Double-wall air-cooled blade simulation part and preparation method and system thereof

Abstract

The present invention discloses a double-walled air-cooled blade simulation part and its preparation method and preparation system, which relate to the field of testing technology. The above-mentioned double-walled air-cooled blade simulation part preparation method can prepare a single crystal high-temperature alloy double-layer thin-walled spoiler column simulation part with controllable secondary orientation and characteristic structure. In practical applications, by adjusting the assembly method and assembly structure of the casting intermediate, single crystal high-temperature alloy double-layer thin-walled spoiler column castings with different primary orientations, secondary orientations, wall thicknesses and spoiler column sizes can be prepared to meet various service test requirements. The double-walled air-cooled blade simulation part preparation system is mainly used to implement the above-mentioned double-walled air-cooled blade simulation part preparation method. The prepared double-walled air-cooled blade simulation part fills the current technical gap in simulation parts for double-walled air-cooled structure turbine blades, and can provide accurate service test data for optimizing the complex cooling structure of turbine blades and improving the service life of turbine blade structures.

Description

Technical Field

[0001] The present invention relates to the field of testing technology, and in particular to a preparation method and system for a double-walled air-cooled blade simulation component, and the double-walled air-cooled blade simulation component obtained by the preparation method. Background Art

[0002] Single-crystal superalloys, due to their excellent high-temperature mechanical properties, are widely used in turbine blades for advanced aeroengines and gas turbines. With the continuous increase in engine thrust demand, turbine inlet temperatures have risen sharply. To improve blade cooling efficiency, advanced aeroengine turbine blades often utilize a complex hollow double-walled air-cooled structure. However, this structure causes single-crystal superalloy blades to experience "thin-wall effects," "structural stress concentration effects," and "thermal stress concentration effects," which have become important considerations for the reliable service of advanced aeroengines.

[0003] However, the current blade development process does not involve material science service testing (tensile, creep, endurance, fatigue, etc.) for double-wall air-cooled structures, and lacks the understanding of the service behavior and damage characteristics of materials under the coupled constraints of double-wall air-cooled structures. Based on this, the present invention proposes a double-wall air-cooled blade simulation preparation method, preparation system, and double-wall air-cooled blade simulation prepared by the preparation method to fill the technical gap in blade simulations based on double-wall air-cooled structures. Summary of the Invention

[0004] The purpose of the present invention is to provide a preparation method and system for a double-walled air-cooled blade simulation part and a double-walled air-cooled blade simulation part prepared by the preparation method. The simulation part can reflect the secondary orientation of the double-walled air-cooled structure of a real blade, and the characteristic structure is controllable. It can be used to study the service damage behavior of materials under different mechanical service tests and ensure the test accuracy. It fills the current technical gap in simulation parts for double-walled air-cooled structure turbine blades and can provide accurate service test data for optimizing the complex cooling structure of turbine blades and improving the service life of turbine blade structures.

[0005] To achieve the above object, the present invention provides the following solutions:

[0006] The present invention provides a method for preparing a double-walled air-cooled blade simulation part, which is used for integrally casting the double-walled air-cooled blade simulation part, comprising the steps of:

[0007] S1. Prepare a core that matches the shape and size of the target casting, wherein a middle section of the core is provided with a plurality of spoiler column forming holes for forming spoiler columns;

[0008] S2. Cutting a seed crystal having the desired primary orientation and secondary orientation from a single crystal high-temperature alloy sample, injecting wax around the periphery of the seed crystal to form a seed crystal amplifier, and connecting the seed crystal amplifier to a secondary amplifier to obtain a combined amplifier;

[0009] S3, attaching wax paper 1 to the surface of the ceramic sheet, wherein the lateral width and thickness of the wax paper 1 are the same as those of one of the inner and outer walls of the target casting, the middle section is disposed directly above the wax paper 1, and the length and lateral width of the wax paper 1 are respectively the same as those of the middle section;

[0010] S4. Connect wax paper 2 and wax paper 3 to the two ends of the length direction of wax paper 1 along the length direction of the ceramic sheet, respectively. The thickness of wax paper 2 and wax paper 3 is the same, and the thickness of wax paper 2 and wax paper 3 is the sum of the thickness of wax paper 1 and the thickness of the middle section. The horizontal width of wax paper 2 and wax paper 3 is the same as the horizontal width of the middle section.

[0011] S5. Laminating and covering the surfaces of the middle section, the second wax paper, and the third wax paper with a fourth wax paper to obtain a casting body adapted to the double-wall spoiler structure of the target casting, wherein the thickness of the fourth wax paper is the same as the thickness of the other of the inner and outer walls of the target casting;

[0012] S6, combining and connecting the combined amplifier obtained in step S2 with the end surfaces of the wax paper third and the wax paper fourth to obtain a casting intermediate;

[0013] S7, assembling the casting intermediate onto a sprue plate, then slurry coating the casting intermediate to form a shell, and dewaxing to obtain a casting mold with seed crystals that matches the shape and size of the target casting;

[0014] S8. Casting the alloy melt into the casting mold to obtain a secondary oriented alloy double-layer thin-walled spoiler column casting, and then opening a plurality of impact holes on the inner wall of the secondary oriented alloy double-layer thin-walled spoiler column casting, and opening a plurality of air film holes on the outer wall of the secondary oriented alloy double-layer thin-walled spoiler column casting to form the double-walled air-cooled blade simulation part.

[0015] In one embodiment, the core is a ceramic core prepared using 3D printing technology.

[0016] In one embodiment, the middle section of the core is a rectangular flat plate structure, and the spoiler column forming hole is opened in the central area of ​​the middle section.

[0017] In one embodiment, positioning ribs are symmetrically provided at both transverse ends of the middle section, and the positioning ribs are used to cooperate with the shell during the process of forming the shell in step S7.

[0018] In one embodiment, in step S4, the width directions of the wax paper 2, the wax paper 3, the wax paper 1 and the middle section are aligned; the wax paper 2 and the wax paper 3 have the same length, and when placed, one end of the wax paper 2 in the length direction is seamlessly connected to the wax paper 1 and the middle section, and one end of the wax paper 3 in the length direction is seamlessly connected to the wax paper 1 and the middle section; the sum of the lengths of the wax paper 2, the wax paper 3 and the wax paper 1 is not less than the length of the ceramic sheet.

[0019] In one embodiment, the alloy melt in step S8 is a single crystal high temperature alloy melt.

[0020] The present invention proposes a double-wall air-cooled blade simulation component preparation system, which can implement the above-mentioned double-wall air-cooled blade simulation component preparation method. The double-wall air-cooled blade simulation component preparation system includes the core, the seed crystal amplifier, the secondary amplifier connected to the seed crystal amplifier, the ceramic sheet, the wax paper one, the wax paper two, the wax paper three and the wax paper four, wherein the middle section of the core is a rectangular flat plate structure, the spoiler column forming hole is opened in the central area of ​​the middle section, and positioning ribs are symmetrically arranged at the two lateral ends of the middle section, and the positioning ribs are used to cooperate and connect with the shell during the process of slurry coating to form the shell.

[0021] In one embodiment, the seed crystal amplifier includes a seed crystal and a transition amplifier wrapped around one end of the seed crystal, the transition amplifier includes a coaxially arranged cone and a cylinder, the large end of the cone is connected to one end of the cylinder, and the other end of the cylinder is connected to the secondary amplifier; the seed crystal and the transition amplifier are coaxially arranged.

[0022] In one embodiment, the secondary amplifier includes a coaxially arranged quadrangular pyramid and a quadrangular prism, the small end of the quadrangular pyramid is coaxially connected to the cylinder, the large end of the quadrangular pyramid is connected to one end of the quadrangular prism, and the other end of the quadrangular prism is connected to wax paper three and wax paper four.

[0023] The present invention proposes a double-walled air-cooled blade simulation part, which is prepared by the above-mentioned double-walled air-cooled blade simulation part preparation method. The double-walled air-cooled blade simulation part includes an inner wall, an outer wall and a spoiler column. The inner wall and the outer wall are arranged in parallel and spaced apart. The interval between the inner wall and the outer wall is an intermediate cavity, and the inner wall and the outer wall are connected by a plurality of the spoiler columns. A plurality of impact holes are opened on the inner wall for introducing external cold air into the intermediate cavity. A plurality of air film holes are opened on the outer wall, and any one of the impact holes and any one of the air film holes are staggered.

[0024] Compared with the prior art, the present invention has achieved the following technical effects:

[0025] The method for preparing a double-walled air-cooled blade simulation part proposed in the present invention is simple to operate and can prepare a single crystal high-temperature alloy double-layer thin-walled spoiler column simulation part with controllable secondary orientation and characteristic structure, wherein the characteristic structure includes but is not limited to the thickness of the inner and outer layers of the simulation part, the spoiler column structure, the spoiler column shape, the spoiler column size, the spoiler column structure arrangement, the volume of the intermediate cavity between the inner and outer walls, etc. In practical applications, by adjusting Figure 1 The assembly method and structure of the casting intermediate shown can produce single-crystal high-temperature alloy double-layer thin-walled spoiler castings with varying primary and secondary orientations, wall thicknesses, and spoiler dimensions to meet a variety of service testing requirements. The preparation of a double-walled air-cooled blade simulation using this method fills the current technological gap in simulations for double-walled air-cooled turbine blades, providing accurate service test data for optimizing complex turbine blade cooling structures and extending their service life.

[0026] The double-walled air-cooled blade simulation preparation system proposed in the present invention is used to implement the above-mentioned double-walled air-cooled blade simulation preparation method, and can prepare a single crystal high-temperature alloy double-layer thin-walled spoiler column simulation with controllable secondary orientation and characteristic structure.

[0027] The double-walled air-cooled blade simulation part proposed in the present invention is made by the above-mentioned double-walled air-cooled blade simulation part preparation method. The simulation part can reflect the secondary orientation of the double-walled air-cooled structure of the real blade, and the characteristic structure is controllable. It can be used to study the service damage behavior of materials under different mechanical service tests and ensure the test accuracy. It fills the current technical gap in simulation parts for double-walled air-cooled structure turbine blades, and can provide accurate service test data for optimizing the complex cooling structure of turbine blades and improving the service life of turbine blade structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0029] Figure 1 It is an overall perspective view of a casting intermediate formed in the preparation method disclosed in an embodiment of the present invention;

[0030] Figure 2 This is a front view of a casting intermediate formed in the preparation method disclosed in an embodiment of the present invention;

[0031] Figure 3 for Figure 2 Side view of

[0032] Figure 4 This is a schematic structural diagram of a core disclosed in an embodiment of the present invention.

[0033] In the figure, the reference numerals are: 100, casting intermediate; 1, core; 11, middle section; 111, spoiler column forming hole; 12, positioning rib; 2, seed crystal amplifier; 21, seed crystal; 22, transition amplifier; 3, secondary amplifier; 4, ceramic sheet; 5, wax paper one; 6, wax paper two; 7, wax paper three; 8, wax paper four. DETAILED DESCRIPTION

[0034] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0035] The purpose of the present invention is to provide a preparation method and system for a double-walled air-cooled blade simulation part and a double-walled air-cooled blade simulation part prepared by the preparation method. The simulation part can reflect the secondary orientation of the double-walled air-cooled structure of a real blade, and the characteristic structure is controllable. It can be used to study the service damage behavior of materials under different mechanical service tests and ensure the test accuracy. It fills the current technical gap in simulation parts for double-walled air-cooled structure turbine blades and can provide accurate service test data for optimizing the complex cooling structure of turbine blades and improving the service life of turbine blade structures.

[0036] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] Example 1

[0038] like Figures 1 to 4As shown, this embodiment provides a method for preparing a double-walled air-cooled blade simulation part. The double-walled air-cooled blade simulation part includes an inner wall, an outer wall, air film holes, impact holes and spoiler columns. The inner wall and the outer wall are arranged in parallel and spaced apart. The space between the two is the middle cavity of the simulation part, and the inner wall and the outer wall are connected by multiple spoiler columns. A plurality of impact holes are provided on the inner wall for introducing external cold air into between the inner wall and the outer wall. A plurality of air film holes are provided on the outer wall, and generally any impact hole and any air film hole are staggered. The above-mentioned double-walled air-cooled blade simulation part is a hollow double-walled air-cooled structure design that simulates a turbine blade. This embodiment preferably prepares the simulation part by integral molding. The following is a specific description of the method for preparing the double-walled air-cooled blade simulation part by taking the process of casting a single-crystal high-temperature alloy double-walled air-cooled blade simulation part as an example. The casting preparation method of a single-crystal high-temperature alloy double-walled air-cooled blade simulation part includes the following steps:

[0039] S1. Prepare a core 1 that matches the shape and size of a target casting; the target casting is a single crystal high-temperature alloy double-walled air-cooled blade simulation part to be prepared.

[0040] S2. A seed crystal having the desired primary and secondary orientations is cut from a single crystal high-temperature alloy specimen, and the seed crystal is placed in a specific wax mold and wax injected to form a seed crystal amplifier 2. The seed crystal amplifier 2 is connected to a secondary amplifier 3 made of wax to form a combined amplifier.

[0041] S3. Attach wax paper 5 to the middle of the surface of the ceramic sheet 4. The wax paper 5 is located directly below the middle section 11 of the core 1. The lateral width and thickness of the wax paper 5 are the same as one of the inner and outer walls of the target casting. The length and lateral width of the wax paper 5 are respectively consistent with the length and lateral width of the middle section 11 of the core 1 (i.e., the length of the wax paper 5 is consistent with the length of the middle cavity section of the target casting). After the casting is demolded, the location of the middle section 11 is the middle cavity between the inner and outer walls of the simulated part. The width of the ceramic sheet 4 should be wider than the overall lateral width of the core 1, and the ends of the length direction of the ceramic sheet 4 should also be sufficiently longer than the ends of the length direction of the middle section 11.

[0042] S4. Connect wax paper 2 6 and wax paper 3 7 to the longitudinal ends of wax paper 1 5 along the longitudinal direction of the ceramic sheet 4. Wax paper 2 6 and wax paper 3 7 have the same thickness, and preferably, the thickness of wax paper 2 6 and wax paper 3 7 is the sum of the single-layer wall thickness of the target casting (i.e., the thickness of wax paper 1 5) and the height of the middle cavity (the height of the middle cavity is the thickness of the middle section 11 of the core 1). Wax paper 2 6 and wax paper 3 7 have the same transverse width and are consistent with the casting width dimension of the target casting, i.e., the transverse width of wax paper 2 6 and wax paper 3 7 is the same as the transverse width of the middle section 11. When placed, wax paper 2 6, wax paper 3 7, wax paper 1 5, and the width direction of the middle section 11 are aligned. The lengths of wax paper 2 6 and wax paper 3 7 are consistent, and when placed, one end of wax paper 2 6 in the length direction is seamlessly connected to one end of wax paper 1 5 and the middle section 11 in the length direction, and one end of wax paper 3 7 in the length direction is seamlessly connected to the other end of wax paper 1 5 and the middle section 11 in the length direction. The sum of the lengths of wax paper 2 6, wax paper 3 7 and the above-mentioned wax paper 1 5 is not less than the length of the above-mentioned ceramic sheet 4.

[0043] After the above-mentioned wax paper 2 6, wax paper 3 7 and wax paper 1 5 are spliced ​​and combined, a groove with wax paper 1 5 as the bottom is formed between wax paper 2 6 and wax paper 3 7, and the length, width and groove depth (or thickness) of the groove are respectively adapted to the length, width and thickness of the above-mentioned middle section 11 (that is, after the middle section 11 of the core 1 is aligned and placed into the groove, the size of the middle section 11 is completely consistent with the size of the groove), the bottom surfaces of wax paper 2 6, wax paper 3 7 and wax paper 1 5 are flush, and after the middle section 11 of the core 1 is placed on wax paper 1 5, the bottom surface of the middle section 11 is seamlessly fitted with the upper surface of wax paper 1 5, and at the same time, the upper surface of the middle section 11 is flush with the upper surfaces of wax paper 2 6 and wax paper 3 7.

[0044] S5. Fit wax paper four 8 to cover the upper surface of the above-mentioned middle section 11, wax paper two 6 and wax paper three 7. The length and lateral width of wax paper four 8 are the same as the target size of the target double-wall spoiler column simulation part, and the thickness of wax paper four 8 is the same as the thickness of the other of the inner and outer walls of the target casting; after fitting, the length direction of the wax 8 should be aligned on both sides of the length direction of the whole after the above-mentioned wax 6, core 1, wax paper one 5, and wax paper three 7 are combined to obtain a casting molding body that is compatible with the double-wall spoiler column structure of the target casting.

[0045] S6. After the casting body is obtained, the amplifier formed by combining the seed crystal amplifier 2 and the secondary amplifier 3 is connected to the end faces of the wax paper 3 7 and the wax paper 4 8. It is best to maintain central symmetry when connecting. After the combination, the following is obtained: Figures 1 to 3The casting intermediate body 100 is shown. In the casting intermediate body 100, the longitudinal axis of the wax paper 3 7 and the wax paper 4 8 are both parallel to the central axis of the amplifier formed by the seed crystal amplifier 2 and the secondary amplifier 3 (which is also the axis of the seed crystal 21). In actual circumstances, the casting body can be regarded as a solid rectangular parallelepiped, and the longitudinal axis of the solid rectangular parallelepiped preferably coincides with the central axis of the amplifier formed by the seed crystal amplifier 2 and the secondary amplifier 3.

[0046] S7. The obtained casting intermediate 100 is assembled onto a sprue tundish. The casting intermediate 100 is then slurry-coated to form a shell. After dewaxing, a casting mold with seed crystals consistent with the desired casting shape is obtained. It should be noted that the dewaxing process herein employs a dewaxing process well known in the art, and the dewaxing targets include all wax materials, including the wax papers 1, 2, 3, and 4, the transition amplifier 22, and the secondary amplifier 3.

[0047] S8. Casting the single crystal high-temperature alloy melt into a casting mold with a seed crystal to obtain a secondary oriented single crystal high-temperature alloy double-layer thin-walled spoiler column casting; finally, opening a plurality of impact holes on the inner wall of the above-mentioned casting and opening a plurality of air film holes on the outer wall to form the final product, that is, a single crystal high-temperature alloy double-layer thin-walled air-cooled blade simulation part.

[0048] In one embodiment, the core 1 is preferably a ceramic core prepared by 3D printing technology. A plurality of spoiler column forming holes 111 are provided on the middle section 11 of the core 1. Any spoiler column forming hole 111 is preferably arranged perpendicular to the thickness direction of the middle section 11. During casting, the molten metal fills the spoiler column forming hole 111 to form a spoiler column. Figure 4 As shown, the cross-sectional shape, cross-sectional dimensions, and arrangement of the spoiler column forming holes 111 on the middle section 11 of the core 1 are identical to the spoiler column structure of the target casting. The core 1 is prepared using 3D printing technology, which simplifies the preparation process. In practical applications, cores 1 of various specifications can be prepared according to the specifications of the target casting. The cross-sectional shape, cross-sectional dimensions, and axial length of the spoiler column forming holes 111 on the cores 1 of different specifications, as well as the distribution form and distribution area of ​​the spoiler column forming holes 111, can all be different. This allows for flexible regulation and multi-specification design of the spoiler column structure in the simulated part, thereby also enabling controllable preparation of the simulated part, including but not limited to wall thickness, spoiler column structure, and intermediate cavity volume.

[0049] In one embodiment, the middle section 11 of the core 1 is preferably rectangular in shape, such as Figure 4As shown, the middle section 11 is a rectangular plate of uniform thickness. Its length and thickness can be flexibly adjusted according to the test requirements, and its transverse width is consistent with the width of the inner and outer plates of the target casting. Positioning ribs 12 are symmetrically provided at both transverse ends of the middle section 11 of the core 1. The aforementioned "transverse width" generally refers to the width value of the middle section 11 between the two positioning ribs 12 (that is, the interval between the two positioning ribs 12). When assembling to form the aforementioned casting molding body, the inner sides of the two positioning ribs 12 are fitted with the width directions of the wax paper 2 6 and the wax paper 3 7. The main function of the positioning ribs 12 is to be tightly connected to the shell during the process of slurry coating to form the shell, to ensure that the core 1 and the shell are relatively fixed during the casting process, to ensure the shape accuracy of the casting in the shell, and thus to ensure the molding accuracy and molding quality of the target casting.

[0050] In one embodiment, the length, width, and thickness of the middle section 11 of the core 1 are adapted to the length, width, and height of the central cavity of the target casting, respectively. The size and arrangement of the spoiler-forming holes 111 in the middle section 11 are identical to the diameter and arrangement of the spoilers in the target casting. In one feasible solution, the width of the middle section 11 can be set to 37 mm and the thickness to 1 mm. The locating ribs 12 on both sides of the core 1 can be set to 54 mm in length, 5 mm in thickness, and 5 to 10 mm in width. The 3D-printed core 1 can be made of alumina or silica-zirconia.

[0051] In one embodiment, the seed crystal amplifier 2 includes a seed crystal 21 and a transition amplifier 22, and the seed crystal 21 is connected to the secondary amplifier 3 via the transition amplifier 22. Specifically, the seed crystal amplifier 2 is formed by opening a wax mold, in which wax material is wrapped around the seed crystal 21 to form the transition amplifier 22; the primary orientation and secondary orientation of the seed crystal 21 can be cut from a single crystal high-temperature alloy substrate according to experimental needs; generally, the seed crystal 21 is in the shape of a quadrangular prism with a square cross section. As a feasible preferred solution, the side length of the cross section is set to 2mm to 4mm, and the overall axial length of the seed crystal 21 is 18mm to 30mm. Figures 1 to 3 As shown, the transition amplifier 22 consists of a coaxially connected truncated cone and a cylindrical cylinder. The overall axial length of the transition amplifier 22 is 15 mm to 20 mm. The cylindrical cylinder has an outer diameter of 15 mm. The large end of the truncated cone has a diameter of 15 mm and is connected to the cylindrical cylinder. The small end of the truncated cone has a diameter of 5 mm. One end of the seed crystal 21 is inserted into the truncated cone from the small end and extends into the cylindrical cylinder. The seed crystal 21 is coaxial with the entire transition amplifier 22. In one feasible solution, the length of the seed crystal 21 extending into the transition amplifier 22 is preferably 6 mm to 10 mm.

[0052] In one embodiment, the secondary amplifier 3 is composed of a quadrangular pyramid and a quadrangular prism coaxially combined, such as Figures 1 to 3As shown, the cross-section of the large end of the quadrangular pyramid is a rectangle with a length (the length extending in the direction corresponding to the transverse width of the middle section 11) of 50 mm and a width (the width extending in the direction corresponding to the thickness of the middle section 11) of 10 mm. The cross-section of the small end of the quadrangular pyramid is a rectangle with a length (the length extending in the direction corresponding to the transverse width of the middle section 11) of 5 mm to 6 mm and a width (the width extending in the direction corresponding to the thickness of the middle section 11) of 5 mm to 6 mm. The small end of the quadrangular pyramid is coaxially connected to the end of the cylinder of the aforementioned transition amplifier 22 that is away from the frustum. The overall axial length of the quadrangular pyramid is 20 mm to 40 mm. The large end of the quadrangular pyramid is connected to one end of the quadrangular prism. The shapes and sizes of the two end faces of the quadrangular prism are exactly the same as those of the large end of the quadrangular pyramid. The axial length of the quadrangular prism is generally greater than 5 mm. The other end of the quadrangular prism is connected to wax paper three 7 and wax paper four 8, and the cast body is coaxial with the quadrangular prism.

[0053] In one embodiment, the thickness of wax paper 1 5 and wax paper 2 8 is adjusted based on the thickness of the inner and outer walls of the target casting, generally ranging from 0.5 mm to 2 mm. Generally, the inner and outer walls of the target casting are of equal thickness, and both inner and outer walls are preferably rectangular. The thickness of wax paper 2 6 and wax paper 3 7 is the sum of the thickness of the target casting's single wall layer and the height of the central cavity, and is generally set to 1.5 mm to 3 mm. The lateral width of wax paper 1 5, wax paper 2 6, wax paper 3 7, and wax paper 4 8 is consistent with the lateral width of the central section 11 of the core 1, preferably 37 mm.

[0054] In one embodiment, the Al2O3 content of the ceramic sheet 4 is greater than 99%, and the thickness is preferably 0.3mm to 1mm; the lateral width of the ceramic sheet 4 is larger than the width of the middle section 11 (i.e., the lateral width of wax paper 1 5, wax paper 2 6 and wax paper 3 7), and is generally close to the overall lateral width of the core 1 (i.e., the sum of the lateral widths of the middle section 11 and the two positioning ribs 12) or 1mm to 5mm larger than the overall lateral width of the core 1.

[0055] In actual applications, there are no special requirements for the fixing methods of wax paper 1 5, wax paper 2 6, wax paper 3 7 and wax paper 4 8, and a fixing method well known in the art can be used, such as pasting; there are no special requirements for the assembly method of the casting intermediate 100, and an assembly method well known in the art can be used; there are no special requirements for the slurry coating process, and a process well known in the art can be used. During the slurry coating process, a mold shell is formed around the casting molding body. In a feasible embodiment, the thickness of the mold shell is preferably 10 mm to 20 mm.

[0056] It can be seen that the above-mentioned method for preparing double-walled air-cooled blade simulation is simple to operate and can prepare a single crystal high-temperature alloy double-layer thin-walled spoiler column simulation with controllable secondary orientation and characteristic structure, wherein the characteristic structure includes but is not limited to the thickness of the inner and outer layers of the simulation, the spoiler column structure, the spoiler column shape, the spoiler column size, the spoiler column structure arrangement, the volume of the intermediate cavity between the inner and outer walls, etc. In practical applications, by adjusting Figure 1 The assembly method and assembly structure of the casting intermediate 100 shown can produce single crystal high temperature alloy double-layer thin-walled spoiler column castings with different primary orientations, secondary orientations, wall thicknesses and spoiler column sizes to meet various service test requirements.

[0057] Example 2

[0058] like Figures 1 to 4 As shown, this embodiment provides a double-walled air-cooled blade simulation production system, primarily used to implement the double-walled air-cooled blade simulation production method described in Example 1 and produce the desired double-walled air-cooled blade simulation. The double-walled air-cooled blade simulation production system primarily includes a core 1 matching the target casting shape and specifications, a seed crystal amplifier 2, a secondary amplifier 3 connected to the seed crystal amplifier 2, a ceramic sheet 4, wax paper 1 5, wax paper 2 6, wax paper 3 7, and wax paper 4 8, as well as other conventional casting equipment.

[0059] In this embodiment, the specific structure and size design of the core 1, seed crystal amplifier 2, secondary amplifier 3, ceramic sheet 4, wax paper 1 5, wax paper 2 6, wax paper 3 7 and wax paper 4 8, as well as the combination of each component are all referred to Example 1 and will not be repeated here.

[0060] Example 3

[0061] This embodiment proposes a double-walled air-cooled blade simulator, manufactured using the double-walled air-cooled blade simulator manufacturing method described in Example 1. This double-walled air-cooled blade simulator utilizes a double-walled structure with inner and outer walls. After the cooling airflow enters the intermediate cavity between the inner and outer walls through the impact holes in the inner wall, it first impacts the inner surface of the outer wall, causing jet impingement cooling. The cooling airflow then bypasses the spoiler columns and flows out through the air film holes distributed in the outer wall, forming a thin air film on the outer surface of the outer wall. Combining this air-cooling flow pattern with external combustion gas impingement enables simulation testing of the double-walled air-cooled structure under conditions similar to service conditions, meeting the service testing requirements of double-walled air-cooled turbine blade simulators under conditions close to actual service conditions.

[0062] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the method and core concept of the present invention. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the present invention. In summary, the contents of this specification should not be construed as limiting the present invention.

Claims

1. A method for preparing a double-walled air-cooled blade simulation, characterized in that: The method is used for integrally casting a double-wall air-cooled blade simulation part, comprising the following steps: S1. Prepare a core that matches the shape and size of the target casting, wherein a middle section of the core is provided with a plurality of spoiler column forming holes for forming spoiler columns; S2. Cutting a seed crystal having the desired primary orientation and secondary orientation from a single crystal high-temperature alloy sample, injecting wax around the periphery of the seed crystal to form a seed crystal amplifier, and connecting the seed crystal amplifier to a secondary amplifier to obtain a combined amplifier; S3, attaching wax paper 1 to the surface of the ceramic sheet, wherein the lateral width and thickness of the wax paper 1 are the same as those of one of the inner and outer walls of the target casting, the middle section is disposed directly above the wax paper 1, and the length and lateral width of the wax paper 1 are respectively the same as those of the middle section; S4. Connect wax paper 2 and wax paper 3 to the two ends of the length direction of wax paper 1 along the length direction of the ceramic sheet, respectively. The thickness of wax paper 2 and wax paper 3 is the same, and the thickness of wax paper 2 and wax paper 3 is the sum of the thickness of wax paper 1 and the thickness of the middle section. The horizontal width of wax paper 2 and wax paper 3 is the same as the horizontal width of the middle section. S5. Laminating and covering the surfaces of the middle section, the second wax paper, and the third wax paper with a fourth wax paper to obtain a casting body adapted to the double-wall spoiler structure of the target casting, wherein the thickness of the fourth wax paper is the same as the thickness of the other of the inner and outer walls of the target casting; S6, combining and connecting the combined amplifier obtained in step S2 with the end surfaces of the wax paper third and the wax paper fourth to obtain a casting intermediate; S7, assembling the casting intermediate onto a sprue plate, then slurry coating the casting intermediate to form a shell, and dewaxing to obtain a casting mold with seed crystals that matches the shape and size of the target casting; S8. Casting the alloy melt into the casting mold to obtain a secondary oriented alloy double-layer thin-walled spoiler column casting, and then opening a plurality of impact holes on the inner wall of the secondary oriented alloy double-layer thin-walled spoiler column casting, and opening a plurality of air film holes on the outer wall of the secondary oriented alloy double-layer thin-walled spoiler column casting to form the double-walled air-cooled blade simulation part.

2. The method for preparing a double-walled air-cooled blade simulation according to claim 1, characterized in that: The core is a ceramic core prepared by 3D printing technology.

3. The method for preparing a double-walled air-cooled blade simulation according to claim 1 or 2, characterized in that: The middle section of the core is a rectangular flat plate structure, and the spoiler column forming hole is opened in the central area of ​​the middle section.

4. The method for preparing a double-walled air-cooled blade simulation according to claim 3, characterized in that: Positioning ribs are symmetrically provided at both transverse ends of the middle section, and the positioning ribs are used to cooperate with the shell during the process of forming the shell in step S7.

5. The method for preparing a double-walled air-cooled blade simulation according to claim 1 or 2, characterized in that: In step S4, the width directions of the wax paper 2, the wax paper 3, the wax paper 1 and the middle section are aligned; the wax paper 2 and the wax paper 3 have the same length, and when placed, one end of the wax paper 2 in the length direction is seamlessly connected to the wax paper 1 and the middle section, and one end of the wax paper 3 in the length direction is seamlessly connected to the wax paper 1 and the middle section; the sum of the lengths of the wax paper 2, the wax paper 3 and the wax paper 1 is not less than the length of the ceramic sheet.

6. The method for preparing a double-walled air-cooled blade simulation according to claim 1 or 2, characterized in that: The alloy melt in step S8 is a single crystal high temperature alloy melt.

7. A double-walled air-cooled blade simulation preparation system, characterized in that: The method for preparing a double-walled air-cooled blade simulation component according to claim 1 can be implemented, and the double-walled air-cooled blade simulation component preparation system includes the core, the seed crystal amplifier, the secondary amplifier connected to the seed crystal amplifier, the ceramic sheet, the wax paper one, the wax paper two, the wax paper three and the wax paper four, wherein the middle section of the core is a rectangular flat plate structure, the spoiler column forming hole is opened in the central area of ​​the middle section, and positioning ribs are symmetrically arranged at both lateral ends of the middle section, and the positioning ribs are used to cooperate and connect with the shell during the process of forming the shell by slurry coating.

8. The double-walled air-cooled blade simulation preparation system according to claim 7, characterized in that: The seed crystal amplifier includes a seed crystal and a transition amplifier wrapped around one end of the seed crystal. The transition amplifier includes a coaxially arranged cone and a cylinder. The large end of the cone is connected to one end of the cylinder, and the other end of the cylinder is connected to the secondary amplifier. The seed crystal and the transition amplifier are coaxially arranged.

9. The double-walled air-cooled blade simulation production system according to claim 8, characterized in that: The secondary amplifier includes a coaxially arranged quadrangular pyramid and a quadrangular prism, the small end of the quadrangular pyramid is coaxially connected to the cylinder, the large end of the quadrangular pyramid is connected to one end of the quadrangular prism, and the other end of the quadrangular prism is connected to wax paper three and wax paper four.

10. A double-walled air-cooled blade simulation, characterized in that: The double-walled air-cooled blade simulation component is prepared by the preparation method of any one of claims 1 to 6, wherein the double-walled air-cooled blade simulation component comprises an inner wall, an outer wall and a spoiler column, wherein the inner wall and the outer wall are arranged in parallel and spaced apart, the space between the inner wall and the outer wall is an intermediate cavity, and the inner wall and the outer wall are connected by a plurality of the spoiler columns, a plurality of impact holes are provided on the inner wall for introducing external cold air into the intermediate cavity, a plurality of air film holes are provided on the outer wall, and any of the impact holes and any of the air film holes are staggered.

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