U.S. patent application number 12/247639 was filed with the patent office on 2009-05-14 for method of producing a component.
Invention is credited to Thomas Dauti, Thomas Peschke, Alexander Winkler.
Application Number | 20090119920 12/247639 |
Document ID | / |
Family ID | 38536537 |
Filed Date | 2009-05-14 |
United States Patent
Application |
20090119920 |
Kind Code |
A1 |
Peschke; Thomas ; et
al. |
May 14, 2009 |
METHOD OF PRODUCING A COMPONENT
Abstract
The present technology relates to a method for producing a
component, especially a gas turbine component, with at least the
following steps: a) production of a component with several
component surfaces, in which at least one transitional area between
two component surfaces has a transition radius that is greater than
0.05 mm and less than 0.30 mm; b) strengthening of the component,
at least on the transitional area or each transitional area, by
ultrasonic shot peening.
Inventors: |
Peschke; Thomas;
(Grobenzell, DE) ; Winkler; Alexander; (Nedudenau,
DE) ; Dauti; Thomas; (Weichs, DE) |
Correspondence
Address: |
MCANDREWS HELD & MALLOY, LTD
500 WEST MADISON STREET, SUITE 3400
CHICAGO
IL
60661
US
|
Family ID: |
38536537 |
Appl. No.: |
12/247639 |
Filed: |
October 8, 2008 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
PCT/DE2007/000610 |
Apr 4, 2007 |
|
|
|
12247639 |
|
|
|
|
Current U.S.
Class: |
29/889.7 ;
419/66; 72/53 |
Current CPC
Class: |
B24C 5/005 20130101;
Y02T 50/673 20130101; F01D 5/286 20130101; C21D 7/00 20130101; F05D
2230/90 20130101; B24C 1/10 20130101; B22F 5/04 20130101; B22F
3/225 20130101; Y10T 29/49336 20150115; C22F 1/00 20130101; Y02T
50/60 20130101 |
Class at
Publication: |
29/889.7 ;
419/66; 72/53 |
International
Class: |
B22F 5/04 20060101
B22F005/04; B22F 3/02 20060101 B22F003/02; C21D 7/06 20060101
C21D007/06 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 11, 2006 |
DE |
10 2006 016 949.2 |
Claims
1. A method for producing a component comprising the following
steps: a) Producing a component having two or more component
surfaces, in which at least one transitional area between two
component surfaces has a transition radius that is greater than
about 0.05 mm and less than about 0.30 mm, and b) Strengthening the
component in at least one transitional area or each transitional
area by ultrasonic shot peening.
2. The method according to claim 1, wherein the method is used to
produce a gas turbine component.
3. The method according to claim 1, wherein the component is
produced by forging, by fine casting, or by powder metallurgical
injection molding.
4. The method according to claim 1, wherein the component produced
is a gas turbine blade having a transitional area between a suction
side surface and a pressure side surface on a blade trailing edge
of a blade body that is greater than about 0.05 mm and less than
about 0.30 mm.
5. The method according to claim 4, wherein the gas turbine blade
is a rotor blade.
6. The method according to claim 3, wherein the component produced
is a gas turbine blade having a transitional area between a suction
side surface and a pressure side surface on a blade trailing edge
of a blade body that is greater than about 0.05 mm and less than
about 0.30 mm.
7. The method according to claim 5, wherein the gas turbine blade
is a rotor blade.
8. The method according to claim 1, wherein the component produced
is a gas turbine blade having at least on one blade foot having a
transitional area between a dendritic or dovetail profiled surface,
running in the longitudinal direction of the gas turbine blade, and
an end surface, running in the transverse direction of the gas
turbine blade, with a transition radius that is greater than about
0.05 mm and less than about 0.30 mm.
9. The method according to claim 5, wherein the gas turbine glad is
a rotor blade.
10. A method according to claim 1, wherein the ultrasonic shot
peening step is carried out with precision balls having a smooth
surface.
11. A method according to claim 8, wherein the ultrasonic shot
peening step is carried out with precision balls having a smooth
surface.
12. A method according to claim 1, further comprising the optional
step of rounding the transitional area by a brush-like tool before
the component is strengthened by the ultrasonic shot peening.
13. A method according to claim 5, further comprising the optional
step of rounding the transitional area by a brush-like tool before
the component is strengthened by the ultrasonic shot peening.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of International
Application Serial No. PCT DE/2007/000610 (International
Publication Number WO 2007/115550), having an International filing
date of Apr. 4, 2007 entitled "Verfahren Zum Herstellen Eines
Bauteils" ("Method of Producing a Component"). International
Application No. PCT DE/2007/000610 claimed priority benefits, in
turn, from German Patent Application No. 10 2006 016 949.2, filed
Apr. 11, 2006. International Application No. PCT DE/2007/000610 and
German Application No. DE 10 2006 016 949.2 are hereby incorporated
by reference herein in their entireties.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] [Not Applicable]
MICROFICHE/COPYRIGHT REFERENCE
[0003] [Not Applicable]
BACKGROUND OF THE INVENTION
[0004] The present technology generally relates to a method for
producing a component, in particular a gas turbine component.
[0005] Modern gas turbines, in particular aircraft engines, must
meet the highest demands with respect to reliability, weight,
power, economic efficiency and lifetime. Choice of material, the
search for new appropriate materials and the search for new
manufacturing methods play a decisive role in the development of
gas turbines. The most important materials used nowadays for
aircraft engines or other gas turbines are titanium alloys, nickel
alloys and high-strength steels. The high-strength steels are used
for shaft parts, transmission parts, compressor housings and the
turbine housing. Titanium alloys are typical materials for
compressor parts, nickel alloys are suitable for hot turbine parts
of the aircraft engine.
[0006] Fine casting, as well as forging, are known as manufacturing
methods for gas turbine components made of titanium alloys, nickel
alloys or other alloys from the prior art. All highly stressed gas
turbine components are forged parts. Components for a turbine, on
the other hand, are generally made as fine castings. Powder
metallurgical injection molding represents an alternative for the
manufacture or production of complex components. Powder
metallurgical injection molding is used, for example, with plastic
injection molding techniques, and is also referred to as metal
injection molding or the metal injection molding method (MIM
method).
[0007] Gas turbine components are components with complex
geometries and surface contours, in which gas turbine blades, in
particular, have transitional areas between component surfaces that
are characterized by relatively small transition radii. In the area
of a blade trailing edge of a blade body of a rotor blade, small
transition radii between a suction side surface and a pressure side
surface are desired, in particular, in order to optimize the
aerodynamic behavior of such blades. Small transition radii between
a dendritic or dovetail profiled surface and a front surface are
also desirable in the area of a blade foot, in order to increase
the support surface of the blade foot.
[0008] To increase the lifetime of such components, the components
are strengthened by shot peening on the surface areas of the
components, as well as in the transitional areas having relatively
small transition radii. According to methods known in the state of
the art, conventional shot peening is used, in which peening
elements formed as balls are directed onto the component being
strengthened by means of compressed air. To avoid undesired
deformations of the component on the transitional areas between
component surfaces of the component, characterized by a limited
transition radius, minimal transition radii of 0.3 mm must be
maintained according to the prior art. It follows from this that in
the area of a blade trailing edge of a blade body, a minimal
thickness of 0.6 mm can be set according to the methods presently
known in the state of the art. However, there remains a demand for
a method to produce a component, with which smaller transition
radii can be achieved on transitional areas between two component
surfaces of the component being produced.
BRIEF SUMMARY OF THE INVENTION
[0009] It is an aspect of the present technology to devise a method
for producing a component achieving the desired outcomes noted
above. This can be achieved by a method for the production of a
component as set forth herein and according to the claims.
According to the present technology, the method includes at least
the following steps: a) production of a component with several
component surfaces, in which at least one transitional area between
two component surfaces has a transition radius that is greater than
0.05 mm and less than 0.30 mm; and b) strengthening of the
component, at least on the transitional area or each transitional
area, by ultrasonic shot peening.
[0010] With the present technology, a process chain is proposed for
the production of a component, in which transition radii between
0.05 mm and 0.30 mm can be preferably maintained between two
component surfaces in transitional areas, without the hazard of
damage to the transitional areas characterized by relatively small
transition radii during strengthening of the overall component.
[0011] Preferred and other modifications of the present technology
are apparent from the appending claims and the following
description. Practical examples of the present technology are
further explained with reference to the drawing, without being
restricted to it.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 illustrates a flow diagram for a process for
producing a component according to one embodiment of the present
technology.
DETAILED DESCRIPTION OF THE INVENTION
[0013] FIG. 1 illustrates a strongly schematized process diagram of
the method according to the present technology for producing a
component. In particular, the present technology concerns a method
for producing a component, preferably a method for producing a
rotor blade of a gas turbine rotor. With reference to FIG. 1, the
present technology is described below for the preferred practical
example of producing a rotor blade. However, the present technology
is not restricted to this specific application. One skilled in the
art will appreciate from the description herein and appended claims
that other applications are envisaged.
[0014] In a first step 10 of the method according to the present
technology, a rotor blade of a gas turbine is produced. Such a
rotor blade has several component surfaces, in which transitional
areas between two component surfaces are characterized by a
transition radius. According to the present technology, a rotor
blade is prepared in step 10, which has a transitional area with a
relatively small transition radius that is greater than about 0.05
mm and less than about 0.30 mm.
[0015] This transitional area with the relatively small transition
radius can be a transitional area on a blade trailing edge of a
blade body of the rotor blade, i.e., a transitional area between a
suction side surface and a pressure side surface of the blade body.
At a transition radius of about 0.05 mm, a thickness of the blade
trailing edge of about 0.10 mm can be produced.
[0016] In addition, the transitional area with the relatively small
transition radius can be a transitional area on a blade foot of the
rotor blade, namely a transitional area between a dendritic or
dovetail profiled support surface, running essentially in the
longitudinal surface of the rotor blade, and an end surface of the
blade foot, running essentially in the transverse direction of the
rotor blade.
[0017] In step 10, the rotor blade is produced by forging or by
fine casting, or also by powder metallurgical injection molding
(MIM).
[0018] After producing the blade according to step 10,
strengthening of the component preferably follows immediately
according to a step 11, at least on the or each transitional area,
by ultrasonic shot peening. Precision balls with a smooth surface
are then used as peening elements.
[0019] During ultrasonic shot peening, the precision balls, used as
peening elements, are not directed onto the transitional areas of
the rotor blade being peened as in conventional shot peening by
means of a directed compressed air jet, but instead the precision
balls are accelerated by means of a sonotrode vibrating in the
ultrasonic range, so that the precision balls encounter the
transitional area or each transitional area of the component being
strengthened in a stochastic distribution and therefore in
undirected fashion. This is an advantage over conventional
processing of such components.
[0020] Optionally, after production according to step 10 and before
strengthening according to step 11, the component is checked,
according to a step 12, whether, because of the manufacturing
tolerance of step 10, before strengthening of the or each
transitional area, its rounding is required. If this is required, a
step 13 is resorted to and rounding of the transitional area or
each transitional area is carried out by means of a brush-like
tool.
[0021] If the manufacturing quality of step 10, however, is
sufficiently good, rounding according to step 13 can be dispensed
with and strengthening according to step 11 can occur directly
after production of the component according to step 10.
[0022] With the method according to the present technology, it is
possible for the first time to produce transitional areas with
transition radii of less than about 0.30 mm on rotor blades of a
gas turbine rotor and strengthen them without hazard of damage.
[0023] The present technology has now been described in such full,
clear, concise and exact terms as to enable a person familiar in
the art to which it pertains, to practice the same. It is to be
understood that the foregoing describes preferred embodiments and
examples of the present technology and that modifications may be
made therein without departing from the spirit or scope of the
present technology as set forth in the claims. Moreover, while
particular elements, embodiments and applications of the present
technology have been shown and described, it will be understood, of
course, that the present technology is not limited thereto since
modifications can be made by those familiar in the art without
departing from the scope of the present disclosure, particularly in
light of the foregoing teachings and appended claims. Moreover, it
is also understood that the embodiments shown in the drawings, if
any, and as described above are merely for illustrative purposes
and not intended to limit the scope of the present technology,
which is defined by the following claims as interpreted according
to the principles of patent law, including the Doctrine of
Equivalents. Further, all references cited herein are incorporated
in their entirety.
* * * * *