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US20040115059A1 - Cored steam turbine bucket - Google Patents

Cored steam turbine bucket Download PDF

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Publication number
US20040115059A1
US20040115059A1 US10/317,190 US31719002A US2004115059A1 US 20040115059 A1 US20040115059 A1 US 20040115059A1 US 31719002 A US31719002 A US 31719002A US 2004115059 A1 US2004115059 A1 US 2004115059A1
Authority
US
United States
Prior art keywords
steam turbine
turbine bucket
dovetail
bucket airfoil
tangential
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.)
Abandoned
Application number
US10/317,190
Inventor
Richard Kehl
Ronald Bunker
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.)
General Electric Co
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to US10/317,190 priority Critical patent/US20040115059A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BUNKER, RONALD SCOTT, KEHL, RICHARD EUGENE
Priority to DE10358166A priority patent/DE10358166B4/en
Priority to JP2003412659A priority patent/JP2004190681A/en
Priority to CNB2003101205072A priority patent/CN1321759C/en
Publication of US20040115059A1 publication Critical patent/US20040115059A1/en
Abandoned legal-status Critical Current

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/22Blade-to-blade connections, e.g. for damping vibrations
    • F01D5/225Blade-to-blade connections, e.g. for damping vibrations by shrouding
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/14Form or construction
    • F01D5/147Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00Manufacture
    • F05D2230/20Manufacture essentially without removing material
    • F05D2230/21Manufacture essentially without removing material by casting

Definitions

  • the present invention is directed to the investment casting of steam turbine buckets. More particularly, the present invention provides a method for investment casting lightweight yet structurally sound steam turbine buckets.
  • a critical design element of steam turbine design is rotor stresses driven by bucket weight. With the given manufacturing processes, however, it is very difficult to reduce bucket weight without compromising mechanical integrity.
  • the present invention proposes a investment casting process for hollow steam turbine buckets, which may also include a lattice-work of crossing channels internal to the airfoil to reduce weight while maintaining mechanical integrity.
  • the new structural design uses a robust investment casting, facilitates an integral cover (or bucket shroud) design and provides the potential for steam turbine bucket cooling.
  • the lattice-work of channels is placed at opposing angles to create a cris-crossed rib structure internal to the airfoil with good stress distribution.
  • a cris-crossed rib structure internal to the airfoil with good stress distribution.
  • the lattice-work of channels is formed from a highly connected ceramic core piece, which leads to very high yield rates for investment castings.
  • the new structural design results in an airfoil having a lower overall weight, which serves to reduce corresponding rotor structures and overall unit size.
  • Advantages of the new structural design include weight reduction and an improved rotor thermal transient response due to reduced weight.
  • investment cast procedures facilitate design features such as integral covers.
  • inventive process provides the ability to tailor design response by altering internal geometry (lattice density).
  • FIG. 1 shows a cut-away section of a steam turbine bucket airfoil to have a lattice-work internal core and with the bucket having a tangential fir-tree dovetail;
  • FIG. 2 shows a cut-away section of a steam turbine bucket airfoil to have a lattice-work internal core and with the bucket having a tangential slot dovetail;
  • FIG. 3 shows a cut-away section of a steam turbine bucket airfoil to have a lattice-work internal core and with the bucket having an axial entry dovetail;
  • FIGS. 1 - 3 show in cut-away section, the use of lattice-works 10 , 20 , 30 that respectively provide high solidity ceramic cores which are much more durable for manufacturing.
  • these steam turbine buckets could be formed by investment casting without the lattice-work internal cores so as to be hollow.
  • FIG. 1 shows a steam turbine bucket having a tangential fir-tree dovetail 11
  • FIG. 2 shows a steam turbine bucket having a tangential slot dovetail 21
  • FIG. 3 shows a steam turbine bucket having an axial entry dovetail.
  • the range of angles for the lattice work crossing channels or ribs is from 25° to 55° on one wall and then ⁇ 25° to ⁇ 55° on the opposite wall.
  • the preferred ratio for size of the channels to the thickness of the ribs is 4:1 to 1:1.
  • ribs 0.1 inch would be spaced 0.25 inches apart.
  • the investment casting process also provides the opportunity to cast-in design features such as integral covers 12 , 22 , 32 that reduce bucket tip steampath leakage.
  • the reduced weight of the cast buckets and associated rotor improve thermal transient response to be more consistent with the static shell structures, improving transient response, maintaining tighter clearances and improved unit performance.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

Steam turbine buckets are formed by investment casting to be hollow or to have a lightweight lattice-work internal core. The process is also used to integrally form steam turbine buckets having a variety of dovetail configurations, including a tangential fir-tree dovetail, a tangential slot dovetail and an axial gas turbine style dovetail. The investment casting process can also be used to integrally cast a cover at one end of the steam turbine bucket.

Description

    FIELD OF THE INVENTION
  • The present invention is directed to the investment casting of steam turbine buckets. More particularly, the present invention provides a method for investment casting lightweight yet structurally sound steam turbine buckets. [0001]
  • BACKGROUND OF THE INVENTION
  • Current steam turbine buckets are machined from plate stock and as such are solid buckets. This includes steam turbine buckets with traditional tangential fir-tree dovetails, tangential slot dovetails, and axial entry dovetails. [0002]
  • A critical design element of steam turbine design is rotor stresses driven by bucket weight. With the given manufacturing processes, however, it is very difficult to reduce bucket weight without compromising mechanical integrity. [0003]
  • The prior art technology for high pressure and intermediate pressure steam turbine rotating bucket airfoils is primarily custom components machined from plate stock. These solid airfoils are necessarily heavy and necessitate significant rotor structures to support them. [0004]
  • SUMMARY OF THE INVENTION
  • It is desirable to replace the conventionally machined solid buckets with lighter parts manufactured by investment casting without compromising structural integrity. The present invention accomplishes the goal of providing a lightweight yet strong, steam turbine airfoil. [0005]
  • The present invention proposes a investment casting process for hollow steam turbine buckets, which may also include a lattice-work of crossing channels internal to the airfoil to reduce weight while maintaining mechanical integrity. The new structural design uses a robust investment casting, facilitates an integral cover (or bucket shroud) design and provides the potential for steam turbine bucket cooling. [0006]
  • The lattice-work of channels is placed at opposing angles to create a cris-crossed rib structure internal to the airfoil with good stress distribution. Preferably, there are no internal main ribs in the design, but could be if mechanical design considerations required such main ribs. [0007]
  • The lattice-work of channels is formed from a highly connected ceramic core piece, which leads to very high yield rates for investment castings. The new structural design results in an airfoil having a lower overall weight, which serves to reduce corresponding rotor structures and overall unit size. [0008]
  • Advantages of the new structural design include weight reduction and an improved rotor thermal transient response due to reduced weight. In addition, investment cast procedures facilitate design features such as integral covers. Moreover, the inventive process provides the ability to tailor design response by altering internal geometry (lattice density). [0009]
  • The use of investment casting provides a high casting yield relative to traditional gas turbine designs. Finally, the use of investment casting provides the potential for steam turbine bucket cooling. [0010]
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 shows a cut-away section of a steam turbine bucket airfoil to have a lattice-work internal core and with the bucket having a tangential fir-tree dovetail; [0011]
  • FIG. 2 shows a cut-away section of a steam turbine bucket airfoil to have a lattice-work internal core and with the bucket having a tangential slot dovetail; [0012]
  • FIG. 3 shows a cut-away section of a steam turbine bucket airfoil to have a lattice-work internal core and with the bucket having an axial entry dovetail; and[0013]
  • DETAILED DESCRIPTION OF THE INVENTION
  • Due to the custom nature of conventional steam turbine designs, steam turbine buckets are traditionally manufactured from plate stock using flexible machining processes. The present inventors were the first to realize that as steam turbine products become more structured or pre-engineered, as are gas turbine products, the re-use of steam turbine bucket designs made an investment casting manufacturing process more feasible. [0014]
  • They were also the first to realize that while investment casting provided an opportunity for significant bucket weight reduction, the fragile nature of traditional gas turbine cores with a few internal radial ribs, often lead to a high rate of ceramic core breakage and variability in cast wall thickness. The proposed investment cast process addresses these problems and issues. [0015]
  • FIGS. [0016] 1-3 show in cut-away section, the use of lattice- works 10, 20, 30 that respectively provide high solidity ceramic cores which are much more durable for manufacturing. Alternatively, these steam turbine buckets could be formed by investment casting without the lattice-work internal cores so as to be hollow.
  • The lattice-works [0017] 10, 20, 30, however, allow greater control of wall thickness in the end product, and improve the mechanical integrity relative to the traditional alternative with large internal cavities. FIG. 1 shows a steam turbine bucket having a tangential fir-tree dovetail 11, FIG. 2 shows a steam turbine bucket having a tangential slot dovetail 21, FIG. 3 shows a steam turbine bucket having an axial entry dovetail.
  • Preferably, the range of angles for the lattice work crossing channels or ribs is from 25° to 55° on one wall and then −25° to −55° on the opposite wall. The preferred ratio for size of the channels to the thickness of the ribs is 4:1 to 1:1. For example, for the midpoint of the range, ribs 0.1 inch would be spaced 0.25 inches apart. [0018]
  • The investment casting process also provides the opportunity to cast-in design features such as [0019] integral covers 12, 22, 32 that reduce bucket tip steampath leakage. The reduced weight of the cast buckets and associated rotor improve thermal transient response to be more consistent with the static shell structures, improving transient response, maintaining tighter clearances and improved unit performance.
  • In a structured steam turbine product line HP and IP buckets will be re-used from unit to unit as steampaths are duplicated. This re-use makes casting tooling and casting buckets as a manufacturing process feasible. Casting opens the opportunity to significantly reduce bucket weight and the associated rotor mass by the use of cores. [0020]
  • While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. [0021]

Claims (32)

What is claimed is:
1. A method of forming a steam turbine bucket airfoil by using an investment casting process and forming a hollow steam turbine bucket airfoil.
2. The method as claimed in claim 1, wherein a cover is integrally cast with the hollow steam turbine bucket airfoil.
3. The method as claimed in claim 1, wherein the formed hollow steam turbine bucket airfoil is integrally cast with a tangential fir-tree dovetail.
4. The method as claimed in claim 1, wherein the formed hollow steam turbine bucket airfoil is integrally cast with a tangential slot dovetail.
5. The method as claimed in claim 1, wherein the formed hollow steam turbine bucket airfoil is integrally cast with an axial entry dovetail.
6. The method as claimed in claim 2, wherein the formed hollow steam turbine bucket airfoil is integrally cast with a tangential fir-tree dovetail.
7. The method as claimed in claim 2, wherein the formed hollow steam turbine bucket airfoil is integrally cast with a tangential slot dovetail.
8. The method as claimed in claim 2, wherein the formed hollow steam turbine bucket airfoil is integrally cast with an axial entry dovetail.
9 A method of forming a steam turbine bucket airfoil, said method comprising utilizing an investment casting process to form an internal core of the steam turbine bucket airfoil having a lattice-work.
10. The method as claimed in claim 9, wherein a cover is integrally cast with the steam turbine bucket airfoil having a lattice work.
11. The method as claimed in claim 9, wherein the formed steam turbine bucket airfoil is integrally cast with a tangential fir-tree dovetail.
12. The method as claimed in claim 9, wherein the formed steam turbine bucket airfoil is integrally cast with a tangential slot dovetail.
13. The method as claimed in claim 9, wherein the formed steam turbine bucket airfoil is integrally cast with an axial entry dovetail.
14. The method as claimed in claim 10, wherein the formed steam turbine bucket airfoil is integrally cast with a tangential fir-tree dovetail.
15. The method as claimed in claim 10, wherein the formed steam turbine bucket airfoil is integrally cast with a tangential slot dovetail.
16. The method as claimed in claim 10, wherein the formed steam turbine bucket airfoil is integrally cast with an axial entry dovetail.
17. A steam turbine bucket airfoil for use in a steam turbine comprising a lattice-work internal core.
18. The steam turbine bucket airfoil as claimed in claim 17, further comprising a cover formed at one end.
19. The steam turbine bucket airfoil claimed in claim 17, further comprising a tangential fir-tree dovetail.
20. The steam turbine bucket airfoil claimed in claim 17, further comprising a tangential slot dovetail.
21. The steam turbine bucket airfoil claimed in claim 17, further comprising an axial entry dovetail.
22. The steam turbine bucket airfoil claimed in claim 18, further comprising a tangential fir-tree dovetail.
23. The steam turbine bucket airfoil claimed in claim 18, further comprising a tangential slot dovetail.
24. The steam turbine bucket airfoil claimed in claim 18, further comprising an axial entry dovetail.
25. A steam turbine bucket airfoil for use in a steam turbine comprising a hollow airfoil core.
26. The steam turbine bucket airfoil as claimed in claim 25, further comprising a cover formed at one end.
27. The steam turbine bucket airfoil claimed in claim 25, further comprising a tangential fir-tree dovetail.
28. The steam turbine bucket airfoil claimed in claim 25, further comprising a tangential slot dovetail.
29. The steam turbine bucket airfoil claimed in claim 25, further comprising an axial entry dovetail.
30. The steam turbine bucket airfoil claimed in claim 26, further comprising a tangential fir-tree dovetail.
31. The steam turbine bucket airfoil claimed in claim 26, further comprising a tangential slot dovetail.
32. The steam turbine bucket airfoil claimed in claim 26, further comprising an axial entry dovetail.
US10/317,190 2002-12-12 2002-12-12 Cored steam turbine bucket Abandoned US20040115059A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US10/317,190 US20040115059A1 (en) 2002-12-12 2002-12-12 Cored steam turbine bucket
DE10358166A DE10358166B4 (en) 2002-12-12 2003-12-10 Core trained steam turbine blade
JP2003412659A JP2004190681A (en) 2002-12-12 2003-12-11 Cored steam turbine bucket
CNB2003101205072A CN1321759C (en) 2002-12-12 2003-12-12 Steam turbine blade with core

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/317,190 US20040115059A1 (en) 2002-12-12 2002-12-12 Cored steam turbine bucket

Publications (1)

Publication Number Publication Date
US20040115059A1 true US20040115059A1 (en) 2004-06-17

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Family Applications (1)

Application Number Title Priority Date Filing Date
US10/317,190 Abandoned US20040115059A1 (en) 2002-12-12 2002-12-12 Cored steam turbine bucket

Country Status (4)

Country Link
US (1) US20040115059A1 (en)
JP (1) JP2004190681A (en)
CN (1) CN1321759C (en)
DE (1) DE10358166B4 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1707742A1 (en) * 2005-03-09 2006-10-04 ABB Turbo Systems AG Turbine blade with dirt collector

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US5350277A (en) * 1992-11-20 1994-09-27 General Electric Company Closed-circuit steam-cooled bucket with integrally cooled shroud for gas turbines and methods of steam-cooling the buckets and shrouds
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US3306577A (en) * 1964-08-25 1967-02-28 Sagara Hideo Turbine device
US3304052A (en) * 1965-03-30 1967-02-14 Westinghouse Electric Corp Rotor structure for an elastic fluid utilizing machine
US3762835A (en) * 1971-07-02 1973-10-02 Gen Electric Foreign object damage protection for compressor blades and other structures and related methods
US3904317A (en) * 1974-11-27 1975-09-09 Gen Electric Bucket locking mechanism
US4526512A (en) * 1983-03-28 1985-07-02 General Electric Co. Cooling flow control device for turbine blades
US5660525A (en) * 1992-10-29 1997-08-26 General Electric Company Film cooled slotted wall
US5350277A (en) * 1992-11-20 1994-09-27 General Electric Company Closed-circuit steam-cooled bucket with integrally cooled shroud for gas turbines and methods of steam-cooling the buckets and shrouds
US5286169A (en) * 1992-12-15 1994-02-15 General Electric Company Bucket for the next-to-last stage of a steam turbine
US5429877A (en) * 1993-10-20 1995-07-04 The United States Of America As Represented By The Secretary Of The Air Force Internally reinforced hollow titanium alloy components
US5584660A (en) * 1995-04-28 1996-12-17 United Technologies Corporation Increased impact resistance in hollow airfoils
US6000908A (en) * 1996-11-05 1999-12-14 General Electric Company Cooling for double-wall structures
US5752801A (en) * 1997-02-20 1998-05-19 Westinghouse Electric Corporation Apparatus for cooling a gas turbine airfoil and method of making same
US6257828B1 (en) * 1997-07-29 2001-07-10 Siemens Aktiengesellschaft Turbine blade and method of producing a turbine blade
US5947688A (en) * 1997-12-22 1999-09-07 General Electric Company Frequency tuned hybrid blade
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US6179556B1 (en) * 1999-06-01 2001-01-30 General Electric Company Turbine blade tip with offset squealer
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1707742A1 (en) * 2005-03-09 2006-10-04 ABB Turbo Systems AG Turbine blade with dirt collector

Also Published As

Publication number Publication date
DE10358166A1 (en) 2004-06-24
JP2004190681A (en) 2004-07-08
CN1321759C (en) 2007-06-20
DE10358166B4 (en) 2009-06-10
CN1506181A (en) 2004-06-23

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AS Assignment

Owner name: GENERAL ELECTRIC COMPANY, NEW YORK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KEHL, RICHARD EUGENE;BUNKER, RONALD SCOTT;REEL/FRAME:013566/0890

Effective date: 20021210

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION