A functionally graded multi-material hollow turbine blade disk and methods and apparatuses for making the same

Abstract

The application discloses a functionally graded multi-material hollow turbine blade disc and a preparation method and equipment thereof. The functionally graded multi-material hollow turbine blade disc comprises a disc body and a blade in an integrated structure, and a hollow structure inner cavity is arranged in the disc body. The turbine blade disc is continuously graded from the hub of the disc body to the blade tip of the blade along the radial direction through additive manufacturing, so that the continuous gradient transition of the material yield strength and the temperature resistance ability and the integration of the structure and the function are realized. The preparation method comprises the following steps: when the multi-channel powder feeding additive manufacturing method is used for preparation, the different channel material powders are mixed by controlling the proportion, so that the turbine blade disc is continuously graded from the hub of the disc body to the blade tip of the blade along the radial direction, and the continuous gradient transition of the material yield strength and the temperature resistance ability and the integration of the structure and the function are realized. The application reduces the self weight of the disc body and effectively improves the temperature resistance ability of the blade and the comprehensive performance of the engine.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of turbine blade disc, in particular, to a functionally graded multi-material hollow turbine blade disc and a preparation method and equipment thereof. BACKGROUND

[0002] In order to meet the temperature resistance of the turbine blade disc blade part and the strength requirement of the disc body at the same time, the conventional solid single-material turbine blade disc can only make a compromise between the comprehensive performance of different materials and adopt the method of precise casting integrated molding. However, this method will cause the temperature resistance of the blade disc to be reduced, the weight to be large, and the disc body to be a solid structure, thereby causing the problem of low material utilization rate of the disc body, and failing to meet the demand of high comprehensive performance aero-engine for high temperature resistance and light weight.

[0003] Some turbine blade discs adopt a double-alloy design of turbine blade disc configuration, that is, the blade and the disc body are made of different materials, or the materials are divided at a certain radius height position. Different material parts are manufactured separately, and finally welded into a shape. This method has great manufacturing process difficulty, few materials that can be welded into a shape, and can improve the temperature resistance of the turbine blade disc to a certain extent. SUMMARY

[0004] The present application provides a functionally graded multi-material hollow turbine blade disc to solve the technical problems of reduced temperature resistance, large weight, great process difficulty, and few materials that can be welded into a shape.

[0005] The present application is implemented by the following solutions:

[0006] A functionally graded multi-material hollow turbine blade disc includes a disc body and a blade in an integrated structure, and the disc body is internally provided with a hollow structure inner cavity. The turbine blade disc continuously transitions the material composition from the hub of the disc body to the tip of the blade along the radial direction through additive manufacturing, so as to realize the continuous gradient transition of the material yield strength and the temperature resistance, and the integration of the structure / function.

[0007] Further, the basic configuration of the hollow structure inner cavity is obtained by a multi-disciplinary topology design optimization method. On the basis of the basic configuration, the profile curve of the hollow structure inner cavity is designed in detail by a non-parametric shape optimization design method.

[0008] Further, a plurality of powder discharge holes communicating with the hollow structure inner cavity are uniformly and spaced apart in the circumferential direction at the web plate of the disc body.

[0009] Further, the radial position of the powder discharge hole is selected by design optimization. In the design optimization, the design parameters of the powder discharge hole, such as the center radius R of the powder discharge hole outlet, the angle θ between the powder discharge hole and the radial direction, and the basic hole type f(x, y) of the powder discharge hole, are considered to maximize the equivalent stress σmax (hole) as the objective function, with the disc average circumferential stress σ zx ≤σ zx0 , the maximum centrifugal radial stress σ JX ≤σ JX0 Constraint conditions, using a gradient optimization algorithm to optimize the design parameters, the model of the gradient optimization algorithm is as follows:

[0010]

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

[0012] Further, the number N of the powder discharge holes is 4-8.

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

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

[0015] Another aspect of the present application also provides a preparation method of the functional gradient multi-material hollow turbine blade disc, comprising the steps of:

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

[0017] Another aspect of the present application also provides a preparation device for implementing the preparation method, comprising:

[0018] A laser head, which is provided with channels for laser beams, protective gas, material A powder and material B powder respectively;

[0019] A substrate located below the laser head;

[0020] The controller is connected with the laser head control, and is used for realizing preparation of the turbine blade disc by using a multi-channel powder feeding additive manufacturing method. During preparation, the functional gradient multi-material hollow turbine blade disc is prepared by additive manufacturing on a substrate through mixing of different channel material powders and then heating and melting by a laser beam, so that the material composition of the turbine blade disc continuously and gradually changes along a radial direction from a hub of the disc body to a blade tip of the blade, and continuous gradient transition of material yield strength and temperature resistance and integration of structure and function are realized.

[0021] The application has the following beneficial effects:

[0022] The functional gradient multi-material hollow turbine blade disc of the application is prepared by using an additive manufacturing method. The hollow structure inner cavity and the functional gradient of the material composition continuously and gradually changing along the radial direction from the hub of the disc body to the blade tip of the blade are arranged in the disc body, so that the functional gradient multi-material hollow turbine blade disc structure is realized. The temperature resistance of the turbine blade disc blade is effectively improved, the weight of the turbine blade disc is reduced, the comprehensive performance of the engine is improved, and the process is simple and easy to implement. Simulation analysis results show that, compared with a traditional solid structure, the turbine blade disc structure of the application can reduce the weight of the turbine blade disc by more than 10% and improve the temperature resistance by more than 100 degrees Celsius.

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

[0024] The accompanying drawings, which form a part of the present application, are included to provide a further understanding of the application, and are incorporated herein for explanation by reference. The present application will be described with reference to these drawings, wherein:

[0025] Figure 1 is a sectional view of the functional gradient multi-material hollow turbine blade disc of the preferred embodiment of the application;

[0026] Figure 2 is a schematic view of the powder discharge hole profile of the preferred embodiment of the application;

[0027] Figure 3 is a side view of the functional gradient multi-material hollow turbine blade disc of the preferred embodiment of the application;

[0028] Figure 4 is a schematic view of the preparation device principle of the functional gradient multi-material hollow turbine blade disc of the preferred embodiment of the application.

[0029] In the drawings: 1, blade; 2, powder discharge hole; 3, hollow structure inner cavity; 4, disc body; 5, protective gas; 6, laser beam; 7, material A powder; 8, material B powder; 9, substrate. Detailed Implementation

[0030] The embodiments of this application are described in detail below with reference to the accompanying drawings; however, this application may be implemented in a variety of different ways as defined and covered below.

[0031] like Figure 1 As shown, a preferred embodiment of this application provides a functionally graded multi-material hollow turbine blade disk, including an integral disk body 4 and blades 1. The disk body 4 has a hollow internal cavity 3. Along the radial direction, the turbine blade disk achieves a continuous gradient transition of material composition 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 material yield strength and temperature resistance, and the integration of structure and function.

[0032] This embodiment of the functionally graded multi-material hollow turbine blade disk adopts an additive manufacturing approach. It achieves this by incorporating a hollow internal cavity 3 within the disk body 4 and a continuous gradient transition of material composition along the radial direction from the center of the disk body 4 to the tip of the blade 1. Specifically, the blade 1 portion uses a material with high temperature resistance, while the portion of the disk body 4 near the center uses a material with high yield strength. This continuous gradient transition of material composition from the center to the tip along the radial direction realizes the functionally graded multi-material hollow turbine blade disk structure. This effectively improves the temperature resistance of the turbine blade disk, reduces the weight of the turbine blade disk, and enhances the overall engine performance. The process is simple and easy to implement. Simulation analysis results show that compared to traditional solid structures, this embodiment achieves improved temperature resistance and overall weight reduction of the turbine blade disk, while also realizing an integrated design of multi-material structure and function to meet the actual operating requirements of high-performance aero-engine turbine blade disks. 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 hollow structure cavity 3 is obtained by a multidisciplinary topology design optimization method. Based on the basic configuration, the contour curve of the hollow structure cavity 3 is obtained by detailed design using a non-parametric shape optimization design method.

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

[0035] Preferably, the disc body 4 has a plurality of powder discharge holes 2 that are evenly spaced along the circumference at the spokes and are connected to the hollow structure cavity 3.

[0036] In this embodiment, a number of powder discharge holes 2 are evenly spaced along the circumference of the spokes of the disc body 4, which are connected to the hollow cavity 3. This facilitates the discharge of powder and impurities inside the hollow cavity 3 after powder feeding and forming of the disc body 4, as well as the cleaning of the surface of the internal cavity. At the same time, due to the setting of the powder discharge holes 2, the hollow cavity 3 of the disc body 4 is not closed, which is conducive to cavity pressure balance.

[0037] Preferably, the radial position of the powder discharge hole 2 is selected through design optimization. The design optimization considers the outlet 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 shape 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 disk body 4 is the objective function. zx ≤σ zx0 Maximum centrifugal radial stress σ JX ≤σ JX0 Given the constraints, the design parameters are optimized using a gradient optimization algorithm. The model of the gradient optimization algorithm is as follows:

[0038]

[0039] Where, σ zx0 σ is the upper limit of the average circumferential stress of the disk. JX0 R represents the upper limit of the average radial stress of the wheel. min R is the minimum radius position of the powder discharge hole. max This represents the maximum radius 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 approximately 86% of the radial direction of the disk body 4, and the powder discharge hole forms a 40-degree angle θ with the radial direction. The optimized powder discharge hole shape is an irregular hole, which is elliptical but slightly different from a pure ellipse. For ease of subsequent hole shape contour detection, an elliptical configuration is selected and the dimensions are rounded. The major radius of the ellipse is 1.6 mm, and the minor radius is 1 mm. Figure 2 As shown in the figure. Under this scheme, with the maximum radial stress and average circumferential stress meeting 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 at 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, there are 6 powder discharge holes 2 evenly distributed around the circumference. Figure 3 As shown. The quantity N can be determined based on the optimization results in the design optimization model, so that the stress at the hole edge is at a low level.

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

[0044] S1. The turbine blade disk is prepared by using a multi-channel powder feeding additive manufacturing method. During the preparation, the proportion of material powder in different channels is controlled and mixed to make the material composition of the turbine blade disk continuously gradient from the wheel center of the disk body 4 to the blade tip of the blade 1 along the radial direction, so as to realize the continuous gradient transition of material yield strength and temperature resistance, and the integration of structure and function.

[0045] This embodiment employs a multi-channel powder feeding additive manufacturing method to fabricate the turbine blade disk, such as... Figure 4As shown, during fabrication, additive manufacturing is performed on substrate 9. In this embodiment, the multi-channel powder feeding additive manufacturing method is used to control the proportion of different material powders at different radii, achieving multi-material gradient manufacturing. Specifically, the blade portion uses a material composition with high temperature resistance, such as material A powder 7, while the portion near the wheel center uses a material composition with high yield strength, material B powder 8. During fabrication, material A powder 7 and material B powder 8 are mixed in different proportions along different channels, then melted under the combined action of laser beam 6 and protective gas 5, and gradually additively manufactured on substrate 9 to form the disk 4 and blade 1, thus achieving a continuous gradient transition of material composition (rather than intermittent) from the wheel center to the blade tip in the radial direction. This fabrication scheme achieves improved temperature resistance and overall weight reduction of the turbine blade disk, while also realizing the integrated design of multi-material structure and function of the turbine blade disk. The process is simple and easy to implement, allowing for convenient control of the yield strength and temperature resistance at different radii of the turbine blade disk to meet the actual operating conditions of high-performance aero-engine turbine blade disks. It can effectively improve the temperature resistance of turbine blade disks, reduce the weight of turbine blade disks, and improve the overall performance of the engine.

[0046] like Figure 4 As shown, this application also provides a preparation apparatus for carrying out the preparation method, comprising:

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

[0048] Substrate 9 is located below the laser head;

[0049] The controller, connected to the laser head, is used to fabricate the turbine blade disk using a multi-channel powder feeding additive manufacturing method. During fabrication, the proportions of different channel material powders are controlled and mixed, and then heated and melted by the laser beam 6 onto the substrate 9 to additively manufacture the functionally graded multi-material hollow turbine blade disk. This results in a continuous gradient transition of material composition from the wheel center of the disk body 4 to the blade tip 1 along the radial direction of the turbine blade disk, achieving a continuous gradient transition of material yield strength and temperature resistance, and the integration of structure and function.

[0050] The fabrication apparatus of this embodiment achieves improved temperature resistance and overall weight reduction of the turbine blade disk. It also realizes the integrated design of multi-material structure and function of the turbine blade disk. The structure is simple and easy to implement, and it can conveniently control the yield strength and temperature resistance at different radii of the turbine blade disk to meet the actual operating conditions of the turbine blade disk of high-performance aero-engines. 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.

[0051] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0052] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A functionally graded multi-material hollow turbine blade disk, comprising an integrally structured disk body (4) and blades (1), characterized in that: The disk body (4) has a hollow inner cavity (3) inside; Along the radial direction, the material composition of the turbine blade disk is continuously gradient transitioned from the wheel center of the disk body (4) to the blade tip (1) through additive manufacturing, so as to realize the continuous gradient transition of material yield strength and temperature resistance, and the integration of structure and function. The disc body (4) has several powder discharge holes (2) that are evenly spaced along the circumference at the spokes and are connected to the hollow structure cavity (3). The radial position of the powder discharge hole (2) was selected through design optimization, taking into account the center radius of the outlet of the powder discharge hole (2). R Angle between the powder discharge hole (2) and the radial direction θ The design parameters of the basic hole type f(x,y) of the powder discharge hole (2) are based on the maximum equivalent stress σ at the powder discharge hole (2). max ( hole The objective function is the average circumferential stress of the disk (4). σ zx ≤ σ zx0 Maximum centrifugal radial stress σ JX ≤ σ JX0 As constrained, the design parameters are optimized using a gradient optimization algorithm. The model of the gradient optimization algorithm is as follows: ； in, σ zx0 This represents the upper limit of the average circumferential stress of the wheel. σ JX0 This represents the upper limit of the average radial stress of the wheel. R min The minimum radius of the powder discharge hole, R max This represents the maximum radius of the powder discharge hole.

2. The functionally graded multi-material hollow turbine blade disk according to claim 1, characterized in that: The basic configuration of the hollow structure cavity (3) is obtained by a multidisciplinary topology design optimization method. Based on the basic configuration, the contour curve of the hollow structure cavity (3) 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 2, characterized in that: The number N of the powder discharge holes (2) is 4 to 8.

4. The functionally graded multi-material hollow turbine blade disk according to claim 3, characterized in that: The number N of the powder discharge holes (2) is proportional to the size of the turbine blade disk.

5. The functionally graded multi-material hollow turbine blade disk according to claim 1, characterized in that: The cross-sectional shape of the powder discharge hole (2) is elliptical.

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