METHOD OF MANUFACTURING A COMPONENT FOR AEROSPACE OR POWER GENERATION APPLICATIONS

Description

DESCRIPTION of the patent for Industrial Invention from the title: “ YMETHODPRODUCING UNCOMPONENTPER APPLICATIONS AEROSPACE DIGENERA ZIONEENERGY ” of MYPARTME CC ANICAS . R . L . of Italian nationality gives : VIALEANTONIOGRAMSCI , 8 5 8 3 0 2 5 MONTORO ( AV ) Inventors : RU SS OM at ss imo XX XXX Cock. SE TT TECHNICAL The present 1invention relates to a method of manufacturing of a component for aerospace applications or of power generation, and the component manufactured with such method . Specifically, the present invention relates to a method of manufacturing a component per turbine and / or compressors and / or afterburners comprising a process of lost-wax casting (also called “investment casting”). A use of such components can be for parts of aircraft or parts of power plants, such as gas turbines or hydroelectric. STATE OF THE ART The standard production methods of components that include a lost wax casting process and provide for the creation of a wax model of the component that is wants to achieve. Consequently, the model of the component to be made has one or more portions or 1 external, and preferably internal, intergeometry desired component to be made. As is known, the lost wax casting process is a particular type of precision foundry process that allows to obtain metal alloy components high precision, which only in some cases require reworks. This wax model is made by injecting the wax in a mold that has the geometry of the component desired. To obtain this mold you need from three to six months. After the wax has been injected into the mold you get the wax component that will be mounted, together to others, through wax connecting elements also called continuators to make liquid metal flow in the next five phases, in a central element of shape cylindrical or truncated conical also called a pouring channel form a cluster. Furthermore, at the upper end of the There is a pouring cup in the pouring channel. The cluster so constituted by one or more models of the component in meltable material via neusatone ll and on cc and ss ivefasidel lost wax casting process to achieve plurality of components contained in the cluster. In other words, a cluster comprises a plurality of same or different component models connected to each other cylindrical or truncated conical shaped casting channel and / or the pouring cup of the bunch itself. In case, you want to modify the geometry of one or more components, it is necessary to make a change on the relative mold. The modification of the mold is also necessary, if, it is noticed that the wax model of the component presents dimensional changes different from those estimated at the design stage following cooling of the same and subsequently to the injection into the mould. However, changing the mold takes at least a month. Consequently, from the first design of the component Its final realization takes a very long time between 7 and 9 months and any further changes will result significant costs and times. Furthermore, when the designer design 1l component, especially when designing the dimensions and external and / or internal geometry of the component, must take into account the mold manufacturing constraints, of the model and the cluster in meltable wax material or wax-like. As a result, the component's performance and of the turbine that could potentially be obtained are limited by the aforementioned feasibility constraints above mentioned. SUMMARY OF THE INVENTION An object of the present invention is to to create a method of producing components for aerospace or power generation applications, in particular rotor or stator components for turbines and / or compressors and / or afterburners according to any of claims 1 to 13. Thanks to the present invention, a reduction of production times which represents a factor crucial to increase your competitiveness and your positioning in commercial and geopolitical scenarios. Furthermore, thanks to this invention it is possible produce components with internal and / or external geometries complex and consequently obtain turbines and / or high-performance compressors and / or afterburners. Thanks to this invention there are fewer constraints when designing the component and 11 cluster, in particular pouring channel, pouring cup and elements I say the bond. Furthermore, there are no binding bonds realizability on the internal and / or external geometry of the component to be made. Furthermore, thanks to this invention it is possible reiterate the design of the product quickly and easily external and / or internal geometry of the component and / or model of the component and / or cluster numerous times on the basis of the tests carried out after the creation of the model of the component and / or cluster and / or component until the required specifications are obtained both in terms of measurement tolerances with respect to the project both in terms of desired performance of the component. Another object of the present invention is to provide a component for aerospace or power generation applications energy that at least reduces at least one of the drawbacks of known art. According to the present invention, a component is provided for aeronautical or power generation applications second claim 1 4 . BRIEF DESCRIPTION OF THE SIGNS Additional features and benefits of this invention are defined in the attached claims employees and will appear clear from the following description of a non-limiting example of implementation, with reference to the attached figures, in which: - Figure 1 is a schematic and simplified view of an example of a cluster comprising a plurality of component models according to a first implementation form of the method ; - Figure 2 is an exploded and simplified view of a example of a cluster comprising a plurality of models of components according to a second form of implementation of the method; and - Figure 3 is an exploded and simplified view of a example of a cluster comprising a plurality of models of components according to a third form of implementation of the method . DESCRIPTION OF THE INVENTION With reference to figure 1, a method is illustrated for the production of components for aerospace applications or of electricity generation, in particular, components for turbines and / or compressors and / or afterburners of aircraft and / or power plants such as gas turbines or hydroelectric. In particular, the present invention relates to a method of manufacturing a turbine component and / or compressors and / or afterburners comprising a process of lost-wax casting (also called “investment casting”). In a non-limiting embodiment of this invention, the said component may be one or more of the selected components in the group comprising the following components: - high and / or low pressure turbine component pressure; - component for industrial turbines; - parts or entire stators with one or more profiles; - ane ll i (in English identified as comering); - morse tt i (in English identified as clamps); - Spacer bushings (in English identified as spacer sleeves); - spheres (in English called comeballs); - bearing with ROS ends (in English called rodendbearing ) ; - bearing race (in English called bearing races) ; - fuel nozzle (in English called fuel nozzle); - swirlers (in English called swirlers); - ronde ll e (in English called washers); - engine component (in English called engine vain) ; - bearing supports (in English called bearing supports); and other static structural parts. In a preferred embodiment, the component to be producing with the said method is a component for applications space or power generation aeros, in particular, rotor and / or stator components for turbines and / or compressors and / or afterburners of aircraft and / or power plants electric, for example gas turbines and hydroelectric. Preferably, the said component is a component rotor or stator for turbines and / or compressors and / or post- burners which is produced through the object method of the patent and which includes the wax casting process lost (called “investment casting” in English). The said component has a certain geometry desired external and / or internal and the fusion process lost wax casting involves the creation of a model of the component made of meltable wax or wax-like material that It may or may not have one or more internal ceramic cores depending on of the desired external and / or internal geometry of the component to be produced. In one embodiment, the component to be produced It is a blade for aerospace or power generation applications. electrical energy, in particular rotor blades or stators for turbines and / or compressors and / or afterburners. In particular, the lost wax casting process provides for the creation of a cluster 1 in the field of meltable wax or wax-like material comprising a plurality of models 2 of the component(s) to be produced. With reference to figure 1, cluster 1 includes: a base 3, a canal dilate 4 preferably shaped cylindrical or truncated cones having a central axis A, a casting cup 5, a plurality of models 2 of the at least one component to be produced, and a plurality of elements 6a and 6b I'm talking about the bond. In particular, channel 4 is connected to the base 3 on one side and to the casting cup 5 on the opposite side. The plurality of models 2 is connected by a side of the casting cup 5 and / or the casting channel 4 via a group 6a of the plurality of connecting elements, and / or on the other side to the base 3 or to the pouring channel 4 through another group 6b of the plurality of the elements of connection 6a and 6b. In a non-limiting embodiment of this invention, the plurality of models 2 of the component is connected only on one side to the casting channel 4 or to the casting cup 5. Consequently, the elements of link 6b can be omitted. Once cluster 1 is made, the fusion method lost wax casting includes the phase of cleaning the cluster 1 from the material cc e ss oe , subsequently , sandblast the 1 cluster 1. At this point, the method involves the phase of realizing of a shell, preferably of a material comprising ceramic, by immersing the bunch 1 in a mixture semi-liquid preferably comprising at least partially semi-liquid ceramic and / or powdered ceramic and / or dust ceramics . Subsequently, the debinding phase takes place in the oven to eliminate 11 material containing wax or wax-like material from the shell. Finally, the method includes the cooking phase of the shell empty ceramic material. At this point, the method involves the phase of inserting the shell in a vacuum oven and pour liquid metal inside the shell. Subsequently, after the metal has solidified, the the method includes the following steps: breaking the shell ceramic, detachment of the metal component from the cluster 1 and from the continuous elements, each one must be aturated metal component made and possible removal of smudges. With reference to figures 2 and 3, in the case where, the 2 component models include at least one core ceramic 7, at least one soul is eliminated ceramic 7 by chemical leaching or breakage. Regarding the creation of cluster 1 mentioned above, it is realized in different ways depending on which 2 component models have at least one ceramic core 7 or less, which in turn depends on the fact of having to realize of the complex internal geometries of the component. With reference to figure 1, in the case where the model 2 of the component is missing at least one core 1 0 ceramic 7 inside, the making of the cluster 1 It involves the following phases: designing a cluster 1 comprising the cast channel 4, a plurality of models 2 of the at least one component and the plurality of elements of connection 6a and / or 6b, and preferably the casting cup 5 and / or base 3, depending on one or more portions or of the entire desired external and / or internal geometry of at least one component to be made. Subsequently, the realization of cluster 1 plans to create and / or print three-dimensionally through an additive manufacturing process with the said meltable material made of wax or wax-like material 11 called grappolo 1 designed, preferably said realization and / or printing of cluster 1 including the casting channel 4, the plurality of models 2 and the connecting elements 6a and / or 6 preferably the casting cup 5 and / or the base 3 It occurs in a single phase and / or in a single piece. In this form of implementation, it is produced in a single piece 1l cluster 1 also including 1 models 2 of the component, consequently each of the plurality of 2 models of the component are made and / or printed preferably already connected on one side to the casting channel 4 and / or to the casting cup 5 through the elements of connection 6 a and 6 b, and / or preferably from the other side to base 3 through connecting elements 6a and 6b, in particular in a single piece and / or in a single phase of manufacturing and / or molding. Consequently, the plurality of models 2 of the component presents a portion or more portions or the entire geometry external, and preferably internal, desired component to be made. The cleaning phase then takes place. cluster 1 and the other subsequent phases as already indicated above. With reference to figure 2, in the case where the model 2 of the component includes at least one ceramic core 7 and, consequently, a particular internal geometry desired shape of the component to be made, the method includes the phase of designing a model 2 of the component to be make at least two pieces 2a and 2b based on the desired external and internal geometry of the component to be to realize; and to design a cluster 1 comprising the pouring channel 4 and preferably the base 3 and the cup of casting 5 depending on the component models to be made and, consequently, as a function of the external geometry and desired internal of the component to be made preferably also taking into account the connections that will be made later between the 2 component models and the casting channel 4 and / or the base 3 and / or the casting cup 5 with the plurality of component models through the 1 2 continuation elements 6a and 6b. I nunaformadia all action, 11 models ll or 2 diun component can include a plurality of souls 7 and the model 2 of the component divided into two pieces 2a and 2b. In in other words, model 2 of a component can include a plurality of souls 7 and 11 model 2 of the divided component in two pieces 2a and 2b in such a way as to allow 1 insertion of the plurality of souls 7 between the two pieces of the model 2. The alternative form for implementation, 1 additionally, 1 l A component model may include a number of cores 7 greater than two and the model 2 is divided into a number of parts greater than the number of souls 7 of a unit, for example The component model 2 can include a number of cores 7 equals four and a number of pieces of the model 2 of the component equal to five. According to one form of implementation of this invention, once the 2 models of the component have been designed and 11 cluster 1 are made separately from each other in the manner illustrated below. Subsequently, the realization of cluster 1 plans to create and / or print three-dimensionally through an additive manufacturing process with the said meltable material made of wax or wax-like material 11 called grappolo 1 designed and comprising 11 casting channels 4 and 1 3 preferably 1the casting cup 5 and / or the base 3, preferably said realization and / or printing of the bunch 1 occurs in a single phase and / or in a single piece. Subsequently they are made and / or printed three-dimensionally through a manufacturing technique additive with the said meltable material of wax or similar wax 1 models 2 of the component in at least two parts 2a and 2b s separate; each of the 7 ceramic cores is made for each model preferably with a technique of additive manufacturing; each respective one is inserted at least one ceramic core 7 between at least two parts 2a and 2b of the respective model 2; each of the at least two parts 2a and 2b between them with the respective at least inside ceramic core 7; each model 2 of the component is fixed thus achieved at cluster 1 preferably via 1 respective connecting elements 6a and 6b, in particular fix 11 casting channel 4 and / or casting cup 5 and / or base 3 of cluster 1. Consequently, the plurality of models 2 of the at least unc component present one portion or more portions or 1 external, and preferably internal, intergeometry desired of the at least component. The cleaning phase then takes place. cluster 1 and the other subsequent phases as already indicated above . In case the component model includes at least one ceramic soul 7 and, consequently, a particular desired internal geometry of the component to be manufactured, in an alternative form of implementation of this e invention, the method includes the phase of designing a model 2 of the said component material to be made in two pieces 2a and 2b based on the external geometry and / or desired internal; design a cluster 1 comprising the casting channel 2 and a plurality of one 2b of the two pieces of the aplurality of ways to bring about plurality of the connecting elements 6a and / or 6b, and preferably the casting cup 5 and / or the base 3, depending on one or more portions or of the entire external and / or internal geometry desired of at least one component. Subsequently, the method is expected to be realised print three-dimensionally through the process of additive manufacturing with 11 said castable material of wax or similar wax the said cluster 1 including the channel dicolata 4 , the plurality of one of the at least two parts of the mo de ll i 2, the connecting elements 6a and ©6b and preferably base 3 and / or casting cup 5, preferably said realization and / or printing three-dimensional occurs in a single phase and / or in a single piece. Furthermore, the method involves making a technique 1 5 of additive manufacturing a plurality of the other of the at least two parts 2a and 2b of model 2 of the component to be realize; realize 1" at least ceramic core 7 preferably with an additive manufacturing technique; interpose at least each ceramic core 7 between the part 2b of model 2 made on cluster 1 and 1the other Part 2a of model 2 made separately from the cluster 1; fix each other part 2a of each model 2 made separately from cluster 1 to part 2b of the respective model 2 made on cluster 1. The cleaning phase then takes place. cluster 1 complete and the other subsequent phases as already indicated above. In particular, 11 additive manufacturing process uses a high intensity laser which preferably produces the entire bunch in particular in less than 24 hours. In one form of implementation, the redesign of the models 2 of the component and / or cluster 1 and / or parts of the cluster 1 can be repeated iteratively until it is reaches the required performance of the component both in terms of physical products, for example, quarries or other, both in terms of component performance. In other words, once a first series of components, these are opposed to a process validation which includes both a process to verify whether 1 6 they comply with the project's technical specifications both to see if they respect the performances they offered during the simulation, in the event that one or more of these tests If the techniques are not satisfactory, cluster 1 is redesigned and / or 1 models 2 of the component and / or a portion of the cluster 1 taking into account the results of the technical tests and they repeat the technical tests until they reach the desired performance. Thanks to the ©present invention with the method illustrated above it is possible to design the entire cluster in so that the whole process is more efficient and they can geometries that would otherwise be impossible to create obtain. In one embodiment, the components produced with This method can be used in rockets. 1 7

Claims

CLAIMS 1. Method of producing by lost wax casting a component for aerospace or power generation applications, in particular a component for turbines and / or compressors and / or afterburners; the method comprises the steps of: designing a cluster (1) comprising a casting channel (4), preferably truncated conical or cylindrical having a longitudinal axis (A), as a function of one or more portions or of the entire desired external and / or internal geometry of at least one component to be produced; manufacturing and / or printing in three dimensions with an additive manufacturing process the said cluster (1) with castable material in particular comprising wax and / or wax-like material; the cluster (1) comprising the casting channel (4) of said castable material is manufactured and / or printed with the said additive manufacturing process in particular in a single piece.

2. The method of claim 1, comprising the step of designing the cluster (1) comprising the sprue (4) and a sprue cup (5) based on one or more portions or the entire desired external and / or internal geometry of the at least one component to be produced; wherein the sprue cup (5) of said material is connected to the sprue (4); wherein the sprue cup (5) is made by said additive manufacturing process with said meltable material together with the sprue (4) preferably in one piece.

3. The method of claim 1 or 2, comprising the step of designing the cluster (1) comprising the sprue (4), a plurality of connecting elements (6a and 6b), and preferably the sprue cup (5), based on one or more portions or the entire desired external and / or internal geometry of the at least one component to be produced; at least one of the plurality of connecting elements (6a, 6b) is connected to the sprue (4) and / or the sprue cup (5); wherein the plurality of connecting elements (6a and 6b) are made by the additive manufacturing process from said meltable material together with the sprue (4) and / or the sprue cup (5) in particular in one piece.

4. The method of any preceding claim, comprising the step of designing a cluster (1) comprising the sprue (4) and a base (3), and preferably the sprue cup (5) and / or the plurality of connecting elements (6a and 6b), based on one or more portions or the entire desired external and / or internal geometry of the at least one component to be produced; wherein the base (3) is connected to the sprue (4) and preferably to at least one portion (6b) of the plurality of connecting elements (6a and 6b); wherein the base (3) is made by the additive manufacturing process from said meltable material together with the sprue (4) and / or the connecting elements (6a and 6b) and / or the sprue cup (5) preferably in one piece.

5. Method of any preceding claim; the method comprises the steps of: designing a cluster (1) comprising the casting channel (4) and a plurality of templates (2) of the at least one component, and preferably the casting cup (5) and / or the plurality of connecting elements (6a and 6b) and / or the base (3), based on one or more portions or the entire desired external and / or internal geometry of the at least one component; manufacturing and / or three-dimensionally printing by additive manufacturing process said cluster (1) comprising the casting channel (4) and the plurality of templates (2), and preferably the connecting elements (6a and 6b) and / or the base (3) and / or the casting cup (5), from said castable material; wherein the plurality of models (2) of the desired at least one component are defined based on a portion or portions or entirely based on the desired external, and preferably internal, geometry of the at least component;preferably the plurality of models of the at least one component present a portion or more portions or the entire desired external, and preferably internal, geometry of the at least component; preferably wherein said models (2) are made by the additive manufacturing process from said castable material together with the casting channel (4) and / or the connecting elements (6a and 6b) and / or the casting cup (5) preferably in one piece.; 6. Method of any of the preceding claims, each of the plurality of models (2) of the at least component being connected on one side to the casting channel (4) and / or to the casting cup (5) through the connecting elements (6a; 6b), and / or on the other side to the base (2) through the connecting elements (6a; 6b).

7. Method of any of the preceding claims, wherein the component model comprises at least one ceramic core; the method comprises the step of designing a model (2) of said component material to be made in two pieces based on the desired external and internal geometry of the component; making the component model (2) in at least two parts (2a, 2b) with an additive manufacturing technique; making the at least ceramic core preferably with an additive manufacturing technique; inserting the at least ceramic core (7) between the at least two parts (2a, 2b); fixing the at least two parts (2a, 2b) together with the at least ceramic core (7) inside; fixing the component model (2) with the at least ceramic core inside the cluster (1) preferably via the connecting elements to the casting channel (4) and / or to the casting cup (5) and / or to the base (3).

8. Method of any of claims 1 to 4, wherein the model (2) of the component to be produced comprises at least one ceramic core (7); the method comprises the steps of: designing a model (2) of said material of the component to be produced in two pieces based on the desired external and internal geometry; designing a cluster (1) comprising the casting channel (4) and a plurality of one of the two pieces of the model (2) of the component to be produced, and preferably the casting cup (5) and / or the plurality of connecting elements (6a and 6b) and / or the base (3), based on one or more portions or the entire desired external and / or internal geometry of the at least one component to be produced;to produce and / or print in three dimensions with the additive manufacturing process the said cluster (1) comprising the casting channel (4) and the plurality of one of the at least two parts (2a, 2b) of the models (2), and preferably the connecting elements (6a, 6b) and / or the base (3) and / or the casting cup (5), with the said meltable material; to produce with an additive manufacturing technique a plurality of the other of the at least two parts (2a, 2b) of the model (2) of the component to be produced; to produce at least the ceramic core preferably with an additive manufacturing technique; to interpose each ceramic core between a part of the model (2) produced on the cluster (1) and the other part of the model (2) produced separately from the cluster (1); to fix each other part of the model (2) produced separately from the cluster (1) to the part of the model produced on the cluster (1);wherein the plurality of models (2) of the at least one desired component are defined based on a portion or portions or entirely based on the desired external, and preferably internal, geometry of the at least component; preferably the plurality of models (2) of the at least one component have a portion or portions or the entire desired external, and preferably internal, geometry of the at least component; preferably wherein one of the at least two parts (2a, 2b) of said models (2) are made by the additive manufacturing process from said castable material together with the casting channel (4) and / or the connecting elements (6a and 6b) and / or the casting cup (5) preferably in one piece.; 9. The method of any preceding claim, wherein the additive manufacturing process employs a high intensity laser that preferably produces the entire cluster in particular in less than 24 hours.

10. Method of any of the preceding claims, comprising the step of cleaning the cluster (1) from excess material after the additive manufacturing and / or three-dimensional molding process; and / or sandblasting the cluster (1).

11. The method of any preceding claim, comprising the step of making a shell, preferably of a material comprising ceramic, by immersing the cluster (1) in a semi-liquid slurry preferably comprising at least partially semi-liquid ceramic and / or powdered ceramic and / or ceramic powder.

12. A method according to any preceding claim, comprising one or more or all of the following steps: debinding in a furnace to remove the material comprising wax or wax-like material from the shell, preferably made of material comprising ceramic; firing the shell made of material comprising ceramic; placing the shell in a vacuum furnace and pouring the liquid metal; breaking the shell after the metal has solidified, detaching the metal component from the metal casting channel and metal follower elements, sandblasting the components and possibly removing the burrs.

13. Methods of any preceding claim, wherein said component is selected from the group comprising the following components: - high-pressure and / or low-pressure turbine component; - industrial turbine component; - stator parts or entires with one or more profiles; - rings; - clamps; - spacer sleeves; - balls; - rod end bearing; - bearing races; - fuel nozzle; - swirlers; - washers; - engine vane; - bearing supports; and - other static structural parts.

14. The method of any of the preceding claims, wherein the component is a blade for aerospace or power generation applications, in particular rotor or stator blades for turbines and / or compressors and / or afterburners.

15. Component for aerospace or power generation applications, in particular rotor and / or stator components for turbines and / or compressors and / or afterburners of aircraft and / or power plants such as gas turbines or hydroelectric power plants, made according to the method of any of claims 1 to 14.

16. Blade for aerospace or power generation applications, in particular rotor or stator blades for turbines and / or compressors and / or afterburners made according to the method of any of claims 1 to 14.

17. Turbine, in particular for aircraft, comprising a plurality of components in accordance with claim 15.

18. Turbine, in particular for aircraft, comprising a plurality of blades made in accordance with claim 16.