Linear friction welding method and product for close-coupled bladed disks
Patent Information
- Application Number
- CN202611153827.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-07-31
- Publication Date
- 2026-11-03
AI Technical Summary
In the existing technology, there is a lack of effective methods for linear friction welding of small-pitch blades and disks, which makes it impossible for the welding surface to get close to the disk surface, increasing manufacturing costs and design challenges.
By numbering the blades and welding them alternately in a manner that alternates between odd and even numbered blades, the welding surface remains unchanged. This increases the number of loading and unloading operations to achieve a reliable connection, avoiding the need to redesign the welding surface and optimize the wheel axis distance.
This achieves a reliable connection between the small-pitch blades and the rotor disk, saving manufacturing materials and processing costs, reducing the weight of the rotor disk, avoiding airflow loss at the tenon, and improving the thrust and efficiency of the aero-engine.
Smart Images
Figure CN123024982A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of blade processing technology, and in particular to the field of linear friction welding of integral bladed disks, specifically a linear friction welding method and product for small-pitch blades and disks. Background Technology
[0002] Integral bladed disks (IBDs) are the latest structural component used in high-performance aero engines. As a core component for achieving structural innovation and technological leaps in next-generation aero engines, IBDs operate under varying loads such as centrifugal force and aerodynamic forces, making them a key structure for high-efficiency, low-fuel-consumption aero engines. Linear friction welding, an advanced solid-state welding technology, has been successfully applied to the manufacturing of IBDs for aero engines due to its high quality, efficiency, and flexibility. Linear friction welding of IBDs involves aligning blades with clamping bosses of nearly the target shape with the welding surfaces of the wheel disk with bosses, and then performing linear high-frequency vibration friction welding to permanently connect the blades and the wheel disk. This eliminates the need for tenons, mortises, and locking devices used in traditional connection methods, simplifying the overall engine structure and avoiding airflow losses associated with tenons.
[0003] Existing linear friction welding sequences typically involve welding blades to the disk one by one in a clockwise / counterclockwise direction. However, in practice, the closer the welding surface is to the disk surface, the lower the overall manufacturing cost of the bladed disk. This is because a welding surface close to the disk surface minimizes the pre-weld disk diameter, thus reducing milling. However, if adjacent blade roots are very close, the welding surface cannot reach the disk surface, requiring adjustments to the axial distance between the welding surface and the disk (i.e., resetting the welding surface and optimizing the blade roots and disk bosses). This method presents significant challenges to the design of blade clamping bosses, disk bosses, clamping fixtures, and practical engineering applications. Currently, there is a lack of effective solutions for linear friction welding of small-pitch blade disks. Summary of the Invention
[0004] To address the problems in the prior art, this invention provides a linear friction welding method and product for small-pitch blades and a disk. This method can maintain the welding surface unchanged and achieve a reliable connection between the blades and the disk by increasing the number of processes (i.e., increasing the number of loading and unloading operations). It is an effective method for realizing the engineering application of linear friction welding of small-pitch blades and disks.
[0005] This invention is achieved through the following technical solution: A linear friction welding method for small-pitch blades and a disk is proposed, wherein all blades are numbered and the spacing between adjacent blades on the disk to be welded is determined to be e, and e is smaller than the spacing between adjacent blades in the conventional manner; while keeping the welding surface unchanged, all blades are welded in an alternating manner.
[0006] Preferably, the value of e is in the range of e≤15mm.
[0007] Preferably, when the total number of blades is odd, the welding method is as follows: Step 1: Number all blades; Step 2: Keeping the welding surface unchanged, weld all odd-numbered blades except the last odd-numbered blade onto the welding surface in sequence; Step 3: Weld even-numbered blades onto the welding surface; Step 4: Weld the last odd-numbered blade.
[0008] Preferably, in step 2, after welding is completed, the clamping bosses of the welded odd-numbered blades are removed.
[0009] Preferably, in step 3, after welding is completed, the clamping boss of the last even-numbered blade is removed.
[0010] Preferably, in step 4, after welding is completed, the clamping bosses of the remaining even-numbered blades are removed.
[0011] Preferably, when the total number of blades is even, the welding method is as follows: Step 1: Number all blades; Step 2: Keeping the welding surface unchanged, weld all odd-numbered blades sequentially onto the welding surface; Step 3: Weld even-numbered blades onto the welding surface.
[0012] Preferably, in step 2, after welding is completed, the clamping bosses of the welded odd-numbered blades are removed.
[0013] Preferably, in step 3, after welding is completed, the clamping bosses of the even-numbered blades that were welded are removed.
[0014] A product manufactured by the linear friction welding method of the small-pitch blades and the disk.
[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention discloses a linear friction welding method for small-pitch blades and a rotor disk. The blades can be welded by alternating the welding of odd and even numbered blades. When linearly friction welding small-pitch blades and a rotor disk, there is no need to redesign the welding surface P, nor to optimize the distance between the welding surface P and the rotor disk axis, nor to redesign the blade root and rotor disk boss. By simply increasing the number of loading and unloading operations and leaving enough space for the blades to be welded, a reliable connection between the small-pitch blades and the rotor disk can be achieved. This can save on the overall rotor disk manufacturing material and processing costs, reduce the rotor disk weight, and avoid airflow loss at the tenon, enabling the aero-engine to obtain higher thrust and efficiency. Attached Figure Description
[0016] Figure 1 This is a flowchart of a linear friction welding method for small-pitch blades and a wheel disk according to the present invention when the total number of blades is odd. Figure 2 This is a flowchart of a linear friction welding method for small-pitch blades and a wheel disk according to the present invention when the total number of blades is even. Figure 3 This is a schematic diagram of the spacing between adjacent blades on the wheel; Figure 4 This is a schematic diagram of welding an odd number of blades when the total number of blades is odd; Figure 5 This is a schematic diagram showing the removal of the odd-numbered blade clamping boss when the total number of blades is odd. Figure 6 This is a schematic diagram of welding an even number of blades when the total number of blades is odd; Figure 7 This is a schematic diagram showing the removal of adjacent blade clamping protrusions when the total number of blades is odd. Figure 8 This is a schematic diagram of the final blades being welded when the total number of blades is odd. Figure 9 This is a schematic diagram showing the removal of even-numbered blades from the clamping boss when the total number of blades is odd. Detailed Implementation
[0017] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.
[0018] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided to fully and completely disclose the invention and to fully convey its scope to those skilled in the art. The terminology used in the exemplary embodiments illustrated in the drawings is not intended to limit the invention. In the drawings, the same units / elements are referred to by the same reference numerals.
[0019] Unless otherwise stated, the terms used herein (including technical terms) have their common meaning as understood by one of ordinary skill in the art. Furthermore, it is understood that terms defined in commonly used dictionaries should be understood to have a meaning consistent with the context of their relevant field, and not to be interpreted as having an idealized or overly formal meaning.
[0020] The present invention will be further described in detail below with reference to specific embodiments. These descriptions are for explanation purposes only and are not intended to limit the scope of the invention.
[0021] A linear friction welding method for small-pitch blades to a wheel disk is proposed. All blades are numbered, and the spacing between adjacent blades on the wheel disk to be welded is defined as 'e', where 'e' is smaller than the conventional spacing between adjacent blades. The value of 'e' is within the range of ≤15mm. Figure 1 As shown. Figure 1 In the diagram, H is the axial height of the bladed disk, P is the welding surface, O is the centroid of the welding area after welding, R is the distance from the disk segment axis to the centroid of the welding area; B is the distance from the bottom surface of the bladed disk to O, C is the chord length, R is the distance from the disk segment axis to the centroid of the welding area, α is the angle between the welding surface P and the vertical line; β is the angle between the chord direction and the vertical axis.
[0022] During welding, all blades are welded in an alternating manner while keeping the welding surface unchanged.
[0023] When the total number of blades is odd, the welding method is as follows: Step 1: Number all blades; Step 2: Keeping the welding surface unchanged, weld all odd-numbered blades except the last odd-numbered blade in sequence on the welding surface; after welding, remove the clamping bosses of the welded odd-numbered blades.
[0024] Step 3: Weld even-numbered blades on the welding surface; after welding, remove the clamping boss of the last even-numbered blade.
[0025] Step 4: Weld the last odd-numbered blade. After welding, remove the clamping bosses from the remaining even-numbered blades.
[0026] When the number of blades is odd, welding is performed in batches. Odd-numbered blades are welded first, without interference from adjacent blades. Immediately after welding, the clamping bosses are removed, freeing up space for subsequent even-numbered blades. Then, even-numbered blades are welded. Since the adjacent odd-numbered blade bosses have been removed, the clamping and welding of even-numbered blades are no longer obstructed. Finally, the last odd-numbered blade is welded. By this time, all other blades have been welded, most clamping bosses have been removed, and this blade has its own welding space, allowing for high-quality welding independently.
[0027] When the total number of leaves is even, refer to Figure 2 The welding method is as follows: Step 1: Number all blades; Step 2: Keeping the welding surface unchanged, weld all odd-numbered blades sequentially on the welding surface; after welding is completed, remove the clamping bosses of the welded odd-numbered blades.
[0028] Step 3: Weld even-numbered blades onto the welding surface. After welding, remove the clamping bosses from the welded even-numbered blades.
[0029] When the number of blades is even, all odd-numbered blades are welded at once and their bosses are removed. Then all even-numbered blades are welded and their bosses are removed at the same time. This process is simpler and more efficient than when there are odd-numbered blades.
[0030] The present invention also discloses a product manufactured by the linear friction welding method of the small-pitch blades and the disk.
[0031] Taking a welding process with 27 blades as an example, refer to... Figures 3-9 The welding method is as follows: Step 1, keep the welding surface unchanged: reduce the distance e between adjacent blades on the disk to be welded, and keep the welding surface P unchanged; Step 2, welding odd-numbered blades: Taking welding 27 blades as an example; weld one every other blade, that is, weld the 13 odd-numbered blades numbered 1, 3, 5...23, 25; then, machine remove the clamping bosses of the odd-numbered blades: remove the clamping bosses of the 13 odd-numbered blades numbered 1, 3, 5...23, 25. Step 3, Weld even-numbered blades: Weld 13 even-numbered blades, that is, weld blades numbered 2, 4, 6...24, 26, a total of 13 even-numbered blades; then, machine remove adjacent blade clamping bosses: Remove adjacent blade clamping bosses, that is, remove blade clamping boss numbered 26, a total of 1 blade clamping boss. Step 4, Weld the final blade: Weld the last blade, i.e., the blade numbered 27, which is 1 blade in total; then, remove the clamping bosses of even-numbered blades by machining: Remove the clamping bosses of 13 blades numbered 2, 4, 6...24, 26.
[0032] Taking the welding of a blade with an even number of blades as an example, weld one blade at a time, that is, weld the blades with odd numbers, remove the clamping bosses of the blades with odd numbers after welding, then weld the blades with even numbers, and remove the clamping bosses of the blades with even numbers after welding.
[0033] In summary, the linear friction welding method for small-pitch blades and disks of the present invention avoids blade collisions, weld misalignment, or clamping damage caused by forced operation by batch welding and time-sharing removal of bosses. It is a method that achieves high-quality and high-consistency linear friction welding under small-pitch conditions by increasing the number of welding batches, thereby gaining physical operating space and thermal control capabilities for each batch, while taking into account both production efficiency and quality stability.
[0034] The above description is merely a preferred embodiment of the present invention and is not intended to limit the technical solution of the present invention in any way. Those skilled in the art should understand that, without departing from the spirit and principles of the present invention, the technical solution can be modified and replaced in several simple ways, and these modifications and replacements are all within the scope of protection covered by the claims.
Claims
1. A method for linear friction welding of small-pitch blades and a wheel disk, characterized in that, Number all blades and determine the spacing e between adjacent blades on the disk to be welded, where e is less than the normal spacing between adjacent blades; while keeping the welding surface unchanged, weld all blades one at a time.
2. The linear friction welding method for small-pitch blades and a wheel disk according to claim 1, characterized in that, The value of e is in the range of e≤15mm.
3. The linear friction welding method for small-pitch blades and a wheel disk according to claim 1, characterized in that, When the total number of blades is odd, the welding method is as follows: Step 1: Number all blades; Step 2: Keeping the welding surface unchanged, weld all odd-numbered blades except the last odd-numbered blade onto the welding surface in sequence; Step 3: Weld even-numbered blades onto the welding surface; Step 4: Weld the last odd-numbered blade.
4. The linear friction welding method for small-pitch blades and a wheel disk according to claim 3, characterized in that, In step 2, after welding is completed, the clamping bosses of the welded odd-numbered blades are removed.
5. The linear friction welding method for small-pitch blades and a wheel disk according to claim 3, characterized in that, In step 3, after welding is completed, the clamping boss of the last even-numbered blade is removed.
6. The linear friction welding method for small-pitch blades and a wheel disk according to claim 3, characterized in that, In step 4, after welding is completed, the clamping bosses of the remaining even-numbered blades are removed.
7. The linear friction welding method for small-pitch blades and a wheel disk according to claim 1, characterized in that, When the total number of blades is even, the welding method is as follows: Step 1: Number all blades; Step 2: Keeping the welding surface unchanged, weld all odd-numbered blades sequentially onto the welding surface; Step 3: Weld even-numbered blades onto the welding surface.
8. The linear friction welding method for small-pitch blades and a wheel disk according to claim 7, characterized in that, In step 2, after welding is completed, the clamping bosses of the welded odd-numbered blades are removed.
9. The linear friction welding method for small-pitch blades and a wheel disk according to claim 7, characterized in that, In step 3, after welding is completed, the clamping bosses of the even-numbered blades that were welded are removed.
10. A product manufactured by the linear friction welding method for small-pitch blades and a wheel disk as described in any one of claims 1 to 9.