Turbine blade air film hole precision forming method

A turbine blade and precision forming technology, applied in chemical instruments and methods, self-solidification method, casting mold composition, etc., can solve the problems of uncontrollable machining dimensional accuracy, inability to process special-shaped holes and multi-angle inclined holes, and low machining efficiency. , to reduce the recast layer and micro-cracks, speed up the rapid research and development, and eliminate the positioning error.

Inactive Publication Date: 2020-01-31
XI AN JIAOTONG UNIV
5 Cites 9 Cited by

AI-Extracted Technical Summary

Problems solved by technology

The electric spark drilling technology uses the potential energy generated by the discharge between the conductive part material and the tool electrode to remove the material, and the production efficiency of this method is low
At the same time, because EDM belongs to thermal processing, it will generate a certain thickness of remelted layer on the processing surface, which has problems such as uncontrollable processing dimensional accuracy, uncontrollable processing taper, low surface roughness, many burrs, and low processing quality.
Electrohydraulic beam machining of gas film...
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Method used

The inventive method, according to material design optimization, the ceramic mold material kind of forming is abundant, comprises aluminum oxide base, silicon oxide base, calcium oxide base and yttrium oxide base, can face the pouring of multiple alloy materials, as iron base High-temperature alloys, nickel-based superalloys, cobalt-based superalloys, titanium-aluminum alloys, etc., forming turbine blades with round holes, wedge-shaped and heterogeneous gas film holes. The air film hole is formed by one-time casting without secondary processing. The invention is reasonable in design and easy to operate, which can eliminate positioning errors, reduce defects such as remelted layers and microcracks, and omit the required equipment and man-hours for mold processing and punching, thereby realizing High-precision, high-performance, high-efficiency forming of reburning turbine blades with fine air film holes. The invention is expected to release the limitation of the traditional drilling method on the development of high-efficiency film holes, promote the development of new film cooling theory and application research, provide new options for the forming of heavy-duty turbine blades with complex cooling channels, and promote new high-efficiency heavy-duty Development of gas turbines.
[0027] The directional solidification process can realize the molding of equiaxed crystal, directional crystal and single crystal blade, and the directional solidification temperature is co...
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Abstract

The invention discloses a turbine blade air film hole precision forming method, and belongs to the field of rapid casting based on a photocuring forming technology. The turbine blade air film hole precision forming method comprises the following steps: 1) manufacturing a turbine blade resin mold by using the photocuring rapid forming technology; 2) pouring ceramic slurry into a resin mold prototype of a turbine blade through a gel casting method to obtain a casting mold blank body, so that forming of an air film hole ceramic core is realized; 3) further strengthening the air film hole ceramiccore through vacuum freeze drying and high-temperature sintering, so that forming of different ceramic-based air film hole ceramic cores is realized; and 4) for the air film hole ceramic cores with different types of ceramic bases, combining a directional solidification technology to realize air film hole casting forming of various high-temperature alloys, and finally removing the ceramic cores remained in a metal blade and an air film hole through a core removing process, so that high-quality forming of the cast air film hole is realized. The turbine blade air film hole precision forming method is reasonable in design and simple and convenient to operate, and can realize forming of the high-quality cast air film hole.

Application Domain

Polycrystalline material growthFoundry moulds +4

Technology Topic

Directional solidificationTurbine blade +7

Image

  • Turbine blade air film hole precision forming method
  • Turbine blade air film hole precision forming method
  • Turbine blade air film hole precision forming method

Examples

  • Experimental program(1)

Example Embodiment

[0028] Example 1
[0029] The precision forming method for the air film hole of the turbine blade includes the following steps:
[0030] 1) Manufacturing turbine blade resin mold
[0031] The present invention uses light curing rapid prototyping technology to manufacture resin molds. First, commercial three-dimensional software is used to design a resin mold CAD model, and a two-dimensional slice file with a layered thickness of 0.07 mm will be generated. The resin mold is quickly and automatically manufactured under the control of the slice file. Light curing prototype, see figure 1 , Where 1 is the leaf body and 2 is the air film pore structure. The manufactured turbine blade resin mold has high precision, high rigidity and good surface quality, and can be used as a ceramic ligand molding mold.
[0032] 2) Prepare ceramic slurry
[0033] First, dissolve the organic matter in deionized water, add dispersant and uniformly mixed alumina ceramic powder and mineralizer powder in sequence to make ceramic slurry, add initiator and catalyst before pouring, mix well and vacuum to remove ceramic slurry Bubbles, the viscosity is less than 1Pa·S; the ceramic slurry is poured into figure 1 Shown in the hollow turbine blade prototype resin mold cavity, and figure 1 The pores of the air film are filled.
[0034] Among them, the ceramic powder uses alumina powder with a particle size of 2 μm, 5 μm or 40 μm; the added mineralizer is zirconia, and the zirconia powder accounts for 5% of the mass of the ceramic powder.
[0035] 3) Freeze drying and high temperature sintering
[0036] After the ceramic slurry is solidified and formed in situ, remove the ceramic slurry pouring system and the peripheral structure of the resin mold, transfer the ceramic body into a vacuum drying oven, control the vacuum degree between 1pa and 10pa, and dry time according to the size of the body. The blade ceramic mold drying time is 48-72 hours, and the green body is taken out after drying. The temperature-raising process is controlled to burn out the resin mold and organic gel, and the ceramic particles are sintered under high temperature conditions to obtain figure 2 The complete ceramic mold shown in, where 3 is a monolithic ceramic mold, and 4 is a gas film hole core. In the present invention, through high-temperature sintering, under the action of the mineralizer, the room temperature flexural strength of the ceramic mold is higher than 70MPa, and the 1500°C high-temperature flexural strength is 15-25MPa.
[0037] 4) Directional solidification and core removal
[0038] After obtaining a ceramic mold that meets the requirements of directional solidification, it is placed in a three-chamber vacuum directional solidification furnace for directional solidification casting of hollow turbine blades. The ceramic mold is preheated to about 1500°C, kept for 30-60 minutes, and high-temperature metal is poured. After the blade is cooled, the ceramic mold on the surface of the blade is directly removed, and the ceramic core remaining inside the blade is removed by strong alkali corrosion. The selected core removal liquid is KOH with a concentration of 50 to 70 wt.%. The core removal process does not affect the gas. The surface quality and accuracy of the membrane holes can achieve such image 3 The turbine blade shown in is completely formed, where 5 is a complete turbine blade, and 6 is a formed air film hole.
[0039] In summary, the method for precise forming of gas film holes of turbine blades disclosed in the present invention combines light curing molding and gel injection molding technology to realize the casting of a ceramic core containing gas film holes. Including: 1) Use light curing rapid prototyping technology to manufacture turbine blade resin mold; 2) Use gel injection molding method to pour ceramic slurry into the resin mold prototype of turbine blade to obtain the casting blank, and realize the formation of air film hole ceramic core 3) Vacuum freeze-drying and high-temperature sintering further strengthen the gas film pore ceramic cores, and realize the formation of different ceramic-based gas film pore ceramic cores; 4) For different types of ceramic-based gas film pore ceramic cores, combined with directional solidification technology, it can be Realize the casting and molding of air film holes of a variety of high-temperature alloys, and finally remove the ceramic core remaining in the metal blades and air film holes through the core removal process to achieve high-quality molding of the cast air film holes.
[0040] According to the method of the present invention, according to the optimization of material design, the formed ceramic mold materials are rich in types, including alumina-based, silica-based, calcium-oxide-based and yttrium-oxide-based, and can be poured into a variety of alloy materials, such as iron-based high-temperature alloys, Nickel-based superalloys, cobalt-based superalloys, titanium aluminum alloys, etc., are formed into turbine blades with round holes, wedge-shaped and heterogeneous air film holes. The air film hole is formed by one-time casting and no secondary processing is required. The present invention has reasonable design and simple operation, can eliminate positioning errors, reduce defects such as remelted layers and micro-cracks, and omit the required equipment and man-hours for mold processing and punching, thereby achieving High-precision, high-performance and high-efficiency forming of reburning turbine blades with fine film holes. The present invention is expected to lift the limitation of the traditional perforating method on the development of high-efficiency film holes, promote the development of new film cooling theory and application research, provide new options for the formation of reburning turbine blades with complex cooling channels, and promote new high-efficiency heavy-duty The development of gas turbines.

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