Turbine assembly manufacturing method

Abstract

Provided is a method for manufacturing a turbine module, which executes: a molded article forming step for forming a laminated molded article having an internal passage and a discharge passage communicating with the internal passage by disposing a metal powder on a base plate and bonding and solidifying the metal powder; and a powder removal step for removing the unwanted metal powder remaining in the internal passage. The internal passage has an introduction opening that opens on an outer surface of the plurality of outer surfaces of the laminated molded object other than a base facing surface, which is an outer surface facing the bottom plate. The discharge passage has a discharge opening that opens on an outer surface of the plurality of outer surfaces other than the base facing surface. In the powder removal step, gas is introduced into the internal passage from the introduction opening of the internal passage, so that the residual powder in the internal passage is discharged from the discharge opening of the discharge passage together with the gas.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a turbine assembly constituting a turbine.

[0002] This application claims priority based on patent application No. 2022-100155 filed in Japan on June 22, 2022, and the contents are incorporated herein by reference. Background Art

[0003] Many turbine components constituting a turbine have three-dimensionally complex shapes. Therefore, in recent years, research has been conducted on methods of manufacturing turbine components using a layered molding method.

[0004] As a method for manufacturing components and the like by the stacking molding method, for example, there is a method disclosed in the following patent document 1. In this method, while arranging metal powder on a base plate, the metal powder is combined and solidified to form a stacked molded object that becomes a component and the like. The stacked molded object has a plurality of outer surfaces and an internal passage that exists in the plurality of outer surfaces. The internal passage has two openings that open on the base opposing surface that is opposite to the base plate among the plurality of outer surfaces. After the stacked molded object is formed, metal powder remains in the internal passage. Therefore, in this method, after the stacked molded object is formed on the base plate, first, an inlet hole that passes through the base plate and is connected to one of the two openings of the internal passage, and an outlet hole that passes through the base plate and is connected to the other of the two openings of the internal passage are formed. Then, compressed air or the like is introduced from the inlet hole of the base plate so that the metal powder and the compressed air or the like are discharged from the outlet hole of the base plate in the internal passage.

[0005] Previous technical literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Publication No. 2004-027328 Summary of the invention

[0008] Technical issues to be solved by the invention

[0009] The method described in Patent Document 1 has a problem that the bottom plate cannot be reused because a hole is formed in the bottom plate, thereby increasing the manufacturing cost.

[0010] Therefore, an object of the present invention is to provide a method for manufacturing a turbine component that can reduce the manufacturing cost while removing residual powder in an internal passage.

[0011] Means for solving technical problems

[0012] In a method for manufacturing a turbine component according to one aspect of the invention for achieving the above-mentioned object,

[0013] The method performs the following steps: a molding forming step, in which metal powder is arranged on a base plate and the metal powder is combined and solidified to form a laminated molding, the laminated molding having a plurality of outer surfaces, an internal passage existing in the plurality of outer surfaces, and an exhaust passage communicating with the internal passage; a powder removing step, in which unnecessary metal powder, i.e., residual powder, remaining in the internal passage is removed; a heat treatment step, in which after the powder removing step, the laminated molding on the base plate is heated to perform heat treatment on the laminated molding; a plate separation step, in which after the heat treatment step, the laminated molding is separated from the base plate; and a finishing step, in which a turbine assembly is completed using the laminated molding separated from the base plate. The internal passage of the laminated molding formed in the molding forming step has an introduction opening, and the introduction opening is opened on an introduction opening surface of one of the plurality of outer surfaces except for the outer surface facing the base plate, i.e., the base facing surface. The discharge passage of the stacked object formed in the object forming step has a discharge opening, and the discharge opening is opened on a discharge opening surface of at least one of the plurality of outer surfaces other than the base facing surface. In the powder removing step, a fluid is introduced into the inner passage from the introduction opening of the inner passage so that the residual powder in the inner passage is discharged from the discharge opening of the discharge passage together with the fluid.

[0014] In this method, the powder removal process is performed after the molding process and before the heat treatment process, so that the unnecessary metal powder, that is, the residual powder, remaining in the internal passage of the stacked molding can be removed. In addition, in this method, an introduction opening and a discharge opening are formed on the outer surface of the stacked molding except the outer surface opposite to the bottom plate, that is, the base opposite surface, and the introduction opening introduces a fluid such as gas into the internal passage in the powder removal process, and the discharge opening discharges the residual powder together with the fluid in the powder removal process, so there is no need to process the bottom plate when removing the powder. Therefore, in this method, the bottom plate can be reused, and the manufacturing cost of the turbine assembly can be suppressed.

[0015] Effects of the Invention

[0016] According to one aspect of the present invention, it is possible to reduce the manufacturing cost of the turbine assembly while removing the residual powder in the internal passage. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic cross-sectional view of a gas turbine in one embodiment according to the present invention.

[0018] Figure 2This is a cross-sectional view of a main part of a gas turbine in one embodiment according to the present invention.

[0019] Figure 3 It is a perspective view of a split ring which is a turbine assembly in one embodiment of the present invention.

[0020] Figure 4 is along Figure 3 Cross-sectional view taken along line IV-IV.

[0021] Figure 5 This is a flowchart showing the manufacturing steps of a turbine assembly in one embodiment of the present invention.

[0022] Figure 6 It is a perspective view of a stacked structure in one embodiment of the present invention.

[0023] Figure 7 is along Figure 6 Cross-sectional view taken along line VII-VII.

[0024] Figure 8 yes Figure 6 View in the VIII direction.

[0025] Fig. 9 It is an explanatory diagram for explaining the powder removing step in one embodiment according to the present invention.

[0026] Fig.10 It is an explanatory diagram for explaining the opening sealing step in one embodiment of the present invention.

[0027] Fig.11 It is an explanatory diagram for explaining the exhaust passage forming portion removing step in one embodiment of the present invention.

[0028] Fig.12 It is an explanatory diagram for explaining a discharge opening closing step of closing the first discharge opening in a modification example of one embodiment according to the present invention.

[0029] Fig.13 It is an explanatory diagram for explaining a discharge opening closing step of closing the second discharge opening in a modification example of one embodiment according to the present invention. DETAILED DESCRIPTION

[0030] Hereinafter, embodiments of a turbine assembly and a turbine equipped with the turbine assembly according to the present invention will be described in detail with reference to the accompanying drawings.

[0031] "How the turbine is implemented"

[0032] refer to Figure 1 to Figure 4 , an implementation method of the turbine is described.

[0033] like Figure 1 As shown, the turbine in this embodiment is a gas turbine 1. The gas turbine 1 includes: a compressor 10 that compresses external air A to generate compressed air Acom; a combustor 20 that burns fuel F from a fuel supply source in the compressed air Acom to generate combustion gas G; and a turbine 30 that is driven by the combustion gas G.

[0034] The compressor 10 has a compressor rotor 11 that rotates around the axis Ar, a compressor housing 15 that covers the compressor rotor 11, and a plurality of fixed blade rows 18. The turbine 30 has a turbine rotor 31 that rotates around the axis Ar, a turbine housing 35 that covers the turbine rotor 31, and a plurality of fixed blade rows 38. In addition, hereinafter, the direction in which the axis Ar extends is referred to as the axial direction Da, the circumferential direction centered on the axis Ar is referred to as the circumferential direction Dc, and the direction perpendicular to the axis Ar is referred to as the radial direction Dr. Furthermore, one side in the axial direction Da is referred to as the axial upstream side Dau, and the side opposite thereto is referred to as the axial downstream side Dad. Furthermore, in the radial direction Dr, the side close to the axis Ar is referred to as the radial inner side Dri, and the side opposite thereto is referred to as the radial outer side Dro.

[0035] The compressor 10 is arranged on the axial upstream side Dau with respect to the turbine 30 .

[0036] The compressor rotor 11 and the turbine rotor 31 are located on the same axis Ar and are connected to each other to form a gas turbine rotor 2. For example, a rotor of a generator GEN is connected to the gas turbine rotor 2. The gas turbine 1 further includes an intermediate casing 6. The intermediate casing 6 is arranged between the compressor casing 15 and the turbine casing 35 in the axial direction Da. The compressor casing 15, the intermediate casing 6, and the turbine casing 35 are connected to each other to form a gas turbine casing 5.

[0037] like Figure 1 and Figure 2 As shown, the compressor rotor 11 has a rotor shaft 12 extending along the axial direction Da with the axis Ar as the center, and a plurality of rotating blade rows 13 mounted on the rotor shaft 12. The plurality of rotating blade rows 13 are arranged in the axial direction Da. Each rotating blade row 13 is composed of a plurality of rotating blades arranged in the circumferential direction Dc. Any one of the plurality of fixed blade rows 18 is arranged on the axial downstream side Dad of each of the plurality of rotating blade rows 13. Each fixed blade row 18 is provided on the inner side of the compressor housing 15. Each fixed blade row 18 is composed of a plurality of fixed blades arranged in the circumferential direction Dc.

[0038] The turbine rotor 31 has a rotor shaft 32 extending along the axial direction Da with the axis Ar as the center, and a plurality of rotating blade rows 33 mounted on the rotor shaft 32. The plurality of rotating blade rows 33 are arranged in the axial direction Da. Each rotating blade row 33 is composed of a plurality of rotating blades arranged in the circumferential direction Dc. Any one of the plurality of fixed blade rows 38 is arranged on the axial upstream side Dau of each of the plurality of rotating blade rows 33. Each fixed blade row 38 is provided on the inner side of the turbine housing 35. Each fixed blade row 38 is composed of a plurality of fixed blades arranged in the circumferential direction Dc.

[0039] The annular space between the outer circumference of the rotor shaft 32 and the inner circumference of the turbine housing 35 and in which the rotating blade row 33 and the fixed blade row 38 are arranged in the axial direction Da constitutes a combustion gas flow path 39 through which the combustion gas G from the combustor 20 flows. The combustion gas flow path 39 is annular with the axis Ar as the center and is long in the axial direction Da.

[0040] like Figure 2 As shown, the turbine housing 35 has a turbine housing body 36 and a plurality of split rings 40. The split ring 40 is located on the radially outer side Dro of the rotating blade row 33 and is opposite to the rotating blade row 33 in the radial direction Dr. The split ring 40 defines a portion of the edge of the radially outer side Dro of the combustion gas flow path 39 at a position in the axial direction Da where the rotating blade row 33 exists. The turbine housing body 36 is cylindrical with the axis Ar as the center in a manner surrounding the outer periphery of the turbine rotor 31. A plurality of fixed blade rows 38 and a plurality of split rings 40 are installed on the inner peripheral side of the turbine housing body 36.

[0041] The burner 20 is mounted on the intermediate casing 6. Figure 2 As shown, the combustor 20 includes a tail pipe (or combustion pipe) 22 in which fuel F is burned, and a plurality of combustion furnaces 21 that inject fuel into the tail pipe 22 .

[0042] like Figure 3 and Figure 4 As shown, the split ring 40 has a base material 41 and a thermal insulation coating 49 formed on a portion of the surface of the base material 41. The base material 41 is formed of, for example, a nickel-based alloy. The thermal insulation coating 49 includes a bonding coating formed on the surface of the base material 41 and a top coating formed on the surface of the bonding coating. The bonding coating is formed of, for example, a metal such as CoNiCrAlY. In addition, the top coating is formed of, for example, a ZrO2-based ceramic.

[0043] The base material 41 has a plate-shaped split ring body 42 extending in the circumferential direction Dc and the axial direction Da, a peripheral wall 47 extending from the peripheral edge of the split ring body 42 to the radially outer side Dro, and a plurality of hooks 48 formed on a portion of the peripheral wall 47. The split ring body 42 has a front end face 43f, a rear end face 43b, a pair of side end faces 43s, a gas path side face 45p, and an anti-gas path side face 45a. The front end face 43f faces the axial upstream side Dau. The rear end face 43b and the front end face 43f are in a back-to-back relationship and face the axial downstream side Dad. The pair of side end faces 43s face the circumferential direction Dc and face each other back-to-back. The gas path side face 45p faces the radially inner side Dr i. The anti-gas path side face 45a faces the radially outer side Dro. The peripheral wall 47 has a front wall 47f, a rear wall 47b, and a pair of side walls 47s. The front wall 47f is formed along the front end face 43f of the split ring body 42. The rear wall 47b is formed along the rear end face 43b of the split ring body 42. The front wall 47f and the rear wall 47b are spaced apart from each other in the axial direction Da. One of the pair of side walls 47s is formed along one of the pair of side end faces 43s of the split ring body 42. The other of the pair of side walls 47s is formed along the other of the pair of side end faces 43s of the split ring body 42. The pair of side walls 47s are spaced apart from each other in the circumferential direction Dc. Among the plurality of hooks 48, a part of the hooks 48 is formed on the radially outer side Dro of the front wall 47f, and another part of the hooks 48 is formed on the radially outer side Dro of the rear wall 47b. Each hook 48 has a portion extending along the radially outer side Dro and a portion extending from the end of the radially outer side Dro of the portion in the axial direction Da. These hooks 48 play a role in mounting the split ring 40 on the turbine housing body 36.

[0044] The split ring body 42 further has a plurality of cooling air passages 46. Each cooling air passage 46 has an introduction passage 46a and a main passage 46b. The introduction passage 46a extends from the position of the boundary between the anti-gas path side surface 45a of the split ring body 42 and the front wall 47f in a manner gradually toward the radial inner side Dri as it moves toward the axial upstream side Dau. The introduction passage 46a has an air inlet 46i opened at the boundary between the anti-gas path side surface 45a of the split ring body 42 and the front wall 47f. The main passage 46b is connected to the introduction passage 46a at the position of the end of the axial upstream side Dau and the end of the radial inner side Dri of the introduction passage 46a. The main passage 46b extends from the communication position with the introduction passage 46a toward the axial downstream side Dad. The main passage 46b has an air outlet 46o opened on the rear end surface 43b of the split ring body 42. In the surface defining the main passage 46b, the portion on the gas path side surface 45p side is formed to repeat concave and convex in the direction in which the main passage extends. That is, the spoiler 57 is formed on the surface defining the main passage 46b.

[0045] The heat-insulating coating 49 is formed on the gas passage side surface 45 p , the front end surface 43 f , the rear end surface 43 b , and the pair of side end surfaces 43 s of the split ring body 42 .

[0046] The components constituting the gas turbine 1 described above are all turbine components. Among the turbine components, the components that come into contact with the high-temperature combustion gas are turbine high-temperature components. The turbine high-temperature components include components constituting the combustor 20, the fixed blades of the turbine 30, the rotating blades of the turbine 30, and the split ring 40.

[0047] "Embodiments of methods for manufacturing turbine components"

[0048] Below, reference Figure 5 to Figure 11 , a method for manufacturing the split ring 40 which is one of the turbine components will be described.

[0049] In the manufacture of the split ring 40, as Figure 5 As shown in the flowchart of FIG. 1 , first, a stacked object is formed (object forming step S1). In this embodiment, the stacked object is formed by a powder bed fusion (PBF) method. In the PBF method, Figure 6 As shown, metal powders forming the stacked object 50 are arranged on a base plate P, and a predetermined region of the metal powder layer on the base plate P is irradiated with a high-density energy beam to melt the metal powder in the region. Then, the molten metal in the region is rapidly cooled to solidify, thereby forming a metal solidified layer of a predetermined shape. In the PBF method, a metal solidified layer of a predetermined shape is repeatedly formed on the metal solidified layer by the above method, thereby forming a stacked object 50 of a predetermined three-dimensional shape.

[0050] Among the PBF methods described above, there are the SLM (Selective Laser Melting) method in which metal powder is melted by laser light to combine and solidify the metal powder, and the EBM (Electron Beam Melting) method in which metal powder is melted by electron beam to combine and solidify the metal powder. In this embodiment, the SLM method is used. However, in this embodiment, the EBM method may also be used.

[0051] The stacked structure 50 becomes the base material 41 of the split ring 40 described above. Therefore, in this embodiment, the metal powder forming the stacked structure 50 is a powder of a nickel-based alloy. Figure 6 to Figure 8As shown, the stacked molding 50 has a main body 52 that becomes the split ring main body 42, a peripheral wall 67 that becomes the peripheral wall 47 of the split ring 40, and a hook 68 that becomes the plurality of hooks 48 of the split ring 40. Similar to the split ring main body 42, the main body 52 has a front end face 53f, a rear end face 53b, a pair of side end faces 53s, a gas path side face 55p, and an anti-gas path side face 55a. The front end face 53f and the rear end face 53b are in a back-to-back relationship with each other. The pair of side end faces 53s are in a back-to-back relationship with each other. The gas path side face 55p and the anti-gas path side face 55a are in a back-to-back relationship with each other. The gas path side face 55p and the anti-gas path side face 55a extend in a direction having a directional component perpendicular to the direction in which the front end face 53f extends, the direction in which the rear end face 53b extends, and the direction in which the pair of side end faces 53s extend. The pair of side end surfaces 53s both connect the front end surface 53f and the rear end surface 53b, and connect the gas path side surface 55p and the anti-gas path side surface 55a.

[0052] The main body 52 of the stacked molding 50 further has a plurality of internal passages 56 and a plurality of exhaust passages 66. The internal passage 56 extends in a direction having a directional component perpendicular to the bottom plate P (in other words, in the up-down direction). The internal passage 56 forms the cooling air passage 46 of the split ring 40. Therefore, the internal passage 56 has a sub-internal passage 56a that becomes the introduction passage 46a of the cooling air passage 46 and a main internal passage 56b that becomes the main passage 46b of the cooling air passage 46. The sub-internal passage 56a extends from the position of the boundary between the anti-gas passage side surface 55a of the main body 52 and the front wall portion 67f in the peripheral wall portion 67 so as to gradually move toward the gas passage side surface 55p as it moves toward the front end surface 53f. The sub-internal passage 56a has an anti-gas passage side opening 56ao that opens at the boundary between the anti-gas passage side surface 55a of the main body 52 and the front wall portion 67f. The anti-gas passage side opening 56ao constitutes the air inlet 46i of the cooling air passage 46. The main internal passage 56b extends from the front end face 53f of the stacked object 50 to the rear end face 53b. The main internal passage 56b has a front opening 56bf opened on the front end face 53f of the stacked object 50 and a rear opening 56bb opened on the rear end face 53b of the stacked object 50. The main internal passage 56b is connected to the auxiliary internal passage 56a at the end of the auxiliary internal passage 56a on the side of the front end face 53f and the end of the side of the gas path 55p. In the surface defining the main internal passage 56b, the part on the side of the gas path 55p is formed to repeat the concave and convex in the direction in which the main internal passage 56b extends. That is, a spoiler 57 is formed on the surface defining the main internal passage 56b.

[0053] The rear end surface 53b of the main body 52 constitutes a base-facing surface 83 that is opposed to the bottom plate P. Furthermore, the front end surface 53f of the main body 52 constitutes a base-opposite surface 84 and an introduction opening surface 85 in which a front opening 56bf of the main internal passage 56b is formed. Furthermore, the front opening 56bf of the main internal passage 56b constitutes an introduction opening 56io.

[0054] Among the plurality of discharge passages 66, a portion of the plurality of discharge passages 66 constitutes a first discharge passage 66a, and another portion of the discharge passages 66 constitutes a second discharge passage 66b. Figure 6 to Figure 8 As shown, the first exhaust passage 66a and the second exhaust passage 66b are both connected to the internal passage 56 at the end close to the bottom plate in the internal passage 56, and extend along the bottom plate P. Here, the end close to the bottom plate in the internal passage 56 is a portion from the end closest to the bottom plate P in the internal passage 56 to a distance of, for example, 1 / 10 of the total length of the internal passage 56.

[0055] The first exhaust passages 66a are connected to the inner passage 56 at the end closest to the bottom plate P in one of the inner passages 56. The first exhaust passage 66a is a groove that is recessed upward from the base facing surface 83 and extends from the communicating position with the inner passage 56 to the gas passage side surface 55p and the rear reverse gas passage side surface 55ab, which is the surface of the rear wall portion 67b and the surface on the reverse gas passage side. In other words, the first exhaust passage 66a is a groove that is recessed upward from the base facing surface 83 and extends from the gas passage side surface 55p to the rear reverse gas passage side surface 55ab of the rear wall portion 67b, and is connected to the inner passage 56 midway. The first exhaust passage 66a has a first exhaust opening 66ao as an exhaust opening 66o, and the first exhaust opening 66ao is opened on the gas passage side surface 55p and the rear reverse gas passage side surface 55ab. Therefore, the gas path side surface 55 p and the rear anti-gas path side surface 55 ab both constitute the first discharge opening surface 86 a as the discharge opening surface 86 .

[0056] The second discharge passage 66b is connected to all the internal passages 56 at a position closer to the end of the bottom plate in the internal passage 56 and closer to the front end surface 53f (base facing surface 83) than the communication position between the first discharge passage 66a and the internal passage 56. The second discharge passage 66b extends from one side end surface 53s of a pair of side end surfaces 53s to the other side end surface 53s, and is connected to all the internal passages 56 in the middle. Therefore, the second discharge passage 66b is connected to each of the plurality of first discharge passages 66a. And, the second discharge passage 66b extends in a direction different from that of the first discharge passage 66a. The second discharge passage 66b has a second discharge opening 66bo as a discharge opening 66o, and the second discharge opening 66bo is opened on a pair of side end surfaces 53s in the main body 52. ​​Therefore, the pair of side end surfaces 53s of the main body 52 each constitute a second discharge opening surface 86b as a discharge opening surface 86.

[0057] In the PBF method, when forming a stacked molded object 50 having an internal passage 56, the metal powder sprayed in the process of forming a plurality of metal solidification layers at a position higher than the first metal solidification layer reaches the internal passage forming portion in the first metal solidification layer, and the metal powder remains in the internal passage forming portion. In particular, as in the present embodiment, a spoiler 57 is formed on the surface defining the internal passage 56, and since there are concave and convex portions on the surface, the metal powder is easily retained in the concave portion. The metal powder is unnecessary metal powder. Therefore, in the present embodiment, when the molded object forming step S1 is completed, a powder removal step S2 is performed to remove the unnecessary metal powder, i.e., the residual powder, remaining in the internal passage 56.

[0058] In the powder removal step S2, as Fig. 9 As shown, a fluid is introduced into the internal passage 56 from the introduction opening 56io, which is the front opening 56bf of the internal passage 56, so that the residual powder in the internal passage 56 is discharged from the two first discharge openings 66ao of the first discharge passage 66a and the two second discharge openings 66bo of the second discharge passage 66b together with the fluid. Here, as the fluid introduced to discharge the residual powder, in addition to gases such as air or nitrogen, it can also be a liquid such as water. In addition, as a method for introducing and discharging the fluid, a method of spraying gas or liquid into the internal passage in the air, a method of spraying gas or liquid into the internal passage in a state where the stacked molding is immersed in the liquid, a method based on sucking the fluid introduced from the internal passage from the discharge passage, etc. can be cited. In addition, in addition to the case where the fluid is introduced from the internal passage, it can also be the case where it is introduced from the discharge passage.

[0059] like Fig.10As shown in FIG. 1 , when the powder removal step S2 is completed, the front opening 56bf of the internal passage 56 is closed (opening closing step S3). In the opening closing step S3, the introduction opening 56io as the front opening 56bf is closed with a cover 91 made of a nickel-based alloy which is the same metal as the metal forming the stacked molded object 50, and the cover 91 is welded to the stacked molded object 50.

[0060] Internal stress may be generated in the stacked structure 50 on the bottom plate P. If the stacked structure 50 is separated from the bottom plate P in a state where the internal stress is generated, the stacked structure 50 may be deformed. In addition, for components exposed to high-temperature combustion gas such as the turbine component of the present embodiment, it is required to extend the high-temperature creep life. Therefore, in the present embodiment, after the powder removal step S2, in order to reduce the internal stress generated in the stacked structure 50 and extend the high-temperature creep life, the stacked structure 50 on the bottom plate P is heated to perform heat treatment on the stacked structure 50 (heat treatment step S4).

[0061] In the heat treatment step S4, the stacked object 50 is heated to a temperature of about 1000° C. for example, over several hours. The heat treatment time and heating temperature are appropriately set according to the component amount of the metal element constituting the stacked object 50. In the heat treatment step S4, the stacked object 50 is heated to a temperature of about 1000° C., so if unnecessary metal powder remains in the internal passage 56 of the stacked object 50, the metal powder may melt and adhere to the inner surface of the internal passage 56. Therefore, the heat treatment step S4 needs to be performed after the opening closing step S3.

[0062] When the heat treatment step S4 is completed, the stacked shaped object 50 is separated from the base plate P (plate separation step S5 ).

[0063] When the plate separation step S5 is completed, various processes are applied to the stacked molded object 50 separated from the bottom plate P, thereby completing the split ring 40 as a turbine assembly (finishing step S6).

[0064] The various processes performed in the finishing process S6 vary depending on the type of turbine assembly, but in this embodiment, machining, thermal insulation coating 49 formation, and passage cleaning are performed in the finishing process S6. In other words, machining process S7, thermal insulation coating formation process S8, and passage cleaning process S9 are performed in the finishing process S6.

[0065] In the machining step S7, the stacked object 50 is subjected to machining to finish the outer surface of the stacked object 50. Through this machining process, the base material 41 of the split ring 40 is completed. In this machining process, the discharge passage forming portion removing step S7a is performed to remove the portion including the base facing surface 83, the first discharge passage 66a, and the second discharge passage 66b in the stacked object 50. By performing the discharge passage forming portion removing step S7a, as shown in FIG. Fig.11 As shown, the rear end surface 43 b in the base material 41 of the split ring 40 is completed, and the air outlet 46 o of the cooling air passage 46 opened on the rear end surface 43 b of the base material 41 is completed.

[0066] In the heat-insulating coating forming step S8, the heat-insulating coating 49 is formed on a portion of the surface of the base material 41 of the split ring 40 completed in the machining step S7. Figure 3 and Figure 4 As shown in the figure, a heat-insulating coating 49 is formed on the gas path side surface 45p, the front end surface 43f, the rear end surface 43b, and the pair of side end surfaces 43s of the split ring body 42 which is a part of the base material 41. When forming the heat-insulating coating 49, first, a metal powder such as CoNiCrAlY is sprayed on the surface of the base material 41 to form a bonding coating on the surface of the base material 41. Then, a ZrO2-based ceramic powder is sprayed on the bonding coating to form a top coating on the bonding coating.

[0067] As described above, in the thermal insulation coating forming step S8, since metal powder or ceramic powder is used, these powders enter the cooling air passage 46 from the air outlet 46o of the cooling air passage 46. Therefore, in this embodiment, after the thermal insulation coating forming step S8, the passage cleaning step S9 of removing the powders entering the cooling air passage 46 is performed.

[0068] In the above, the split ring 40 as a turbine assembly is completed. In addition, if necessary, an accessory mounting step of mounting accessories on the base material 41 may be added after the machining step S7.

[0069] As described above, in the present embodiment, the powder removal step S2 is performed after the molded object forming step S1 and before the heat treatment step S4, so that it is possible to remove unnecessary metal powder, that is, residual powder, remaining in the internal passage 56 of the stacked molded object 50. In addition, in the present embodiment, a plurality of discharge passages 66 communicating with the internal passage 56 are formed, so that the residual powder in the internal passage 56 can be effectively discharged. In addition, in the present embodiment, the first discharge passage 66a and the second discharge passage 66b extend in directions different from each other and communicate with each other, so from this point of view, the residual powder in the internal passage 56 can also be effectively discharged.

[0070] Furthermore, in the present embodiment, an inlet opening 56io and a discharge opening 66o are formed on the outer surfaces of the stacked molded object 50 except for the outer surface opposite to the bottom plate P, that is, the base opposite surface 83. The inlet opening 56io introduces fluid into the internal passage 56 in the powder removal process S2, and the discharge opening 66o discharges the residual powder together with the fluid in the powder removal process S2, so it is not necessary to process the bottom plate P when removing the powder. Therefore, in the present embodiment, the bottom plate P can be reused, and the manufacturing cost of the turbine assembly can be suppressed.

[0071] Furthermore, in the present embodiment, since the exhaust passage forming portion removing step S7 a is performed, it is possible to manufacture a turbine assembly without the exhaust passage 66 .

[0072] "Variation"

[0073] In any of the above embodiments, the discharge passage 66 has two openings. However, the discharge passage 66 may have only one opening.

[0074] The above embodiment includes the first discharge passage 66a and the second discharge passage 66b as the discharge passage 66. However, only one of the first discharge passage 66a and the second discharge passage 66b may be provided.

[0075] In the above embodiment, the main internal passage 56b formed in the molding forming step S1 has a front opening 56bf opened on the front end surface 53f which is the opposite surface 84 of the base. However, the main internal passage 56b formed in the molding forming step S1 may not have the front opening 56bf. In this case, the reverse gas path side opening 56ao of the auxiliary internal passage 56a connected to the main internal passage 56b is set as an introduction opening, and in the powder removal step S2, gas is introduced into the internal passage 56 from the introduction opening. Therefore, in this case, the reverse gas path side opening 56ao of the auxiliary internal passage 56a constitutes not only the air inlet 46i of the cooling air passage 46, but also the introduction opening.

[0076] In the above embodiment, in the finishing step S6, the discharge passage forming portion removal step S7a is performed to remove the portion including the base facing surface 83, the first discharge passage 66a and the second discharge passage 66b in the stacked molded object 50. However, the discharge passage forming portion removal step S7a may be omitted, and the first discharge passage 66a and the second discharge passage 66b may be retained on the split ring 40 as a finished product. In this case, the discharge opening closing step S3a (refer to FIG. 2 ) may be performed to close the first discharge opening 66ao of the first discharge passage 66a and the second discharge opening 66bo of the second discharge passage 66b after the powder removal step S2. Figure 5). In the discharge opening sealing step S3a, as Fig.12 As shown, the first discharge opening 66ao is closed by a cover 92 made of a nickel-based alloy which is the same metal as the metal forming the stacked molded object 50, and the cover 92 is welded to the stacked molded object 50. Fig.13 As shown, the second discharge opening 66bo is closed by a cover 93 made of a nickel-based alloy which is the same metal as the metal forming the stacked molded object 50, and the cover 93 is welded to the stacked molded object 50. In addition, here, both the first discharge opening 66ao and the second discharge opening 66bo are closed, but only one of the openings, for example, the second discharge opening 66bo, may be closed.

[0077] Furthermore, the discharge opening closing step S3a and the opening closing step S3 described above are performed after the powder removing step S2, but may also be performed after the heat treatment step S4 or the plate separating step S5. For example, the discharge opening closing step S3a and the opening closing step S3 described above may also be performed as one of the steps in the finishing step S6. However, when welding is performed in the discharge opening closing step S3a and the opening closing step S3, it is preferably performed before the heat treatment step S4.

[0078] The turbine component of the above embodiment is the split ring 40 of the gas turbine 1. However, as long as it is a component having an internal passage 56, other gas turbine high temperature components of the gas turbine 1 can be manufactured by the method described above. As such other gas turbine high temperature components, there are components of a combustor, fixed blades of a turbine, rotating blades of a turbine, etc. as described above. Moreover, the turbine component is not limited to the component of the gas turbine 1, and as long as it has an internal passage, it can be a component of a steam turbine, for example.

[0079] The present invention is not limited to the above-described embodiments and modifications, and various additions, changes, substitutions, partial deletions, etc. are possible without departing from the conceptual idea and spirit of the present invention derived from the contents specified in the claims and their equivalents.

[0080] "P.S."

[0081] The method for manufacturing the turbine assembly in the above-mentioned embodiment and the modified example can be understood, for example, as follows.

[0082] (1) The manufacturing method of the turbine assembly in the first aspect performs the following steps:

[0083] The object forming step S1 is to arrange metal powder on the base plate P and combine and solidify the metal powder to form a stacked object 50, wherein the stacked object 50 has multiple outer surfaces, an internal passage 56 existing in the multiple outer surfaces, and an exhaust passage 66 connected to the internal passage 56; the powder removing step S2 is to remove unnecessary metal powder, i.e. residual powder, remaining in the internal passage 56; the heat treatment step S4 is to heat the stacked object 50 on the base plate P after the powder removing step S2 to perform heat treatment on the stacked object 50; the plate separation step S5 is to separate the stacked object 50 from the base plate P after the heat treatment step S4; and the finishing step S6 is to use the stacked object 50 separated from the base plate P to complete the turbine assembly. The internal passage 56 of the stacked object 50 formed in the object forming step S1 has an introduction opening 56io, which opens on an introduction opening surface 85 that is one of the outer surfaces other than the base facing surface 83, which is the outer surface facing the bottom plate P, among the plurality of outer surfaces. The discharge passage 66 of the stacked object 50 formed in the object forming step S1 has a discharge opening 66o, which opens on a discharge opening surface 86 that is at least one of the outer surfaces other than the base facing surface 83, among the plurality of outer surfaces. In the powder removing step S2, a fluid is introduced into the internal passage 56 from the introduction opening 56io of the internal passage 56, so that the residual powder in the internal passage 56 is discharged from the discharge opening 66o of the discharge passage 66 together with the fluid.

[0084] In this embodiment, the powder removal step S2 is performed after the molding forming step S1 and before the heat treatment step S4, so that the unnecessary metal powder, that is, the residual powder, remaining in the internal passage 56 of the stacked molding 50 can be removed. In addition, in this embodiment, the outer surface of the stacked molding 50, except for the outer surface facing the bottom plate P, that is, the base facing surface 83, is formed with an introduction opening 56io and a discharge opening 66o. The introduction opening 56io introduces a fluid such as gas into the internal passage 56 in the powder removal step S2, and the discharge opening 66o discharges the residual powder together with the fluid in the powder removal step S2, so that the bottom plate P does not need to be processed when removing the powder. Therefore, in this embodiment, the bottom plate P can be reused, and the manufacturing cost of the turbine assembly can be suppressed.

[0085] (2) A method for manufacturing a turbine assembly according to a second aspect In the method for manufacturing a turbine assembly according to the first aspect,

[0086] The discharge passage 66 has discharge openings 66 o opened in two outer surfaces other than the base facing surface 83 among the plurality of outer surfaces, and the two outer surfaces both constitute the discharge opening surface 86 .

[0087] In this embodiment, since the discharge passage 66 has two discharge openings 66 o , the residual powder in the internal passage 56 can be efficiently discharged to the outside of the internal passage 56 .

[0088] (3) A method for manufacturing a turbine assembly according to a third aspect In the method for manufacturing a turbine assembly according to the first aspect or the second aspect,

[0089] In the molded object forming step S1 , a plurality of the discharge passages 66 communicating with the internal passage 56 are formed.

[0090] In this embodiment, a plurality of discharge passages 66 communicating with the internal passage 56 are formed, so that the residual powder in the internal passage 56 can be efficiently discharged to the outside of the internal passage 56 .

[0091] (4) A method for manufacturing a turbine assembly according to a fourth aspect is the method for manufacturing a turbine assembly according to the third aspect,

[0092] Among the plurality of discharge passages 66 , the first discharge passage 66 a and the second discharge passage 66 b extend in directions intersecting each other, and communicate with each other.

[0093] Compared with a case where the first discharge passage 66 a and the second discharge passage 66 b extend in the same direction as each other, the residual powder in the internal passage 56 can be efficiently discharged to the outside of the internal passage 56 .

[0094] (5) A method for manufacturing a turbine assembly according to a fifth aspect In the method for manufacturing a turbine assembly according to any one of the first to fourth aspects,

[0095] At least a portion of the surface defining the internal passage 56 is formed so as to repeat projections and depressions in the direction in which the internal passage 56 extends.

[0096] If there are irregularities on the surface defining the internal passage 56, residual powder is likely to accumulate in the irregularities. Therefore, if there are irregularities on the surface defining the internal passage 56, it is preferable that the powder removal step S2 is always performed as in the present embodiment.

[0097] (6) A method for manufacturing a turbine assembly according to a sixth aspect is the method for manufacturing a turbine assembly according to any one of the first to fifth aspects, wherein:

[0098] The internal passage 56 includes a main internal passage 56b and a secondary internal passage 56a, the main internal passage 56b including the introduction opening 56io opened on the base opposite surface 84 in a back-to-back relationship with the base opposite surface 83, and the secondary internal passage 56a opened on the outer surface other than the base opposite surface 83 and the base opposite surface 84 among the plurality of outer surfaces and communicated with the main internal passage 56b. After any one of the powder removal step S2, the heat treatment step S4, and the plate separation step S5, an opening closing step S3 of closing the introduction opening 56io opened on the base opposite surface 84 of the main internal passage 56b is performed.

[0099] In this embodiment, the introduction opening 56io is closed after the opening closing step S3. Therefore, in this embodiment, a turbine assembly having no introduction opening 56io on the opposite-to-base surface 84 can be manufactured.

[0100] (7) A method for manufacturing a turbine assembly according to a seventh aspect is the method for manufacturing a turbine assembly according to any one of the first to sixth aspects, wherein:

[0101] The internal passage 56 extends in a direction having a directional component perpendicular to the bottom plate P. The exhaust passage 66 extends in a direction having a directional component parallel to the bottom plate P.

[0102] (8) A method for manufacturing a turbine assembly according to an eighth aspect is characterized in that in the method for manufacturing a turbine assembly according to the seventh aspect,

[0103] The exhaust passage 66 communicates with the internal passage 56 at an end portion of the internal passage 56 close to the bottom plate, and extends along the bottom plate P.

[0104] (9) A method for manufacturing a turbine assembly according to a ninth aspect is characterized in that in the method for manufacturing a turbine assembly according to the eighth aspect,

[0105] The discharge passage 66 is a groove that is recessed upward from the base facing surface 83 and extends from a position communicating with the internal passage 56 to the discharge opening surface 86 .

[0106] (10) A method for manufacturing a turbine assembly according to a tenth aspect is characterized in that in the method for manufacturing a turbine assembly according to the eighth aspect,

[0107] The discharge passage 66 extends from a portion of the stacked structure 50 that is close to the bottom plate and above the base facing surface 83 , from a position communicating with the internal passage 56 to the discharge opening surface 86 .

[0108] (11) A method for manufacturing a turbine assembly according to an eleventh aspect comprises the method for manufacturing a turbine assembly according to the eighth aspect,

[0109] The discharge passage 66 includes a first discharge passage 66a and a second discharge passage 66b. The first discharge passage 66a is a groove that communicates with the internal passage 56 at the end of the internal passage 56 on the bottom plate P side, is recessed upward from the base facing surface 83, and extends from a communication position with the internal passage 56 to a first discharge opening surface 86a as the discharge opening surface 86. The second discharge passage 66b communicates with the internal passage 56 at a portion of the internal passage 56 close to the bottom plate P and from a position on the bottom plate P above the first discharge passage 66a, and extends from a communication position with the internal passage 56 to a second discharge opening surface 86b as the discharge opening surface 86. The second discharge opening surface 86b is a surface other than the base facing surface 83 and the first discharge opening surface 86a among the plurality of outer surfaces. The first discharge opening surface 86a and the second discharge opening surface 86b are both outer surfaces connected to the edge of the base facing surface 83 among the plurality of outer surfaces.

[0110] In this embodiment, a plurality of discharge passages 66 are formed to communicate with the internal passage 56, so that the residual powder in the internal passage 56 can be effectively discharged to the outside of the internal passage 56. In addition, in this embodiment, the first discharge passage 66a and the second discharge passage 66b extend in different directions from each other and communicate with each other, so from this point of view, the residual powder in the internal passage 56 can also be effectively discharged to the outside of the internal passage 56.

[0111] (12) A method for manufacturing a turbine assembly according to a twelfth aspect is a method for manufacturing a turbine assembly according to any one of the eighth aspect to the eleventh aspect, wherein:

[0112] The finishing step S6 includes a discharge passage forming portion removing step S7 a of removing a portion including the base facing surface 83 and the discharge passage 66 from the stacked molded object 50 .

[0113] In this embodiment, a turbine assembly without the exhaust passage 66 can be manufactured.

[0114] (13) A method for manufacturing a turbine assembly according to a thirteenth aspect is a method for manufacturing a turbine assembly according to any one of the first to eleventh aspects, wherein:

[0115] After any one of the powder removing step S2 , the heat treatment step S4 , and the plate separating step S5 , a discharge opening closing step S3 a of closing the discharge opening 66 o of the discharge passage 66 is performed.

[0116] In this embodiment, it is possible to manufacture a turbine assembly in which the discharge passage 66 does not function as the discharge passage 66 even if the discharge passage 66 remains.

[0117] (14) A method for manufacturing a turbine assembly according to a fourteenth aspect is a method for manufacturing a turbine assembly according to any one of the first to thirteenth aspects, wherein:

[0118] The finishing step S6 includes a heat-insulating coating forming step S8 , in which a heat-insulating coating 49 is formed on at least a portion of the plurality of outer surfaces of the stacked structure 50 .

[0119] Industrial Applicability

[0120] According to one aspect of the present invention, it is possible to reduce the manufacturing cost of the turbine assembly while removing the residual powder in the internal passage.

[0121] Explanation of symbols

[0122] 1-gas turbine, 2-gas turbine rotor, 5-gas turbine housing, 6-intermediate housing, 10-compressor, 11-compressor rotor, 12-rotor shaft, 13-rotating blade row, 15-compressor housing, 18-fixed blade row, 20-combustor, 21-combustion furnace, 22-tail tube (or combustion tube), 30-turbine, 31-turbine rotor, 32-rotor shaft, 33-rotating blade row, 35-turbine housing, 36-turbine housing body, 38-fixed blade row, 39-combustion gas flow path, 40-dividing ring , 41-base material, 42-splitting ring body, 43f-front end face, 43b-rear end face, 43s-side end face, 45p-gas path side, 45a-reverse gas path side, 46-cooling air passage, 46i-air inlet, 46o-air outlet, 46a-introduction passage, 46b-main passage, 47-peripheral wall, 47f-front wall, 47b-rear wall, 47s-side wall, 48-hook, 49-insulation coating, 50-stacked molding, 52-main body, 53f-front end face, 53b-rear end face, 53s-side end surface, 55p-gas path side, 55a-reverse gas path side, 55ab-rear reverse gas path side, 56-internal passage, 56a-secondary internal passage, 56ao-reverse gas path side opening, 56b-main internal passage, 56bf-front opening, 56io-introduction opening, 56bb-rear opening, 57-turbulator, 66-exhaust passage, 66o-exhaust opening, 66a-first exhaust passage, 66ao-first exhaust opening, 66b-second exhaust passage, 66bo-second exhaust opening, 67-peripheral wall, 67 f-front wall portion, 68-hook portion, 83-base opposite surface, 84-base opposite surface, 85-inlet opening surface, 86-discharge opening surface, 86a-first discharge opening surface, 86b-second discharge opening surface, 91, 92, 93-cover, A-external air, Acom-compressed air, G-combustion gas, F-fuel, P-bottom plate, Ar-axis line, Da-axis line direction, Dau-axis line upstream side, Dad-axis line downstream side, Dc-circumferential direction, Dr-radial direction, Dri-radial inner side, Dro-radial outer side.

Claims

1. A method for manufacturing a turbine assembly, comprising: a molding forming step of arranging metal powder on a base plate and combining and solidifying the metal powder to form a laminated molding, wherein the laminated molding has a plurality of outer surfaces, an inner passage existing in the plurality of outer surfaces, and a discharge passage communicating with the inner passage; a powder removing step of removing unnecessary metal powder, i.e. residual powder, remaining in the internal passage; a heat treatment step, after the powder removal step, heating the stacked shaped object on the base plate to perform heat treatment on the stacked shaped object; a plate separation step of separating the stacked molding from the base plate after the heat treatment step; and A finishing step is to complete the turbine assembly using the stacked molding separated from the base plate, The internal passage of the stacked object formed in the object forming step has an introduction opening, and the introduction opening is opened on an introduction opening surface of one of the plurality of outer surfaces other than the outer surface opposing the bottom plate, i.e., the base opposing surface, The discharge passage of the stacked object formed in the object forming step has a discharge opening, and the discharge opening is opened on at least one discharge opening surface of the plurality of outer surfaces other than the base-opposing surface. In the powder removal step, a fluid is introduced into the internal passage from the introduction opening of the internal passage so that the residual powder in the internal passage is discharged from the discharge opening of the discharge passage together with the fluid.

2. The method for manufacturing a turbine assembly according to claim 1, wherein: The discharge passage has discharge openings that open respectively on two outer surfaces other than the base-facing surface among the plurality of outer surfaces, and the two outer surfaces both constitute the discharge opening surface.

3. The method for manufacturing a turbine assembly according to claim 1, wherein: In the molded object forming step, a plurality of the discharge passages communicating with the internal passage are formed.

4. The method for manufacturing a turbine assembly according to claim 3, wherein: Among the plurality of exhaust passages, a first exhaust passage and a second exhaust passage extend in directions different from each other and communicate with each other.

5. The method for manufacturing a turbine assembly according to any one of claims 1 to 4, wherein: At least a portion of a surface defining the internal passage is formed to repeat projections and depressions in a direction in which the internal passage extends.

6. The method for manufacturing a turbine component according to any one of claims 1 to 4, wherein: The internal passage includes a main internal passage and a secondary internal passage, the main internal passage includes the introduction opening opened on the base opposite surface in a back-to-back relationship with the base opposite surface, and the secondary internal passage opens on an outer surface other than the base opposite surface and the base opposite surface among the plurality of outer surfaces and communicates with the main internal passage, After any one of the powder removing step, the heat treatment step, and the plate separating step, an opening closing step of closing the introduction opening opened on the opposite surface of the base of the main internal passage is performed.

7. The method for manufacturing a turbine component according to any one of claims 1 to 4, wherein: The internal passage extends in a direction having a directional component perpendicular to the bottom plate, The exhaust passage extends in a direction having a directional component parallel to the bottom plate.

8. The method for manufacturing a turbine assembly according to claim 7, wherein: The exhaust passage communicates with the internal passage at an end portion of the internal passage close to the bottom plate, and extends along the bottom plate.

9. The method for manufacturing a turbine assembly according to claim 8, wherein: The discharge passage is a groove that is recessed upward from the base-opposing surface and extends from a position communicating with the internal passage to the discharge opening surface.

10. The method for manufacturing a turbine assembly according to claim 8, wherein: The discharge passage extends from a communicating position with the internal passage to the discharge opening surface at a portion of the stacked structure that is close to the bottom plate and above the base-facing surface.

11. The method for manufacturing a turbine assembly according to claim 8, wherein: The exhaust passage has a first exhaust passage and a second exhaust passage, The first discharge passage is a groove that communicates with the internal passage at an end portion of the internal passage on the bottom plate side, is recessed upward from the base-opposing surface, and extends from a communication position with the internal passage to a first discharge opening surface that is the discharge opening surface. The second discharge passage is connected to the internal passage at a portion of the internal passage close to the bottom plate and at a position above the bottom plate relative to the first discharge passage, and extends from the connection position with the internal passage to a second discharge opening surface serving as the discharge opening surface. The second discharge opening surface is a surface of the plurality of outer surfaces excluding the base-facing surface and the first discharge opening surface. The first discharge opening surface and the second discharge opening surface are both outer surfaces connected to the edge of the base facing surface among the plurality of outer surfaces.

12. The method for manufacturing a turbine assembly according to claim 8, wherein: The finishing step includes a discharge passage forming portion removing step of removing a portion including the base facing surface and the discharge passage in the stacked molded object.

13. The method for manufacturing a turbine assembly according to any one of claims 1 to 4, wherein: After any one of the powder removing step, the heat treatment step, and the plate separating step, a discharge opening closing step of closing the discharge opening of the discharge passage is performed.

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