A method for controlling the temperature of an integral bladed disk heating system.

Abstract

This invention discloses a method for controlling the heating temperature of an integral bladed disk, relating to the field of metal heat treatment technology. The method includes: dividing the integral bladed disk into sections; wrapping the upper and lower surfaces of each section with a layer of thermally conductive material of different thicknesses or thermal conductivity, and wrapping the side surface of the integral bladed disk with a layer of insulating material; establishing an integral bladed disk model based on simulation parameters and performing heat treatment simulation to obtain simulation results; determining whether the simulation results meet design standards; if not, returning to the sectioning step; if the design standards are met, determining the simulation parameters as target parameters; wrapping the initial integral bladed disk according to the target parameters, placing it in an induction heating furnace for heat treatment, and cooling it after heat treatment to obtain the target integral bladed disk. This invention simplifies the operation process, reduces manufacturing costs, and ensures that the microstructure and performance of the integral bladed disk meet service requirements.

Description

Technical Field

[0001] This invention relates to the field of metal heat treatment technology, and in particular to a method for controlling the heating temperature of an integral bladed disk. Background Technology

[0002] The structural design of integral bladed disks for aero engines was first proposed in the 1960s. This design integrates blades, the rotor, and other components into a single, integral disk. Compared to combined bladed disks, this type of disk reduces weight by about one-third and eliminates friction between components, avoiding the risk of wear-related failures. It also improves the aerodynamic stability of the compressor and extends the service life of components. Therefore, the use of integral bladed disks in modern engines is an important measure to improve various aspects of engine performance.

[0003] To achieve more stable microstructure and performance in integral bladed disks (IBDs), numerous manufacturing methods have been developed, such as localized high-frequency induction heating, zoned temperature-controlled heat treatment, and dual microstructure heat treatment (DMHT). The primary goal of these technologies is to obtain different microstructures in different regions of the IBD and to achieve controllable gradual temperature changes, thereby ensuring that the microstructure and performance of each part of the bladed disk meet service requirements. In these manufacturing methods, the heating method, the design of the heating device, and the control of process parameters are core elements. Furthermore, precise control of the temperature distribution and microstructure evolution in different regions of the bladed disk during heating is necessary to achieve a gradual microstructure in the final IBD. These processes are complex and costly. Summary of the Invention

[0004] The purpose of this invention is to provide a method for controlling the heating temperature of an integral bladed disk, so as to simplify the operation process, reduce the manufacturing cost, and ensure that the microstructure and performance of the integral bladed disk can meet the service requirements.

[0005] To achieve the above objectives, the present invention provides the following solution:

[0006] A method for controlling the temperature of an integral bladed disk heating system includes:

[0007] Based on the functional characteristics and organizational performance requirements of the integral bladed disk, the integral bladed disk is divided into zones;

[0008] The upper and lower surfaces of each section of the integral bladed disk are wrapped with a layer of thermally conductive material of different thickness or thermal conductivity, and the side surface of the integral bladed disk is wrapped with a layer of thermal insulation material.

[0009] An integral bladed disk model was established based on the simulation parameters of the integral bladed disk, and heat treatment simulation was performed to obtain simulation results. The simulation parameters include: structure, size, thickness of the wrapping material, and thermal conductivity of the wrapping material. The simulation results include: temperature and performance of each section of the integral bladed disk.

[0010] Determine whether the simulation results meet the design standards; if they do not meet the design standards, return to the step of dividing the overall bladed disk into zones based on its functional characteristics and organizational performance requirements; if they meet the design standards, then determine the simulation parameters as the target parameters.

[0011] After the initial integral bladed disk is wrapped according to the target parameters, it is placed in an induction heating furnace for heat treatment, and then cooled after the heat treatment to obtain the target integral bladed disk.

[0012] Optionally, the partitioned integral bladed disk includes a core area, a rim area, and a transition area; the core area is located in the central region of the integral bladed disk; the rim area is located in the edge region of the integral bladed disk; and the transition area is located between the core area and the rim area.

[0013] Optionally, the functional characteristics and structural performance requirements of the integral bladed disk include: the core area is required to have set high-temperature creep resistance and damage tolerance performance; the edge area is required to have set fatigue performance; the microstructure of the core area is required to be basket webbing or lamellar structure; the microstructure of the edge area is required to be bimodal structure; and the microstructure of the transition area is required to change smoothly along the radial direction of the integral bladed disk.

[0014] Optionally, the relationship between the thickness of the wrapping material and the thermal conductivity of the wrapping material is as follows:

[0015] L = kA(ΔT / Q);

[0016] Where L is the thickness of the wrapping material, Q is the heat flow rate through area A per unit time, k is the thermal conductivity of the wrapping material, A is the contact area between the heat source and the wrapping material, and ΔT is the temperature difference between the furnace temperature and the overall bladed disk.

[0017] Optionally, after wrapping the initial integral bladed disk according to the target parameters, it is placed in an induction heating furnace for heat treatment, and then cooled after the heat treatment to obtain the target integral bladed disk, specifically including:

[0018] The initial integral bladed disk is wrapped according to the thickness and thermal conductivity of the wrapping material in the simulation parameters to obtain an initial integral bladed disk containing a wrapping layer and an insulation layer; the wrapping layer is composed of a thermally conductive material; the insulation layer is composed of a thermally insulating material.

[0019] The initial integral bladed disk containing the cladding layer and the insulation layer is placed in an induction heating furnace for heat treatment. Thermocouples arranged in the furnace are used to measure the temperature of each section of the initial integral bladed disk in real time until the temperature of each section of the initial integral bladed disk reaches the target temperature, and the initial integral bladed disk after heat treatment is obtained.

[0020] The initial integral bladed disk after heat treatment is cooled by a set cooling rate to obtain the target integral bladed disk.

[0021] Optionally, after wrapping the initial integral bladed disk according to the target parameters, it is placed in an induction heating furnace for heat treatment, and then cooled after the heat treatment to obtain the target integral bladed disk, which also includes:

[0022] The initial blank is rough-machined according to the structure and dimensions in the simulation parameters to obtain the initial integral bladed disk.

[0023] Optionally, the disk rim area is subjected to α+β zone heat treatment; the disk core area is subjected to β zone heat treatment; and the radial gradual temperature gradient of the initial integral bladed disk is greater than 250℃.

[0024] Optionally, the set cooling rate is 1-3℃ / s.

[0025] Optionally, the structure of the target integral bladed disk is a disk structure.

[0026] Optionally, the material of the target integral bladed disk is: titanium alloy or high-temperature alloy.

[0027] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0028] The method for controlling the heating temperature of an integral bladed disk provided by this invention involves establishing an integral bladed disk model and simulating heat treatment to determine target parameters such as the thickness and thermal conductivity of the wrapping material that enable the simulation results to meet design standards. Based on these target parameters, the initial integral bladed disk is wrapped and then placed in an induction heating furnace for heat treatment. After heat treatment, it is cooled to obtain the target integral bladed disk. Specifically, by wrapping the upper and lower surfaces of each section of the integral bladed disk with a layer of thermally conductive material of different thickness or thermal conductivity, and wrapping the side surface of the integral bladed disk with a layer of insulating material, a smooth and gradual transition of the microstructure from the disk core area to the disk edge area can be ensured. This facilitates the formation of a controllable gradual temperature, thereby obtaining the required microstructure for each section. Furthermore, the operation process is relatively simple, consistent, and has relatively low manufacturing costs. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 A flowchart of the processing method for controlling the heating temperature of the integral bladed disk provided by the present invention;

[0031] Figure 2 A detailed flowchart of the overall bladed disk heating temperature control method provided by the present invention;

[0032] Figure 3 This invention provides a schematic diagram of the overall bladed disk zoned heating and the location of each zone;

[0033] Figure 4 This is a schematic diagram of the initial integral bladed disk provided by the present invention;

[0034] Figure 5 A schematic diagram of the gradient thickness wrapping layer and the heat insulation layer provided by the present invention;

[0035] Figure 6 A schematic diagram of the initial integral bladed disk containing a wrapping layer and an insulation layer provided by the present invention;

[0036] Figure 7 This is a schematic diagram of the heat treatment furnace chamber of the induction heating furnace provided by the present invention.

[0037] Symbol explanation:

[0038] Integral bladed disk-1, disk core area-101, disk edge area-102, transition area-103, wrapping layer-2, insulation layer-3, support-4, heating coil-5, thermocouple-6. Detailed Implementation

[0039] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] The purpose of this invention is to provide a method for controlling the heating temperature of an integral bladed disk, which simplifies the operation process, reduces manufacturing costs, and enables gradual heating of the integral bladed disk. This allows for precise and controllable temperature control of various parts of the bladed disk, thus realizing the dual structure characteristics of the integral bladed disk and ensuring that the structural performance of the integral bladed disk meets service requirements.

[0041] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0042] like Figure 1 and Figure 2 As shown, the processing method for overall bladed disk heating temperature control provided by the present invention includes:

[0043] Step S1: Divide the integral bladed disk into zones according to its functional characteristics and organizational performance requirements.

[0044] Specifically, based on the functional characteristics of the integral bladed disk (IBD), which requires different mechanical properties in different radial locations to meet service environment requirements, high fatigue performance is required at the disk rim, and high high-temperature creep resistance and damage tolerance are required at the disk core, the IBD can be divided into three different regions: the disk core region 101, the disk rim region 102, and the transition region 103. The disk core region 101 is located in the central region of the IBD, the disk rim region 102 is located at the edge region, and the transition region 103 is located between the disk core region 101 and the disk rim region 102. Figure 3 As shown. The disk edge region 102 is required to have an equiaxed, uniform, fine dual-state structure, the disk core region 101 is required to have a fine-grained basketweave structure or lamellar structure, and the transition region 103 is required to have a microstructure that changes gently along the radial direction of the entire bladed disk, exhibiting an orderly and gradual change characteristic.

[0045] Based on the different microstructures of each zone, appropriate heat treatment processes and corresponding process parameters are selected to determine the required heat treatment temperature for each zone. Specifically, the α+β zone heat treatment of the disk rim zone 102 can produce a fine bimodal microstructure, giving the disk rim high strength and high plasticity. The precise and controllable β zone heat treatment of the disk core zone 101 can produce a basket-like microstructure or lamellar microstructure, giving the disk core properties such as high-temperature creep and damage tolerance, ensuring that the performance of each zone of the overall bladed disk meets the service requirements.

[0046] Step S2: Wrap a layer of thermally conductive material of different thickness or thermal conductivity on the upper and lower surfaces of each section of the overall bladed disk, and wrap a layer of thermal insulation material on the side surface of the overall bladed disk.

[0047] Preferably, the thermally conductive material is gradient-wrapped, that is, when the thermal conductivity is the same, the thickness of the thermally conductive material wrapped on the upper and lower surfaces of each section of the overall bladed disk gradually changes radially; when the thickness is the same, the thermal conductivity of the thermally conductive material wrapped on the upper and lower surfaces of each section of the overall bladed disk gradually changes radially.

[0048] Specifically, based on the zoning of the bladed disk and the selected overall bladed disk heat treatment scheme, a preliminary design of the matching heat treatment furnace is conducted, and the corresponding heating and cooling rates of the heat treatment furnace are calculated. To precisely control the zoning heating of the overall bladed disk, a layer of thermally conductive material of different thicknesses or thermal conductivity is wrapped around the upper and lower surfaces of the overall bladed disk, and a layer of insulating material is wrapped around the side surface of the overall bladed disk. The thickness of the wrapping material is calculated based on the thermal conductivity of the wrapping materials (including thermally conductive and insulating materials). The formula for calculating the thickness of the wrapping material can be derived from the heat conduction formula: Q=kA(ΔT / L), specifically L=kA(ΔT / Q); where Q is the heat flow rate through area A per unit time (in W), k is the thermal conductivity of the wrapping material (in W / (m·K)), and A is the contact area between the heat source and the wrapping material (in m²). 2 ), where ΔT is the temperature difference between the furnace temperature and the overall bladed disk (in K), and L is the thickness of the wrapping material (in m).

[0049] Step S3: Establish an integral bladed disk model based on the simulation parameters of the integral bladed disk, and perform heat treatment simulation to obtain simulation results; the simulation parameters include: structure, size, thickness of the wrapping material and thermal conductivity of the wrapping material; the simulation results include: temperature and performance of each section of the integral bladed disk.

[0050] Specifically, the Deform software is used to establish an overall bladed disk heat treatment model. After inputting relevant simulation parameters (such as dimensions, set furnace temperature, thickness of the wrapping material, thermal conductivity of the wrapping material, etc.), the heat treatment simulation is performed to obtain the simulation results.

[0051] Step S4: Determine whether the simulation results meet the design standards; if they do not meet the design standards, return to the step of dividing the overall bladed disk into zones according to the functional characteristics and organizational performance requirements of the overall bladed disk (i.e., step S1); if they meet the design standards, then determine the simulation parameters as the target parameters.

[0052] Specifically, if the temperature in each region of the simulation results can achieve the required gradual distribution and the performance of the impeller meets the requirements, the design can be considered reasonable. Otherwise, return to steps S1 to S3, adjust the simulation parameters such as the heating power, cooling power, insulation material and gradual thickness of the cladding layer of the existing heat treatment furnace, and re-simulate the overall impeller heating process until it meets the expected standards.

[0053] Step S5: After wrapping the initial integral bladed disk according to the target parameters, it is placed in an induction heating furnace for heat treatment, and then cooled after the heat treatment to obtain the target integral bladed disk. Specifically, this includes the following steps:

[0054] (1) Based on the structure and dimensions in the simulation parameters, the initial blank is rough-machined to obtain the initial integral bladed disk, such as... Figure 4 As shown.

[0055] (2) The initial integral bladed disk is wrapped according to the thickness and thermal conductivity of the wrapping material in the simulation parameters to obtain an initial integral bladed disk containing a wrapping layer and an insulation layer, such as... Figure 5 and Figure 6 As shown; wherein, the wrapping layer 2 on the upper and lower surfaces of the integral bladed disk 1 is made of thermally conductive material, specifically, a layer of thermally conductive material with the same thermal conductivity but different thicknesses, or a layer of thermally conductive material with the same thickness but different thermal conductivityes and different thermal conductivityes; the insulation layer 3 on the side surface of the integral bladed disk 1 is made of insulation material.

[0056] Specifically, the thickness of both the thermally conductive material and the thermally insulating material can be calculated using the derived formula. Materials with low thermal conductivity are preferred as thermally insulating materials, which can reduce the thickness of the wrapping material and facilitate subsequent operations.

[0057] (3) The initial integral bladed disk containing the wrapping layer and the insulation layer is placed in an induction heating furnace for heat treatment, and thermocouples arranged in the furnace are used to measure the temperature of each section of the initial integral bladed disk in real time until the temperature of each section of the initial integral bladed disk reaches the target temperature, and the initial integral bladed disk after heat treatment is obtained.

[0058] Preferably, the rim area is heat-treated in the α+β zone; the core area is heat-treated in the β zone; and the radial gradient temperature gradient of the initial integral bladed disk is greater than 250℃.

[0059] The gradual temperature control of the integral bladed disk utilizes variations in the thickness or thermal conductivity of the thermally conductive material to achieve temperature changes in different zones. During heating of the integral bladed disk, the varying thickness or thermal conductivity of the thermally conductive material on the upper and lower surfaces, combined with the outer insulation material, allows for precise control of the radial gradual temperature gradient of the bladed disk, with a temperature gradient greater than 250℃.

[0060] like Figure 7 As shown, the induction heating furnace is equipped with several supports 4, with evenly distributed heating coils 5 at the top and bottom. Multiple thermocouples 6 are also distributed within the furnace. The supports 4 are used to hold the integral bladed disk; the heating coils 5 are used to heat the integral bladed disk; there are at least five thermocouples 6, used to measure the temperature of the disk core area, the transition areas on both sides of the core area, and the edge areas on both sides of the transition areas. After the integral bladed disk is placed in the furnace, the temperature of each part of the integral bladed disk is measured in real time using the thermocouples 6 until the temperature of each part reaches the target temperature.

[0061] Specifically, a general heating furnace or a heating furnace that is compatible with the integral bladed disk can be selected. However, the calculation of the insulation material thickness is more precise when using a general heating furnace, while the calculation of the insulation material thickness can be reduced when using a matching heating furnace. The relevant adjustments can be made according to the user's needs.

[0062] In addition, since the surface of the impeller has been coated with materials with different thermal conductivity, the purpose of zoned heating has been achieved. It is also necessary to control the heating power of the heating furnace to ensure that the impeller temperature meets the requirements.

[0063] (4) The initial integral bladed disk after heat treatment is cooled by a set cooling rate to obtain the target integral bladed disk.

[0064] The target integral bladed disk has the following structure: a disc structure; and the target integral bladed disk is made of titanium alloy or high-temperature alloy.

[0065] Specifically, after heat treatment, in order to ensure that the gradient structure and properties of the integral bladed disk meet the requirements and obtain good tensile strength and low cyclic fatigue strength, it is necessary to cool it within a certain cooling rate range.

[0066] Preferably, setting the cooling rate to 1-3℃ / s can enable the entire bladed disk to obtain a fine crystalline layer structure.

[0067] This invention considers the functional characteristics and structural performance requirements of integral bladed disks (IBDs), specifically requiring the IBDs to possess different mechanical properties in different radial regions to meet service environment requirements. Before heat treatment, the IBDs are divided into zones. Based on the zoning and thermal conductivity formulas, the thickness of the thermally conductive material in each zone is calculated. The upper and lower surfaces of the IBDs are then gradient-wrapped with thermally conductive material, while the side surfaces are wrapped with insulating material. The wrapped IBDs are then placed in a heating furnace for heat treatment, thus achieving a continuous, gradual temperature change from the disk rim to the disk core. To further enhance the continuous, gradual microstructure and improve the mechanical properties of the IBDs, multiple thermocouples are installed in the heating furnace to measure the temperature of different regions of the IBDs. After heating, the IBDs need to be cooled within a certain cooling rate range. This method is not only simple to operate and has no special requirements for the heating furnace, significantly reducing manufacturing costs while ensuring a high yield rate.

[0068] In summary, this invention aims at gradient heating of dual-performance bladed disks by implementing zoned heating of the disk, reducing the complexity of the heating furnace and facilitating furnace production. This invention can calculate the type and thickness of the thermally conductive material covering the upper and lower surfaces of the integral bladed disk, as well as the type of thermal insulation material covering the side surfaces, based on thermal conductivity formulas. This ensures a smooth and gradual transition in microstructure from the disk body to the blades, making it easier to achieve a controllable gradual temperature change and thus obtaining the desired microstructure in each zone. Furthermore, the process is relatively simple and consistent.

[0069] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0070] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A method for controlling the heating temperature of an integral bladed disk, characterized in that, include: Based on the functional characteristics and organizational performance requirements of the integral bladed disk, the integral bladed disk is divided into zones; The partitioned integral bladed disk includes a core area, a rim area, and a transition area; the core area is located in the central region of the integral bladed disk; the rim area is located in the edge region of the integral bladed disk; and the transition area is located between the core area and the rim area. The upper and lower surfaces of each section of the integral bladed disk are wrapped with a layer of thermally conductive material of different thickness or thermal conductivity, and the side surface of the integral bladed disk is wrapped with a layer of thermal insulation material. The thermally conductive material is wrapped in a gradient manner. When the thermal conductivity is the same, the thickness of the thermally conductive material wrapped on the upper and lower surfaces of each section of the integral bladed disk gradually changes radially. When the thickness is the same, the thermal conductivity of the thermally conductive material wrapped on the upper and lower surfaces of each section of the integral bladed disk gradually changes radially. An integral bladed disk model was established based on the simulation parameters of the integral bladed disk, and heat treatment simulation was performed to obtain simulation results. The simulation parameters include: structure, dimensions, wrapping material thickness, and wrapping material thermal conductivity; the simulation results include: temperature and performance of each zone of the overall bladed disk; the relationship between the wrapping material thickness and the wrapping material thermal conductivity is: L=kA(ΔT / Q); where L is the wrapping material thickness, k is the wrapping material thermal conductivity, Q is the heat flow through area A per unit time, A is the contact area between the heat source and the wrapping material, and ΔT is the temperature difference between the furnace temperature and the overall bladed disk; Determine whether the simulation results meet the design standards; if they do not meet the design standards, return to the step of dividing the overall bladed disk into zones based on its functional characteristics and organizational performance requirements; if they meet the design standards, then determine the simulation parameters as the target parameters. After wrapping the initial integral bladed disk according to the target parameters, it is placed in an induction heating furnace for heat treatment, and then cooled after the heat treatment to obtain the target integral bladed disk, specifically including: The initial integral bladed disk is wrapped according to the thickness and thermal conductivity of the wrapping material in the simulation parameters to obtain an initial integral bladed disk containing a wrapping layer and an insulation layer; the wrapping layer is composed of a thermally conductive material; the insulation layer is composed of a thermally insulating material. The initial integral bladed disk containing the cladding layer and the insulation layer is placed in an induction heating furnace for heat treatment. Thermocouples arranged in the furnace are used to measure the temperature of each section of the initial integral bladed disk in real time until the temperature of each section of the initial integral bladed disk reaches the target temperature, and the initial integral bladed disk after heat treatment is obtained. The initial integral bladed disk after heat treatment is cooled by a set cooling rate to obtain the target integral bladed disk.

2. The method for controlling the heating temperature of the integral bladed disk according to claim 1, characterized in that, The functional characteristics and organizational performance requirements of the integral bladed disc include: The core region is required to have set high-temperature creep resistance and damage tolerance performance; the edge region is required to have set fatigue performance; the microstructure of the core region is required to be basket webbing or lamellar structure; the microstructure of the edge region is required to be bimorphic structure; the microstructure of the transition region is required to change smoothly along the radial direction of the entire bladed disk.

3. The method for controlling the heating temperature of the integral bladed disk according to claim 1, characterized in that, After the initial integral bladed disk is wrapped according to the target parameters, it is placed in an induction heating furnace for heat treatment, and then cooled after the heat treatment to obtain the target integral bladed disk, which also includes: The initial blank is rough-machined according to the structure and dimensions in the simulation parameters to obtain the initial integral bladed disk.

4. The method for controlling the heating temperature of the integral bladed disk according to claim 1, characterized in that, The disk rim area is heat-treated in the α+β zone; the disk core area is heat-treated in the β zone; and the radial gradient temperature gradient of the initial integral bladed disk is greater than 250℃.

5. The method for controlling the heating temperature of the integral bladed disk according to claim 1, characterized in that, The set cooling rate is 1-3℃ / s.

6. The method for controlling the heating temperature of the integral bladed disk according to claim 1, characterized in that, The structure of the target integral bladed disk is a disk structure.

7. The method for controlling the heating temperature of the integral bladed disk according to claim 1, characterized in that, The material of the target integral bladed disk is: titanium alloy or high-temperature alloy.

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