Functional gradient multi-material hollow turbine blade disc and preparation method and equipment thereof

Abstract

The invention discloses a functional gradient multi-material hollow turbine blade disc and a preparation method and equipment thereof.The functional gradient multi-material hollow turbine blade disc comprises a disc body and blades which are of an integrated structure, and an inner cavity of a hollow structure is formed in the disc body; according to the turbine blade disc, in the radial direction, continuous gradient transition of material components from the wheel center of the disc body to the blade tips of the blades is achieved through additive manufacturing, and continuous gradient transition of the material yield strength and the temperature resistance and structure / function integration are achieved. The preparation method comprises the steps that when a multi-channel powder feeding additive manufacturing mode is adopted for preparation, mixing is conducted by controlling the proportion of material powder of different channels, so that material components of the turbine blade disc are in continuous gradient transition from the wheel center of a disc body to the blade tip of a blade in the radial direction; the continuous gradient transition of the yield strength and the temperature resistance of the material and the structure / function integration are realized. The self-weight of the disc body is reduced, and the temperature resistance of the blades and the comprehensive performance of an engine are effectively improved.

Description

Technical Field

[0001] The present application relates to the technical field of turbine blade disks, and in particular, to a functionally gradient multi-material hollow turbine blade disk and a preparation method and equipment thereof. Background Art

[0002] In order to simultaneously meet the requirements of the heat resistance of the blades of the turbine blade disc and the strength of the disc body, conventional solid single-material turbine blade discs can usually only make a compromise between the comprehensive performance of different materials and adopt the method of precision casting and one-piece molding. However, this approach will lead to reduced heat resistance and heavy weight of the blade disc, and the disc body can only be a solid structure, resulting in low utilization of the disc body material, which cannot meet the requirements of high comprehensive performance aircraft engines for high heat resistance and light weight.

[0003] Some turbine blade discs are designed with dual alloys, that is, the blades and the disc body are made of different materials, or the material boundary is made at a certain radius height. The different material parts are manufactured separately and finally welded into shape. This method has a difficult manufacturing process and few matching materials that can be welded into shape. It can improve the temperature resistance of the turbine blade disc to a certain extent. Summary of the invention

[0004] On the one hand, the present application provides a functionally gradient multi-material hollow turbine blade disk to solve the existing technical problems of reduced temperature resistance, heavy weight, difficult process, and few matching materials that can be welded and formed.

[0005] This application is implemented through the following scheme:

[0006] A functionally gradient multi-material hollow turbine blade disk comprises an integrated disk body and blades, wherein the disk body is provided with a hollow structure inner cavity; the turbine blade disk is manufactured by additive manufacturing along the radial direction to achieve a continuous gradient transition of material composition from the wheel center of the disk body to the blade tip, thereby achieving a continuous gradient transition of material yield strength and temperature resistance and structural / functional integration.

[0007] Furthermore, the basic configuration of the inner cavity of the hollow structure is obtained by a multidisciplinary topological design optimization method, and based on the basic configuration, the contour curve of the inner cavity of the hollow structure is obtained by detailed design using a non-parametric shape optimization design method.

[0008] Furthermore, a plurality of powder discharge holes communicating with the inner cavity of the hollow structure are evenly spaced along the circumferential direction on the spoke plate of the disc body.

[0009] Furthermore, the radial position of the powder discharge hole is selected through design optimization, and the design optimization considers the center radius R of the powder discharge hole outlet, the angle θ between the powder discharge hole and the radial direction, the design parameters of the basic hole type f(x, y) of the powder discharge hole, and the maximum equivalent stress σ at the powder discharge hole.max (hole) is the objective function, and the average circumferential stress σ of the disk is zx ≤σ zx0 , maximum centrifugal radial stress σ JX ≤σ JX0 Constraints, gradient optimization algorithm is used to optimize the design parameters. The model of gradient optimization algorithm is as follows:

[0010]

[0011] Among them, σ zx0 is the upper limit of the average circumferential stress of the wheel, σ JX0 is the upper limit of the average radial stress of the wheel, R min is the minimum radius position of the powder discharge hole, R max It is the maximum radius position of the powder discharge hole.

[0012] Furthermore, the number N of the powder discharge holes is 4 to 8.

[0013] Furthermore, the number N of the powder discharge holes is proportional to the size of the turbine blade disk.

[0014] Furthermore, the cross-sectional shape of the powder discharge hole is elliptical.

[0015] On the other hand, the present application also provides a method for preparing the functionally gradient multi-material hollow turbine blade disk, comprising the steps of:

[0016] The turbine blade disk is prepared by a multi-channel powder feeding additive manufacturing method. During the preparation, the proportion of powders of different channel materials is controlled for mixing, so that the material composition of the turbine blade disk is continuously gradiently transitioned from the center of the disk body to the tip of the blade along the radial direction, thereby realizing a continuous gradient transition of the material yield strength and temperature resistance and the integration of structure / function.

[0017] On the other hand, the present application also provides a preparation device for implementing the preparation method, comprising:

[0018] A laser head, wherein the laser head is provided with channels for a laser beam, a protective gas, a powder of material A and a powder of material B respectively;

[0019] A substrate, located below the laser head;

[0020] The controller is connected to the laser head control and is used to prepare the turbine blade disk by using a multi-channel powder feeding additive manufacturing method. During the preparation, the functional gradient multi-material hollow turbine blade disk is additively manufactured by controlling the proportion of powders of different channel materials to mix them and then using a laser beam to heat and melt them on a substrate, so that the material composition of the turbine blade disk is continuously gradiently transitioned from the wheel center of the disk body to the blade tip along the radial direction, thereby realizing a continuous gradient transition of material yield strength and temperature resistance and structural / functional integration.

[0021] This application has the following beneficial effects:

[0022] The functional gradient multi-material hollow turbine blade disk of the present application adopts an additive manufacturing-oriented method, and realizes a functional gradient multi-material hollow turbine blade disk structure by providing a hollow structure inner cavity inside the disk body and a functional gradient with a continuous gradient transition of the material composition from the wheel center of the disk body to the blade tip along the radial direction. It can effectively improve the temperature resistance of the turbine blade disk blades, reduce the weight of the turbine blade disk, and improve the overall performance of the engine. The process is simple and easy to implement. The simulation analysis results show that compared with the traditional solid structure, the turbine blade disk structure of the present application can reduce the weight of the turbine blade disk by more than 10% and improve the temperature resistance by more than 100 degrees Celsius.

[0023] In addition to the above-described purposes, features and advantages, the present application also has other purposes, features and advantages. The present application will be further described in detail with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The drawings constituting a part of the present application are used to provide a further understanding of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application.

[0025] Figure 1 is a cross-sectional schematic diagram of a functionally gradient multi-material hollow turbine blade disk according to a preferred embodiment of the present application;

[0026] Figure 2 This is a schematic diagram of the powder discharge hole type of the preferred embodiment of the present application;

[0027] Figure 3 is a schematic side view of a functionally gradient multi-material hollow turbine blade disk according to a preferred embodiment of the present application;

[0028] Figure 4 It is a schematic diagram of the principle of a device for preparing a functionally gradient multi-material hollow turbine blade disk according to a preferred embodiment of the present application.

[0029] In the figure: 1. Blade; 2. Powder discharge hole; 3. Inner cavity of hollow structure; 4. Disc; 5. Protective gas; 6. Laser beam; 7. Material A powder; 8. Material B powder; 9. Matrix. DETAILED DESCRIPTION

[0030] The embodiments of the present application are described in detail below in conjunction with the accompanying drawings, but the present application can be implemented in a variety of different ways defined and covered below.

[0031] like Figure 1 As shown, a preferred embodiment of the present application provides a functionally gradient multi-material hollow turbine blade disk, including an integrated disk body 4 and a blade 1, wherein the disk body 4 is provided with a hollow structure inner cavity 3; the turbine blade disk is manufactured along the radial direction, and the material composition is continuously gradiently transitioned from the wheel center of the disk body 4 to the blade tip of the blade 1 through additive manufacturing, thereby realizing a continuous gradient transition of the material yield strength and temperature resistance, and structural / functional integration.

[0032] The functional gradient multi-material hollow turbine blade disk of this embodiment adopts an additive manufacturing-oriented method. By providing a hollow structure inner cavity 3 inside the disk body 4 and a continuous gradient transition of the material composition from the wheel center of the disk body 4 to the blade tip of the blade 1 along the radial direction, specifically, the blade 1 part adopts a material composition with high temperature resistance, while the disk body 4 part close to the wheel center adopts a material composition with high yield strength. The material composition is continuously gradiently transitioned from the wheel center to the blade tip along the radial direction, realizing a functional gradient multi-material hollow turbine blade disk structure, which can effectively improve the temperature resistance of the turbine blade disk blades, reduce the weight of the turbine blade disk, and improve the comprehensive performance of the engine. The process is simple and easy to implement. The simulation analysis results show that compared with the traditional solid structure, this embodiment realizes the improvement of the temperature resistance of the turbine blade disk and the overall weight reduction design, and at the same time realizes the multi-material structure and functional integrated design of the turbine blade disk to meet the actual operating conditions of the turbine blade disk of a high-performance aircraft engine. The turbine blade disk structure of this embodiment can reduce the weight of the turbine blade disk by more than 10% and improve the temperature resistance by more than 100 degrees Celsius.

[0033] Preferably, the basic configuration of the inner cavity 3 of the hollow structure is obtained by a multidisciplinary topological design optimization method, and based on the basic configuration, the contour curve of the inner cavity 3 of the hollow structure is designed in detail using a non-parametric shape optimization design method.

[0034] This embodiment designs and optimizes the innovative structure of the turbine blade disk by adopting a multidisciplinary topology optimization design method for additive manufacturing. A hollow structure cavity 3 is arranged inside the disk body 4 of the turbine blade disk. The basic configuration of the hollow structure cavity 3 is obtained by the multidisciplinary topology design optimization method. Based on the basic configuration, the contour curve of the hollow structure cavity 3 is designed in detail by a non-parametric shape optimization design method. Different from conventional size optimization and shape optimization methods, the non-parametric shape optimization design method is optimized by moving the finite element mesh nodes of the boundary, which has greater design freedom and can minimize the stress value at the hollow structure of the cavity.

[0035] Preferably, a plurality of powder discharge holes 2 communicating with the inner cavity 3 of the hollow structure are evenly spaced along the circumferential direction at the spoke plate of the disc body 4 .

[0036] In this embodiment, a plurality of powder discharge holes 2 connected to the hollow structure inner cavity 3 are evenly spaced along the circumferential direction at the spoke plate of the disc body 4, so as to facilitate the discharge of powder impurities in the hollow structure inner cavity 3 and the cleaning of the surface state of the inner cavity after the disc body 4 delivers powder to form. At the same time, due to the arrangement of the powder discharge holes 2, the hollow structure inner cavity 3 of the disc body 4 is not closed, which is conducive to the balance of cavity pressure.

[0037] Preferably, the radial position of the powder discharge hole 2 is selected through design optimization, and the design optimization considers the center radius R of the powder discharge hole 2 outlet, the angle θ between the powder discharge hole 2 and the radial direction, the design parameters of the basic hole type f(x, y) of the powder discharge hole 2, and the maximum equivalent stress σ at the powder discharge hole 2. max (hole) as the objective function, and the average circumferential stress σ of the disk body 4 zx ≤σ zx0 , maximum centrifugal radial stress σ JX ≤σ JX0 Constraints, gradient optimization algorithm is used to optimize the design parameters. The model of gradient optimization algorithm is as follows:

[0038]

[0039] Among them, σ zx0 is the upper limit of the average circumferential stress of the wheel, σ JX0 is the upper limit of the average radial stress of the wheel, R min is the minimum radius position of the powder discharge hole, R max It is the maximum radius position of the powder discharge hole.

[0040] The cross-sectional shape of the powder discharge hole 2 is elliptical.

[0041] In this embodiment, the outlet position of the powder discharge hole 2 is about 86% of the radial direction of the disc body 4, and the angle θ between the powder discharge hole and the radial direction is 40 degrees. The hole shape of the powder discharge hole after design optimization is a special-shaped hole, which is elliptical but slightly different from a pure ellipse. For the convenience of later hole shape contour detection, the elliptical configuration is selected and the size is rounded, where the large radius of the ellipse is 1.6mm and the small radius is 1mm. Figure 2 In this scheme, when the maximum radial stress and the average circumferential stress meet the requirements, the maximum equivalent stress at the powder discharge hole 2 is the lowest, which can ensure the static strength of the disc body 4 and the fatigue life of the powder discharge hole 2.

[0042] Preferably, the number N of the powder discharge holes 2 is 4 to 8, and the specific number N is proportional to the size of the turbine blade disk. In this embodiment, in this case, the number of powder discharge holes 2 is 6 evenly distributed in the circumferential direction. Figure 3 The number N can be determined based on the optimization results in the design optimization model so that the hole edge stress is at a lower level.

[0043] Preferably, another embodiment of the present application provides a method for preparing the functionally gradient multi-material hollow turbine blade disk as described above, comprising the steps of:

[0044] S1. The turbine blade disk is prepared by a multi-channel powder feeding additive manufacturing method. During the preparation, the proportion of powders of different channel materials is controlled for mixing, so that the material composition of the turbine blade disk is continuously gradiently transitioned from the wheel center of the disk body 4 to the tip of the blade 1 along the radial direction, thereby realizing a continuous gradient transition of the material yield strength and temperature resistance, and the integration of structure / function.

[0045] This embodiment uses a multi-channel powder feeding additive manufacturing method to realize the preparation of turbine blade disks. Figure 4As shown, during preparation, additive manufacturing is performed on the substrate 9, and the multi-channel powder feeding additive manufacturing method of this embodiment is used to control the proportion of different material powders at different radii to achieve multi-material gradient manufacturing. Specifically, the blade part uses a material component with high temperature resistance, such as material A powder 7, while the part close to the wheel center uses a material component with high yield strength, material B powder 8. During the preparation process, material A powder 7 and material B powder 8 are mixed in different proportions along different channels, and then melted under the joint action of laser beam 6 and protective gas 5, and then gradually additively manufactured on the substrate 9 to form a disc body 4 and blade 1, so that the material composition is continuously gradient transitioned (rather than discontinuous) from the wheel center to the blade tip in the radial direction. This preparation scheme realizes the improvement of the temperature resistance of the turbine blade disk and the overall weight reduction design, and at the same time realizes the integrated design of the multi-material structure and function of the turbine blade disk. The process is simple and easy to implement, and the yield strength and temperature resistance of the turbine blade disk at different radii can be conveniently controlled to meet the actual operating conditions of the turbine blade disk of a high-performance aircraft engine, which can effectively improve the temperature resistance of the turbine blade disk blades, reduce the weight of the turbine blade disk, and improve the overall performance of the engine.

[0046] like Figure 4 As shown, the present application also provides a preparation device for implementing the preparation method, comprising:

[0047] A laser head, wherein the laser head is provided with channels for a laser beam 6, a protective gas 5, a material A powder 7, and a material B powder 8;

[0048] A substrate 9, located below the laser head;

[0049] The controller is connected to the laser head control and is used to prepare the turbine blade disk by multi-channel powder feeding additive manufacturing. During the preparation, the powders of different channel materials are mixed by controlling the ratio and then heated and melted by laser beam 6 on the substrate 9 for additive manufacturing of the functional gradient multi-material hollow turbine blade disk, so that the material composition of the turbine blade disk is continuously gradiently transitioned from the wheel center of the disk body 4 to the blade tip of the blade 1 along the radial direction, thereby realizing the continuous gradient transition of the material yield strength and temperature resistance and the integration of structure / function.

[0050] The preparation device of this embodiment realizes the improvement of the temperature resistance and overall weight reduction design of the turbine blade disc, and at the same time realizes the multi-material structure and functional integrated design of the turbine blade disc. The structure is simple and easy to implement, and the yield strength and temperature resistance of the turbine blade disc at different radii can be conveniently controlled to meet the actual operating conditions of the turbine blade disc of high-performance aircraft engines. It can effectively improve the temperature resistance of the turbine blade disc blades, reduce the weight of the turbine blade disc, and improve the overall performance of the engine.

[0051] Although the preferred embodiments of the present application have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications falling within the scope of the present application.

[0052] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is also intended to include these modifications and variations.

Claims

1. A functionally gradient multi-material hollow turbine blade disk, comprising a disk body (4) and a blade (1) of an integrated structure, characterized in that: The disk body (4) is provided with a hollow structure inner cavity (3); The turbine blade disk has a continuous gradient transition of material composition from the wheel center of the disk body (4) to the blade tip of the blade (1) along the radial direction through additive manufacturing, thereby achieving a continuous gradient transition of material yield strength and temperature resistance and structural / functional integration.

2. The functionally graded multi-material hollow turbine blade disk according to claim 1, characterized in that: The basic configuration of the inner cavity (3) of the hollow structure is obtained by a multidisciplinary topological design optimization method. Based on the basic configuration, the contour curve of the inner cavity (3) of the hollow structure is obtained by detailed design using a non-parametric shape optimization design method.

3. The functionally graded multi-material hollow turbine blade disk according to claim 1, characterized in that: A plurality of powder discharge holes (2) communicating with the inner cavity (3) of the hollow structure are evenly spaced along the circumferential direction at the spoke plate of the disk body (4).

4. The functionally graded multi-material hollow turbine blade disk according to claim 2, characterized in that: The radial position of the powder discharge hole (2) is selected through design optimization, and the design optimization takes into account the center radius R of the powder discharge hole (2), the angle θ between the powder discharge hole (2) and the radial direction, the design parameters of the basic hole type f (x, y) of the powder discharge hole (2), and the maximum equivalent stress σ at the powder discharge hole (2). max (hole) is the objective function, and the average circumferential stress σ of the disk (4) is zx ≤σ zx0 , maximum centrifugal radial stress σ JX ≤σ JX0 Constraints, gradient optimization algorithm is used to optimize the design parameters. The model of gradient optimization algorithm is as follows: Among them, σ zx0 is the upper limit of the average circumferential stress of the wheel, σ JX0 is the upper limit of the average radial stress of the wheel, R min is the minimum radius position of the powder discharge hole, R max It is the maximum radius position of the powder discharge hole.

5. The functionally graded multi-material hollow turbine blade disk according to claim 2, characterized in that: The number N of the powder discharge holes (2) is 4 to 8.

6. The functionally graded multi-material hollow turbine blade disk according to claim 5, characterized in that: The number N of the powder discharge holes (2) is proportional to the size of the turbine blade disk.

7. The functionally graded multi-material hollow turbine blade disk according to claim 4, characterized in that: The cross-sectional shape of the powder discharge hole (2) is an ellipse.

8. A method for preparing a functionally graded multi-material hollow turbine blade disk as claimed in any one of claims 1 to 7, characterized in that: Includes steps: The turbine blade disk is prepared by a multi-channel powder feeding additive manufacturing method. During preparation, the proportion of powders of materials in different channels is controlled for mixing, so that the material composition of the turbine blade disk is continuously gradiently transitioned from the wheel center of the disk body (4) to the blade tip (1) along the radial direction, thereby achieving a continuous gradient transition of the material yield strength and temperature resistance and structural / functional integration.

9. A preparation device for implementing the preparation method according to claim 8, characterized in that: include: A laser head, wherein the laser head is provided with channels for supplying a laser beam (6), a protective gas (5), a material A powder (7), and a material B powder (8); A substrate (9), located below the laser head; The controller is connected to the laser head control and is used to realize the preparation of the turbine blade disk by multi-channel powder feeding additive manufacturing. During the preparation, the powders of different channel materials are mixed by controlling the ratio and then heated and melted by laser beam (6) on the substrate (9) to additively manufacture the functional gradient multi-material hollow turbine blade disk, so that the material composition of the turbine blade disk is continuously gradiently transitioned from the wheel center of the disk body (4) to the blade tip of the blade (1) along the radial direction, thereby realizing the continuous gradient transition of the material yield strength and temperature resistance and the integration of structure / function.

Images