US20070169913A1 - Method to manufacture components for gas turbines - Google Patents
Method to manufacture components for gas turbines Download PDFInfo
- Publication number
- US20070169913A1 US20070169913A1 US10/555,042 US55504204A US2007169913A1 US 20070169913 A1 US20070169913 A1 US 20070169913A1 US 55504204 A US55504204 A US 55504204A US 2007169913 A1 US2007169913 A1 US 2007169913A1
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- US
- United States
- Prior art keywords
- component
- semi
- casting
- finished part
- manufactured
- 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
Links
- 238000000034 method Methods 0.000 title claims abstract description 24
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 238000005266 casting Methods 0.000 claims abstract description 24
- 229910052582 BN Inorganic materials 0.000 claims abstract description 15
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims abstract description 15
- 238000003723 Smelting Methods 0.000 claims abstract description 12
- 229910000601 superalloy Inorganic materials 0.000 claims description 15
- 238000012360 testing method Methods 0.000 claims description 9
- 238000005242 forging Methods 0.000 claims description 7
- 238000007689 inspection Methods 0.000 claims description 7
- 238000002601 radiography Methods 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims 1
- 239000000463 material Substances 0.000 description 7
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 229910000990 Ni alloy Inorganic materials 0.000 description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 3
- 230000002028 premature Effects 0.000 description 3
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 229910001069 Ti alloy Inorganic materials 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 230000003313 weakening effect Effects 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
Definitions
- the invention relates to a method to manufacture components or semi-finished parts for gas turbines.
- the most important materials for gas turbines known from the prior art are nickel alloys, titanium alloys and high-strength steels.
- the high-strength steels are used mainly for shafts and gear parts.
- Titanium alloys are typical materials for compressor parts and nickel alloys or super alloys with a nickel basis are particularly suited for the so-called hot engine parts.
- engine parts made of the above-mentioned materials are manufactured by casting or forging.
- moving blades and guide blades for gas turbines are cast.
- Highly stressed disks and rings, as well as all turbine blades in the compressor area, are preferably manufactured by forging.
- Engine disks, which are made of the super alloy Udimet 720 LI, can be fabricated in a suitable quality by so-called casting plus forging.
- Smelting crucibles are used when casting engine parts of super alloys, whereby, according to the prior art, the smelting crucibles are manufactured of oxidic materials, preferably aluminum oxide.
- oxidic materials preferably aluminum oxide.
- reactions can occur between the super alloy and the crucible material, in particular aluminum oxide.
- oxidic inclusions can be incorporated in the component or semi-finished part being manufactured, which can lead to premature failure of the engine part. Consequently, before further processing of the component or semi-finished part, it is important that these kinds of inclusions be reliably detected so that the component or semi-finished part manufactured by casting can be discarded if need be.
- detecting these types of oxidic inclusions in super alloys in accordance with the prior art causes considerable difficulties. Reliable detection is not possible.
- the present invention is based on the objective of creating a new type of method to manufacture components or semi-finished parts for gas turbines.
- a smelting crucible that is manufactured of boron nitride is used in casting.
- oxidic inclusions in the component or semi-finished part are avoided, on the one hand, and inclusions, which are based on abrasion or wear of the boron nitride, can be detected with great reliability, on the other hand.
- the component or semi-finished part is subjected to an inspection for undesired inclusions subsequent to casting. Premature failure of the components or the gas turbines can be minimized as a result.
- the present invention concerns the manufacture or fabrication of components or semi-finished parts for gas turbines, such as aircraft engines, by casting or by casting plus forging.
- a so-called fine casting can also be used as a casting method.
- a smelting crucible that is manufactured of boron nitride is used for casting. Accordingly, a basic idea of the present invention is not using any smelting crucibles that are based on oxidic materials, such as aluminum oxide, rather smelting crucibles that are made of boron nitride.
- oxidic materials such as aluminum oxide
- smelting crucibles that are made of boron nitride.
- inclusions that might form due to abrasion or wear of the smelting crucible or boron nitride can be securely and reliably detected.
- the component or semi-finished part is subjected to an x-ray test or a neutron radiography test. If undesired boron nitride inclusions are incorporated into the component or semi-finished part made of a super alloy, the boron induces a much stronger neutron weakening as compared with all other alloy elements. Compared with nickel, boron induces neutron weakening that is approximately 100 times stronger. As a result, the inclusions are high in contrast and can be detected securely. FIG. 1 shows this especially clearly.
- FIG. 1 shows the result of a neutron radiography test of a component made of nickel alloys and super alloys with a boron nitride strip applied to the component.
- the boron nitride grains with a size of approx. 150 ⁇ m are high in contrast and can be depicted clearly vis-à-vis the elements of the super alloys.
- the component or semi-finished part can be subjected to a further processing method, for example a coating process. If, on the other hand, undesired inclusions are detected during the inspection, the component or semi-finished part can be discarded in time.
- the method in accordance with the invention that is described above is especially preferred in manufacturing engine disks of a super alloy, such as Udimet 720 LI, whereby these types of engine disks are manufactured by casting plus forging. These types of engine disks are subject to the highest mechanical stress and it is therefore especially important to avoid inclusions in the case of engine disks and detect them securely as well as reliably.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Forging (AREA)
Abstract
The invention relates to a method to manufacture components or semi-finished parts for gas turbines, in particular for aircraft engines, preferably by casting.
According to the invention, a smelting crucible that is manufactured of boron nitride is Used (FIG. 1).
Description
- This application claims the priority of International Application No. PCT/DE2004/000587, filed Mar. 23, 2004, and German Patent Document No. 103 19 495.9, filed Apr. 30, 2003, the disclosures of which are expressly incorporated by reference herein.
- The invention relates to a method to manufacture components or semi-finished parts for gas turbines.
- Modern gas turbines, in particular aircraft engines, must do justice to the highest demands with respect to reliability, power, weight, economic efficiency and service life. Over the course of years, aircraft engines were developed that met the aforementioned requirements fully and have achieved a high degree of technical perfection. The selection or development of new materials, as well as suitable fabrication processes or manufacturing methods, plays a crucial role in optimizing gas turbines, in particular aircraft engines.
- The most important materials for gas turbines known from the prior art are nickel alloys, titanium alloys and high-strength steels. The high-strength steels are used mainly for shafts and gear parts. Titanium alloys are typical materials for compressor parts and nickel alloys or super alloys with a nickel basis are particularly suited for the so-called hot engine parts.
- In accordance with the prior art, engine parts made of the above-mentioned materials are manufactured by casting or forging. As a rule, moving blades and guide blades for gas turbines are cast. Highly stressed disks and rings, as well as all turbine blades in the compressor area, are preferably manufactured by forging. Engine disks, which are made of the super alloy Udimet 720 LI, can be fabricated in a suitable quality by so-called casting plus forging.
- Smelting crucibles are used when casting engine parts of super alloys, whereby, according to the prior art, the smelting crucibles are manufactured of oxidic materials, preferably aluminum oxide. When casting engine components of super alloys, reactions can occur between the super alloy and the crucible material, in particular aluminum oxide. A consequence of this is that oxidic inclusions can be incorporated in the component or semi-finished part being manufactured, which can lead to premature failure of the engine part. Consequently, before further processing of the component or semi-finished part, it is important that these kinds of inclusions be reliably detected so that the component or semi-finished part manufactured by casting can be discarded if need be. However, detecting these types of oxidic inclusions in super alloys in accordance with the prior art causes considerable difficulties. Reliable detection is not possible.
- Starting from this situation, the present invention is based on the objective of creating a new type of method to manufacture components or semi-finished parts for gas turbines.
- In accordance with the invention, a smelting crucible that is manufactured of boron nitride is used in casting. As a result of this, oxidic inclusions in the component or semi-finished part are avoided, on the one hand, and inclusions, which are based on abrasion or wear of the boron nitride, can be detected with great reliability, on the other hand.
- According to an advantageous embodiment of the invention, the component or semi-finished part is subjected to an inspection for undesired inclusions subsequent to casting. Premature failure of the components or the gas turbines can be minimized as a result.
- Preferred developments of the invention are yielded from the description. Without being restricted to this, one exemplary embodiment of the invention is explained in more detail making reference to the only figure.
- The present invention concerns the manufacture or fabrication of components or semi-finished parts for gas turbines, such as aircraft engines, by casting or by casting plus forging. A so-called fine casting can also be used as a casting method.
- It is within the sense of the present invention that a smelting crucible that is manufactured of boron nitride is used for casting. Accordingly, a basic idea of the present invention is not using any smelting crucibles that are based on oxidic materials, such as aluminum oxide, rather smelting crucibles that are made of boron nitride. One the one hand, the incorporation of oxidic inclusions in the component or semi-finished part is avoided as a result of this. On the other hand, inclusions that might form due to abrasion or wear of the smelting crucible or boron nitride can be securely and reliably detected.
- Consequently, it is within the meaning of the present invention, on the one hand, to use a smelting crucible made of boron nitride for casting, and, on the other hand, to subject the component or semi-finished part to an inspection for undesired inclusions after casting. If these sorts of inclusions are detected, the component or semi-finished part can be discarded before further processing. The fabrication of spoiled goods can be markedly reduced as a result. In addition, premature failure of components caused by these types of undesired inclusions can be reduced.
- According to the invention, in order to check the component or semi-finished part for undesired inclusions, the component or semi-finished part is subjected to an x-ray test or a neutron radiography test. If undesired boron nitride inclusions are incorporated into the component or semi-finished part made of a super alloy, the boron induces a much stronger neutron weakening as compared with all other alloy elements. Compared with nickel, boron induces neutron weakening that is approximately 100 times stronger. As a result, the inclusions are high in contrast and can be detected securely.
FIG. 1 shows this especially clearly. - Thus,
FIG. 1 shows the result of a neutron radiography test of a component made of nickel alloys and super alloys with a boron nitride strip applied to the component. The boron nitride grains with a size of approx. 150 μm are high in contrast and can be depicted clearly vis-à-vis the elements of the super alloys. - If the inspection of the component or semi-finished part reveals that no undesired inclusions are present, the component or semi-finished part can be subjected to a further processing method, for example a coating process. If, on the other hand, undesired inclusions are detected during the inspection, the component or semi-finished part can be discarded in time.
- The method in accordance with the invention that is described above is especially preferred in manufacturing engine disks of a super alloy, such as Udimet 720 LI, whereby these types of engine disks are manufactured by casting plus forging. These types of engine disks are subject to the highest mechanical stress and it is therefore especially important to avoid inclusions in the case of engine disks and detect them securely as well as reliably.
Claims (18)
1-8. (canceled)
9. A method to manufacture a component or a semi-finished part for a gas turbine, in particular for an aircraft engine, preferably by casting, wherein a smelting crucible that is manufactured of boron nitride is used.
10. The method according to claim 9 , wherein the component or semi-finished part is subsequently subjected to an inspection for an undesired inclusion.
11. The method according to claim 10 , wherein the component or semi-finished part is examined for the undesired inclusion with an x-ray test.
12. The method according to claim 10 , wherein the component or semi-finished part is examined for the undesired inclusion with a neutron radiography test.
13. The method according to claim 10 , wherein after the inspection the component or semi-finished part is subjected to a further processing, for example a coating process.
14. The method according to claim 9 , wherein the component or semi-finished part is manufactured of a super alloy.
15. The method according to claim 9 , wherein the component or semi-finished part is embodied as an engine disk, which is manufactured of a super alloy, in particular of Udimet 720 LI, by casting plus forging.
16. A method to manufacture a component or a semi-finished part for a gas turbine, in particular for an aircraft engine, of a super alloy by casting, wherein:
a) a smelting crucible that is manufactured of boron nitride is used in casting; and
b) subsequent to casting, the component or semi-finished part is subjected to an inspection for an undesired boron nitride inclusion.
17. A method to manufacture a component of a gas turbine engine, comprising the step of casting the component in a smelting crucible that is made of boron nitride.
18. The method according to claim 17 , further comprising the step of inspecting the component for a boron nitride inclusion.
19. The method according to claim 18 , wherein the step of inspecting includes testing with an x-ray test.
20. The method according to claim 18 , wherein the step of inspecting includes testing with a neutron radiography test.
21. The method according to claim 18 , further comprising the step of coating the component after the steps of casting the component and inspecting the component.
22. The method according to claim 17 , wherein the component is manufactured of a super alloy.
23. The method according to claim 22 , wherein the component is an engine disk.
24. The method according to claim 22 , wherein the super alloy is Udimet 72 LI.
25. The method according to claim 17 , wherein the step of casting includes the step of forging.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10319495A DE10319495A1 (en) | 2003-04-30 | 2003-04-30 | Process for the production of components for gas turbines |
| DE10319495.9 | 2003-04-30 | ||
| PCT/DE2004/000587 WO2004096467A1 (en) | 2003-04-30 | 2004-03-23 | Method for producing parts fo gas turbines |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20070169913A1 true US20070169913A1 (en) | 2007-07-26 |
Family
ID=33305073
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US10/555,042 Abandoned US20070169913A1 (en) | 2003-04-03 | 2004-03-23 | Method to manufacture components for gas turbines |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US20070169913A1 (en) |
| EP (1) | EP1617961A1 (en) |
| DE (1) | DE10319495A1 (en) |
| WO (1) | WO2004096467A1 (en) |
Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3595712A (en) * | 1968-10-08 | 1971-07-27 | United Aircraft Corp | Processing of aluminide-coated nickel-base superalloys |
| US4814023A (en) * | 1987-05-21 | 1989-03-21 | General Electric Company | High strength superalloy for high temperature applications |
| US5143563A (en) * | 1989-10-04 | 1992-09-01 | General Electric Company | Creep, stress rupture and hold-time fatigue crack resistant alloys |
| US5161950A (en) * | 1989-10-04 | 1992-11-10 | General Electric Company | Dual alloy turbine disk |
| US5197857A (en) * | 1991-06-06 | 1993-03-30 | General Electric Company | Multiple rotor disk assembly |
| US5351938A (en) * | 1990-11-13 | 1994-10-04 | Endress U. Hauser Gmbh U. Co. | Apparatus for fabricating a foil |
| US5897718A (en) * | 1996-04-24 | 1999-04-27 | Rolls-Royce Plc | Nickel alloy for turbine engine components |
| US5975188A (en) * | 1997-10-30 | 1999-11-02 | Howmet Research Corporation | Method of casting with improved detectability of subsurface inclusions |
| US6004408A (en) * | 1997-11-21 | 1999-12-21 | Aubert & Duval (societe anonyme) | Nickel-chrome-iron based alloy composition |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS57169079A (en) * | 1981-04-08 | 1982-10-18 | Mitsubishi Heavy Ind Ltd | Surface treatment for heat resistant alloy |
-
2003
- 2003-04-30 DE DE10319495A patent/DE10319495A1/en not_active Ceased
-
2004
- 2004-03-23 EP EP04722528A patent/EP1617961A1/en not_active Ceased
- 2004-03-23 US US10/555,042 patent/US20070169913A1/en not_active Abandoned
- 2004-03-23 WO PCT/DE2004/000587 patent/WO2004096467A1/en not_active Ceased
Patent Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3595712A (en) * | 1968-10-08 | 1971-07-27 | United Aircraft Corp | Processing of aluminide-coated nickel-base superalloys |
| US4814023A (en) * | 1987-05-21 | 1989-03-21 | General Electric Company | High strength superalloy for high temperature applications |
| US5143563A (en) * | 1989-10-04 | 1992-09-01 | General Electric Company | Creep, stress rupture and hold-time fatigue crack resistant alloys |
| US5161950A (en) * | 1989-10-04 | 1992-11-10 | General Electric Company | Dual alloy turbine disk |
| US5351938A (en) * | 1990-11-13 | 1994-10-04 | Endress U. Hauser Gmbh U. Co. | Apparatus for fabricating a foil |
| US5197857A (en) * | 1991-06-06 | 1993-03-30 | General Electric Company | Multiple rotor disk assembly |
| US5897718A (en) * | 1996-04-24 | 1999-04-27 | Rolls-Royce Plc | Nickel alloy for turbine engine components |
| US6132527A (en) * | 1996-04-24 | 2000-10-17 | Rolls-Royce Plc | Nickel alloy for turbine engine components |
| US5975188A (en) * | 1997-10-30 | 1999-11-02 | Howmet Research Corporation | Method of casting with improved detectability of subsurface inclusions |
| US6004408A (en) * | 1997-11-21 | 1999-12-21 | Aubert & Duval (societe anonyme) | Nickel-chrome-iron based alloy composition |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2004096467A1 (en) | 2004-11-11 |
| DE10319495A1 (en) | 2004-11-18 |
| EP1617961A1 (en) | 2006-01-25 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: MTU AERO ENGINES GMBH, GERMANY Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:BAMBERG, JOACHIM;REEL/FRAME:018639/0040 Effective date: 20060116 |
|
| STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |