DE102006008836A1 - Method for producing and / or repairing an integrally bladed rotor - Google Patents

Abstract

The invention relates to a method for producing and / or repairing an integrally bladed rotor, the method comprising at least the following steps: a) providing a rotor base body, the rotor base body having at least one hump-like projection for connecting a respective rotor blade to the rotor base body; b) providing at least one rotor blade, the or each rotor blade having a hump-like projection for connecting the same to a hollow-out projection of the rotor base body; c) joining the or each rotor blade to the rotor base body by inductive high-frequency pressure welding, the or each rotor blade being connected at its hump-like projection to a hump-like projection of the rotor base body; d) contour machining of the or each rotor blade joined to the rotor base body.

Description

The The invention relates to a process for the production and / or repair an integrally bladed rotor, in particular an integral one bladed gas turbine rotor.

modern Gas turbines, in particular aircraft engines, must meet the highest demands in the In terms of reliability, Weight, performance, economy and durability meet. In the development of gas turbines plays, among other things, the choice of materials, the search for new, suitable materials as well as the search for new manufacturing processes are crucial.

The most importantly, nowadays for Aeroengines or other gas turbines used materials are titanium alloys, nickel alloys and high strength steels. The high strength steels be used for shaft parts, Gear parts, compressor housing and turbine housing used. Titanium alloys are typical materials for compressor parts. Nickel alloys are for the hot ones Turbine parts of the aircraft engine suitable. As a manufacturing process for gas turbine components Titanium alloys, nickel alloy or other alloys are from the state of the art primarily the investment casting as well Forging known. All highly stressed gas turbine components, such as for example the blades for a compressor, are forgings. Components for a turbine, however, become usually executed as precision castings.

to Increasing the efficiency of gas turbines become the rotors the same increasingly designed as integrally bladed rotors. Integral bladed Rotors are also called blisk (bladed disk) or bling (bladed ring) referred, depending of whether a disc-shaped Rotor body or a ring-shaped Rotor body is present. All previously known from the prior art process for the preparation Integrally bladed rotors require a high manufacturing cost and are therefore expensive. Furthermore, the repair is integral bladed rotors difficulties.

Of these, Based on the present invention, the problem underlying a novel process for the manufacture and / or repair of an integral to create bladed rotor.

This Problem is solved by a method of manufacturing and / or repair an integrally bladed rotor according to claim 1 solved. According to the invention the method comprises at least the following steps: a) providing a rotor body, wherein the rotor body at least one hump-like Having projection for connecting each of a blade to the rotor body; b) providing at least one blade, the or each Blade a humpy Having projection for connecting the same to a hump-like projection of the rotor body; c) joining the or each blade to the rotor body by inductive high frequency pressure welding, wherein the or each blade at its hump-like projection with a hump-like Projection of the rotor body is connected; d) contouring of the or each blended to the rotor body blade.

With The present invention is a sequence of process steps for the manufacture and / or repair of an integrally bladed Rotors proposed that in their entirety alike for the manufacture as well as repair of integrally bladed rotors is suitable and further about a high reproducibility distinguishes. In the for the production and / or repair of integrally bladed rotors in combination used steps, in particular in inductive high frequency pressure welding, acts it is to a large extent automatable process steps, so that integrally bladed Rotors effective and inexpensive can be manufactured and repaired.

To An advantageous development of the invention is particularly in a repair of an integrally bladed rotor after Add according to step c) and before contouring according to step d) a heat treatment the or each joint, namely the or each weld.

preferred Further developments of the invention will become apparent from the dependent claims and the following description. Embodiments of the invention without being limited to this to be closer to the drawing explained. Showing:

1 a schematic representation of an integrally bladed rotor;

2 a schematic axial section through a hump-like projection of rotor body or blade;

3 a schematic radial section through the hump-like projection of the rotor body or blade before joining; and

4 a schematic radial section through the hump-like projection of the rotor body or blade after joining.

1 shows a perspective view of a highly schematized to manufacture or repair using the inventive method integrally bladed gas turbine rotor 10 wherein the integrally bladed gas turbine rotor 10 a rotor body 11 as well as several blades 12 having.

The blades 12 are unsolvable on an outer hub 13 of the rotor body 11 attached and therefore an integral part of the same. The blades 12 are about the circumference of the rotor body 11 or its hub 13 equidistant or arranged at the same distance from each other.

The present invention now relates to a process for the preparation and repair of in 1 illustrated, integrally bladed gas turbine rotor 10 ,

To produce an integrally bladed gas turbine rotor, the procedure is such that first a preferably forged rotor body 11 provided. The forged rotor body 11 has hump-like projections for connecting one blade to the rotor body 11 , wherein the number of bump-like projections corresponds to the number of blades to be connected.

At the in 1 shown gas turbine rotor 10 is located at a circumferential position such a hump-like projection 14 for connecting a blade 12 , At the other circumferential positions are already corresponding blades 12 on humpy projections 14 together.

In addition to the preferably forged rotor body 11 is in the sense of the method according to the invention further at least one also preferably forged blade 12 provided with the or each forged blade 12 also a hump-like projection 15 to connect the same to a hump-like projection 14 of the rotor body 11 having.

Shall now a blade 12 with her hump-like projection 15 to a corresponding hump-like projection 14 of the rotor body 11 be joined, so first the corresponding blade 12 relative to the rotor body 11 aligned (see 3 ), in which case the two hump-like projections 14 and 15 from blade 12 and rotor body 11 come into contact with each other, and then the blade 12 with the rotor body 11 by inductive high frequency pressure welding to form a weld zone 16 is connected.

In order to provide a good weld in high-pressure inductive welding, have the hump-like projection 14 of the rotor body 11 as well as the hump-like projection 15 to the rotor body 11 to be connected blade 12 over a uniform or constant profile thickness (see 2 ), so over the entire profile of the blade 12 a good welded connection to the rotor body 11 can be guaranteed. Will with such uniform profile thickness of the hump-like projections 14 . 15 from blade 12 and rotor body 11 worked, an optimal selection of the welding parameters of inductive high-frequency pressure welding is possible. The inductive high-frequency pressure welding works with low pressing forces, so that the forged rotor body 11 is preferably provided with a final contour.

After joining the or each blade 12 to the rotor body 11 By inductive high frequency pressure welding takes place in the sense of the present invention, a final contour machining of or each of the rotor body 11 patched blade 12 preferably by PECM, ie by Precise Elektro Chemical Machining. When PECM is using electrodes from the blades 12 Material removed, wherein the geometric contour of the electrodes used corresponds to the geometric contour to be produced. This blade edge contours can be produced with high accuracy, so that post-processing after the PECM is not required.

The final contour machining of the blades can thereby over the entire radial extent of the same between a radially outer blade tip and a radially inner connection region thereof to the rotor body 11 and over the entire axial extension end contour processing between a flow inlet edge and a flow outlet edge done. 2 and 4 show in dashed lines in the final contour machining to be produced target contours 17 ,

Through the hump-like projections 14 and 15 in the area of the rotor body 11 and the blades 12 is a constructive decoupling of rotor body 11 and blade of the blades 12 guaranteed. Through the hump-like projections 14 . 15 can be between the Ro torgrundkörper 11 and the blade 12 a targeted transition to the aerodynamic profile of the blade of the blades are provided. The bumpy projections 14 . 15 with their uniform profile thicknesses continue to allow the inductive high frequency pressure welding, the formation of high-precision welds, so that the connection between the rotor body 11 and blades 12 characterized by a high strength. In case of repair, repeated blade changes are possible.

In particular, when using the method according to the invention, a rotor 10 is to be repaired, carried out after joining by inductive high frequency pressure welding and before the PECM machining of the blades, a heat treatment of the weld, preferably by inductive heating of the same.

Then, when an integrally bladed rotor is to be repaired, a damaged Blade forming a humpy ledge in the area of the rotor body separated from the rotor body, then to this hump-like Lead a new blade can be joined.

The inventive method allows an economical manufacture as well as repair of integrally bladed Rotors, wherein the forging processes for the rotor main body and the Blades optimally to the desired component strength of these Components are tuned. The inventive method is safe, simple testable and good reproducible. The blades can be made of a different material be forged like the rotor base body.

10

integral bladed rotor

11

Rotor body

12

blade

13

hub

14

hump-like head Start

15

hump-like head Start

16

welding zone

17

target contour

Claims (9)

Method for producing and / or repairing a integrally bladed rotor, in particular an integrally bladed Gas Turbine Rotor, with the following steps: a) Provide a rotor body, wherein the rotor body at least one hump-like projection for connecting in each case a blade to the rotor base body; b) Providing at least one blade, the or each Blade a hump-like projection to connect the same to a hump-like projection of the rotor body; c) Add the or each blade to the rotor body by inductive high frequency pressure welding, wherein the or each blade at its hump-like projection with a hump-like Projection of the rotor body is connected; d) contouring of the or each blended to the rotor body blade. Method according to claim 1, characterized in that that the or each hump Projection of the rotor body has a uniform profile thickness. Method according to claim 1 or 2, characterized that the humpy Projection of the or each blade a uniform profile thickness having. Method according to one or more of claims 1 to 3, characterized in that the contour machining according to step d) by PECM or by Precise Electro Chemical Machining. Method according to claim 4, characterized in that in contouring the or each blade, an airfoil portion same and a transitional area the same to the rotor body is processed. Method according to one or more of claims 1 to 5, characterized in that the blades and the rotor body forged are. Method according to Claim 6, characterized that the blades are forged from a different material like the basic rotor body. Method according to one or more of claims 1 to 7, characterized in that after the joining according to step c) and before contouring according to step d) a heat treatment of the or each joint, namely the or each weld, carried out becomes. Method according to claim 8, characterized in that that the heat treatment by inductive heating of the or each weld he follows.