U.S. patent application number 13/488892 was filed with the patent office on 2013-02-07 for wind turbine component having a lightweight structure.
This patent application is currently assigned to GENERAL ELECTRIC COMPANY. The applicant listed for this patent is Junyoung Park, Jason Robert Parolini. Invention is credited to Junyoung Park, Jason Robert Parolini.
Application Number | 20130032303 13/488892 |
Document ID | / |
Family ID | 47002541 |
Filed Date | 2013-02-07 |
United States Patent
Application |
20130032303 |
Kind Code |
A1 |
Parolini; Jason Robert ; et
al. |
February 7, 2013 |
WIND TURBINE COMPONENT HAVING A LIGHTWEIGHT STRUCTURE
Abstract
A wind turbine component having a lightweight structure is
provided and includes a metallic matrix defining a cavity, metallic
foam enclosed within the cavity and a solidification metallurgical
bond formed at an entire interface between the metallic matrix and
the metallic foam.
Inventors: |
Parolini; Jason Robert;
(Greer, SC) ; Park; Junyoung; (Greer, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Parolini; Jason Robert
Park; Junyoung |
Greer
Greer |
SC
SC |
US
US |
|
|
Assignee: |
GENERAL ELECTRIC COMPANY
Schenectady
NY
|
Family ID: |
47002541 |
Appl. No.: |
13/488892 |
Filed: |
June 5, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13204386 |
Aug 5, 2011 |
|
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13488892 |
|
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Current U.S.
Class: |
164/6 |
Current CPC
Class: |
B22D 15/00 20130101;
B22D 19/02 20130101 |
Class at
Publication: |
164/6 |
International
Class: |
B22D 25/02 20060101
B22D025/02; B22C 9/00 20060101 B22C009/00 |
Claims
1. A method to form a wind turbine component the method comprising:
shaping a mold cavity between metallic foam and an exterior mold;
filling a molten metallic matrix into the mold cavity to enclose
the metallic foam; and, as the molten metallic matrix cools,
forming a solidification metallurgical bond at an entire interface
between the metallic matrix and the metallic foam, the forming
comprising forming the metallic matrix and the metallic foam as a
multi-ton, complex shaped component.
2. The method according to claim 1, further comprising controlling
a distribution of metallic material in the metallic foam.
3. The method according to claim 1, wherein the shaping comprises
at least one or more of cleaning a surface of the metallic foam and
pre-heating the metallic foam.
4. The method according to claim 1, further comprising forming a
sacrificial layer about a surface of the metallic foam.
5. The method according to claim 1, further comprising: defining
core regions in the mold cavity; inserting cores into the core
regions, the cores being configured to survive the filling; and
removing the cores following the filling.
6. The method according to claim 1, further comprising conducting a
heat treatment to improve the solidification metallurgical
bond.
7. The method according to claim 1, wherein the shaping comprises:
building an expendable foam pattern in the mold cavity; coating a
surface of the expendable foam pattern; and burning out the
expendable foam pattern around preformed metallic foam inserts
during the filling.
8. The method according to claim 1, further comprising forming the
metallic matrix and the metallic foam with annular and angular
features.
9. A method to form a wind turbine component configured to have a
lightweight structure, the method comprising: shaping a mold cavity
between metallic foam and an exterior mold; building a coated
expendable foam pattern in the mold cavity; filling a molten
metallic matrix into the mold cavity to enclose the metallic foam
such that the expendable foam pattern is burned out around
preformed metallic foam inserts during the filling; and, as the
molten metallic matrix cools, forming a solidification
metallurgical bond at an entire interface between the metallic
matrix and the metallic foam.
10. The method according to claim 7, wherein the coating comprises
coating the surface of the expendable foam pattern with a
refractory coating.
11. The method according to claim 9, wherein the building of the
coated expendable foam pattern comprises coating an expendable foam
pattern with a refractory coating.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of priority of
co-pending U.S. application Ser. No. 13/204,386, which was filed on
Aug. 5, 2011. The entire contents of U.S. application Ser. No.
13/204,386 are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The subject matter disclosed herein relates to a wind
turbine component and, more particularly, to a wind turbine
component having a lightweight structure.
[0003] Wind turbine powertrain components are often subject to
large vibrational stresses. These vibrations can lead to premature
failure of powertrain components and significant noise
generation.
BRIEF DESCRIPTION OF THE INVENTION
[0004] According to one aspect of the invention, a wind turbine
component having a lightweight structure is provided and includes a
metallic matrix defining a cavity, metallic foam enclosed within
the cavity and a solidification metallurgical bond formed at an
entire interface between the metallic matrix and the metallic
foam.
[0005] According to another aspect of the invention, a method to
form a wind turbine component configured to have a lightweight
structure is provided and includes shaping a mold cavity between
metallic foam and an exterior mold, filling a molten metallic
matrix into the mold cavity to enclose the metallic foam and, as
the molten metallic matrix cools, forming a solidification
metallurgical bond at an entire interface between the metallic
matrix and the metallic foam.
[0006] According to yet another aspect of the invention, a method
to form a wind turbine component configured to have a lightweight
structure is provided and includes shaping a mold cavity within a
metallic matrix having an opening, filling the mold cavity with
molten metallic material and a foaming agent, closing the opening
such that the metallic matrix encloses the mold cavity and, as the
molten metallic material cools and foams within the mold cavity,
forming a solidification metallurgical bond at an entire interface
between the metallic matrix and the metallic foam.
[0007] These and other advantages and features will become more
apparent from the following description taken in conjunction with
the drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0008] The subject matter, which is regarded as the invention, is
particularly pointed out and distinctly claimed in the claims at
the conclusion of the specification. The foregoing and other
features, and advantages of the invention are apparent from the
following detailed description taken in conjunction with the
accompanying drawings in which:
[0009] FIG. 1 is a schematic view of a wind turbine component
configured to have a lightweight structure in accordance with
embodiments;
[0010] FIG. 2 is a schematic view of a solidification metallurgical
bond line;
[0011] FIG. 3 is a cross-sectional view of a wind turbine component
configured to have a lightweight structure in accordance with
alternate embodiments;
[0012] FIG. 4 is a cross-sectional view of a wind turbine component
configured to have a lightweight structure in accordance with
alternate embodiments;
[0013] FIG. 5 is an illustration of a method of forming a wind
turbine component having a lightweight structure according to
embodiments;
[0014] FIG. 6 is an illustration of a substantially finished wind
turbine component having a lightweight structure;
[0015] FIG. 7 is an illustration of a method of forming a wind
turbine component having a lightweight structure according to
embodiments;
[0016] FIG. 8 is an illustration of a substantially finished wind
turbine component having a lightweight structure;
[0017] FIG. 9 is an illustration of a method of forming a wind
turbine component having a lightweight structure according to
alternative embodiments; and
[0018] FIG. 10 is an illustration of a substantially finished wind
turbine component having a lightweight structure.
[0019] The detailed description explains embodiments of the
invention, together with advantages and features, by way of example
with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In accordance with aspects, a vibration damping noise
reduction lightweight structure is provided for use as a multi-ton
component of various types of apparatuses. These apparatuses may
include, for example, wind turbines and similar components of power
generation plants. The lightweight structure may include, for
example, hollow tubing and/or castings of metallic materials filled
by foams of metallic materials with a solidification metallurgical
bond formed at an entire interface between the metallic materials
and the foams.
[0021] With reference now to FIG. 1, a wind turbine component
configured to have a lightweight structure 10 to provide vibration
damping and noise reduction is provided. The lightweight structure
10 includes a metallic matrix 20 formed to define a cavity 21,
metallic foam 30 enclosed within the cavity 21 and a solidification
metallurgical bond 40. The metallic matrix 20 may include any metal
or metal alloy, such as, for example, aluminum, magnesium, iron,
nickel, titanium, cobalt, copper, chromium and alloys thereof The
metallic foam 30 may similarly include any metal or metal alloy,
such as, for example, aluminum, magnesium, iron, nickel, titanium,
cobalt, copper, chromium and alloys thereof along with a foaming
agent that eventually evolves outwardly or is dispersed evenly
throughout. The metallic foam 30 may also include ceramic foam
mixed into or arranged in coaxial layers with the metallic foam
30.
[0022] With reference to FIG. 2, the solidification metallurgical
bond 40 is formed at an entire interface between the metallic
matrix 20 and the metallic foam 30 and includes an interface region
41 in which eutectic precipitates 42 or, for some materials,
eutectic-type precipitates form on solidification. Additional
regions 43, 44 where at least one of grain growth and partial
re-crystallization occurs may also be formed in solid-state on
opposite sides of the newly solidified interface region 41. The
additional regions 43, 44 are respectively interposed between the
interface region 41 and the main body of the metallic matrix 20 on
one side and between the interface region 41 and the main body of
the metallic foam 30 on the other side. The interface region 41 may
be substantially wider than the additional regions 43, 44.
[0023] With reference to FIGS. 3 and 4, the wind turbine component
configured to have the lightweight structure 10 may be provided for
use as a multi-ton complex shaped component of an apparatus such
as, for example, a wind turbine and/or similar components of power
generation plants (i.e., wind turbine gearbox housings or
bedplates). For example, as shown in FIG. 3, the lightweight
structure 10 may be provided for use in a cast housing torque arm
11 of a gearbox that may be several feet in diameter and may weigh
several tons. Alternatively, the lightweight structure 10 may be
provided for use in a wind turbine casing 12, as shown in FIG. 4.
In each example, the lightweight structure 10 is formed as an
annular member within a core of the larger apparatus to at least
allow the apparatus to maintain its strength and to decrease an
overall weight and vibration of the apparatus.
[0024] In the case of the wind turbine, by replacing conventional
multi-ton components with simple or complex shapes with the
lightweight structure 10, the height of the wind turbine can be
increased as necessary to comply with local regulations and to
place the rotor blades in the wind stream as much as possible. Due
to the resulting decrease in the overall weight of the wind
turbine, operational noise and wind turbine vibrations may be
dampened. Moreover, since wind turbines configured to have
lightweight components are increasingly flexible in terms of being
usable in various environments and localities, the use of wind
power as an alternate source of energy may increase.
[0025] With reference to FIGS. 5 and 6, a method to form the
lightweight structure 10 is provided. The method includes shaping a
mold cavity 100 between a metallic foam 101, materials of which are
similar to those of the metallic foam 30 described above, and an
exterior mold 102 of, for example, packed sand or permanent steel
molds. The method further includes filling (i.e., mold filling) the
mold cavity with 100 a molten metal to form a metallic matrix 103,
materials of which are similar to those of the metallic matrix 20
described above. As the molten metallic matrix 103 cools following
the filling operation, the method also includes allowing for
formation of a solidification metallurgical bond 104, which is
similar in terms of structure and formation processes to the
solidification metallurgical bond 40 described above, at an entire
interface between the metallic matrix 103 and the metallic foam
101.
[0026] The shaping may include cleaning a surface of the metallic
foam 101 by at least one or more of sand blasting, grit blasting,
dry ice blasting, electrolytic cleaning, acid cleaning to create
desired surface topography and by the removal of oxides and/or
other non-metallic surface compounds. The shaping may further
include pre-heating the metallic foam 101 to limit or prevent
cracking or porosity upon exposure thereof to the heat of the
molten metal of the metallic matrix 103. The method may also
include forming a sacrificial layer 105 about a surface of the
metallic foam 101 to further limit or prevent cracking or to assist
with bonding. This sacrificial layer 105 will be consumed by the
molten metallic materials 103 upon the filling operation or will
otherwise be dispersed throughout the lightweight structure 10 such
that the solidification metallurgical bond 104 can be formed at the
entire interface between the metallic matrix 103 and the metallic
foam 101. Still further, the method may also include defining core
regions 106 in the mold cavity by, for example, inserting cores
therein. These cores may be formed to, for example, survive the
filling operation such that, following the filling operation, the
cores can be removed with the core regions 106 left in tact.
[0027] Once the metallic matrix 103 has solidified and cooled by a
predefined degree, the method may further include conducting a heat
treatment, such as at least one of a solution heat treatment to
improve the solidification metallurgical bond 104 and an age heat
treatment depending on a type of materials being used for the
metallic matrix 103 and the metallic foam 101.
[0028] With reference to FIGS. 7 and 8, the shaping described above
may be conducted in accordance with a lost foam process whereby the
shaping includes building an expendable foam pattern 107 about a
surface of the metallic foam 101 in the mold cavity 100, coating a
surface of the foam pattern 107 with, for example, a refractory
coating 108 or some other similar coating and surrounding the
entire expendable foam pattern 107 and the refractory coating 108
with sand and then burning out the expendable foam pattern 107
during the filling operation. The refractory coating 108 may be
formed of silica, graphite or another similar material such that
the refractory coating 108 permits the reacted products of the
expendable foam pattern 107 to move out of the mold cavity 100
during the casting operation. With the expendable foam pattern 107
being replaced by molten metal, the metallic matrix 103 is formed
around the metallic foam 101 similarly as described above. The use
of such a lost foam process may permit generation of a better
solidification metallurgical bond and may allow for control of
bonding depth to permit formation of particular shapes and
prevention of a shifting of preformed metallic foam inserts.
[0029] With reference to FIGS. 9 and 10, a method to form the
lightweight structure 10 in accordance with alternative embodiments
is provided. The method includes shaping a mold cavity 200 within a
metallic matrix 201 having an opening 2010 formed therein, filling
(i.e., mold filling) the mold cavity 200 with molten metallic
material 202 and a foaming agent 203 via the opening 2010 and
closing the opening 2010 such that the metallic matrix 201 encloses
the mold cavity 200. The method further includes allowing, as the
molten metallic material 202 cools and foams within the mold cavity
200, for formation of a solidification metallurgical bond 204 at an
entire interface between the metallic matrix 201 and the previously
molten and now foamed metallic material 202.
[0030] The shaping may include cleaning a surface of the metallic
matrix 201 by at least one or more of sand blasting, grit blasting,
dry ice blasting, electrolytic cleaning, acid cleaning to create
desired surface topography and by the removal of oxides and/or
other non-metallic surface compounds. The shaping may further
include pre-heating the metallic matrix 201 to limit or prevent
cracking or porosity upon exposure to the molten metallic material
202. The method may also include forming a sacrificial layer 205
similar to the sacrificial layer described above about a surface of
the metallic matrix 201 to further limit or prevent cracking or to
assist with bonding. Still further, the method may also include
defining core regions 206 in the mold cavity 200 by, for example,
inserting cores therein in a process similar to what is described
above. The inserted cores can be removed once solidification is
complete by way of a through-hole or a similar feature formed in
the metallic matrix 201.
[0031] Once the metallic matrix 201 has cooled by a predefined
degree, the method may further include conducting at least one of a
solution heat treatment to improve the solidification metallurgical
bond 204 and an age heat treatment.
[0032] In accordance with still further embodiments, the methods
described above may also include controlling a distribution of the
metallic material in the metallic foam 30 in accordance with known
methods.
[0033] While the invention has been described in detail in
connection with only a limited number of embodiments, it should be
readily understood that the invention is not limited to such
disclosed embodiments. Rather, the invention can be modified to
incorporate any number of variations, alterations, substitutions or
equivalent arrangements not heretofore described, but which are
commensurate with the spirit and scope of the invention.
Additionally, while various embodiments of the invention have been
described, it is to be understood that aspects of the invention may
include only some of the described embodiments. Accordingly, the
invention is not to be seen as limited by the foregoing
description, but is only limited by the scope of the appended
claims.
* * * * *