Turbo-machine impeller manufacturing

Abstract

A method of manufacturing a turbo-machine impeller, which includes a hub and a plurality of blades, using powder material in an additive-manufacturing process. The method includes: applying energy to the powder material by way of a high energy source, and solidifying the powder material. At least one bulky portion of the hub is irradiated such that the powder material solidifies in a lattice structure surrounded by an outer solid skin structure enclosing the lattice structure.

Claims

1. A method of manufacturing a turbo-machine impeller comprising a hub defining an impeller foot, a shroud and a plurality of blades using powder material in an additive-manufacturing process, the method comprising: irradiating the powder material with a high energy source; and solidifying the powder material to form the turbo-machine impeller, wherein the powder material is irradiated such that the impeller foot and an inner portion of the shroud solidify, respectively, in a lattice structure surrounded by an outer solid skin structure enclosing the lattice structure.

2. The method according to claim 1, further comprising: depositing a first layer of powder material onto a target surface; irradiating a first portion of the first layer of powder material with the high energy source and solidifying the first portion of powder material, the first portion corresponding to a first cross-sectional region of the turbo-machine impeller; depositing a second layer of powder material onto the first portion; irradiating a second portion of said second layer of powder material with the high energy source and solidifying the second portion of powder material, the second portion corresponding to a second cross-sectional region of the turbo-machine impeller, the first portion and the second portion being joined to one another; depositing successive layers of powder material onto the previous portion and irradiating a portion of each successive layer to produce the turbo-machine impeller, further comprising a plurality of solidified, wherein each of the plurality of solidified layer portions correspond to a cross-sectional region of the turbo-machine impeller; wherein at least some of the successive solidified layer portions respectively comprise at least one inner portion having a lattice structure surrounded by an outer solid skin.

3. The method according to claim 1, wherein the high energy source comprises an electronic beam generator.

4. The method according to claim 1, wherein the high energy source comprises a laser source.

5. The method according to claim 2, wherein the layers of powder material are deposited in a heated confinement structure.

6. The method according to claim 2, further comprising controlling the temperature of the turbo-machine impeller after formation of the layer portions to avoid high temperature gradients in the turbo-machine impeller to minimize the residual stresses.

7. The method according to claim 1, wherein the powder material is melted and solidified.

8. The method according to claim 1, wherein the powder material is solidified by sintering.

9. The method according to claim 1, wherein the high energy source is pulsed to generate the lattice structures.

10. The method according to claim 1, further comprising the step of forming a lattice structure in more than one inner portion of the hub.

11. The method according to claim 1, further comprising forming at least one aperture through the outer solid skin for removing un-solidified powder material.

12. The method according to claim 1, further comprising removing un-solidified powder material from the lattice structures after all the layers of the turbo-machine impeller have been completely formed.

13. The method according to claim 12, wherein the un-solidified powder material is removed by blowing or sucking a gaseous flow through the lattice structures.

14. A method of manufacturing a turbo-machine impeller comprising a hub defining an impeller foot, a shroud defining an impeller eye, and a plurality of blades using powder material in an additive-manufacturing process, the method comprising: irradiating the powder material with a high energy source; and solidifying the powder material to form the turbo-machine impeller, wherein the powder material is irradiated such that the impeller foot and the impeller eye solidify, respectively, in a lattice structure surrounded by an outer solid skin structure enclosing the lattice structure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

(2) FIG. 1 illustrates a perspective view of a shrouded impeller according to the state of the art;

(3) FIG. 2 illustrates a schematic cross section of a shrouded impeller according to the state of the art;

(4) FIG. 3 illustrates a schematic of an electron-beam melting machine;

(5) FIG. 4 illustrates a cross-section of a shrouded impeller according to the present disclosure;

(6) FIGS. 5A, 5B and 5C schematically represent alternative lattice structures which can be formed in the bulky areas of the impeller.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(7) The following detailed description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Additionally, the drawings are not necessarily drawn to scale. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.

(8) Reference throughout the specification to one embodiment or an embodiment or some embodiments means that the particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrase in one embodiment or in an embodiment or in some embodiments in various places throughout the specification is not necessarily referring to the same embodiment(s). Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

(9) FIG. 3 illustrates an electron-beam melting machine designated 100 as a whole. The structure and operation of the electron-beam melting machine are known per se and will not be described in great detail herein. The electron-beam melting machine 100 includes an electron-beam gun 101 comprising an electron emitter 103 which generates an electron beam EB. The electron beam EB is directed towards a target surface TS, arranged under the electron-beam gun 101. Along the electron-beam path a focusing coil 105 and a deflection coil 107 are arranged. The focusing coil 105 focuses the electron beam on the target surface TS and the deflection coil 107 controls the movement of the electron beam EB along a pattern according to which a powder material has to be melted and solidified. A computer device 109 controls the deflection coil 107 and the movement of the electron beam EB. The movement of the electron beam EB is controlled by the computer device 109 based on data from a file representing the three-dimensional product to be manufactured.

(10) Under the electron-beam gun 101 a confinement structure 111 is arranged. The confinement structure 111 can be combined to temperature control means, for example comprising a heater shown schematically at 113, e.g. an electrical heater. A movable table 115 can be arranged in the confinement structure 111. The movable table 115 can be controlled to move vertically according to double arrow f115. The vertical movement of the movable table 115 can be controlled by the computer device 109. A powder material container 117 is arranged above the target surface TS and is controlled to move horizontally according to double arrow f117, for example under the control of the computer device 109.

(11) The manufacturing process performed by the electron-beam melting machine 100 can be summarized as follows. A first layer of powder material from the powder container 117 is distributed on the movable table 115 by moving the powder material container 117 according to arrow f117 one or more times along the movable table 115 which is placed at the height of the target surface TS. Once the first layer of powder material has been distributed, the electron-beam gun 101 is activated and the electron beam EB is controlled by the deflection coil 107 such as to locally melt the powder material in a restricted portion of the layer, corresponding to a cross-section of the product to be manufactured. After melting, the powder material is allowed to cool and solidify. Powder material outside the boundaries of the cross-section of the product to be manufactured remains in the powder form. Once the first layer has been processed as described above, the movable table 115 is lowered and a subsequent layer of powder material is distributed on top of the first layer. The second layer of powder material is in turn selectively melted and subsequently allowed to cool and solidify. Melting and solidifying are performed such that each layer portion will adhere to the previously formed payer portion. The process is repeated stepwise, until the entire product is formed, by subsequently adding one powder material layer after the other and selectively melting and solidifying layer portions corresponding to subsequent cross sections of the product.

(12) Once the product has been completed, the powder material which has not been melted and solidified can be removed and recycled. The product thus obtained can be subjected to further processing if required, such as surface finishing processes or machining.

(13) The above described process can be carried out under controlled temperature conditions by means of the heater 113. The temperature within the confinement structure 111 is controlled such that the entire process is performed at high temperature and virtually no residual stresses remain in the product at the complexion of the manufacturing cycle. After the construction process has been completed, the product can be allowed to cool down from a processing temperature to an environment temperature following a cooling curve which prevents residual stresses in the final product.

(14) The interior of the confinement structure 111 is maintained under hard vacuum conditions, such that oxygen absorption by the powder material and the melted material is prevented.

(15) In the representation of FIG. 3, an impeller 120 is schematically shown in an intermediate step of the above summarized additive-manufacturing-type manufacturing process.

(16) By suitably controlling the electron beam emission a complete melting and subsequent solidification of the powder material is possible, thus obtaining a final compact and solid structure. Alternatively, it is also possible to control the electron beam emission such that the powder material is melted and subsequently solidified only in limited volumes, i.e. in a factional manner. By so doing, restricted volumes of powder material are melted and subsequently solidified, said volumes being arranged one adjacent to the other, such that they will connect to one another forming a lattice structure. The lattice structure obtained will be immersed in a bed of powder material which has not been melted. This residual powder material can be subsequently removed, leaving an empty lattice structure.

(17) According to an embodiment, a mixed arrangement is suggested, comprising solid portions and lattice-structured portions, which together form the final product, e.g. a turbo-machine impeller.

(18) In FIG. 4, a cross-sectional view of an impeller for a centrifugal turbo-machine manufactured using the layer-by-layer manufacturing process described above is shown. The impeller 120 comprises a hub 121, a shroud 123, blades 125 extending inside the volume between the hub 121 and the shroud 123. Vanes 127 are defined between adjacent blades 125.

(19) The impeller 120 comprises a central hole 129 for a shaft (not shown). The hole 129 is surrounded by a bulky portion 131 of the hub 121 of the impeller 120, commonly named impeller foot.

(20) As can be appreciated from the sectional view of FIG. 4, the thickness of the material forming the various parts of the impeller 120 differs from one portion of the impeller to the other. For example, the blades 125 have a relatively thin cross-section, similarly to the radially outer part of the hub 121, i.e. the portion labeled 121A of the hub 121. The radially inner part of the hub 121 forms the above mentioned impeller foot 131, the thickness of which, is remarkably larger than the remaining part of the hub 121.

(21) Also the shroud 123 has a radially outer portion 123B which is thinner than the radially inner portion 123A.

(22) In the exemplary embodiment shown in FIG. 4, the interior of the bulkier portions of the impeller 120 and more specifically the interior of the impeller foot 131 as well as the bulkier portion 123A of the shroud 123, commonly named impeller eye are manufactured with a lattice structure labeled L. The lattice structure L can be produced as mentioned above, by suitably controlling the electron beam EB. The lattice structure L is surrounded by a solid skin structure or portion S, which is fluid impervious and compact.

(23) In the exemplary embodiment shown in FIG. 4 the impeller has only two areas formed by a lattice structure. Those skilled in the art will however understand that a different arrangement of lattice structure portions can be provided, depending upon the design of the impeller. For example, if the shroud has a limited thickness, it can be manufactured as a single compact and solid part, without a lattice structure inside. Similarly, un-shrouded impellers can be provided with a lattice structure only in the impeller hub, and more particularly, in the impeller foot, which has a bulkier structure than the remaining parts of the hub. The radial extension of the lattice structure in both the hub and the shroud (if present) depends upon the shape of the cross section of the impeller in a radial plane. Providing lattice-structured blades or blade portions is also not excluded, if allowed by the cross-sectional dimensions and shape of the blades.

(24) In an embodiment, each lattice-structured part of the impeller will be surrounded and encapsulated in a solid skin structure, which forms a fluid impervious barrier, preventing gas or liquid from penetrating the internal lattice structure and providing a smooth outer flow surface for the fluid being processed by the turbo-machine. The solid skin structure can be machined in the same way as any other solid part of the impeller, e.g. for surface finishing purposes.

(25) The entire outer surface of the impeller 120 is therefore formed by a continuous solid structure, with no porosity, while the lattice structure L is confined inside said solid skin structure S and does not surface on the outside of the impeller 120.

(26) As discussed above, both the lattice structure L and the solid parts, including the solid skin structure S, of the turbo-machine impeller can be manufactured layer-by-layer by suitably controlling the electron-beam emission. Along the same layer of powder material the electron beam EB can be controlled such as to provoke a complete melting of the powder material along those portions of the layer which are intended to form the solid structure, including the solid skin structure S surrounding the lattice structure L. In the areas of the layer where a lattice structure L is required, such as in the impeller foot, the electron beam can be, for example, pulsed, i.e. choppered, and moved such that the powder material is melted spot-wise, each spot of melted material contacting the adjacent spots of melted material and solidifying in the required lattice structure L.

(27) In order to more easily remove the loose powder material which remains trapped between the melted and solidified spots of the lattice structure L, according to some embodiments one or more apertures are provided in the solid skin structure S surrounding each lattice structure L formed in the inner volume of the impeller.

(28) In FIG. 4, two apertures A are shown by way of example in the solid skin structure S surrounding the lattice structure L of the impeller foot 131. The apertures A can be used to blow air or suck air through the lattice structure L thus removing the unsolidified powder material therefrom. Preferably the apertures are positioned on the outer surface of the impeller, such as not to negatively affect the flow of the fluid being processed by the impeller, as shown in the example illustrated in the drawings.

(29) FIGS. 5A to 5C schematically illustrate possible lattice structures obtained by electron beam local melting. As can be appreciated from these figures, the lattice structure contains large empty volumes, which reduce the overall amount of material forming the impeller and reducing therefore the weight of the impeller.

(30) While the disclosed embodiments of the subject matter described herein have been shown in the drawings and fully described above with particularity and detail in connection with several exemplary embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without materially departing from the novel teachings, the principles and concepts set forth herein, and advantages of the subject matter recited in the appended claims. Hence, the proper scope of the disclosed innovations should be determined only by the broadest interpretation of the appended claims so as to encompass all such modifications, changes, and omissions. In addition, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments.