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EP2781622A1 - Procédé génératif, notamment de fabrication d'un revêtement, dispositif d'exécution du procédé, revêtement et procédé de fabrication de composant et composant - Google Patents

Procédé génératif, notamment de fabrication d'un revêtement, dispositif d'exécution du procédé, revêtement et procédé de fabrication de composant et composant Download PDF

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Publication number
EP2781622A1
EP2781622A1 EP13160283.1A EP13160283A EP2781622A1 EP 2781622 A1 EP2781622 A1 EP 2781622A1 EP 13160283 A EP13160283 A EP 13160283A EP 2781622 A1 EP2781622 A1 EP 2781622A1
Authority
EP
European Patent Office
Prior art keywords
powder
coating
component
layer
material mixture
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.)
Withdrawn
Application number
EP13160283.1A
Other languages
German (de)
English (en)
Inventor
Bernd Burbaum
Torsten Melzer-Jokisch
Sebastian Piegert
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.)
Siemens AG
Siemens Corp
Original Assignee
Siemens AG
Siemens Corp
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 Siemens AG, Siemens Corp filed Critical Siemens AG
Priority to EP13160283.1A priority Critical patent/EP2781622A1/fr
Priority to PCT/EP2014/055235 priority patent/WO2014146997A1/fr
Publication of EP2781622A1 publication Critical patent/EP2781622A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • F01D5/288—Protective coatings for blades
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • 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

Definitions

  • the invention relates to a generative process, in particular for the production of a coating, to a device for carrying out the process and to a coating. Furthermore, the invention relates to a component manufacturing method and a component.
  • a rotor of a turbomachine for example a rotor of a gas turbine or steam turbine, has a rotor main body and a plurality of blades mounted on the rotor main body. Each blade has a blade root and an airfoil and a tip and is mounted with the blade root in a corresponding recess of the rotor body.
  • cooling is often insufficient, especially at the blade tip.
  • a temperature difference of about 100 ° Celsius is present. Therefore occurs in the blade tip by the thermal and mechanical stress, in particular by shrinkage in so-called counter-sealing surfaces, often wear on. Cracking on the blade tip is the result.
  • a method of repairing a nozzle of a gas turbine in which a damaged portion is cut out of the nozzle to be repaired and a spare part for the cut-out portion is manufactured by means of a rapid manufacturing process becomes.
  • the spare part produced by the rapid manufacturing process is integrated into the guide vane to be repaired by welding or soldering.
  • a first object of the invention is therefore to specify a generative method with which the above-mentioned problem can be reduced or even avoided.
  • a second object is the disclosure of a device for carrying out the method.
  • a third task is to specify a coating that solves the above problem.
  • a fourth and a fifth object are the specification of a component production method and a component which solves the above-mentioned problem.
  • the second powder may be locally characterized by a high wear resistance and / or oxidation resistance and / or a low thermal expansion coefficient with respect to high temperatures. Since the proportion of the second powder in the powder material mixture was increased continuously with increasing number of layers, this means that the mechanical and / or thermal properties change continuously with increasing layer.
  • the proportion of the second powder in the first layer is preferably 0%. In a preferred embodiment, the proportion of the first powder in the last layer is 0%. Thus, the appropriate properties of the second powder are maximized with respect to high temperatures.
  • the method described above can be carried out very easily and easily.
  • the third object is to specify a coating for producing or repairing a component, in particular that of a fluid-flow machine comprising at least a first layer with a first solidifiable powder material mixture and a last layer with a last solidifiable powder material mixture, wherein between the first and the last layer a defined number of further layers of solidifiable powder material mixtures is provided, solved.
  • the solidifiable powder material mixture of at least a first powder and a second powder, wherein the proportion of the second powder from the first layer to the last layer increases continuously and wherein the second powder with respect to high temperatures suitable properties, in particular wear resistance and / or oxidation resistance and / or a low thermal expansion coefficient with respect to high temperatures.
  • a coating is created which has different properties due to the different powder composition in different areas.
  • the change Properties also not abrupt, but slowly merge into each other or change continuously.
  • the coating is thus adapted, for example, to the different thermal expansion coefficients or to the expected temperature gradients. This means that the thermal expansion due to the higher temperature in, for example, the last layer is the same as the first layer, although this layer is directly exposed to the hot gas or the higher temperatures. In the optimal case, this means a complete compensation of the thermo-mechanical stresses. Due to the properties such as wear resistance and / or oxidation resistance, such a coating is therefore particularly suitable for use in power plants.
  • the proportion of the second powder in the first layer is 0%.
  • the proportion of the first powder in the last layer is 0%.
  • the coating is preferably produced by the above-mentioned generative process and / or the above-mentioned device. As a result, the coating can be produced particularly easily.
  • the component manufacturing process according to the invention now makes repair of e.g. High-temperature loaded components with a suitable coating possible.
  • the coating can be manufactured separately and on / in-place of the component to be repaired on / in this.
  • an application to the new part is possible;
  • a blade can be cast without a tip and the tip made from a coating.
  • a particularly temperature-resistant blade can be manufactured with a long service life.
  • the joining preferably takes place by joining, in particular friction welding. But it can also be used any other welding / joining process.
  • abrasion occurs by the connection by friction welding of the coating and the base component.
  • the recontouring of the end component includes the post-processing of the abrasion by mechanical processing, in particular by turning or milling. This can be done very easily.
  • the coating is heat treated prior to bonding to the base member.
  • This can be, for example, a hot isostatic pressing (HIP process) to set the optimum mechanical properties and, where appropriate, to eliminate hot cracks.
  • HIP process hot isostatic pressing
  • the final component is heat-treated, so that the structure gets the optimal properties.
  • the fourth object is achieved by specifying a component which is repaired or manufactured according to the above component manufacturing method.
  • This may in particular be a component of a gas turbine, for example a blade.
  • the blade at its tip, which is formed by the last layer, a large proportion of the second powder, which, for example, a thermal is highly resilient material.
  • the thermal expansion coefficient at the tip of the component or the coating can be adapted to the expected temperature gradients.
  • the second powder may also have other or additional properties.
  • the first powder has similar or the same material properties as the base component. If the thermal expansion is chosen as the material property, then it can be adjusted by means of this combination that the thermal expansion due to the higher temperature at the last layer (top) of the coating is just as great as in the first layer of the coating, although between the tip and the first Layer of the coating is a large temperature gradient. This means a complete compensation of the thermo-mechanical stresses.
  • FIG. 1 shows a turbine blade 1 with a wing profile 3 according to the prior art.
  • This has a blade root 2.
  • the blade 1 comprises a tip 4, which has a crown 5 with an inner crown bottom 6 and an outer crown edge 7.
  • the turbine blade 1 is designed to rotate within a housing (not shown). It is important that the blade tip 4 fits precisely into the housing (not shown) so as to prevent an outward flow of the combustion gases on the blade tip 4 as far as possible, since the gases taking this bypass no energy transferred to the airfoil 3 of the blade 1.
  • the blade 1 may have a thermal barrier coating at its tip. Nevertheless, one or more cracks 10 may occur in the crown 5 of the turbine bucket 1, due to material fatigue at low load cycles occurring during operation of the turbine and acting on the bucket tip 4. If a crack 10 exceeds a critical length, the turbine blade 1 must be taken out of service and / or repaired. So far, cracks 10, unless they exceed a critical length, have been laser-deposited, e.g. with the filler or by e.g. Tungsten inert gas welding (TIG welding) repaired.
  • Tungsten inert gas welding Tungsten inert gas welding
  • the material on the crown bottom 6, that is to say at the transition from the airfoil 3 to the crown 5, should be approximately identical to the material of the airfoil 3, so that different thermal expansion coefficients do not lead to critical loads during the heating phase or cooling phase during operation of the turbine blade 1 lead.
  • a high resistance to wear and oxidation resistance is required locally, which can not be reconciled with the chemical / metallurgical composition of the airfoil 3.
  • FIG. 2 shows a coating 35 according to the invention, which can be used to repair the blade tip 4.
  • the blade tip 4 can first be completely removed, so that a base wing 15, which may be identical to the wing profile 3, remains.
  • the coating 35 comprises at least a first layer 21 with a first solidified powder material mixture and a last layer 25 comprising a last consolidated powder material mixture, and between the first and the last layer 25 a defined number of further layers 22-24, wherein the number is not fixed here to three.
  • the number can be zero, of course; ie no further layer can be provided.
  • the solidified powder material mixture consists of at least a first powder 100 and a second powder 200, wherein the proportion of the second powder 200 from the first layer 21 to the last layer 25 increases.
  • the powder material mixture can also consist of several powders.
  • This first powder 100 is later or when applied to a first, solidified powder 100.
  • the powder 100 or solidified powder 100 is similar or equal to the material and / or has similar or the same properties as the base wing 15. In this case is to be mentioned as a similar or identical property, especially the thermal expansion coefficient.
  • the powder 100 is applied to a mold 50 (FIG. FIG. 4 ) and then solidified into a first coating section 31. Also, the mold 50 ( FIG. 4 ) Of course, the base wing 15 itself.
  • At least one second powder 200 is added to the first powder 100 to form a second powder material mixture.
  • a second layer 22 is generated, which subsequently solidifies with the first coating section 31 to form a new coating section 32.
  • the subsequent layers 23 and 24 are successively applied to the coating sections 32 and 33 produced analogously thereto.
  • the last layer 25 is therefore applied to a coating section 34.
  • the powder 200 now has properties which are required in particular for high temperatures.
  • the proportion of powder 200 in the powder material mixture is increased as the number of layers increases.
  • the last layer 25, ie the layer which is exposed directly to the hot temperature, in particular by hot gas, consists essentially only of the powder 200, which is subsequently solidified or applied.
  • the solidified powder 200 is later exposed directly to the hot gas or the hot temperatures.
  • the solidified powder 200 of the last layer 25 represents the crown edge 7, so to speak later.
  • the solidified powder 200 now has properties which are required in particular for high temperatures. These are mainly wear resistance and oxidation resistance and a low coefficient of thermal expansion. Since the proportion of powder 200 in the powder material mixture was continuously increased with increasing number of layers, this means that the mechanical and / or thermal properties change continuously with increasing layer.
  • the blade tip 4 is therefore made graduated.
  • the mixture of the at least two powders 100 and powders 200 can be effected by two separately controllable powder conveyors 101 and 201 and a coaxial mixing nozzle 70 ( FIG. 4 ).
  • the powder material mixture can be mixed in any ratio.
  • the mixture is applied to a mold 50 (FIG. FIG. 4 ) applied and solidified.
  • the last solidified powder 200 Since the last layer 25 is directly exposed to the hot gas or temperatures, the last solidified powder 200 also requires a low coefficient of thermal expansion than the layer 21 of the first solidified powder 100 and the base wing 15 in such a way that the thermal expansion at the last layer 25 is the same as at the first layer 21. This, and the continuous change of the mechanical and / or thermal properties with increasing layer ideally lead to an almost complete Compensation of the thermal stresses in the operation of the blade 1 and reduced cracking.
  • the solidification of the layer can be done for example by welding. This can be, for example, a build-up welding or laser sintering / laser melting by means of a heat source 60 (FIG. FIG. 4 ) or another generative manufacturing process.
  • the layers 21-25 are thus connected to one another in a material-locking manner and thereby ultimately form the desired coating 35.
  • the coating 35 is cut to fit the base blade 15, for example, the blank of the coating 35 can be used as a replacement blade tip 30 (FIG. FIG. 3 ) be.
  • the coating 35 can be tailored to any other component, such as heat shields or other parts in the power plant. An application is also conceivable outside of power plant technology.
  • the replacement blade tip 30 (FIG. FIG. 3 ), eg by hot isostatic pressing (HIP), to eliminate joining defects and to produce the optimum mechanical properties.
  • the replacement blade tip 30 (FIG. FIG. 3 ) to the base bucket 15 ( FIG. 3 ) to a replacement vane 41 ( FIG. 3
  • the joining 12 for example by means of friction welding ( FIG. 3 ) or other known joining methods.
  • the resulting from the joining 12 abrasion or burrs or seams are remedied by a post-processing (re-contouring) by means of mechanical processing, such as milling or grinding. Subsequently, the replacement blade 41 (FIG. FIG. 3 ) are heat treated again.
  • the base blade 15 can be produced and continued as described above, or the complete blade 1 (FIG. FIG. 1 ) graduated as described above.
  • other components such as burners, heat shields, etc. can be manufactured or repaired with the invention.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
EP13160283.1A 2013-03-21 2013-03-21 Procédé génératif, notamment de fabrication d'un revêtement, dispositif d'exécution du procédé, revêtement et procédé de fabrication de composant et composant Withdrawn EP2781622A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP13160283.1A EP2781622A1 (fr) 2013-03-21 2013-03-21 Procédé génératif, notamment de fabrication d'un revêtement, dispositif d'exécution du procédé, revêtement et procédé de fabrication de composant et composant
PCT/EP2014/055235 WO2014146997A1 (fr) 2013-03-21 2014-03-17 Procédé génératif servant en particulier à fabriquer un revêtement, dispositif servant à la mise en œuvre dudit procédé, revêtement et procédé de production de composant ainsi que composant

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP13160283.1A EP2781622A1 (fr) 2013-03-21 2013-03-21 Procédé génératif, notamment de fabrication d'un revêtement, dispositif d'exécution du procédé, revêtement et procédé de fabrication de composant et composant

Publications (1)

Publication Number Publication Date
EP2781622A1 true EP2781622A1 (fr) 2014-09-24

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EP13160283.1A Withdrawn EP2781622A1 (fr) 2013-03-21 2013-03-21 Procédé génératif, notamment de fabrication d'un revêtement, dispositif d'exécution du procédé, revêtement et procédé de fabrication de composant et composant

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EP (1) EP2781622A1 (fr)
WO (1) WO2014146997A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102014221222A1 (de) * 2014-10-20 2016-04-21 MTU Aero Engines AG Pulverpatrone für ein Verfahren und eine Vorrichtung zur generativen Herstellung von Bauteilen sowie entsprechend hergestellte Bauteile
DE102017200749A1 (de) 2017-01-18 2018-07-19 Siemens Aktiengesellschaft Schichtsystem mit zwei Zwischenschichten und Verfahren
EP3933067A1 (fr) * 2020-07-03 2022-01-05 Flender GmbH Procédé de fabrication d'un revêtement, revêtement, composant doté d'un revêtement
US12129769B2 (en) 2022-10-25 2024-10-29 Ge Infrastructure Technology Llc Erosion-shielded turbine blades and methods of manufacturing the same

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1993005194A1 (fr) * 1991-09-05 1993-03-18 Technalum Research, Inc. Procede de production de revetements a gradient de composition continu
EP1382707A1 (fr) * 2002-07-17 2004-01-21 Siemens Aktiengesellschaft Systeme stratifie
DE10319494A1 (de) 2003-04-30 2004-11-18 Mtu Aero Engines Gmbh Verfahren zur Reparatur und/oder Modifikation von Bauteilen einer Gasturbine
EP1712657A2 (fr) * 2005-04-14 2006-10-18 United Technologies Corporation Methode de fabrication et dispositif pour fabriquer un materiauà gradient fonctionnel par pulvérisation à froid
DE102006019900A1 (de) * 2006-04-28 2007-11-08 Siemens Ag Piezoaktor mit Gradient-Verkapselungsschicht und Verfahren zu seiner Herstellung
WO2008009267A1 (fr) * 2006-07-19 2008-01-24 Mtu Aero Engines Gmbh Procédé de réparation d'aubes de turbine
DE102008058140A1 (de) * 2008-11-20 2010-05-27 Mtu Aero Engines Gmbh Verfahren zur Reparatur von einkristallinen Turbinenschaufeln
WO2011008143A1 (fr) * 2009-07-15 2011-01-20 Arcam Ab Procédé et appareil de production d’objets tridimensionnels
DE102011008809A1 (de) * 2011-01-19 2012-07-19 Mtu Aero Engines Gmbh Generativ hergestellte Turbinenschaufel sowie Vorrichtung und Verfahren zu ihrer Herstellung

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1993005194A1 (fr) * 1991-09-05 1993-03-18 Technalum Research, Inc. Procede de production de revetements a gradient de composition continu
EP1382707A1 (fr) * 2002-07-17 2004-01-21 Siemens Aktiengesellschaft Systeme stratifie
DE10319494A1 (de) 2003-04-30 2004-11-18 Mtu Aero Engines Gmbh Verfahren zur Reparatur und/oder Modifikation von Bauteilen einer Gasturbine
EP1712657A2 (fr) * 2005-04-14 2006-10-18 United Technologies Corporation Methode de fabrication et dispositif pour fabriquer un materiauà gradient fonctionnel par pulvérisation à froid
DE102006019900A1 (de) * 2006-04-28 2007-11-08 Siemens Ag Piezoaktor mit Gradient-Verkapselungsschicht und Verfahren zu seiner Herstellung
WO2008009267A1 (fr) * 2006-07-19 2008-01-24 Mtu Aero Engines Gmbh Procédé de réparation d'aubes de turbine
DE102008058140A1 (de) * 2008-11-20 2010-05-27 Mtu Aero Engines Gmbh Verfahren zur Reparatur von einkristallinen Turbinenschaufeln
WO2011008143A1 (fr) * 2009-07-15 2011-01-20 Arcam Ab Procédé et appareil de production d’objets tridimensionnels
DE102011008809A1 (de) * 2011-01-19 2012-07-19 Mtu Aero Engines Gmbh Generativ hergestellte Turbinenschaufel sowie Vorrichtung und Verfahren zu ihrer Herstellung

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102014221222A1 (de) * 2014-10-20 2016-04-21 MTU Aero Engines AG Pulverpatrone für ein Verfahren und eine Vorrichtung zur generativen Herstellung von Bauteilen sowie entsprechend hergestellte Bauteile
DE102017200749A1 (de) 2017-01-18 2018-07-19 Siemens Aktiengesellschaft Schichtsystem mit zwei Zwischenschichten und Verfahren
EP3933067A1 (fr) * 2020-07-03 2022-01-05 Flender GmbH Procédé de fabrication d'un revêtement, revêtement, composant doté d'un revêtement
US12129769B2 (en) 2022-10-25 2024-10-29 Ge Infrastructure Technology Llc Erosion-shielded turbine blades and methods of manufacturing the same

Also Published As

Publication number Publication date
WO2014146997A1 (fr) 2014-09-25

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