Method and apparatus for manufacturing a dual material turbine engine disk and disk produced using the method

Abstract

One aspect of the invention relates to a method for manufacturing a dual material turbine engine disk comprising the operations of providing a rough hole made of a first material; mounting the rough hole around a rotation axis of a rotating device; rotating the rough hole; spraying a second material, different from the first material, which creates a columnar or single crystal microstructure, onto the outer surface of the rough hole under solidification conditions to produce a dual material part; and machining the dual material part to produce a turbine engine disk. A second aspect of the invention relates to a device for implementing the method. A third aspect of the invention relates to a turbine engine disk produced with the method.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a dual-material turbine disk, wherein the central region of the turbine disk is made of a first material and the peripheral region of the turbine disk is made of a second material. The invention also relates to a manufacturing apparatus for implementing this method and a dual-material disk obtained by this method.

[0002] This invention has applications in the aerospace field, particularly in the manufacture of turbine compressors or turbine disks. Background Technology

[0003] It is well known in aviation that aircraft engines or turbines are becoming increasingly efficient. As a result, the temperature within certain turbine components tends to rise. This is especially true for turbine disks and compressor disks. Due to this increased heat, the properties of disks, typically made of equiaxed nickel-based materials, deteriorate with rising temperatures. In particular, the disks become prone to creep, meaning they tend to deform irreversibly, which is detrimental to the operation of the turbine or compressor, and indeed, the entire turbine.

[0004] To limit the harmful effects of these high temperatures, it is known to cool the hot elements of a turbine by means of a cooling airflow. For example, it is known to cool the turbine disks by drawing in cooling air from what is called a "cold" location within the turbine, and by injecting such cooling air near the turbine disks. However, drawing in cooling air has the effect of reducing turbine efficiency.

[0005] To maintain optimal turbine efficiency, new alloys that are more resistant to high temperatures are being developed, which will enable the achievement of maximum operating temperatures of up to 100°C.

[0006] The use of single-crystal or directionally solidified materials to manufacture turbine disks is also being considered. These materials offer advantages over traditional equiaxed alloys, particularly in terms of high-temperature resistance and creep resistance. However, such single-crystal disks would exhibit anisotropic material properties.

[0007] Therefore, there is indeed a need for a method that can manufacture turbine disks with both good creep resistance and good fatigue resistance, while keeping the manufacturing technology close to known technologies, in order to limit the manufacturing cost. Summary of the Invention

[0008] To address the creep and fatigue resistance issues of turbine disks discussed above, the applicant provides a method for manufacturing a dual-material turbine disk, wherein the central region of the dual-material turbine disk is made of a first fatigue-resistant material, and the peripheral region of the dual-material turbine disk is made of a second creep-resistant material having a columnar or single-crystal solidified structure.

[0009] According to a first aspect, the present invention relates to a method for manufacturing a dual-material turbine disk, comprising the following operations:

[0010] Provides coarse holes made of a first material,

[0011] The coarse hole is installed around the axis of rotation of the rotating device.

[0012] Rotate the coarse hole,

[0013] Under solidification conditions, a second material, different from the first material, that produces columnar or single-crystal microstructures, is sprayed onto the outer surface of coarse pores to obtain a dual-material component.

[0014] The dual-material component is machined to obtain a turbine disk.

[0015] This manufacturing method allows for the formation of a peripheral region made of a high-temperature-resistant material around coarse pores made of conventional materials. The coarse pores, which withstand relatively low temperatures, are fatigue-resistant, while the peripheral region, which withstands high temperatures, is creep-resistant.

[0016] In addition to the features just discussed in the previous paragraph, individually or in any technically possible combination, according to one aspect of the invention, the method for manufacturing a disk may have one or more of the following additional features:

[0017] The second material is a powdered nickel-based single crystal material.

[0018] The spraying operation involves laser spraying single-crystal material by making at least one hole on the outer surface of the coarse hole, inserting a seed crystal of single-crystal material therein, and melting the seed crystal to form a oriented crystal.

[0019] The second material is a powdered, directionally solidified material.

[0020] The coarse pore has a circular cross-section.

[0021] The second material is sprayed by the spraying device along a direction perpendicular to the tangent of the outer surface of the coarse hole.

[0022] The connection between the coarse hole and the second material is located in the middle area between the central hole of the disk and the edge of the disk.

[0023] After processing the dual-material disc, the disc must undergo hot isostatic pressing.

[0024] Another aspect of the invention relates to an apparatus for manufacturing a dual-material turbine disk, the apparatus comprising a spraying device equipped with nozzles for spraying a second material and monitored by a drive device, the manufacturing apparatus being characterized in that it implements the method defined above.

[0025] Advantageously, the spray nozzle of this device is oriented perpendicular to the tangential direction of the outer surface of the coarse hole.

[0026] Another aspect of the invention relates to a dual-material turbine disk, characterized in that it is obtained by the method described above, the disk comprising a central region formed of a first material and a peripheral region formed of a second material, wherein the grains or crystals of the second material are oriented radially. Attached Figure Description

[0027] Further advantages and features of the invention will become apparent after reading the following description, illustrated in the accompanying drawings, wherein:

[0028] Figure 1 illustrates, in the form of a functional diagram, different operations of an embodiment of the manufacturing method according to the present invention;

[0029] Figure 2 shows a schematic diagram of an apparatus for manufacturing a turbine disk according to an embodiment of the present invention;

[0030] Figure 3 shows a perspective view of an exemplary turbine disk fabricated using the method of Figure 1; and

[0031] Figure 4 shows a perspective view of an exemplary bladed disk fabricated using the method of Figure 1. Detailed Implementation

[0032] An exemplary embodiment of a method and apparatus for manufacturing a turbine disk is described in detail below with reference to the accompanying drawings, wherein the central region and the peripheral region of the turbine disk are made of different materials. This example illustrates the features and advantages of the invention. However, it should be noted that the invention is not limited to this example.

[0033] In the figures, identical components are labeled with the same reference numerals. For the sake of readability, the dimensions between the components shown are not proportional.

[0034] Figure 1 illustrates an exemplary embodiment of a method 100 for manufacturing a dual-material turbine disk. The method 100 includes spraying a highly creep-resistant material 340 onto the circumference 350 of a coarse-hole 320 using a spraying apparatus 200 (an example of which is shown in Figure 2).

[0035] The coarse-hole 320 is a component, which, for example, has a circular cross-section and is made of a metallic material or alloy commonly used in the field of turbine disks, according to conventional techniques. This material, referred to as the primary material, can be, for example... Or any other alloy commonly used in the field of turbine disk manufacturing for forged disks. This coarse hole 320 can be a new component intended to be transformed into a disk by the method according to the invention; or, this coarse hole 320 can be a turbine disk whose damaged circumference is reconstructed by applying a creep-resistant material according to the method according to the invention.

[0036] In the example of Figure 1, method 100 includes step 110 of providing coarse holes and selecting material to be sprayed onto the circumference of the coarse holes 320. This material can be, for example, a nickel-based single-crystal material, ceramic, or directionally solidified material. A single-crystal material is a solid material, such as a metal or alloy, composed of a single crystal or crystal formed from a single seed crystal. A directionally solidified material is a metal or alloy whose crystals expand along a predetermined direction during the solidification stage. In this specification, the term "second material" will be used to refer to either the single-crystal material or the directionally solidified material, because both of these materials have improved creep properties compared to the first material forming the coarse holes.

[0037] According to the invention, a second material is sprayed layer by layer onto the circumference of the coarse holes 320. For this purpose, the coarse holes 320 are mounted around the rotation axis 360 of the rotating device (step 120 in FIG. 1) and are rotatably driven by the rotating device (step 130 in FIG. 1), as indicated by arrow R in FIG. 2. The rotation axis 360 is an axis parallel to a transverse axis passing through the center of the disk.

[0038] As the coarse orifice 320 rotates (step 130), the spraying device 200 sprays the second material onto the periphery or circumference of the coarse orifice at a predetermined speed, so that a layer of predetermined thickness is deposited on the circumference of the coarse orifice. This step of spraying the second material 240 (step 140) is performed by the spraying device 200 as shown in FIG. 2. The spraying device 200 may be, for example, a laser device 210 equipped with a nozzle 230, thereby ensuring that the second material is sprayed in a selected orientation. The laser device 210 is connected to a drive device 220, which ensures control and monitoring of parameters of the laser device 210, such as the speed, flow rate, and / or heating temperature of the second material. The laser device 210 may be, for example, the laser device described in patent application FR 2,874,624 or any other laser device suitable for spraying material along a selected direction.

[0039] According to some embodiments, the coarse orifice 320 is driven in a continuous rotational motion at a predetermined speed, adapted to the flow rate of the second material exiting the nozzle 230 of the spraying apparatus. The second material, whether single-crystal or directionally solidified, is sprayed as a uniform powder 240 along the circumferential direction of the coarse orifice 320 and on the same axis AA as the laser beam 212. This powder 240 is melted by the laser beam and, upon contact with the heated coarse orifice 320, transforms into liquid beads 340. Beads 340 of several thicknesses can be applied on top of each other and / or adjacent to each other to form a uniform layer on the circumference or outer surface of the coarse orifice 320. The thickness of the beads 340 is determined according to the parameters of the spraying apparatus and the second material; for example, this thickness can be on the order of 1 mm.

[0040] As described above, the powder 240 of the second material transforms into beads 340 upon contact with the coarse orifice 320. For this purpose, the coarse orifice 320 is heated by a heating device (not visible in the figure) positioned near the orifice. This heating device can be, for example, a heating plate mounted inside the orifice or near a portion of the outer surface of the orifice receiving the powder, substantially aligned with the nozzle 230. This heating device can be associated with one or more thermal monitoring devices, such as a thermal sensor, thermal camera, pyrometer, etc., allowing it to be thermally controlled. Therefore, in the presence of the heated coarse orifice, the powder 240 of the second material transforms into fluid beads 340, which are able to adhere to the peripheral region of the coarse orifice 320. Thus, the thickness and / or width of the peripheral region of the coarse orifice gradually increases with each new layer of beads 340.

[0041] In some embodiments, powder 240 is a powder of a selected single-crystal material. In these embodiments, a seed crystal (a sheet of single-crystal material oriented in the desired direction) is placed in the hole and on the outer surface of the coarse hole, wherein the seed crystal is remelted by a laser during the spraying of the single-crystal material powder. Although single-crystal materials have different mechanical properties depending on the angle, this method enables the generation of curved single crystals, i.e., with low local dedirection, which allows the principal axis of the single crystal to be oriented along the radial direction of the disk. Therefore, the peripheral region 350 of the single-crystal material is a region with high temperature resistance, especially creep resistance.

[0042] In some other embodiments, powder 240 is a powder of a directionally solidified material, such as a DS200 alloy. In these embodiments, the directionally solidified material is sprayed onto the outer surface of the coarse pores by a spraying device (e.g., a laser device), where it is transformed into beads 340. The directionally solidified material is anisotropic, meaning its properties are not uniform in all directions. However, the properties of this material in the axial / tangential plane (AA-Tg) (i.e., along the grain direction of the material and along the solidification direction) are relatively close to those of the coarse pores. Therefore, although its creep resistance is not as good as that of a single-crystal material, the directionally solidified material exhibits better creep resistance than conventional equiaxed materials, and the connection between the coarse pores 320 and the surrounding region 350 in the directionally solidified material is greater than that in a single-crystal material.

[0043] Regardless of the material chosen, powder 240 is sprayed onto the coarse holes 320 in a predetermined direction. As shown in Figure 2, powder 240 is sprayed along a direction AA perpendicular to the tangent Tg of the circumference of the coarse holes 320. By spraying the second material along this direction AA, each grain or crystal of the material is radially positioned along the disk. In other words, each grain of the second material is deposited along the radius r of the disk, making the peripheral region 350 of the coarse holes the region with optimal creep properties, while the central region of the disk retains the optimal fatigue properties of conventional materials.

[0044] Therefore, the temperature gradient of the disk 300 manufactured according to the method of the present invention extends from the center of the disk to the circumference of the disk, and the grains or crystals in the peripheral region are deposited along the same direction as this temperature gradient.

[0045] When a dual-material component is obtained according to any embodiment of the method described above, this component can be processed (step 150 of FIG. 1) to obtain a turbine disk. In fact, at the end of step 140, when the second material is sprayed onto the coarse holes, the resulting component is a dual-material component comprising a central region made of the first material and a peripheral region made of the second material. This component can then be processed by any known machining technique, just like any other turbine disk. The resulting disk can be a disk 300 equipped with a blade connection system, as shown in FIG. 3, or a one-piece blade disk 400, as shown in FIG. 4. In fact, if the size of the dual-material component is large enough, the disk and blades can be machined within the dual-material component such that the blades (which are the most temperature-sensitive components) are also made of the second material. This type of processing not only increases the mass of the blades but also the mass of the disk because less mass is required to support it. Furthermore, it allows for the elimination of the mechanical connection between the blades and the disk.

[0046] The disks 300 and 400 obtained at the end of processing step 150 can be processed, like any turbine disk, to improve or optimize their inherent properties. For example, as shown in Figure 1, disks 300 and 400 can undergo hot isostatic pressing (more simply called HIC processing) to eliminate any porosity on the disk surface and thereby optimize the properties of the first and second materials.

[0047] As previously stated, the disk obtained using the method according to the present invention, such as disk 300 shown in FIG. 3 or blade disk 400 shown in FIG. 4, is composed of two different materials that form several zones of the disk:

[0048] The central region 351, at least partially corresponding to the coarse hole, is located near the transverse axis BB of the disk and is formed of one of the first materials commonly used to manufacture turbine disks;

[0049] Edge 352, which is formed by a peripheral region of a second material; and

[0050] Web 354 or intermediate zone, located between edge 352 and central zone 251.

[0051] In the turbine industry, it is known that the bore is the part least exposed to high temperatures, while the edges, and even more so the blades, are highly exposed to high temperatures. For example, in normal use, the edges can be exposed to a maximum temperature of 750°C, while the blades can be exposed to a maximum temperature of 1150°C. Since the central region 351 is the coolest part of the disk, it can be formed of conventional materials and therefore has good fatigue resistance. Conversely, the edges 352 are the parts of the disk most easily exposed to high temperatures, and it is advantageous for the edges to be made of a second material. For example, the connection 353 between the first and second materials can be accommodated, for example, in the web 354, as shown in Figure 3, because the web 354 is the part of the disk with the least mechanical stress. In fact, since the connection between the two materials is a weak point in the structure, it is best to place the connection in an area where the load is low, such as the web.

[0052] Although described by way of examples, alternatives and embodiments, the method for manufacturing a dual-material disk according to the present invention includes various alternatives, modifications and improvements, which will be apparent to those skilled in the art and should be understood to be within the scope of the present invention.

Claims

1. A method for manufacturing a dual-material turbine disk (300, 400), comprising the following operations: - Provide (110) a coarse hole (320) with a circular cross-section made of a first material. - The coarse hole (120) is installed around the rotation axis (360) of a rotating device. - Rotate (130) the coarse hole, - Under solidification conditions that produce columnar or single-crystal microstructures, a second material, different from the first material, is sprayed (140) onto the outer surface (350) of the coarse hole, with the spraying direction perpendicular to the tangent of the coarse hole circumference, so that each grain or crystal of the second material is positioned along the radial direction of the turbine disk, and a bimaterial component with a temperature gradient extending from the center of the turbine disk to the circumference of the turbine disk is obtained. - Process (150) the dual-material component to obtain turbine disk (300, 400).

2. The method according to claim 1, characterized in that, The second material is a powdered nickel-based single crystal material.

3. The method according to claim 2, characterized in that, The spraying operation (140) is to laser spray the single crystal material by opening at least one hole on the outer surface of the coarse hole (320), inserting a seed crystal of the single crystal material therein, and melting the seed crystal.

4. The method according to claim 1, characterized in that, The second material is a powdered, directionally solidified material.

5. The method according to claim 1 or 2, characterized in that, The connection (353) between the coarse hole (320) and the second material (340) is located in the middle area between the central area (351) of the turbine disk and the edge (352) of the turbine disk.

6. The method according to claim 1 or 2, characterized in that, After machining the dual-material components, the turbine disk (300, 400) is subjected to hot isostatic pressing.

7. An apparatus for manufacturing a dual-material turbine disk, comprising a spraying device (210) equipped with nozzles (230) for spraying a second material and monitored by a drive device (220), characterized in that, The device includes a heating element configured to heat the coarse hole (320), and it implements the method according to claim 1 or 2.

8. The apparatus according to claim 7, characterized in that, The nozzle (230) is perpendicular to the tangent (Tg) to the outer surface (350) of the coarse hole.

9. A dual-material turbine disk, characterized in that, It is obtained by the method according to claim 1 or 2, wherein the turbine disk (300, 400) includes a central region (351) formed of a first material and a peripheral region (350) formed of a second material (340), wherein the grains or crystals of the second material are oriented in a radial direction.

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