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CN106337696A - 用于涡轮叶片修理的系统及方法 - Google Patents

用于涡轮叶片修理的系统及方法 Download PDF

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Publication number
CN106337696A
CN106337696A CN201610535062.1A CN201610535062A CN106337696A CN 106337696 A CN106337696 A CN 106337696A CN 201610535062 A CN201610535062 A CN 201610535062A CN 106337696 A CN106337696 A CN 106337696A
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turbo blade
squealer tip
sintering
extension
scheme
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崔岩
S.C.科蒂林加姆
B.L.托利森
D.E.施克
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General Electric Co
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General Electric Co
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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
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/181—Blades having a closed internal cavity containing a cooling medium, e.g. sodium
    • 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
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up 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
    • B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
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    • B33Y10/00—Processes of additive manufacturing
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    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/187—Convection cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/20—Specially-shaped blade tips to seal space between tips and stator
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B22F2007/068—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts repairing articles
    • 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
    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
    • F05D2220/32—Application in turbines in gas 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
    • F05D2230/10—Manufacture by removing material
    • 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
    • F05D2230/10—Manufacture by removing material
    • F05D2230/13—Manufacture by removing material using lasers
    • 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
    • F05D2230/22—Manufacture essentially without removing material by sintering
    • 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
    • F05D2230/234—Laser 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods
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    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
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    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05D2240/307—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the tip of a rotor blade
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Abstract

本发明涉及用于涡轮叶片修理的系统及方法。具体而言，本申请提供了一种修理涡轮叶片的方法。该方法可包括以下步骤：从涡轮叶片整体或部分地除去现有凹槽状叶顶、将涡轮叶片定位在增材制造系统中，以及在涡轮叶片上整体或部分地构建替换凹槽状叶顶的延伸部。

Description

用于涡轮叶片修理的系统及方法
技术领域
本申请和所得的专利大体上涉及燃气涡轮发动机，并且更具体地涉及利用改善的内部冷却几何形状进行三维涡轮翼型件凹槽状叶顶修理来延长构件寿命的系统及方法。
背景技术
铸造的涡轮叶片通常包括称为"凹槽状叶顶"(squealer tip)的结构。凹槽状叶顶是叶片的相对小的延伸部。凹槽状叶顶可具有与叶片的截面形状相符的截面形状，且可与叶片的径向外端整体结合或安装在其上。在使用一段时间之后，凹槽状叶顶可由热燃烧气体的冲击侵蚀、氧化和/或腐蚀。由于涡轮叶片可能制造昂贵，故如果可能的话受损叶片的修理或整修可为优选的。涡轮叶片凹槽状叶顶的修理可通过磨削掉受损的材料且然后焊接或以其它方式附接替换材料来执行。冷却凹槽状叶顶还可延长总体有用的构件寿命。然而，由于制造约束，提供冷却很难。
因此，期望用于涡轮叶片凹槽状叶顶修理和整修的改善的系统及方法。此外，此改善的系统及方法还可提供内部凹槽状叶顶冷却通路，以便延长总体构件寿命。
发明内容
本申请和所得的专利提供了一种修理涡轮叶片的方法。该方法可包括以下步骤：从涡轮叶片整体或部分地除去现有凹槽状叶顶、将涡轮叶片定位在增材制造系统中，以及在涡轮叶片上整体或部分地构建替换凹槽状叶顶的延伸部。构建替换凹槽状叶顶的延伸部可包括形成穿过延伸部的一个或多个冷却通路。
本申请和所得的专利还提供了一种用于燃气涡轮发动机中的涡轮叶片。涡轮叶片可包括翼型件和在翼型件上构建的凹槽状叶顶。凹槽状叶顶可在其中包括冷却通路。凹槽状叶顶可由适用于增材制造过程的超级合金制成。
本申请及所得的专利还提供了一种修理涡轮叶片的方法。该方法可包括以下步骤：从涡轮叶片整体或部分地除去现有凹槽状叶顶，将涡轮叶片定位在增材制造系统中，在涡轮叶片上整体或部分地构建替换凹槽状叶顶的超级合金延伸部，以及形成穿过超级合金延伸部的冷却通路。
技术方案1. 一种修理涡轮叶片的方法，包括：
从所述涡轮叶片整体或部分地除去现有凹槽状叶顶；
将所述涡轮叶片定位在增材制造系统中；以及
在所述涡轮叶片上整体或部分地构建替换凹槽状叶顶的延伸部。
技术方案2. 根据技术方案1所述的方法，其中，从所述涡轮叶片除去现有凹槽状叶顶的步骤包括整体或部分地加工所述现有凹槽状叶顶。
技术方案3. 根据技术方案1所述的方法，其中，将所述涡轮叶片定位在增材制造系统中的步骤包括将所述涡轮叶片定位在直接金属激光烧结系统或电子束焊接系统中。
技术方案4. 根据技术方案3所述的方法，其中，将所述涡轮叶片定位在增材制造系统中的步骤包括改变所述直接金属激光烧结系统的构造板以适应所述涡轮叶片。
技术方案5. 根据技术方案1所述的方法，其中，构建替换凹槽状叶顶的延伸部的步骤包括直接金属激光烧结。
技术方案6. 根据技术方案1所述的方法，其中，构建替换凹槽状叶顶的延伸部的步骤包括烧结和粘结金属粉末材料。
技术方案7. 根据技术方案6所述的方法，其中，烧结和粘结金属粉末材料的步骤包括烧结和粘结具有Al≤-0.5Ti+3的超级合金粉末。
技术方案8. 根据技术方案6所述的方法，其中，烧结和粘结金属粉末材料的步骤包括烧结和粘结具有Al≥-0.5Ti+3的超级合金粉末。
技术方案9. 根据技术方案6所述的方法，其中，烧结和粘结金属粉末材料的步骤包括烧结和粘结具有高抗氧化性的超级合金粉末。
技术方案10. 根据技术方案1所述的方法，其中，构建替换凹槽状叶顶的延伸部的步骤包括在所述延伸部内形成冷却通路。
技术方案11. 根据技术方案10所述的方法，其中，构建替换凹槽状叶顶的延伸部的步骤包括在所述延伸部内形成其中具有粗糙表面的冷却通路。
技术方案12. 根据技术方案10所述的方法，其中，构建替换凹槽状叶顶的延伸部的步骤包括在所述延伸部内形成具有铝化物涂层的冷却通路。
技术方案13. 一种用于燃气涡轮发动机中的涡轮叶片，包括：
翼型件；以及
在所述翼型件上构建的凹槽状叶顶；
所述凹槽状叶顶在其中包括冷却通路；
所述凹槽状叶顶包括适用于增材制造过程的超级合金。
技术方案14. 根据技术方案13所述的涡轮叶片，其中，所述凹槽状叶顶包括替换凹槽状叶顶。
技术方案15. 根据技术方案13所述的涡轮叶片，其中，所述凹槽状叶顶包括在所述翼型件上构建的凹槽状叶顶延伸部。
技术方案16. 一种修理涡轮叶片的方法，包括：
从所述涡轮叶片整体或部分地除去现有凹槽状叶顶；
将所述涡轮叶片定位在增材制造系统中；
在所述涡轮叶片上整体或部分地构建替换凹槽状叶顶的超级合金延伸部；以及
形成穿过所述超级合金延伸部的冷却通路。
技术方案17. 根据技术方案16所述的方法，其中，从所述涡轮叶片除去现有凹槽状叶顶的步骤包括整体或部分地加工所述现有凹槽状叶顶。
技术方案18. 根据技术方案16所述的方法，其中，将所述涡轮叶片定位在增材制造系统中的步骤包括将所述涡轮叶片定位在直接金属激光烧结系统或电子束焊接系统中。
技术方案19. 根据技术方案18所述的方法，其中，将所述涡轮叶片定位在增材制造系统中的步骤包括改变所述直接金属激光烧结系统的构造板以适应所述涡轮叶片。
技术方案20. 根据技术方案16所述的方法，其中，构建替换凹槽状叶顶的超级合金延伸部的步骤包括直接金属激光烧结金属粉末材料。
在连同若干附图和所附权利要求阅读以下详细描述时，本申请和所得的专利的这些及其它特征和改善对于本领域的普通技术人员将变得清楚。
附图说明
图1为示出压缩机、燃烧器、涡轮和负载的燃气涡轮发动机的示意图。
图2为在凹槽状叶顶内具有裂纹的涡轮叶片的透视图。
图3为除去凹槽状叶顶的图2的涡轮叶片的透视图。
图4为具有可如本文所述的改善的凹槽状叶顶的修理的涡轮叶片的透视图。
图5为具有冷却通路的图4的凹槽状叶顶的局部截面视图。
图6为示出修理可如本文所述的凹槽状叶顶中的示例性步骤的流程图。
零件清单
10 燃气涡轮发动机
15 压缩机
20 空气
25 燃烧器
30 燃料
35 燃烧气体
40 涡轮
45 轴
50 负载
55 涡轮叶片
60 翼型件
62 前缘
64 后缘
66 凹形压力侧外壁
68 凸形吸力侧外壁
70 柄部
75 燕尾部
80 平台
85 凹槽状叶顶
90 叶顶罩
95 裂纹
100 涡轮叶片
110 凹槽状叶顶
120 凹槽状叶顶延伸部
130 冷却通路
140 加工步骤
150 改变步骤
160 打印步骤。
具体实施方式
现在参看附图，其中相似的数字表示贯穿若干视图的相似元件，图1示出了可如本文使用的燃气涡轮发动机10的示意图。燃气涡轮发动机10可包括压缩机15。压缩机15压缩空气20的入流。压缩机15将压缩的空气20的流输送至燃烧器25。燃烧器25使压缩的空气20的流与加压的燃料30的流混合，且点燃混合物以形成燃烧气体35的流。尽管仅示出了单个燃烧器25，但燃气涡轮发动机10可包括任何数目的燃烧器25。燃烧气体35的流继而又输送至涡轮40。燃烧气体35的流驱动涡轮40以便产生机械功。涡轮40中产生的机械功经由轴45驱动压缩机15，以及诸如发电机等的外部负载50。
燃气涡轮发动机10可使用天然气、各种类型的合成气、液体燃料和/或其它类型的燃料和它们的混合物。燃气涡轮发动机10可为由纽约州斯卡奈塔第(Schenectady, NewYork)的通用电气公司提供的多种不同燃气涡轮发动机中的任一种，包括但不限于诸如7或9系列重型燃气涡轮发动机等的那些。燃气涡轮发动机10可具有不同构造，且可使用其它类型的构件。其它类型的燃气涡轮发动机也可在本文中使用。多个燃气涡轮发动机、其它类型的涡轮和其它类型的功率生成设备也可在本文中一起使用。
图2为涡轮叶片55的实施例的透视图。在该示例中，涡轮叶片55可为第一级动叶，但任何类型的叶片也可在其中使用。大体上描述，涡轮叶片55包括翼型件60。翼型件60可从前缘62延伸至后缘64，具有凹形压力侧外壁66和凸形吸力侧外壁68。涡轮叶片55还可包括向下延伸的柄部70，以及燕尾部75形式的附接件。平台80可在翼型件60和柄部70以及燕尾部75之间横向地延伸。翼型件60的径向端可包括凹槽状叶顶85。凹槽状叶顶85可为外侧壁66、68的延伸部。凹槽状叶顶86可在其中限定凹入的叶顶罩90。本文所述的涡轮叶片55和凹槽状叶顶85仅用于举例的目的。许多其它设计和构造可为已知的。
如上文所述，凹槽状叶顶85可经历高温，且可摩擦密封结构(诸如静止护罩)。结果，裂纹95可由于热诱发的应力和氧化造成的材料损失等形成在凹槽状叶顶85中。为了修理涡轮叶片55，凹槽状叶顶85可如图3中所示加工，以便除去裂纹95或其它类型的磨损、破坏位置或其它缺陷位置。凹槽状叶顶材料可以以常规方式加工。
图4和图5示出了可如本文所述的改善的涡轮叶片100。涡轮叶片100可为上文所述的涡轮叶片55，其具有下方加工的凹槽状叶顶85，且具有构造在其上的改善的凹槽状叶顶110。改善的凹槽状叶顶110可包括构造在其上的凹槽状叶顶延伸部120，以便从外侧壁66、68沿径向向上延伸。凹槽状叶顶延伸部120可以以任何适合的尺寸、形状或构造来构建。
改善的凹槽状叶顶110可具有构造到凹槽状叶顶延伸部120中或其他方式的一个或多个冷却通路。冷却通路130可具有任何适合的尺寸、形状或构造。冷却通路130可与诸如空气的冷却介质的源连通，其从压缩机15或别处延伸穿过翼型件60。冷却通路130的内部可具有粗糙表面，诸如凹座或其它类型的表面特征，以便提高总体热传递效果。铝化物涂层等也可用于冷却通路130内以提高升高温度下的抗氧化性。本文中可使用其它构件和其它构造。
替代将凹槽状叶顶延伸部常规地焊接或以其它方式附接到翼型件60，在该示例中，凹槽状叶顶延伸部120可在增材制造过程(即，三维打印)中构造在翼型件60上。具体而言，凹槽状叶顶延伸部120可经由直接金属激光烧结(DMLS)过程等以任何适合的尺寸、形状或构造打印或构造。DMLS为增材制造过程，其使用激光来烧结金属粉末材料，且将材料粘结在一起以形成致密结构。选择性激光烧结和其它类型的烧结和/或熔化技术或其它类型的增材制造过程等也可在本文中使用以形成凹槽状叶顶110或其它构件。此外，DMLS过程或其它类型的三维打印的使用允许冷却通路130或其它类型的复杂内部几何形状的形成。DMLS或其它类型的三维打印过程允许在其中形成具有任何期望的几何形状的冷却通路130，以便向其提供改善的冷却。电子束(EB)焊接过程等可在本文中使用。
由于三维打印为焊接过程，故可使用具有足够的可焊接性的材料。例如，原翼型件60附近的粉末材料可为针对"预堆边焊"或初始构建的容易焊接范围(根据超级合金的应变时效开裂敏感性的图表，Al ≤ -0.5 Ti + 3)中的超级合金粉末。适合的材料可包括Haynes 230、Haynes 282和类似的材料。难以焊接的超级合金粉末(Al ≥ -0.5 Ti + 3)然后可用于构建凹槽状叶顶延伸部120。适合的材料可包括Haynes 214、GTD111、Rene 108和类似的材料。超级合金材料大体上可具有高抗氧化性。本文中也可使用其它类型的材料。
图6示出了整体或部分地执行本文所述的方法的示例性步骤的流程图。在步骤140处，现有的凹槽状叶顶85可如图3中所示在翼型件60上加工。在步骤150处，DMLS机器或其它装置中的构造板可改变以接收涡轮叶片55的翼型件60。在步骤160处，DMLS机器可将改善的凹槽状叶顶110的凹槽状叶顶延伸部120直接地打印或构造在翼型件60上。该打印或构造步骤还可包括在其中形成冷却通路130或其它类型的内部几何形状。改善的涡轮叶片100现在可准备用于使用或其它类型的处理。本文所述的方法步骤不是排他的。其它或不同的方法步骤可以以任何期望的顺序使用以形成本文的凹槽状叶顶110或其它构件。
因此，本文所述的系统和方法提供了使用具有改善的抗氧化性的高级超级合金材料来快速且有效修理涡轮叶片和凹槽状叶顶。此外，改善的涡轮叶片100可包括凹槽状叶顶110内的冷却通路130，以用于改善的冷却和延长的总体构件寿命。假定现有制造约束，则此冷却通路130大体上不可行。此外，本文所述的系统和方法可用于将现有涡轮叶片升级为具有此冷却特征。
应当清楚的是，前文仅涉及本申请和所得的专利的某些实施例。本领域的普通技术人员可作出许多变化和改型，而不会脱离由所附权利要求及其等同物限定的本发明的总体精神和范围。

Claims (10)

1.一种修理涡轮叶片的方法，包括：
从所述涡轮叶片整体或部分地除去现有凹槽状叶顶；
将所述涡轮叶片定位在增材制造系统中；以及
在所述涡轮叶片上整体或部分地构建替换凹槽状叶顶的延伸部。
2.根据权利要求1所述的方法，其特征在于，从所述涡轮叶片除去现有凹槽状叶顶的步骤包括整体或部分地加工所述现有凹槽状叶顶。
3.根据权利要求1所述的方法，其特征在于，将所述涡轮叶片定位在增材制造系统中的步骤包括将所述涡轮叶片定位在直接金属激光烧结系统或电子束焊接系统中。
4.根据权利要求3所述的方法，其特征在于，将所述涡轮叶片定位在增材制造系统中的步骤包括改变所述直接金属激光烧结系统的构造板以适应所述涡轮叶片。
5.根据权利要求1所述的方法，其特征在于，构建替换凹槽状叶顶的延伸部的步骤包括直接金属激光烧结。
6.根据权利要求1所述的方法，其特征在于，构建替换凹槽状叶顶的延伸部的步骤包括烧结和粘结金属粉末材料。
7.根据权利要求6所述的方法，其特征在于，烧结和粘结金属粉末材料的步骤包括烧结和粘结具有Al≤-0.5Ti+3的超级合金粉末。
8.根据权利要求6所述的方法，其特征在于，烧结和粘结金属粉末材料的步骤包括烧结和粘结具有Al≥-0.5Ti+3的超级合金粉末。
9.根据权利要求6所述的方法，其特征在于，烧结和粘结金属粉末材料的步骤包括烧结和粘结具有高抗氧化性的超级合金粉末。
10.根据权利要求1所述的方法，其特征在于，构建替换凹槽状叶顶的延伸部的步骤包括在所述延伸部内形成冷却通路。
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CN110202158A (zh) * 2019-05-23 2019-09-06 中国人民解放军第五七一九工厂 一种航空发动机涡轮转子叶片叶冠纵向密集损伤的整体式修复方法

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