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EP0513407B1 - Method of manufacture of a turbine blade - Google Patents

Method of manufacture of a turbine blade Download PDF

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Publication number
EP0513407B1
EP0513407B1 EP91107707A EP91107707A EP0513407B1 EP 0513407 B1 EP0513407 B1 EP 0513407B1 EP 91107707 A EP91107707 A EP 91107707A EP 91107707 A EP91107707 A EP 91107707A EP 0513407 B1 EP0513407 B1 EP 0513407B1
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EP
European Patent Office
Prior art keywords
hot
process according
blade
casting
carried out
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.)
Expired - Lifetime
Application number
EP91107707A
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German (de)
French (fr)
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EP0513407A1 (en
Inventor
Mohamed Dr. Nazmy
Markus Staubli
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.)
ABB Asea Brown Boveri Ltd
ABB AB
Original Assignee
ABB Asea Brown Boveri Ltd
Asea Brown Boveri AB
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Publication date
Priority to DE59106047T priority Critical patent/DE59106047D1/en
Application filed by ABB Asea Brown Boveri Ltd, Asea Brown Boveri AB filed Critical ABB Asea Brown Boveri Ltd
Priority to EP91107707A priority patent/EP0513407B1/en
Priority to US07/880,036 priority patent/US5299353A/en
Priority to CA002068504A priority patent/CA2068504A1/en
Priority to JP4116420A priority patent/JPH07166802A/en
Priority to PL92294502A priority patent/PL168950B1/en
Priority to KR1019920008009A priority patent/KR920021236A/en
Priority to SU925011799A priority patent/RU2066253C1/en
Priority to CN92103469A priority patent/CN1025358C/en
Publication of EP0513407A1 publication Critical patent/EP0513407A1/en
Application granted granted Critical
Publication of EP0513407B1 publication Critical patent/EP0513407B1/en
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C14/00—Alloys based on titanium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/16—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of other metals or alloys based thereon
    • C22F1/18—High-melting or refractory metals or alloys based thereon
    • C22F1/183—High-melting or refractory metals or alloys based thereon of titanium or alloys based thereon
    • 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
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49318—Repairing or disassembling
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making

Definitions

  • the invention is based on a method for producing a turbine blade, comprising an airfoil, a blade root and, if appropriate, a casting body having a blade cover band and made of an alloy based on a dopant-containing gamma-titanium aluminide.
  • Gamma-titanium aluminides have properties which favor their use as a material for turbine blades exposed to high temperatures. This includes, among other things, their low density compared to commonly used superalloys, which is more than twice as large, for example, in Ni superalloys.
  • turbine blades made of niobium-doped gamma titanium aluminide are known. Such blades have high heat resistance, but their ductility at room temperature is low, so that damage to parts subject to bending stresses cannot be ruled out with certainty.
  • FR-A-2 136 170 describes a method for producing a turbine blade, consisting of a cast body made of an alloy containing aluminum or titanium and having a blade blade and a blade root.
  • a melt of the alloy is first poured into a precision casting mold.
  • the mold, with its part located above the blade root, is then brought into an inductively heatable graphite container.
  • the one above The part of the casting body located in the casting mold of the blade root is then melted inductively and solidified by slowly moving the graphite container away towards the tip of the blade.
  • crystals are formed in the airfoil parallel to the longitudinal axis of the airfoil, which give the airfoil a high tensile and creep resistance.
  • the blade root however, consists of non-directional, ductile alloy material. This method is not suitable for producing a turbine blade made of gamma-titanium aluminide, which can withstand high thermal and mechanical loads.
  • the invention is based on the object of specifying a method of the type mentioned, with which a turbine blade consisting of doped gamma-titanium aluminide and having a high thermal and mechanical strength and in a simple and suitable manner for series production high creep rupture strength can be produced.
  • the method according to the invention provides a thermally and mechanically highly resilient turbine blade which is characterized by a long service life even when subjected to bending loads. This is made possible by the fact that the differently stressed parts of the turbine blade have differently specified modifications of the doped gamma titanium aluminide used as the material. It proves to be particularly advantageous from a manufacturing point of view that the turbine blade is merely molded out of an inexpensive, one-piece cast body. In addition, this method can be designed for series production in a simple manner by using conventional means, such as casting molds, ovens, seizing and mechanical and electrochemical processing devices.
  • the annealed, hot-isostatically pressed, thermoformed and heat-treated cast body shown in the figure has the essential material and shape properties of the turbine blade produced by the method according to the invention. It contains an elongated airfoil 1, a blade root 2 formed on one end of the airfoil 1 and a blade cover band 3 molded on the opposite end of the airfoil.
  • the turbine blade is produced from this cast body by slight material-lifting processing.
  • the material-lifting processing essentially consists in adapting the dimensions of the cast body to the desired dimensions of the turbine blade. With blade root 2 and blade cover band 3, this is advantageously done by grinding and polishing.
  • the fastening grooves 4 of the blade root 2 which are shown in dashed lines in the figure, can also be formed.
  • the airfoil is preferably adapted to the desired airfoil shape by electrochemical processing.
  • the cast body shown in the figure consists essentially of an alloy based on a dopant-containing gamma titanium aluminide. At least in Parts of the airfoil 1 is present in the form of a material with a coarse-grained structure and with a structure that leads to high tensile and creep strength. At least in parts of the blade root 2 and the blade shroud 3, the alloy is in the form of a material with a fine-grained structure and with a higher ductility than the material in the blade 1. This ensures a long service life for the airfoil.
  • the turbine blade according to the invention can be used advantageously at medium and high temperatures, i. H. Use at temperatures between 200 and 1000 ° C, especially in gas turbines and in compressors.
  • the blade cover sheet 3 may be present or omitted.
  • Suitable alloys are gamma titanium aluminides in which at least one or more of the elements B, Co, Cr, Ge, Hf, Mn, Mo, Nb, Pd, Si, Ta, V, Y, W and Zr are contained as dopant.
  • the amount of dopant added is preferably 0.5 to 8 atomic percent.
  • the melt is poured into a mold corresponding to the turbine blade to be manufactured.
  • the cast body formed can then advantageously be annealed at approximately 1100 ° C. for 10 hours in an argon atmosphere and cooled to room temperature for the purposes of its homogenization.
  • the cast skin and scale layer are then removed by, for example, removing a surface layer approximately 1 mm thick by mechanical or chemical means.
  • the descaled cast body is inserted into a suitable capsule made of soft carbon steel and the latter welded gas-tight.
  • the encapsulated cast body is then hot isostatically pressed and cooled at a temperature of 1260 ° C. for 3 hours under a pressure of 120 MPa.
  • the annealing of the alloy should be carried out at temperatures between 1000 and 1100 ° C for at least half and for a maximum of thirty hours.
  • hot isostatic pressing which should advantageously be carried out at temperatures between 1200 and 1300 ° C and a pressure between 100 and 150 MPa for at least one and at most five hours.
  • thermoforming of the part of the annealed and hot-isostatically pressed cast body corresponding to the blade root 2 and / or the blade cover band 3, forming the material with a fine-grained structure, and heat treating at least the part of the annealed and hot corresponding to the airfoil 1 -isostatically pressed cast body before or after the isothermal thermoforming to form the material with a coarse-grained structure.
  • the annealed and hot-isostatically pressed cast body is heat-treated prior to the isothermal thermoforming to form the material with a coarse-grained structure
  • the part of the annealed and hot-isostatically pressed cast body after the isothermal thermoforming is heat-treated to form the material with a coarse-grained structure. It has proven to be expedient to heat the annealed and hot-isostatically pressed cast body to the temperature required for hot-working at a rate of between 10 and 50 ° C./min before the isothermal hot-working.
  • the parts to be thermoformed such as the blade root 2 and possibly also the blade cover band 3, can advantageously be kneaded in the forging press by upsetting in at least two directions transverse to the longitudinal axis of the turbine blade and then pressed to the final shape.
  • the finished pressed parts have a fine-grained structure with one compared to that in the airfoil located material on increased ductility.
  • the tensile strength or the ductility of the material in the airfoil 1 is 390 MPa or 0.3% and in the blade root 2 and in the blade cover band 3 is 370 MPa or 1.3%.
  • the cast body is heated to 1100 ° C., for example, at a heating rate of 10 to 50 ° C./min and is kept at this temperature.
  • the blade root 2 and / or the blade shroud 3 are then isothermally forged at 1100 ° C. in accordance with the previously described method.
  • the forged parts also have a fine-grained structure with an increased ductility compared to the material located in the airfoil 1.
  • the airfoil is then heated to a temperature of 1200 to 1400 ° C. and, depending on the heating temperature and alloy composition, heat-treated for between 0.5 and 25 hours. When cooling, another 1 to 5 h heat treatment can be carried out. After the heat treatment, the airfoil predominantly has a coarse-grained structure and a structure that leads to high tensile and creep resistance. In such a turbine blade manufactured in this way, the tensile strength and ductility of the material in the airfoil 1 or in the blade root 2 and in the blade shroud 3 have almost the same values as in the turbine blade produced by the previously described method.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Forging (AREA)
  • Powder Metallurgy (AREA)

Description

TECHNISCHES GEBIETTECHNICAL AREA

Bei der Erfindung wird ausgegangen von einem Verfahren zur Herstellung einer Turbinenschaufel, enthaltend einen Schaufelblatt, Schaufelfuss und gegebenenfalls Schaufeldeckband aufweisenden Gusskörper aus einer Legierung auf der Basis eines dotierstoffhaltigen gamma-Titanaluminids.The invention is based on a method for producing a turbine blade, comprising an airfoil, a blade root and, if appropriate, a casting body having a blade cover band and made of an alloy based on a dopant-containing gamma-titanium aluminide.

STAND DER TECHNIKSTATE OF THE ART

Gamma-Titanaluminide haben Eigenschaften, welche deren Einsatz als Werkstoff für hohen Temperaturen ausgesetzte Turbinenschaufeln begünstigen. Dazu gehört unter anderem ihre gegenüber üblicherweise verwendeten Superlegierungen niedrige Dichte, die beispielsweise bei Ni-Superlegierungen mehr als doppelt so gross ist.Gamma-titanium aluminides have properties which favor their use as a material for turbine blades exposed to high temperatures. This includes, among other things, their low density compared to commonly used superalloys, which is more than twice as large, for example, in Ni superalloys.

Aus G. Sauthoff, "Intermetallische Phasen", Werkstoffe zwischen Metall und Keramik, Magazin neue Werkstoffe 1/89, S. 15-19 sind Turbinenschaufeln aus mit Niob dotiertem gamma-Titanaluminid bekannt. Solche Schaufeln weisen eine hohe Warmfestigkeit auf, jedoch ist deren Duktilität bei Raumtemperatur gering, so dass an biegebeanspruchten Teilen Beschädigungen nicht mit Sicherheit auszuschliessen sind.From G. Sauthoff, "Intermetallic phases", materials between metal and ceramic, magazine new materials 1/89, pp. 15-19, turbine blades made of niobium-doped gamma titanium aluminide are known. Such blades have high heat resistance, but their ductility at room temperature is low, so that damage to parts subject to bending stresses cannot be ruled out with certainty.

In FR-A-2 136 170 ist ein Verfahren zur Herstellung einer Turbinenschaufel, bestehend aus einem ein Schaufelblatt und einen Schaufelfuss aufweisenden Gusskörper aus einer Aluminium oder Titan enthaltenden Legierung, beschrieben. Bei diesem Verfahren wird zunächst eine Schmelze der Legierung in eine Präzisionsgussform abgegossen. Die Gussform wird sodann mit ihrem oberhalb des Schaufelfusses gelegenen Teil in einen induktiv beheizbaren Graphitbehälter gebracht. Der oberhalb des Schaufelfusses gelegene Teil des in der Gussform befindlichen Gusskörpers wird sodann induktiv aufgeschmolzen und durch langsames Wegführen des Graphitbehälters zur Schaufelspitze hin gerichtet erstarrt. Hierbei bilden sich im Schaufelblatt parallel zur Schaufellängsachse ausgerichtete Kristalle, welche dem Schaufelblatt eine hohe Zug- und Zeitstandfestigkeit verleihen. Der Schaufelfuss besteht hingegen aus nichtgerichtetem, duktilem Legierungsmaterial. Zur Herstellung einer thermisch und mechanisch hoch belastbaren Turbinenschaufel aus dotierstoffhaltigem gamma-Titanaluminid ist dieses Verfahren nicht geeignet.FR-A-2 136 170 describes a method for producing a turbine blade, consisting of a cast body made of an alloy containing aluminum or titanium and having a blade blade and a blade root. In this process, a melt of the alloy is first poured into a precision casting mold. The mold, with its part located above the blade root, is then brought into an inductively heatable graphite container. The one above The part of the casting body located in the casting mold of the blade root is then melted inductively and solidified by slowly moving the graphite container away towards the tip of the blade. Here, crystals are formed in the airfoil parallel to the longitudinal axis of the airfoil, which give the airfoil a high tensile and creep resistance. The blade root, however, consists of non-directional, ductile alloy material. This method is not suitable for producing a turbine blade made of gamma-titanium aluminide, which can withstand high thermal and mechanical loads.

KURZE DARSTELLUNG DER ERFINDUNGSUMMARY OF THE INVENTION

Der Erfindung, wie sie in den Patentansprüchen angegeben ist, liegt die Aufgabe zugrunde, ein Verfahren der eingangs genannten Art anzugeben, mit dem in einfacher und in einer für eine Serienfertigung geeigneten Weise eine aus dotiertem gamma-Titanaluminid bestehende Turbinenschaufel hoher thermischer und mechanischer Belastbarkeit und hoher Zeitstandfestigkeit hergestellt werden kann.The invention, as specified in the claims, is based on the object of specifying a method of the type mentioned, with which a turbine blade consisting of doped gamma-titanium aluminide and having a high thermal and mechanical strength and in a simple and suitable manner for series production high creep rupture strength can be produced.

Das Verfahren nach der Erfindung liefert eine thermisch und mechanisch hoch belastbare Turbinenschaufel, welche sich auch bei Biegebelastung durch eine hohe Lebensdauer auszeichnet. Dies wird dadurch ermöglicht, dass die unterschiedlich beanspruchten Teile der Turbinenschaufel unterschiedlich spezifizierte Modifikationen des als Werkstoff verwendeten dotierten gamma-Titanaluminids aufweisen. Hierbei erweist es sich fertigungstechnisch von besonderem Vorteil, dass die Turbinenschaufel lediglich aus einem preisgünstig herzustellenden, einstückigen Gusskörper herausgeformt wird. Zudem kann dieses Verfahren durch den Einsatz gängiger Mittel, wie Giessformen, Öfen, Fressen und mechanische und elektrochemische Bearbeitungsvorrichtungen, in einfacher Weise für eine Serienfertigung ausgebildet werden.The method according to the invention provides a thermally and mechanically highly resilient turbine blade which is characterized by a long service life even when subjected to bending loads. This is made possible by the fact that the differently stressed parts of the turbine blade have differently specified modifications of the doped gamma titanium aluminide used as the material. It proves to be particularly advantageous from a manufacturing point of view that the turbine blade is merely molded out of an inexpensive, one-piece cast body. In addition, this method can be designed for series production in a simple manner by using conventional means, such as casting molds, ovens, seizing and mechanical and electrochemical processing devices.

Bevorzugte Ausführungsbeispiele der Erfindung und die damit erzielbaren Vorteile werden nachfolgend anhand einer Zeichnung näher erläutert.Preferred exemplary embodiments of the invention and the advantages which can be achieved thereby are explained in more detail below with reference to a drawing.

KURZE BESCHREIBUNG DER ZEICHNUNGBRIEF DESCRIPTION OF THE DRAWING

In der einzigen Figur ist ein geglühter, heiss-isostatisch gepresster, warmverformter und wärmebehandelter Gusskörper dargestellt, aus dem durch Materialabheben eine nach dem erfindungsgemässen Verfahren hergestellte Turbinenschaufel herausgearbeitet wurde.In the single figure, an annealed, hot-isostatically pressed, thermoformed and heat-treated cast body is shown, from which a turbine blade produced by the method according to the invention has been worked out.

WEGE ZUR AUSFÜHRUNG DER ERFINDUNGWAYS OF CARRYING OUT THE INVENTION

Der in der Figur dargestellte geglühte, heiss-isostatisch gepresste, warmverformte und wärmebehandelte Gusskörper weist die wesentlichen Material-und Formeigenschaften der nach dem erfindungsgemässen Verfahren hergestellten Turbinenschaufel auf. Er enthält ein langgestrecktes Schaufelblatt 1, einen am einen Ende des Schaufelblattes 1 angeformten Schaufelfuss 2 sowie ein am entgegengesetzten Ende des Schaufelblattes angeformtes Schaufeldeckband 3. Aus diesem Gusskörper wird durch geringfügige materialabhebende Bearbeitung die Turbinenschaufel hergestellt. Die materialabhebende Bearbeitung besteht im wesentlichen in einer Anpassung der Abmessungen des Gusskörpers an die erwünschten Abmessungen der Turbinenschaufel. Beim Schaufelfuss 2 und beim Schaufeldeckband 3 erfolgt dies mit Vorteil durch Schleifen und Polieren. Hierbei können zugleich auch die in der Figur gestrichelt dargestellten tannenbaumartig angeordneten Befestigungsnuten 4 des Schaufelfusses 2 gebildet werden. Das Schaufelblatt wird vorzugsweise durch elektrochemische Bearbeitung an die erwünschte Schaufelblattform angepasst.The annealed, hot-isostatically pressed, thermoformed and heat-treated cast body shown in the figure has the essential material and shape properties of the turbine blade produced by the method according to the invention. It contains an elongated airfoil 1, a blade root 2 formed on one end of the airfoil 1 and a blade cover band 3 molded on the opposite end of the airfoil. The turbine blade is produced from this cast body by slight material-lifting processing. The material-lifting processing essentially consists in adapting the dimensions of the cast body to the desired dimensions of the turbine blade. With blade root 2 and blade cover band 3, this is advantageously done by grinding and polishing. At the same time, the fastening grooves 4 of the blade root 2, which are shown in dashed lines in the figure, can also be formed. The airfoil is preferably adapted to the desired airfoil shape by electrochemical processing.

Der in der Figur dargestellte Gusskörper besteht im wesentlichen aus einer Legierung auf der Basis eines dotierstoffhaltigen gamma-Titanaluminids. Zumindest in Teilen des Schaufelblattes 1 liegt diese Legierung in Form eines Werkstoffs mit grobkörniger Struktur und mit einem zu hoher Zug- und Zeitstandfestigkeit führendem Gefüge vor. Zumindest in Teilen des Schaufelfusses 2 und des Schaufeldeckbandes 3 liegt die Legierung in Form eines Werkstoffs mit feinkörniger Struktur und mit einer gegenüber dem im Schaufelblatt 1 befindlichen Werkstoff erhöhten Duktilität vor. Hierdurch wird eine hohe Lebensdauer des Schaufelblattes erreicht. Dies ist zum einen dadurch bedingt, dass das bei Betrieb der Turbine auf hohen Temperaturen befindliche Schaufelblatt aufgrund seiner grobkörnigen Struktur und seines Gefüges eine gute Zug- und Zeitstandfestigkeit aufweist, wohingegen seine bei tiefen Temperaturen vorhandene geringe Duktilität ohne Bedeutung ist. Zum anderen ist dies auch dadurch bedingt, dass sich bei Betrieb der Turbine der Schaufelfuss und das Schaufeldeckband auf vergleichsweise tiefen Temperaturen befinden und dann aufgrund ihrer feinkörnigen Struktur und ihres Gefüges eine verglichen mit dem im Schaufelblatt vorgesehenen Material eine hohe Duktilität aufweisen. Vom Schaufelfuss und vom Schaufeldeckband können so über einen grossen Zeitraum vergleichsweise grosse Torsions- und Biegekräfte aufgenommen werden, ohne dass Spannungsrisse gebildet werden.The cast body shown in the figure consists essentially of an alloy based on a dopant-containing gamma titanium aluminide. At least in Parts of the airfoil 1 is present in the form of a material with a coarse-grained structure and with a structure that leads to high tensile and creep strength. At least in parts of the blade root 2 and the blade shroud 3, the alloy is in the form of a material with a fine-grained structure and with a higher ductility than the material in the blade 1. This ensures a long service life for the airfoil. On the one hand, this is due to the fact that the airfoil, which is in operation at high temperatures, has good tensile and creep resistance due to its coarse-grained structure and structure, whereas its low ductility, which is present at low temperatures, is of no importance. On the other hand, this is also due to the fact that when the turbine is in operation, the blade root and the blade shroud are at comparatively low temperatures and then, owing to their fine-grained structure and structure, have a high ductility compared to the material provided in the blade. Comparatively large torsional and bending forces can be absorbed by the blade root and the blade shroud over a long period of time without stress cracks being formed.

Die Turbinenschaufel nach der Erfindung lässt sich mit Vorteil bei mittleren und hohen Temperaturen, d. h. bei Temperaturen zwischen 200 und 1000°C, insbesondere in Gasturbinen und in Verdichtern, einsetzen. Je nach Ausführungsform der Gasturbine oder des Verdichters kann hierbei das Schaufeldeckblatt 3 vorhanden sein oder entfallen.The turbine blade according to the invention can be used advantageously at medium and high temperatures, i. H. Use at temperatures between 200 and 1000 ° C, especially in gas turbines and in compressors. Depending on the embodiment of the gas turbine or the compressor, the blade cover sheet 3 may be present or omitted.

Der Gusskörper gemäss der Figur wird wie folgt hergestellt: Unter Schutzgas, wie etwa Argon, oder unter Vakuum wird in einem Induktionsofen folgende Legierung auf der Basis eines gamma-Titanaluminids mit Chrom als Dotierstoff erschmolzen:
   Al = 48   At.-%
   Cr = 3   At.-%
   Ti = Rest.The cast body according to the figure is produced as follows: In protective gas, such as argon, or under vacuum, in the following alloy was melted in an induction furnace based on a gamma titanium aluminide with chromium as dopant:
Al = 48 at%
Cr = 3 at .-%
Ti = rest.

Andere geeignete Legierungen sind gamma-Titanaluminide in denen als Dotierstoff mindestens eines oder mehrere der Elemente B, Co, Cr, Ge, Hf, Mn, Mo, Nb, Pd, Si, Ta, V, Y, W sowie Zr enthalten sind. Die Menge an zugesetztem Dotierstoff beträgt vorzugsweise 0,5 bis 8 Atomprozent.Other suitable alloys are gamma titanium aluminides in which at least one or more of the elements B, Co, Cr, Ge, Hf, Mn, Mo, Nb, Pd, Si, Ta, V, Y, W and Zr are contained as dopant. The amount of dopant added is preferably 0.5 to 8 atomic percent.

Die Schmelze wird in einer der herzustellenden Turbinenschaufel entsprechenden Gussform abgegossen. Der gebildete Gusskörper kann hierauf mit Vorteil zu Zwecken seiner Homogenisierung bei ca. 1100°C während beispielsweise 10h in Argonatmosphäre geglüht und auf Raumtemperatur abgekühlt werden. Sodann werden Gusshaut und Zunderschicht entfernt, indem beispielsweise eine Oberflächenschicht von ca. 1 mm Dicke auf mechanischem oder chemischem Wege abgetragen wird. Der entzunderte Gusskörper wird in eine passende Kapsel aus weichem Kohlenstoffstahl eingeschoben und letztere gasdicht verschweisst. Der eingekapselte Gusskörper wird nun bei einer Temperatur von 1260°C während 3 h unter einem Druck von 120 MPa heiss-isostatisch gepresst und abgekühlt.The melt is poured into a mold corresponding to the turbine blade to be manufactured. The cast body formed can then advantageously be annealed at approximately 1100 ° C. for 10 hours in an argon atmosphere and cooled to room temperature for the purposes of its homogenization. The cast skin and scale layer are then removed by, for example, removing a surface layer approximately 1 mm thick by mechanical or chemical means. The descaled cast body is inserted into a suitable capsule made of soft carbon steel and the latter welded gas-tight. The encapsulated cast body is then hot isostatically pressed and cooled at a temperature of 1260 ° C. for 3 hours under a pressure of 120 MPa.

Das Glühen der Legierung sollte je nach Zusammensetzung bei Temperaturen zwischen 1000 und 1100 °C während mindestens einer halben und während höchstens dreissig Stunden durchgeführt werden. Entsprechendes gilt für das heiss-isostatische Pressen, welches mit Vorteil bei Temperaturen zwischen 1200 und 1300°C und einem Druck zwischen 100 und 150 MPa mindestens eine und höchstens fünf Stunden lang durchgeführt werden sollte.Depending on the composition, the annealing of the alloy should be carried out at temperatures between 1000 and 1100 ° C for at least half and for a maximum of thirty hours. The same applies to hot isostatic pressing, which should advantageously be carried out at temperatures between 1200 and 1300 ° C and a pressure between 100 and 150 MPa for at least one and at most five hours.

Anschliessend erfolgt ein ein- bis mehrmaliges isothermes Warmverformen des dem Schaufelfuss 2 und/oder dem Schaufeldeckband 3 entsprechenden Teils des geglühten und heiss-isostatisch gepressten Gusskörpers unter Bildung des Werkstoffs mit feinkörniger Struktur und eine Wärmebehandlung zumindest des dem Schaufelblatt 1 entsprechenden Teils des geglühten und heiss-isostatisch gepressten Gusskörpers vor oder nach dem isothermen Warmverformen unter Bildung des Werkstoffs mit grobkörniger Struktur.This is then followed by one or more isothermal thermoforming of the part of the annealed and hot-isostatically pressed cast body corresponding to the blade root 2 and / or the blade cover band 3, forming the material with a fine-grained structure, and heat treating at least the part of the annealed and hot corresponding to the airfoil 1 -isostatically pressed cast body before or after the isothermal thermoforming to form the material with a coarse-grained structure.

Hierbei können mit Vorteil zwei Wege beschritten werden. Beim Beschreiten des ersten Weges wird der geglühte und heiss-isostatisch gepresste Gusskörper vor dem isothermen Warmverformen unter Bildung des Werkstoffs mit grobkörniger Struktur wärmebehandelt, wohingegen beim Beschreiten des zweiten Weges der das Schaufelblatt umfassende Teil des geglühten und heiss-isostatisch gepressten Gusskörpers nach dem isothermen Warmverformen unter Bildung des Werkstoffs mit grobkörniger Struktur wärmebehandelt wird.Es hat sich als zweckmässig erwiesen, vor dem isothermen Warmverformen den geglühten und heiss-isostatisch gepressten Gusskörper mit einer Geschwindigkeit zwischen 10 und 50°C/min auf die zum Warmverformen benötigte Temperatur zu erwärmen.There are two ways to do this. When the first route is followed, the annealed and hot-isostatically pressed cast body is heat-treated prior to the isothermal thermoforming to form the material with a coarse-grained structure, whereas when the second route is followed, the part of the annealed and hot-isostatically pressed cast body after the isothermal thermoforming is heat-treated to form the material with a coarse-grained structure. It has proven to be expedient to heat the annealed and hot-isostatically pressed cast body to the temperature required for hot-working at a rate of between 10 and 50 ° C./min before the isothermal hot-working.

Beim Beschreiten des ersten Weges wird der Gusskörper auf eine Temperatur von 1200 bis 1400°C aufgeheizt und je nach Aufheiztemperatur und Legierungszusammensetzung zwischen 0,5 und 25h wärmebehandelt. Beim Abkühlen kann eine weitere 1 bis 5h dauernde Wärmebehandlung durchgeführt werden. Nach der Wärmebehandlung weist der Gusskörper grobkörnige Struktur und ein zu hoher Zug- und Zeitstandfestigkeit führendes Gefüge auf. Der wärmebehandelte Gusskörper wird auf 1100°C erwärmt und auf dieser Temperatur gehalten. Sodann werden der Schaufelfuss 2 und/oder das Schaufeldeckband 3 bei 1100°C isotherm geschmiedet. Das verwendete Werkzeug ist vorzugsweise eine Schmiedepresse, bestehend etwa aus einer Molybdänlegierung mit dem Handelsnamen TZM mit folgender Zusammensetzung:
   Ti = 0,5   Gew.-%
   Zr = 0,1   Gew.-%
   C = 0,02   Gew.-%
   Mo = Rest
Die Fliessgrenze des zu schmiedenden Werkstoffs beträgt ca. 260 MPa bei 1100°C . Die Umformung wird durch Stauchen bis zu einer Verformung ε = 1,3 erreicht, wobei

Figure imgb0001

mit

ho =
ursprüngliche Höhe des Werkstücks und
h =
Höhe des Werkstücks nach Umformung
bedeuten. Die lineare Verformungsgeschwindigkeit (Stempelgeschwindigkeit der Schmiedepresse) beträgt bei Beginn des Schmiedeprozesses 0,1 mm/s. Der Anfangsdruck der Schmiedepresse liegt bei ca. 300 MPa.When the first route is followed, the cast body is heated to a temperature of 1200 to 1400 ° C and, depending on the heating temperature and alloy composition, heat-treated for between 0.5 and 25 hours. When cooling, another 1 to 5 h heat treatment can be carried out. After the heat treatment, the cast body has a coarse-grained structure and a structure that leads to high tensile and creep resistance. The heat-treated cast body is heated to 1100 ° C. and kept at this temperature. Then the blade root 2 and / or that Blade cover band 3 isothermally forged at 1100 ° C. The tool used is preferably a forging press consisting, for example, of a molybdenum alloy with the trade name TZM with the following composition:
Ti = 0.5% by weight
Zr = 0.1% by weight
C = 0.02% by weight
Mo = rest
The yield point of the material to be forged is approx. 260 MPa at 1100 ° C. The deformation is achieved by upsetting up to a deformation ε = 1.3, where
Figure imgb0001
With
h o =
original height of the workpiece and
h =
Workpiece height after forming
mean. The linear deformation speed (stamping speed of the forging press) is 0.1 mm / s at the start of the forging process. The initial pressure of the forging press is around 300 MPa.

In Abhängigkeit von der Legierungszusammemsetzung kann die Warmverformung bei Temperaturen zwischen zwischen 1050 und 1200°C mit einer zwischen 5 · 10⁻⁵s⁻¹ und 10⁻²s⁻¹ gelegenen Verformungsgeschwindigkeit bis zu einer Verformung ε = 1,6 durchgeführt werden. Hierbei können mit Vorteil die warmzuverformenden Teile, wie der Schaufelfuss 2 und gegebenenfalls auch das Schaufeldeckband 3, in der Schmiedepresse durch Stauchen in mindestens zwei quer zur Längsachse der Turbinenschaufel verlaufenden Richtungen zunächst geknetet und dann zur Endform fertiggepresst werden. Die fertiggepressten Teile weisen feinkörnige Struktur mit einer gegenüber dem im Schaufelblatt befindlichen Werkstoff erhöhten Duktilität auf. Bei der wie vorstehend beschrieben hergestellten Turbinenschaufel liegen die Zugfestigkeit bzw. die Duktilität des Werkstoffs im Schaufelblatt 1 bei 390 MPa bzw. bei 0,3% und im Schaufelfuss 2 sowie im Schaufeldeckband 3 bei 370 MPa bzw. 1,3%.Depending on the alloy composition, the hot deformation can be carried out at temperatures between 1050 and 1200 ° C with a deformation rate between 5 · 10⁻⁵s⁻¹ and 10⁻²s⁻¹ up to a deformation ε = 1.6. The parts to be thermoformed, such as the blade root 2 and possibly also the blade cover band 3, can advantageously be kneaded in the forging press by upsetting in at least two directions transverse to the longitudinal axis of the turbine blade and then pressed to the final shape. The finished pressed parts have a fine-grained structure with one compared to that in the airfoil located material on increased ductility. In the turbine blade manufactured as described above, the tensile strength or the ductility of the material in the airfoil 1 is 390 MPa or 0.3% and in the blade root 2 and in the blade cover band 3 is 370 MPa or 1.3%.

Beim Beschreiten des zweiten Weges wird der Gusskörper beispielsweise mit einer Aufheizgeschwindigkeit von 10 bis 50°C/min auf 1100°C erwärmt und auf dieser Temperatur gehalten. Sodann werden der Schaufelfuss 2 und/oder das Schaufeldeckband 3 bei 1100°C entsprechend dem zuvor beschriebenen Verfahren isotherm geschmiedet. Die fertiggeschmiedeten Teile weisen ebenfalls feinkörnige Struktur mit einer gegenüber dem im Schaufelblatt 1 befindlichen Werkstoff erhöhten Duktilität auf.When the second path is followed, the cast body is heated to 1100 ° C., for example, at a heating rate of 10 to 50 ° C./min and is kept at this temperature. The blade root 2 and / or the blade shroud 3 are then isothermally forged at 1100 ° C. in accordance with the previously described method. The forged parts also have a fine-grained structure with an increased ductility compared to the material located in the airfoil 1.

Mittels einer um das Schaufelblatt 1 angebrachten Induktionsspule wird das Schaufelblatt sodann auf eine Temperatur von 12oo bis 1400°C aufgeheizt und je nach Aufheiztemperatur und Legierungszusammensetzung zwischen 0,5 und 25h wärmebehandelt. Beim Abkühlen kann eine weitere 1 bis 5h dauernde Wärmebehandlung durchgeführt werden. Nach der Wärmebehandlung weist das Schaufelblatt überwiegend grobkörnige Struktur und ein zu hoher Zug- und Zeitstandfestigkeit führendes Gefüge auf. Bei einer solchermassen hergestellten Turbinenschaufel weisen Zugfestigkeit und Duktilität des Werkstoffs im Schaufelblatt 1 bzw. im Schaufelfuss 2 sowie im Schaufeldeckband 3 nahezu die gleichen Werte auf wie bei der nach dem zuvor beschriebenen Verfahren hergestellten Turbinenschaufel.By means of an induction coil attached to the airfoil 1, the airfoil is then heated to a temperature of 1200 to 1400 ° C. and, depending on the heating temperature and alloy composition, heat-treated for between 0.5 and 25 hours. When cooling, another 1 to 5 h heat treatment can be carried out. After the heat treatment, the airfoil predominantly has a coarse-grained structure and a structure that leads to high tensile and creep resistance. In such a turbine blade manufactured in this way, the tensile strength and ductility of the material in the airfoil 1 or in the blade root 2 and in the blade shroud 3 have almost the same values as in the turbine blade produced by the previously described method.

Claims (14)

  1. Process for producing a turbine blade containing a casting having a blade leaf (1), blade foot (2) and, if appropriate, blade cover strip (3) and composed of an alloy based on a dopant-containing gamma-titanium aluminide, characterized in that the following process steps are carried out:
    - melting of the alloy,
    - pouring of the melt to form a casting in the form of the turbine blade,
    - hot-isostatic pressing of the casting,
    - once-only to repeated isothermal hot forming of the part of the hot-isostatically pressed casting corresponding to the blade foot (2) and/or to the blade cover strip (3) to form a material of fine-grained structure and with a ductility increased in relation to the material contained in the blade leaf (1),
    - heat treatment at least of the part of the hot-isostatically pressed casting corresponding to the blade leaf (1) before or after the isothermal hot forming to form a material of coarse-grained structure and with a texture resulting in high tensile and creep strength, and
    - material-removing machining of the hot-isostatically pressed, hot-formed and heat-treated casting to form the turbine blade.
  2. Process according to Claim 1, characterized in that at least one or more of the elements B, Co, Cr, Ge, Hf, Mn, Mo, Nb, Pd, Si, Ta, V, Y, W and Zr are used as dopant in the alloy.
  3. Process according to Claim 2, characterized in that the alloy has at least 0.5 and at most 8 atomic per cent of dopant.
  4. Process according to one of Claims 1 to 3, characterized in that the hot-isostatically pressed casting is heat-treated before the isothermal hot forming to form the material of coarse-grained structure.
  5. Process according to one of Claims 1 to 3, characterized in that the part of the hot-isostatically pressed casting comprising the blade leaf (1) is heat-treated after the isothermal hot forming to form the material of coarse-grained structure.
  6. Process according to Claim 5, characterized in that the heat treatment is carried out by means of an induction coil.
  7. Process according to Claims 1 to 6, characterized in that the heat treatment is carried out at between 1200 and 1400°C.
  8. Process according to Claim 8, characterized in that a further heat treatment at between 800 and 1000°C is subsequently carried out.
  9. Process according to one of Claims 1 to 8, characterized in that the hot forming is carried out at between 1050 and 1200°C with a deformation rate of between 5 . 10⁻⁵s⁻¹ and 10⁻²s⁻¹, up to a deformation ε = 1.6, in which
    Figure imgb0003
    ho =   original height of the workpiece and
    h =   height of the workpiece after forming.
  10. Process according to Claim 9, characterized in that the hot forming is carried out in a forging press.
  11. Process according to Claim 10, characterized in that the parts to be hot-formed are first kneaded in the forging press by upsetting in at least two directions transverse to the longitudinal axis of the turbine blade and are then finish-pressed to the final form.
  12. Process according to one of Claims 1 to 11, characterized in that, before the isothermal hot forming, the hot-isostatically pressed casting is cooled to room temperature and is subsequently heated at a speed of between 10 and 50°C/min to the temperature set during the hot forming.
  13. Process according to one of Claims 1 to 12, characterized in that the casting is homogenized at temperatures of between 1000 and 1100°C before the hot forming and the heat treatment.
  14. Process according to one of Claims 1 to 13, characterized in that the hot-isostatic pressing is carried out at temperatures of between 1200 and 1300°C and under a pressure of between 100 and 150 MPa.
EP91107707A 1991-05-13 1991-05-13 Method of manufacture of a turbine blade Expired - Lifetime EP0513407B1 (en)

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EP91107707A EP0513407B1 (en) 1991-05-13 1991-05-13 Method of manufacture of a turbine blade
DE59106047T DE59106047D1 (en) 1991-05-13 1991-05-13 Process for manufacturing a turbine blade.
CA002068504A CA2068504A1 (en) 1991-05-13 1992-05-08 Turbine blade and process for producing this turbine blade
JP4116420A JPH07166802A (en) 1991-05-13 1992-05-08 Turbine blade and manufacture of turbine blade thereof
US07/880,036 US5299353A (en) 1991-05-13 1992-05-08 Turbine blade and process for producing this turbine blade
PL92294502A PL168950B1 (en) 1991-05-13 1992-05-11 Turbine blade and method of making same
KR1019920008009A KR920021236A (en) 1991-05-13 1992-05-12 Turbine Blades and Manufacturing Method Thereof
SU925011799A RU2066253C1 (en) 1991-05-13 1992-05-12 Method of making turbine blades
CN92103469A CN1025358C (en) 1991-05-13 1992-05-12 Turbine blades and manufacture method thereof

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CA2068504A1 (en) 1992-11-14
US5299353A (en) 1994-04-05
PL294502A1 (en) 1992-11-30
RU2066253C1 (en) 1996-09-10
EP0513407A1 (en) 1992-11-19
JPH07166802A (en) 1995-06-27
CN1025358C (en) 1994-07-06
CN1066706A (en) 1992-12-02
KR920021236A (en) 1992-12-18
PL168950B1 (en) 1996-05-31

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