COMPONENT HAVING WEAR-PROTECTED OPENINGS AND RECESSES AND PROCESS FOR THE PRODUCTION THEREOF

Abstract

The present invention relates to a method for producing and/or repairing wear-stressed recesses or openings on components (22) of a turbomachine, especially of elements of a flow passage boundary, and also to corresponding components, wherein the method comprises:

producing an at least two-layer molded repair part (15), one layer (2) of which is formed by an Ni-solder and a further layer (3) of which is formed from a mixture of an Ni-solder (4) and hard material particles (5) of hard alloys on a base of cobalt or nickel and which at least partially has an outer shape which is complementary to the inner shape of the recess (20) or opening which is to be repaired,

inserting the molded repair part (15) into the recess (20) or opening and

at least partially heat-treating the component (22) for soldering the molded repair part (15) onto the component.

Claims

1-14. (canceled)

15. A method for producing and/or repairing a wear-stressed recess or opening of a component of a turbomachine, wherein the method comprises: inserting into the recess or opening to be repaired an at least two-layered molded repair part, a first layer of which is formed by an Ni-solder and a second layer of which is formed from a mixture of an Ni-solder and hard material particles of hard alloys based on cobalt or nickel and which at least partially has an outer shape which is complementary to an inner shape of the recess or opening, and at least partially heat-treating the component to solder the molded repair part onto the component.

16. The method of claim 15, wherein producing of the molded repair part is carried out such that the Ni-solder layer at least partially constitutes an outer edge of the molded repair part which comes into contact with an inner surface of the recess or opening when inserted into the recess or opening.

17. The method of claim 15, wherein producing of the molded repair part is carried out by deep drawing or pressing an at least two-layered tape or two-layered plate comprising the first layer and the second layer into a die in order to at least partially obtain an outer shape which is complementary to an inner shape of the recess or opening.

18. The method of claim 15, wherein the method further comprises preparing the recess or opening by material removal prior to insertion of the molded repair part.

19. The method of claim 15, wherein the second layer of the molded repair part comprises 20 to 60 wt. % of hard material particles.

20. The method of claim 15, wherein the second layer of the molded repair part comprises 35 to 45 wt. % of hard material particles.

21. The method of claim 15, wherein the first layer does not contain hard material particles.

22. The method of claim 15, wherein heat-treating the component is carried out under vacuum conditions.

23. The method of claim 15, wherein before heat-treating the component, air-drying at temperatures of from 50° C. to 80° C. is carried out.

24. The method of claim 15, wherein heat-treating the component comprises ageing at a temperature of from 1150° C. to 1200° C. for 10 to 25 minutes.

25. The method of claim 15, wherein heat-treating the component comprises ageing at a temperature of from 1170° C. to 1180° C. for 15 to 20 minutes.

26. The method of claim 15, wherein heat-treating the component comprises heating up under vacuum conditions with a heating up rate of from 5° C./min to 30° C./min, and/or intermediate ageing at temperatures of from 400° C. to 1100° C. for a time period of from 5 to 40 minutes.

27. The method of claim 15, wherein the hard alloy comprises a Co—Mo—Cr—Si-alloy.

28. The method of claim 27, wherein the hard alloy comprises from 16.5 to 18.5 wt. % Cr, from 27 to 30 wt. % Mo, from 3 to 3.8 wt. % Si, up to 3 wt. % Ni and Fe, and up to 0.1 wt. % S, N, O, C and P in each case, remainder Co and unavoidable impurities.

29. The method of claim 15, wherein the Ni-solder is an alloy which comprises Cr and Si.

30. The method of claim 29, wherein the Ni-solder is an alloy which comprises from 15 to 25 wt. % Cr and from 5 to 15 wt. % Si, remainder Ni and unavoidable impurities.

31. A component of a turbomachine, wherein the component comprises at least one opening or recess that comprises an inner wall region which at least partially encompasses the opening or recess and which on a surface thereof has an at least two-layered solder layer, a first layer of which is formed by an Ni-solder and a second layer of which is formed from a mixture of an Ni-solder and hard material particles of hard alloys based on cobalt or nickel.

32. The component of claim 31, wherein the component has been produced by the method of claim 15.

33. The component of claim 31, wherein the component is a turbine intermediate casing.

34. The component of claim 31, wherein the first layer is arranged on a base material of the component.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0025] In the attached drawings, in a purely schematic manner:

[0026] FIG. 1 shows a sectional view through a two-layer soldering tape, as used in the present invention,

[0027] FIG. 2 shows a sectional view of a die-punch arrangement for producing a conical molded repair part according to the present invention,

[0028] FIG. 3 shows a sectional view of a conical molded repair part according to the invention, and

[0029] FIG. 4 shows a sectional view through a part of a component in which the molded repair part from FIG. 3 has been inserted.

WORKING EXAMPLES

[0030] Further advantages, characteristics and features of the present invention become clear in the following detailed description of exemplary embodiments. However, the invention is not limited to these exemplary embodiments.

[0031] FIG. 1 shows a so-called soldering tape 1 which is constructed from two layers, specifically one layer 2 of Ni-solder and one layer 3 of a mixture of Ni-solder 4 and hard material particles 5.

[0032] The layer 3 of nickel solder 4 and hard material particles 5 is composed in the depicted exemplary embodiment so that the layer 3 has about 60 wt. % Ni-solder 4 and 40 wt. % hard material particles in the form of a hard alloy on a base of cobalt.

[0033] The nickel solder, as used in the pure nickel-solder layer 2 and in the layer 3 with a mixture of nickel solder 4 and hard material particles 5, can be composed of 19 wt. % chromium, 10 wt. % silicon and remainder nickel and unavoidable impurities. In the case of the hard material alloy, it can be a cobalt-based alloy which can have 16.5-18.5 wt. % chromium, 27-30 wt. % molybdenum, 3-3.8 wt. % silicon, up to 3 wt. % nickel and iron, 0.080 wt. % carbon, 0.07 wt. % nitrogen, 0.05 wt. % oxygen, 0.03 wt. % phosphor and 0.03 wt. % sulfur and the remainder unavoidable impurities.

[0034] The soldering tape 1, which can be designed not only in tape form but also in plate form or in other suitable forms, can comprise the Ni-solder 4 and also the hard material particles 5 in powder form with a binding agent, such as a plastic, so that the soldering tape 1 or a corresponding soldering plate is deformable. Accordingly, a three-dimensionally formed molded repair part can be formed from the flat soldering tape 1, as is shown in FIG. 3 for example. To this end, provision can be made for a die 10 which has a corresponding negative mold 11 into which the soldering tape is pressed by means of a punch 12. By compressing the soldering tape 1 in the negative mold 11 by means of the punch 12 and by removing the surplus pieces of the soldering tape 1, a corresponding conical molded repair part 15 can be formed, as is shown in FIG. 3 for example. However, the molded repair part 15 can also be formed in another suitable mold. The soldering tape 1 is pressed into the negative mold 11 of the die 10 in this case so that the pure Ni-solder layer 2 butts against the die and is first of all impressed into the negative mold 11 by means of the punch 12. The result is therefore a conical molded repair part 15 in which an outer, pure Ni-solder layer 2 is located in the region of the cone surface, whereas the cone body is formed from a mixture layer 3 of Ni-solder 4 and hard material particles 5. The outer surface of the base of the conical molded repair part 15 is also formed by the mixture layer 3 of Ni-solder 4 and hard material particles 5.

[0035] The corresponding molded repair part 15 can now be inserted into an opening or recess of a component 22, wherein the inner wall 21 of the component 22, which encompasses the opening or recess, is formed complementarily to at least a part of the surface of the conical molded repair part 15, wherein the complementary shape of the opening or recess of the component 22 can be achieved by means of corresponding material machining both of the opening or recess of the component 22 and of the molded repair part. It is particularly advantageous to prepare the opening or recess of the component 22 by material removal for insertion of a correspondingly formed molded repair part 15 since as a result of this not only the shapes are mutually adapted but also undesirable oxide layers or other foreign substances, which could impair connecting of the molded repair part 15 to the base material of the component 22, are removed from the inner wall 21 of the opening or recess of the component 22.

[0036] FIG. 4 shows a recess 20 in a component 22 with a central axis 23, into which a corresponding molded repair part 15 has been inserted. As a result of a suitable heat treatment for melting the solder in the pure Ni-solder layer 2 and in the mixture layer 3, and also by removing a possibly existing binding agent in the molded repair part 15, the molded repair part is bonded as a solid coating to the base material of the component 22. The cavity of the recess 20 of the component 22 can be re-created in the desired shape by means of subsequent material machining of the mixture layer 3 by for example a corresponding hole being introduced in the mixture layer 3. Other types of material machining such as milling and the like are naturally also possible.

[0037] As a result, a wear-resistant coating with a high proportion of hard material particles 5 has been applied in an opening or recess 20 of a component 22 in a simple and reliable manner.

[0038] Although the present invention has been described in detail based on the exemplary embodiments, it is obvious to the person skilled in the art that the invention is not limited thereto but that rather modifications are possible in a way that individual features are omitted or other types of combinations of features are realized providing there is no departure from the scope of protection of the attached claims.

LIST OF REFERENCE NUMERALS

[0039] 1 Soldering tape [0040] 2 Layer of Ni-solder [0041] 3 Mixture layer of Ni-solder and hard material particles [0042] 4 Ni-solder [0043] 5 Hard material particles [0044] 10 Die [0045] 11 Negative mold [0046] 12 Punch [0047] 15 Conical molded repair part [0048] 20 Recess [0049] 21 Inner wall of the recess before insertion of the molded repair part [0050] 22 Component [0051] 23 Central axis of the recess