• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a mold (3) of ceramic material for use in molding a turbine engine blade from a molten metal, the blade comprising a foot, a platform, a blade, and a heel; the mold comprising: a cavity (4) having the shape of the blade, and an auxiliary grain line (5) comprising a first portion (51) and a second portion (52) extending the first portion, said first portion opening at one end (511) in a first portion (40) of the cavity forming the root of the blade and at another end (512) in a second portion (412) of the cavity forming a spoiler of the platform of the dawn , said second portion (52) opening at one end (521) in said second portion (412) of the cavity and at another end (522) in a third portion (432) of the cavity forming a spoiler of the heel of the dawn. The invention also relates to an installation and a manufacturing method implementing such a mold.
    公开号:FR3052088A1
    申请号:FR1655021
    申请日:2016-06-02
    公开日:2017-12-08
    发明作者:Ngadia Taha Niane；Said Boukerma；Serge Dillenseger；Julien Gelebart；David Grange；Jean-Claude Marcel Auguste Hanny；Philippe Metron
    申请人:Safran SA；SNECMA SAS；
    IPC主号:
    专利说明:

    Background rinenvention
    The present invention relates to the general field of foundry parts manufacturing processes. The invention relates more particularly to a mold for manufacturing a monocrystalline turbine engine blade by lost-wax casting.
    In some cases, and in particular in aviation turbomachines, it is necessary to have metal or metal alloy parts which have a controlled monocrystalline structure. For example, in aerospace turbine engine turbine distributors, the blades must withstand significant thermomechanical stresses due to the high temperature and the centrifugal forces to which they are subjected. A controlled monocrystalline structure in the metal alloys forming these blades makes it possible to limit the effects of these constraints.
    In order to produce a metal part of this type, processes of the lost wax casting type are known. In a manner known per se, in such a method, a wax model of the part to be manufactured is produced first, around which a ceramic shell forming a mold is formed. A molten metal is then poured into the mold, and directed solidification of the metal provides, after removal of the mold, the wet part. This method is advantageous for manufacturing metal parts of complex shapes, and allows to obtain parts having a monocrystalline structure using for example a germ or a grain selector conduit.
    The blades usually consist of a foot, a platform with spoilers, a blade, a heel provided with spoilers, and wipers. When manufacturing monocrystalline blades by a process such as that presented above, certain problems arise, due in particular to the shape of the blades.
    During the directional solidification of the molten metal present in the mold having the shape of the blade, the parts of the mold cavity forming in particular the spoilers of the platform and the heel solidify with a certain delay compared to the other parts of the mold. cavity like the one forming the blade. This delay can cause the appearance of unwanted porosities in the final part.
    In addition, it has been observed that after a heat treatment carried out after the directed solidification, the blade may present in certain places and in particular on the leading edge or the trailing edge near the platform or the heel, recrystallized parasitic grains. This is not desirable when one wishes to obtain a monocrystalline blade.
    Finally, the blades obtained can have a significant variation in size between the wax model and the final part, and can sometimes be deformed or twisted.
    There is therefore a need to have a mold for the manufacture of a turbomachine blade, and a method of manufacturing such a blade which reduces the appearance of the aforementioned defects.
    Object and summary of the invention
    The main purpose of the present invention is therefore to overcome such drawbacks by proposing a mold made of ceramic material intended to be used for molding a turbine engine blade from a molten metal, the blade comprising a foot, a platform, a blade , and a heel, the mold comprising: - a cavity having the shape of the blade, and - an auxiliary grain conduit comprising a first portion and a second portion extending the first portion, said first portion opening at an end in a first portion of the cavity forming the foot of the blade and at another end in a second portion of the cavity forming a spoiler of the platform of the blade, said second portion opening at one end in said second portion of the cavity and at another end in a third part of the cavity forming a spoiler of the heel of dawn.
    The presence of the auxiliary grain duct in the mold according to the invention makes it possible to minimize the defects introduced previously. Firstly, the auxiliary grain line makes sure that the platform and the dawn's heel do not solidify last, which reduces the appearance of porosity-like defects in these portions of the dawn .
    Then, the auxiliary grain duct plays the role of a stay that keeps the dawn and rigidifies throughout the manufacturing process.
    By maintaining it thus, the residual stresses that can remain in the blade are reduced, and the appearance of recrystallized grains after heat treatment is also reduced.
    The inventors have observed that the blade obtained with a mold according to the invention has dimensions that are closer to those desired, compared to a blade made in a mold without auxiliary grain conduit. The inventors have also observed that the blade obtained is less twisted when it is manufactured in a mold according to the invention.
    The auxiliary grain line may be positioned in front of the leading edge or the trailing edge of the blade.
    The following optional characteristics relating to the auxiliary grain duct make it possible to limit the thickness of the ceramic shell, which enables it to break more easily and thus to reduce the appearance of recrystallized grains: the first portion of the auxiliary grain duct may extend from a wall of the first portion of the cavity in a direction forming an angle between 54® and 62® with said wall, - the second portion of the auxiliary grain duct may extend from the second portion of the cavity in a direction forming an angle between 110® and 115® with said second portion; - the second portion of the auxiliary grain duct may extend from the third portion of the cavity in a direction forming at an angle between 110® and 115® with said third portion, the second portion of the auxiliary grain duct may have at least one portion having an circular portion of diameter D, said portion being spaced a distance L from the cavity, a ratio R = L / D between the distance L and the diameter D being between 15.4 and 18.9 along said portion.
    To further reduce the appearance of pores in the platform and the heel, the second portion of the auxiliary grain duct may comprise a flyweight at each of its ends. The first portion may include a counterweight at one end. The dawn may be an aerospace turbine engine turbine blade.
    To facilitate the demolding of the blade, the second portion of the auxiliary grain duct may have a necking, that is to say a local narrowing of its section, for example at the middle of said second portion. Indeed, the auxiliary grain duct can break more easily at this necking during demolding.
    The invention also relates to an installation for manufacturing a blade molded from a molten metal, comprising a mold such as that presented above, and means for obtaining monocrystalline grain connected to the mold.
    The means for obtaining monocrystalline grain may comprise a monocrystalline seed or a grain selector conduit. The invention finally relates to a method of manufacturing a single-crystal turbomachine blade, comprising the following steps: filling a mold of an installation such as that presented previously with a molten metal, and directing the solidification of the metal present in the mold so as to obtain a molded blade.
    The method may further comprise a step of heat treatment of the blade obtained. This heat treatment makes it possible to relax the residual stresses inside the molded blade which may be due in particular to the molding and solidification of the metal, in order to obtain a stable microstructure and controlled mechanical properties in the final part.
    BRIEF DESCRIPTION OF THE DRAWINGS Other features and advantages of the present invention will emerge from the description given below, with reference to the accompanying drawings which illustrate embodiments having no limiting character. In the figures: FIG. 1 is a perspective view of an installation according to the invention, FIG. 2 is a sectional view of a mold according to an embodiment of the invention, FIGS. 3 and 4 are sectional views of molds according to various embodiments of the invention, and - Figure 5 is a flowchart showing the main steps of a method of manufacturing a single crystal blade according to an embodiment of the invention.
    Detailed description of the invention
    FIG. 1 shows a plant 1 for manufacturing by casting a single-crystal aerospace turbine engine turbine blade according to the invention. The installation 1 comprises a bucket 2 through which a molten metal can be poured, the bucket 2 is configured to fill with this metal a mold 3 comprising a cavity 4 here having the shape of an aerospace turbine engine turbine blade. The mold 3 comprises, according to the invention, an auxiliary grain duct 5. The mold 4 overcomes and is connected to a grain selector duct 6 which makes it possible to obtain a monocrystalline blade after a directed solidification of the metal present in the mold 3. Note that the installation shown in Figure 1 is intended to manufacture a single blade, it is of course conceivable to have an installation for manufacturing a plurality of blades.
    FIG. 2 shows a sectional view of the cavity 4 of the mold 3 to which the auxiliary grain duct 5 is connected. It will be noted that in FIGS. 1 and 2, for greater clarity, the ceramic material wall of the installation 1 and the mold 3 has not been shown; in other words, these figures only show the internal parts of the plant 1 or the mold 3 in which a molten metal can be introduced.
    Throughout the disclosure, the terms "lower" and "upper" are defined with respect to the direction DR, the arrow of the direction DR pointing outward. The terms "upstream" and "downstream" are defined relative to the direction DA, the arrow of the direction DA pointing downstream. In other words, upstream and downstream are defined with respect to the flow direction of the gas flow around the blade when the blade is mounted in a turbomachine.
    The cavity 4 has the shape of an aerospace turbine engine turbine blade and comprises: a portion 40 forming the root of the blade, a portion 41 forming the platform of the blade, a portion 42 forming the blade of the blade and a portion 43 forming the heel of the dawn. The foot portion 40 is connected at its bottom to the grain selector conduit 6. In known manner, the blade extends longitudinally between a foot and a top. In the molded dawn, the platform is positioned on the lower end of the blade, between the foot and the pay gate, and the blade is positioned at the upper end of the blade, that is to say at the end of the blade. top of the dawn. The platform extends transversely between a downstream end, also called downstream spoiler, and an upstream end, also called upstream spoiler. The heel extends transversely between an upstream end, also called upstream spoiler, and a downstream end, also called downstream spoiler. The platform and the heel in particular have the role of defining the flow vein of the gas flow in the turbine. The blade extends longitudinally between the platform and the heel, and transversely between a leading edge and a trailing edge.
    The portion 41 of the cavity 4 forming a platform is provided with a sub-portion 411 forming a spoiler upstream of the platform, and a sub-portion 412 forming a spoiler downstream of the platform. The spoiler parts 411, 412 have a substantially planar shape and extend substantially in the direction DA.
    The portion 43 of the cavity 4 forming a heel is provided with a sub-portion 431 forming spoiler upstream of the heel (or a first end of the heel), and a sub-portion 432 forming spoiler avai heel (or a second end heel). Subparts 431, 432 forming spoilers are substantially planar. Subpart 432 forming the spoiler downstream of the heel extends downstream substantially in the direction DA, while the subpart 431 forming the upstream spoiler extends upstream and is inclined relative to the direction DA. Part 43 further comprises subparts 433 which generally extend in the direction DR and which are intended to form the darts of the blade. The filling of the cavity 4 is performed by its upper part at the portion 43, the filling ducts from the bucket 2 of the installation 1 are shown in dashed lines in FIG.
    According to the invention, the mold 3 comprises an auxiliary grain duct 5 comprising a first portion 51 and a second portion 52 extending the first portion 51. The first 51 and second 52 portions of the duct 5 are in fluid communication with each other. the other. The first portion 51 opens at a lower end 511 in the portion 40 of the cavity 3 forming a foot, and at an upper end 512 in the sub-portion 412 forming spoiler downstream of the platform. The second portion 52 opens at a lower end 521 in the sub-portion 412, here at the same place as the first portion 51, and at an upper end 522 in the sub-portion 432 forming spoiler downstream of the heel.
    The first portion 51 of the duct 5 extends, at its lower end 511, from a downstream wall 401 of the portion 40 of the cavity 4. In the example illustrated, the first portion 51 extends to from the downstream wall 401 at an angle α with it of about 60 °, this angle a may be between 54 ° and 62 °. The first portion 51 describes a curved or rounded shape between the portion 40 and the sub-portion 412.
    The second portion 52 of the duct 5 extends, at its lower end 521, from the sub-portion 412 forming spoiler downstream of the platform. In the illustrated example, the second portion 52 extends from the sub-portion 412 forming an angle β with it of about 115 °, this angle β can be between 110 ° and 115 °. At its upper end 522, the second portion 52 extends from the subpart 432 forming spoiler downstream of the heel. In the illustrated example, the second portion 54 extends from the sub-portion 432 forming an angle γ of about 115 ° with it, this angle γ can also be between 110 ° and 115 °.
    The second portion 52 may have at least partly a circular section of diameter D. In the example illustrated, the second portion 52 may have portions 523 which are remote from the portion 42 of the cavity 3 forming a blade distance L The portions 523 here are substantially rectilinear. The ratio R = L / D may, along these portions 523, be between 16.4 and 18.9.
    In the illustrated example, the second portion 52 has, at a middle portion thereof, a necking 524, corresponding to a local decrease in the diameter of the second portion 52. This necking may subsequently allow easier breakage of the second portion 52. the second portion 52 of the duct 5 after directed solidification of the metal, in order to reduce the constraints imposed on the molded blade.
    The first portion 51 may have at its upper end 512 a flyweight 513 visible in Figure 1. The second portion 52 may have at its lower end 521 and at its upper end 522 two mass 525 and 526 (Figure 1). The masses correspond to an enlargement of the portions 51, 52 of the duct 5 at the spoilers 412, 432. As indicated above, these massifiers 513, 525, 526 can reduce the appearance of porosities in the spoilers of the molded blade . In fact, the massifers make it possible to improve the supply of liquid metal to the parts of the cavity 4 forming the spoilers of the blade, which modifies the cooling isotherms in these parts and reduces the formation of porosities during solidification.
    Note that, in the example shown, the duct 5 is positioned on the downstream side of the cavity 4 (that is to say, in particular connected to the sub-parts 412, 432 forming spoiler avals), it is however possible to position on the upstream side by connecting it in particular to the subparts 411,431 forming spoilers upstream.
    It will also be noted that the preferred characteristics relating to the angles α, β and γ, as well as the ratio R, have been illustrated on the same mold 3, but may not be applied simultaneously.
    Figures 3 and 4 respectively show the mold 3 presented above and a mold 3 'according to another embodiment of the invention. In these figures, the molds 3, 3 'are shown provided with their ceramic shell 7. The ceramic shells of the molds 3 and 3' are made according to the same procedure to be compared.
    The auxiliary grain duct 5 'of the mold 3' has a first portion 51 'which is rectilinear and extends at an angle strictly less than 54 ° from the portion 40, this angle is here of the order of 45 ° . The duct 5 'has a second portion 52' which extends the first portion 51 'and extends from the sub-portion 412 forming spoiler downstream of the platform with an angle of the order of 90 °.
    It can be seen that the geometry of the duct 5 of the mold 3 (FIG. 3) makes it possible to obtain a thickness e of ceramic shell 7 at the level of the wall of the portion 42 facing the duct 5, which is less than the thickness e . ' obtained for the mold 3 '(Figure 4). This difference in thickness is made possible thanks to the optimized shape of the duct 5, presented above, with respect to the duct 5 '. In addition, in the mold 3, it can be seen that the geometry of the first duct 51 makes it possible to obtain a void space 70 between the first duct 51 and the portion 40; while in the mold 3 ', the geometry of the first duct 5Γ can result in the filling of this space with ceramic and form a thicker ceramic shell. As explained above, the reduction of the thickness of the ceramic shell makes it possible to further reduce the stresses exerted on the molded blade, and the eventual appearance of recrystallized grains following a heat treatment.
    The installation 1 which has been previously described may be made entirely of ceramic material, for example by a lost wax casting process. In a manner known per se, a model of the installation 1 in wax must first be manufactured. Then, this wax model is covered with a ceramic shell by successive quenching in a suitable slip (quenching / stuccoing). The ceramic is then fired and the wax removed to obtain the installation 1 of ceramic material.
    FIG. 5 illustrates the main steps of a process for manufacturing a casting molded from a molten metal using a plant 1 such as that described previously. The first step E1 of the method consists of filling the mold 3, 3 'of the installation 1 by pouring a molten metal into the installation. To do this, we can pour the metal directly into the bucket 2 of the Installation 1, and it can walk by gravity to fill the mold 3, 3 '.
    The second step E2 consists in achieving directed solidification of the metal present in the mold, so as to obtain the molded blade. Directed solidification is carried out in a suitable furnace in which the Installation is placed. The furnace makes it possible to control the growth of the crystallized grains in order to obtain a monocrystalline blade by virtue of the presence of a grain selector duct 6 or a monocrystalline seed. The carapace may have already begun to break at the end of the directed solidification. Once the piece is solidified, it can be unchecked. It is then possible to cut the parts connected to the blade corresponding in particular to the auxiliary grain duct 5, 5 '.
    Finally, it is possible to perform a last step E3 consisting of a heat treatment which allows in particular to dissipate the residual stresses in the molded part. For a AMI-type superalloy blade, the heat treatment may for example consist in subjecting the blade to a temperature of between 1270 ° C. and 1330 ° C. for a period of between 18 hours and 23 hours. Thanks to the use of a mold 3, 3 'according to the invention, a reduction in the appearance of recrystallized grains following this step has been observed.
    Throughout the presentation, the terms "between ... and ..." must be understood to include the terminals.
    权利要求:
    Claims (10)
    [1" id="c-fr-0001]
    REVENDICATONS
    A ceramic material mold (3; 3 ') for use in molding a turbomachine blade from a molten metal, the blade comprising a foot, a platform, a blade, and a heel, the mold comprising - a cavity (4) having the shape of the blade, and - an auxiliary grain duct (5, 5 ') comprising a first portion (51; 51') and a second portion (52; 52 ') proiongeant ia first portion, iadite first portion opening at one end (511) in a first portion (40) of the cavity forming the foot of the blade and at another end (512) in a second portion (412) of the cavity forming a spoiler of the blade platform, said second portion (52; 52 ') opening at one end (521) into said second portion (412) of the cavity and at another end (522) into a third portion (432) of the cavity forming a spoiler of the heel of dawn.
    [2" id="c-fr-0002]
    The mold (3) according to claim 1, wherein the first portion (51) of the auxiliary grain conduit (5) extends from a wall (401) of the first portion (40) of the cavity ( 4) in a direction forming an angle (a) between 54 ° and 62 ° with said wall.
    [3" id="c-fr-0003]
    3. Mold (3) according to any one of claims 1 and 2, wherein the second portion (52) of the auxiliary grain duct (5) extends from the second portion (412) of the cavity (4). ) in a direction forming an angle (β) between 110 ° and 115 ° with said second part.
    [4" id="c-fr-0004]
    4. Mold (3) according to any one of claims 1 to 3, wherein the second portion (52) of the auxiliary grain duct (5) extends from the third portion (432) of the cavity (4). ) in a direction forming an angle (γ) between 110 ° and 115 ° with said third part.
    [5" id="c-fr-0005]
    5. Mold (3) according to any one of claims 1 to 4, wherein the second portion (52) of the auxiliary grain duct (5) has at least one portion (523) having a circular section of diameter D, said part being away from a distance L of the cavity, a ratio R = L / D between the distance L and the diameter D being between 16.4 and 18.9 along said portion.
    [6" id="c-fr-0006]
    6. Mold (3) according to any one of claims 1 to 5, wherein the second portion (52) of the auxiliary grain duct (5) comprises a counterweight (525, 526) at each of its ends.
    [7" id="c-fr-0007]
    7. Mold according to any one of claims 1 to 6, wherein the blade is an aerospace turbine engine turbine blade.
    [8" id="c-fr-0008]
    8. Installation (1) for manufacturing a blade molded from a molten metal, comprising: - a mold (3; 3 ') according to any one of claims 1 to 7, and - means for obtaining grain monocrystalline (6) connected to the mold.
    [9" id="c-fr-0009]
    9. Installation (1) according to claim 8, wherein the means for obtaining monocrystalline grain comprise a monocrystalline seed or a grain selector conduit (6).
    [10" id="c-fr-0010]
    10. A method for manufacturing a monocrystalline turbomachine blade, comprising the following steps: filling (El) of a mold (3; 3 ') of an installation (1) according to any one of claims 8 and 9 with a molten metal, and - the directed solidification (E2) of the metal present in the mold (3; 3 ') so as to obtain a molded blade.
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    引用文献:
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    DE10033688A1|2000-07-11|2002-01-24|Alstom Power Nv|Producing a rigid cast part used as gas turbine blade comprises connecting the overhang or cross-section extension with a single crystal guide or a transition piece with a single crystal starter or another suitable site of the cast part|
    EP2092996A1|2008-02-14|2009-08-26|United Technologies Corporation|Method and apparatus for as-cast seal on turbine blades|
    EP2223755A1|2009-02-04|2010-09-01|Rolls-Royce plc|Casting method|
    WO2014135782A1|2013-03-07|2014-09-12|Snecma|Method for producing a rotor vane for a turbomachine|
    WO2014195634A1|2013-06-05|2014-12-11|Snecma|Turbine engine blade preform|CN109940131A|2019-03-26|2019-06-28|中国科学院金属研究所|A method of reducing the formation of single crystal super alloy blade tenon internal defect defect|RU2239520C1|2003-03-21|2004-11-10|Федеральное государственное унитарное предприятие "Всероссийский научно-исследовательский институт авиационных материалов"|Apparatus for making casting of monocrystalline turbine blade|
    FR2927270B1|2008-02-08|2010-10-22|Snecma|PROCESS FOR MANUFACTURING DIRECTED SOLIDIFICATION AUBES|CN109226691A|2018-10-10|2019-01-18|深圳市万泽中南研究院有限公司|Manufacturing method, ceramic shell mould and the manufacturing equipment of guide vane|
    FR3094655B1|2019-04-08|2021-02-26|Safran|A method of manufacturing a plurality of distributor sectors by foundry|
    法律状态:
    2017-04-13| PLFP| Fee payment|Year of fee payment: 2 |
    2017-12-08| PLSC| Search report ready|Effective date: 20171208 |
    2018-06-05| PLFP| Fee payment|Year of fee payment: 3 |
    2020-05-20| PLFP| Fee payment|Year of fee payment: 5 |
    2021-05-19| PLFP| Fee payment|Year of fee payment: 6 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1655021A|FR3052088B1|2016-06-02|2016-06-02|MOLD FOR THE MANUFACTURE OF A MONOCRYSTALLINE DARK BY FOUNDRY, INSTALLATION AND METHOD OF MANUFACTURING THE SAME|
    FR1655021|2016-06-02|FR1655021A| FR3052088B1|2016-06-02|2016-06-02|MOLD FOR THE MANUFACTURE OF A MONOCRYSTALLINE DARK BY FOUNDRY, INSTALLATION AND METHOD OF MANUFACTURING THE SAME|
    EP17733496.8A| EP3463714B1|2016-06-02|2017-06-01|Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same|
    RU2018146438A| RU2730827C2|2016-06-02|2017-06-01|Casting mould for production of monocrystalline vane by casting, installation and method of manufacturing, using casting mould|
    CN201780033664.XA| CN109219489B|2016-06-02|2017-06-01|Mould, device for manufacturing single crystal blade by casting and manufacturing method for realizing same|
    CA3025331A| CA3025331A1|2016-06-02|2017-06-01|Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same|
    BR112018074832-3A| BR112018074832A2|2016-06-02|2017-06-01|molding of ceramic material, installation to make a molded blade, and process of manufacturing a turbocharger blade.|
    PCT/FR2017/051371| WO2017207933A1|2016-06-02|2017-06-01|Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same|
    US16/305,326| US10576535B2|2016-06-02|2017-06-01|Mold for fabricating a monocrystalline blade by casting, a fabrication installation and method using the mold|
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