DE102008058142A1 - Method for producing and / or repairing a rotor of a turbomachine and rotor for this purpose - Google Patents

Abstract

The invention relates to a method for producing and / or repairing a rotor of a turbomachine, in particular an integrally bladed blisk and / or bling of a gas turbine, wherein at least the steps provide a rotor base body, providing at least one blade, which comprises a porous shaped body, at least partially is coated with a metal alloy, arranging the at least one blade on the rotor base body and connecting the at least one blade are performed with the rotor base body. The invention further relates to a rotor for a turbomachine and a turbomachine with at least one rotor.

Description

The The invention relates to a method for manufacturing and / or repairing a rotor of a turbomachine. The invention further relates to a rotor for a turbomachine in the preamble of the claim 11 specified type and a turbomachine specified in the preamble of claim 13 with at least type a rotor.

rotors of turbomachinery, in particular rotors for Gas turbines are technically complex and cost-intensive can be produced and repaired. The rotors are becoming increasingly formed as integrally bladed rotors, which, when a disc-shaped rotor body is present, as a blisk (bladed disk) or, if an annular rotor body is present, called bling (bladed ring). From the state of the art known methods for production or repair thereby require Shovels with a massive blade foot to the forces of linear friction welding process, the one to join the blade with the rotor body is used to initiate. Such blades, so-called hollow blades, are usually by superplastic forming processes and diffusion bonding of two blade halves made with a third, folded liner. The liner is alternately tied on one or the other blade half and increased so the blade stiffness.

When A disadvantage of the known rotors is the fact that this technically complex and correspond costly in the Production are.

task It is therefore the object of the present invention to provide such a rotor to provide the simpler and cheaper to produce and / or repair is.

The The object is achieved by a Process according to claim 1 for producing and / or repairing a rotor of a turbomachine, a rotor having the features of claim 11 for a turbomachine and a turbomachine solved with the features of claim 13. Advantageous embodiments with appropriate training The invention are specified in the respective subclaims, wherein advantageous Embodiments of the method - as far as to be used - as advantageous embodiments of the rotor or the turbomachine and vice versa.

at a method according to the invention, which a simpler and cheaper Production and / or repair of a rotor of a turbomachine allows become a rotor body and at least one blade provided, wherein the blade a porous one moldings comprises, at least partially coated with a metal alloy is. The at least one blade is arranged on the rotor base body and with the rotor body connected. In addition to the simpler, cheaper and material-reduced Process implementation the rotor thus produced is also weight reduced and has a high vibration stiffness. The vibration stiffness is characterized by the difference in the modulus of elasticity (modulus of elasticity) between the preferably isotropic shaped body and that as a surface or wall material serving metal alloy of at least one Scoop reached. The achieved in the manufacture of the rotor Advantages are basically also achieved in the case of a repair, because missing or damaged surface material the at least one blade by re-coating with the Metal alloy can be repaired easily and inexpensively.

In an advantageous embodiment of the invention is provided that at least one blade is provided, which has a sintered and / or glued and / or foamed molding. This can the most suitable blade is variably selected and provided, whereby the rotor in the production optimally to its respective Application time can be adjusted. The same applies in the case of a Repair the rotor, so that the advantages mentioned, for example are also given at a blade replacement. The molding can for example, a sintered or glued hollow spheres produced molding be, wherein the hollow spheres of a metallic or ceramic Material may consist of a composite material or the like. As well can be provided that one consisting of a metal foam moldings provided. Alternatively or additionally, the shaped body also be made of several parts or of different materials.

Further Benefits arise by providing at least one blade in which a titanium alloy is used as the metal alloy becomes. As a result, a high mechanical, chemical and thermal Load capacity of the blade and thus the rotor at the same time low weight ensured.

In a further advantageous embodiment of the invention, it is provided that at least one blade is provided, in which the metal alloy is applied to the shaped body by means of a thermal spraying method, in particular a cold-kinetic compacting method. The Me The alloy can thus be applied to the molding without melting or melting it. In addition, a high surface quality of the blade and thus an optimized functionality of the rotor is ensured. The use of a cold-kinetic compacting method (so-called K3 or cold spray method) has the particular advantage that the supply of thermal energy can at least largely be dispensed with and thus the requirements for oxide-poor surface layers can be reliably fulfilled. In addition, particularly precise layer thicknesses, hardnesses and porosities can be produced. However, basically, for example, flame spraying method, plasma spraying method, detonation spraying method, arc wire spraying method and the like can also be used. The same applies in the case of a repair of the blade or the rotor, by missing or damaged surface material can be easily repaired by re-coating with the metal alloy.

In a further advantageous embodiment of the invention is provided that the at least one blade before and / or after joining with the rotor body edited, in particular finely worked and / or repaired, is. This preserves reliable a desired one Reference outer contour the blade or the rotor, whereby in particular its mechanical and aerodynamic properties are optimized. It can be provided be that a blade is provided, wherein the metal alloy in terms of the desired outer contour the blade applied at least partially with an oversize on the molding has been. With the help of such an over- or measure any Better taken into account manufacturing tolerances and an actual outer contour The blade can be easily adapted to the desired outer contour. Furthermore, it can be provided that a blade provided which is an excess in one provided for connecting the blade to the rotor main body of the rotor Has connection area, resulting in an improved mechanical stability and weldability is achieved. Furthermore, it can be provided that the desired outer contour the blade after the coating of the molding at least in the area of excess by means of a separation process, in particular by means of a chip process and / or an electrochemical removal process. In this way, the desired Reference outer contour fast, reliable and precise getting produced.

there In particular, has the use of machining methods with geometrically defined cutting edge, such as milling, as Advantageously shown to the target outer contour of the blade cost with the desired precision manufacture. Alternatively or additionally, electrochemical Ablation method (ECM), in particular precise electrochemical metalworking methods (PECM), shown as advantageous, since this also a reproducible surface treatment with high process reliability is. In this context, it can be provided that the blade in which provided for connection to the rotor main body of the rotor Joining area is not machined to the improved weldability to get in this area. The separation process can in the case of Repair of the blade or the rotor analogous to the simple, fast and precise Remove excess metal alloy be used.

Further Benefits arise by the at least one blade with the Rotor body is welded. In this way, the bucket can be simple, inexpensive and be reliably connected to the rotor body.

In a further advantageous embodiment of the invention is provided in that one provided for connecting the at least one blade to the rotor Connecting region of the at least one blade over the entire surface the rotor body is welded and / or that serving as a wall material metal alloy with the rotor body is welded. When the molding the shovel completely or coated at least in the connection region with the metal alloy is, the blade can according to the full surface with the rotor body of the Rotor welded be used to achieve a mechanically high-strength connection. Alternatively it can be provided that only one with the metal alloy coated outside wall area the blade preferably notch-free with the rotor body of the Rotor is welded. This speeds up the production and facilitates in case of eventual damage the scoop a later Bucket replacement or repair of the rotor. The testability the connection quality is due to the achievable smooth weld beads given.

In a further embodiment, it has proven to be advantageous for an inductive low-frequency pressure welding method and / or an inductive high-frequency pressure welding method and / or a diffusion welding method to be used for welding. The use of inductive low-frequency or high-frequency pressure welding (IHFP) reliably allows notch-free joining of the blade and rotor body. Also for the possibility of repair of the rotor and an exchange of the at least one blade, the pressure welding methods mentioned can be advantageously used. The use of a diffusion welding process allows the blade to be joined with a comparatively low compression pressure the joint surface, so that can be advantageously dispensed with collars and the like and mechanical deformation of the rotor are excluded particularly reliable.

In a further advantageous embodiment of the invention is provided that the rotor after connecting the at least one blade with the rotor body at least in the connecting region of the at least one blade by means a separation process, in particular a chip removal process and / or an ablation process is processed. This also will both in the manufacture as well as in the repair of the rotor a high mechanical stability and an optimization of the aerodynamic properties of the rotor ensured.

By doing several blades can be connected to the rotor main body can a rotor comprising a plurality of blades with the above-mentioned Benefits are produced and / or repaired.

One Another aspect of the invention relates to a rotor for a turbomachine, in particular an integrally bladed blisk and / or bling for a gas turbine, with a rotor body, which is connected to at least one blade. There is one simpler and cheaper Produceability of the rotor according to the invention given by the fact that at least one blade comprises a porous shaped body, at least partially coated with a metal alloy. In addition to the simpler, cheaper and material-reduced manufacturability is the rotor according to the invention also reduced weight and has a high vibration stiffness. The vibration stiffness is thereby by the difference in the modulus of elasticity (Modulus of elasticity) between the preferably isotropic shaped body and which as a surface or wall material serving metal alloy reaches the blade.

Further Benefits arise by the rotor by a method manufactured according to one of the preceding embodiments and / or repaired. The resulting benefits are the corresponding descriptions.

In In another aspect, the invention relates to a turbomachine, in particular a gas turbine, with at least one rotor, in particular with an integrally blisked blisk and / or bling, the Rotor according to the invention by means a method according to one of the preceding embodiments manufactured and / or according to a the previous embodiments is trained. The resulting benefits are also the corresponding descriptions.

Further Advantages, features and details of the invention will be apparent from the following description of an embodiment.

First, be a rotor body and at least one blade provided, wherein the blade a porous one moldings comprises, at least partially coated with a metal alloy is. The porous one moldings For example, from a metal foam and / or sintered together or -glued hollow balls to be made. The molded body, the preferably already one with a desired outer contour of the blade corresponding outer contour is subsequently with a titanium alloy encased in a cold-kinetic compacting process with oversize or oversize on the moldings is applied. It can also be provided that the shaped body several times with the metal alloy and / or with different metal alloys is coated to obtain special properties of the blade. As well can be provided that the molding in particular in one intended for connecting the blade to a rotor base body Connection area is not coated, so in a later connection step only coated wall portions of the blade connected to the rotor body become. The excess of metal alloy will over mill or electrochemical metal working (ECM) or precise electrochemical Metal machining (PECH) removed, so that the desired target outer contour the blade is generated. It can be provided that the blade not later Connection or welding area, the shit the blade is used with a rotor body, is processed.

The blade is placed on the rotor body and connected thereto. For bonding, an inductive high-frequency pressure welding process (IHFP) is used as joining method, whereby a notch-free connection between the blade and the rotor base body is achieved. Here, as already mentioned, only coated wall areas of the blade can be connected to the rotor base body, so that no full-surface welding between blade and rotor base body is carried out, but only the relevant wall area is joined. The testability of the joint connection is given thanks to the smooth weld bead. The repair possibility of the rotor is given in this production route. In particular, a blade exchange via IHFP is possible. Alternatively, if necessary after a finishing step, a blade can be provided, which is also coated in the joining region with the metal alloy and thereby completely over the surface as Hub serving rotor body are welded. Any existing or produced during welding on or oversize in the joining area can be easily removed, for example, by a subsequent milling process. Preferably, a plurality of blades are connected in one of the aforementioned ways with the rotor base body, whereby a multi-blade rotor can be produced with the said advantages.

in the Case of repair, for example, missing surface material a damaged shovel be supplemented with the help of the cold-kinetic Kompaktierverfahrens and by adaptive milling or händisches Matching be brought back to the desired outer contour.

Of the Rotor can be fast, easy, inexpensive and material reduced getting produced. Furthermore the rotor produced by this is very resistant to vibration and compared to conventional Rotors weight reduced. The vibration stiffness is thereby in particular by the difference in modulus of elasticity (modulus of elasticity) between the isotropic shaped body and the metal alloy wall material of the blade reached.

Claims (13)

Method for manufacturing and / or repairing a rotor of a turbomachine, in particular, an integrally bladed blisk and / or bling one Gas turbine, comprising the following steps: - Providing a rotor body; - Provide at least one blade, which comprises a porous molding, at least partially coated with a metal alloy; - Arrange the at least one blade on the rotor body; and - Connect the at least one blade with the rotor base body. Method according to claim 1, characterized in that that at least one blade is provided, which has a sintered and / or glued and / or foamed molding. Method according to claim 1 or 2, characterized that at least one blade is provided, in which as Metal alloy is a titanium alloy is used. Method according to one of claims 1 to 3, characterized that at least one blade is provided, in which the Metal alloy by means of a thermal spraying method, in particular a cold-kinetic compacting method, applied to the molding is. Method according to one of claims 1 to 4, characterized that the at least one blade before and / or after joining with the rotor body edited, in particular finely worked and / or repaired, is. Method according to one of claims 1 to 5, characterized that the at least one blade is welded to the rotor base body. Method according to Claim 6, characterized that for connecting the at least one blade to the rotor provided connection region of the at least one blade over the entire surface the rotor body welded is and / or that serving as a wall material metal alloy with the rotor body is welded. Method according to claim 6 or 7, characterized that for welding an inductive high frequency pressure welding process and / or a diffusion welding process is used. Method according to one of claims 1 to 8, characterized that the rotor after connecting the at least one blade with the rotor body at least in the connecting region of the at least one blade by means a separation process, in particular a chip removal process and / or an ablation process is processed. Method according to one of claims 1 to 9, characterized that several blades are connected to the rotor body. Rotor for a turbomachine, in particular integrally bladed blisk and / or bling for a gas turbine, with a rotor base body, which is connected to at least one blade, characterized in that the at least one blade comprises a porous shaped body which at least partially coated with a metal alloy. Rotor according to claim 11, characterized in that that this by means of a method according to one of claims 1 to 10 is manufactured and / or repaired. Flow machine, in particular gas turbine, with at least one rotor, in particular with an integrally bladed blisk and / or bling, characterized that the rotor by means of a method according to one of claims 1 to 10 manufactured and / or according to a the claims 11 or 12 is formed.