 12 mit ihrem höckerartigen Vorsprung 15 an einen entsprechenden höckerartigen Vorsprung 14 des Rotorgrundkörpers 11 gefügt werden, so wird zuerst die entsprechende Laufschaufel 12 relativ zum Rotorgrundkörper 11 ausgerichtet (siehe Fig. 3) , wobei hierbei die beiden hockerartigen Vorsprunge 14 und 15 von Laufschaufel 12 und Rotor- grundkorper 11 aneinander zur Anlage kommen, und wobei anschließend die Laufschaufel 12 mit dem Rotorgrundkorper 11 durch induktives Hochfrequenzpressschweißen unter Ausbildung einer Schweißzone 16 verbunden wird.If now a blade 12 are added with their hump-like projection 15 to a corresponding hump-like projection 14 of the rotor body 11, so the corresponding blade 12 is first aligned relative to the rotor body 11 (see Fig. 3), in which case the two stool-like protrusions 14 and 15 of blade 12 and rotor main body 11 come to rest against each other, and then wherein the blade 12 is connected to the Rotorgrundkorper 11 by inductive high frequency pressure welding to form a weld zone 16.
Um beim induktiven Hochfrequenzpressschweißen eine gute Schweißverbindung bereitstellen zu können, verfugen der hockerartige Vorsprung 14 des Ro- torgrundkorpers 11 sowie der hockerartige Vorsprung 15 der an den Rotorgrundkorper 11 anzubindenden Laufschaufel 12 über eine gleichmaßige bzw. konstante Profildicke (siehe Fig. 2), so dass über das gesamte Profil der Laufschaufel 12 eine gute Schweißverbindung zum Rotorgrundkorper 11 gewahrleistet werden kann. Wird mit derart gleichmaßigen Profildicken der hockerartigen Vorsprunge 14, 15 von Laufschaufei 12 und Rotorgrundkorper 11 gearbeitet, so ist eine optimale Auswahl der Schweißparameter des induktiven Hochfrequenzpressschweißens möglich. Das induktive Hochfrequenzpressschweißen arbeitet mit geringen Presskraften, so dass der geschmiedete Rotorgrundkorper 11 vorzugsweise endkonturgenau bereitgestellt wird.In order to be able to provide a good weld in inductive high-frequency compression welding, the stool-like projection 14 of the rotor base body 11 and the stool-like projection 15 of the rotor blade 12 to be bonded to the rotor base body 11 have a uniform profile thickness (see FIG. 2), so that can be ensured over the entire profile of the blade 12 a good weld to Rotorgrundkorper 11. If one works with such uniform profile thicknesses of the stool-like projections 14, 15 of rotor blade 12 and rotor base body 11, an optimum selection of the welding parameters of the inductive high-frequency pressure welding is possible. The inductive high frequency pressure welding works with low compression forces, so that the forged Rotorgrundkorper 11 is preferably provided with a final contour.
Nach dem Fugen der oder jeder Laufschaufei 12 an den Rotorgrundkorper 11 durch induktives Hochfrequenzpressschweαßen erfolgt im Sinne der hier vorliegenden Erfindung eine Endkonturbearbeitung der oder ;jeder an den Rotorgrundkorper 11 gefugten Laufschaufel 12 vorzugsweise durch PECM, also durch Precise Elektro Chemical Machimng. Beim PECM wird mit Hilfe von Elektroden von den Laufschaufeln 12 Material abgetragen, wobei die geometrische Kontur der verwendeten Elektroden der herzustellenden geometrischen Kontur entspricht. Hiermit können Schaufelblattkonturen hochgenau hergestellt werden, so dass eine Nachbearbeitung nach dem PECM nicht erforderlich ist.After the or each rotor blade 12 is attached to the rotor body 11 by inductive high-frequency compression welding, a final contour machining or of each rotor blade 12 attached to the rotor body 11 is preferably carried out by PECM, ie by Precise Elektro Chemical Machimng. In the case of PECM, material is removed from the rotor blades 12 by means of electrodes, with the geometric contour of the electrodes used corresponding to the geometric contour to be produced. This blade edge contours can be produced with high accuracy, so that post-processing after the PECM is not required.
Die Endkonturbearbeitung der Laufschaufeln kann dabei über die gesamte radiale Erstreckung derselben zwischen einer radial außen liegenden Schaufelspitze und einem radial innen liegenden Anbmdungsbereich derselben an den Rotorgrundkorper 11 und über die gesamte axiale Erstreckung Endkonturbearbeitung zwischen einer Stromungseintrittskante und einer Stromungsaustrittskante erfolgen. Fig. 2 und 4 zeigen m gestrichelter Linienführung bei der Endkonturbearbeitung herzustellende Sollkonturen 17.The final contour machining of the blades can take place over the entire radial extension of the same between a radially outer blade tip and a radially inner Anbmdungsbereich same to the Rotorgrundkorper 11 and over the entire axial extent Endkontearbeitearbeitung between a flow inlet edge and a flow exit edge. 2 and 4 show dashed lines in the final contour machining to be produced desired contours 17th
Durch die hockerartigen Vorsprunge 14 und 15 im Bereich des Rotorgrund- korpers 11 sowie der Laufschaufeln 12 ist eine konstruktive Entkopplung von Rotorgrundkorper 11 und Schaufelblatt der Laufschaufeln 12 gewährleistet. Durch die hockerartigen Vorsprunge 14, 15 kann zwischen dem Ro- torgrundkorper 11 und der Laufschaufel 12 ein gezielter Übergang ms aerodynamische Profil des Schaufelblatts der Laufschaufeln bereitgestellt werden. Die hockerartigen Vorsprunge 14, 15 mit ihren gleichmaßigen Profildicken ermöglichen weiterhin beim induktiven Hochfrequenzpressschweißen die Ausbildung hochgenauer Schweißnahte, so dass die Verbindung zwischen Rotorgrundkorper 11 und Laufschaufeln 12 durch eine hohe Festigkeit gekennzeichnet ist. Im Reparaturfall sind wiederholte Laufschaufeltausche möglich.The stool-like projections 14 and 15 in the region of the rotor base body 11 and of the rotor blades 12 ensure a constructive decoupling of the rotor base body 11 and the blade of the rotor blades 12. Through the stool-like projections 14, 15 can between the Ro- torgrundkorper 11 and the blade 12 a targeted transition ms aerodynamic profile of the blade of the blades are provided. The stool-like projections 14, 15 with their gleichmaßigen profile thickness continue to allow the inductive high frequency pressure welding, the formation of high-precision weld, so that the connection between Rotorgrundkorper 11 and blades 12 is characterized by a high strength. In case of repair, repeated blade changes are possible.
Insbesondere dann, wenn mit dem erfmdungsgemaßen Verfahren ein Rotor 10 zu reparieren ist, erfolgt nach dem Fugen durch induktives Hochfrequenz- pressschweαßen und vor der PECM-Bearbeitung der Laufschaufeln eine Warmbehandlung der Schweißstelle vorzugsweise durch induktive Erwärmung derselben.In particular, when a rotor 10 is to be repaired with the method according to the invention, a heat treatment of the weld, preferably by inductive heating thereof, takes place after the joint has been formed by inductive high-frequency compression welding and before the PECM machining of the rotor blades.
Dann, wenn ein integral beschaufelter Rotor zu reparieren ist, wird eine beschädigte Laufschaufel unter Bildung eines hockerartigen Vorsprungs im Bereich des Rotorgrundkorpers vom Rotorgrundkorper getrennt, wobei dann an diesen hockerartigen Vorsprung eine neue Laufschaufel gefugt werden kann.Then, when an integrally bladed rotor is to be repaired, a damaged blade is separated from the rotor body to form a stool-like projection in the region of the rotor body, and then a new blade can be grooved against this stool-like projection.
Das erfindungsgemaße Verfahren ermöglicht eine wirtschaftliche Herstellung sowie Reparatur von integral beschaufelten Rotoren, wobei die Schmiedeprozesse für den Rotorgrundkorper sowie die Laufschaufeln optimal auf die gewünschte Bauteilfestigkeit dieser Bauteile abgestimmt sind. Das erfindungsgemaße Verfahren ist sicher, einfach prufbar und gut reproduzierbar. Die Laufschaufeln können aus einem anderen Werkstoff geschmiedet werden wie der Rotorgrundskorper . The inventive method enables economical production and repair of integrally bladed rotors, wherein the forging processes for Rotorgrundkorper and the blades are optimally matched to the desired component strength of these components. The inventive method is safe, easy to test and well reproducible. The blades can be forged from a different material as the Rotorgrundskorper.

Claims

Patentansprüche claims
1. Verfahren zur Herstellung und/oder Reparatur eines integral beschaufelten Rotors, insbesondere eines integral beschaufelten Gasturbi- nenrotors, mit folgenden Schritten: a) Bereitstellen eines Rotorgrundkorpers, wobei der Rotorgrundkor- per mindestens einen hockerartigen Vorsprung zur Änbmdung jeweils einer Laufschaufei an den Rotorgrundkorper aufweist; b) Bereitstellen mindestens einer Laufschaufei, wobei die oder jede Laufschaufel einen hockerartigen Vorsprung zur Anbindung derselben an einen hockerartigen Vorsprung des Rotorgrundkorpers aufweist; c) Fugen der oder jeder Laufschaufei an den Rotorgrundkorper durch induktives Hochfrequenzpressschweißen, wobei die oder jede Laufschaufel an ihrem hockerartigen Vorsprung mit einem hockerartigen Vorsprung des Rotorgrundkorpers verbunden wird; d) Konturbearbeiten der oder jeder an den Rotorgrundkorper gefugten Laufschaufei .1. A method for producing and / or repairing an integrally bladed rotor, in particular an integrally bladed gas turbine rotor, comprising the following steps: a) providing a Rotorgrundkorpers, wherein the Rotorgrundkor- at least one stool-like projection for Änbmdung each having a rotor blade to the Rotorgrundkorper ; b) providing at least one rotor blade, wherein the or each blade has a stool-like projection for connecting the same to a stool-like projection of the Rotorgrundkorpers; c) jointing the or each rotor blade to the rotor body by inductive high frequency pressure welding, wherein the or each blade is connected at its stool-like projection with a stool-like projection of the Rotorgrundkorpers; d) contouring of the or each of the Rotorgrundkorper grooved Laufschaufei.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der oder jeder hockerartige Vorsprung des Rotorgrundkorpers eine gleichmäßige Profildicke aufweist2. The method according to claim 1, characterized in that the or each stool-like projection of Rotorgrundkorpers has a uniform profile thickness
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass der hockerartige Vorsprung der oder jeder Laufschaufei eine gleichmaßige Profildicke aufweist.3. The method according to claim 1 or 2, characterized in that the stool-like projection of the or each rotor blade has a gleichmaßige profile thickness.
4 Verfahren nach einem oder mehreren der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass die Konturbearbeitung gemäß Schritt d) durch PECM bzw. durch Precise Electro Chemical Machining erfolgt.4. The method according to one or more of claims 1 to 3, characterized in that the contour machining according to step d) by PECM or by Precise Electro Chemical Machining takes place.
5. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass bei der Konturbearbeitung der oder jeder Laufschaufei ein Schaufelblattbereich derselben und ein Ubergangsbereich derselben zum Rotorgrundkorpers bearbeitet wird.5. The method according to claim 4, characterized in that in the contour machining of the or each rotor blade an airfoil portion thereof and a transition region thereof is processed to the Rotorgrundkorpers.
6. Verfahren nach einem oder mehreren der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass die Laufschaufeln und der Rotorgrundkorper geschmiedet sind. 6. The method according to one or more of claims 1 to 5, characterized in that the rotor blades and the Rotorgrundkorper are forged.
7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass die Laufschaufeln aus einem anderen Werkstoff geschmiedet sind wie der Rotorgrundskόrper.7. The method according to claim 6, characterized in that the blades are forged from a different material as the Rotorgrundskόrper.
8. Verfahren nach einem oder mehreren der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass nach dem Fügen gemäß Schritt c) und vor der Konturbearbeitung gemäß Schritt d) eine Warmbehandlung der oder jeder Fügestelle, nämlich der oder jeder Schweißstelle, durchgeführt wird.8. The method according to one or more of claims 1 to 7, characterized in that after joining according to step c) and prior to contouring according to step d), a heat treatment of the or each joint, namely the or each weld is performed.
9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass die Warmbehandlung durch induktive Erwärmung der oder jeder Schweißstelle erfolgt. 9. The method according to claim 8, characterized in that the heat treatment is carried out by inductive heating of the or each weld.
PCT/DE2007/000282 2006-02-25 2007-02-15 Method for producing and repairing an integrally bladed rotor WO2007095902A1 (en)

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DE102009033835A1 (en) * 2009-07-18 2011-01-20 Mtu Aero Engines Gmbh Method for replacing a blade of a rotor with integrated blading and such a rotor
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