TURBINE ROTOR BLADE AND MEMBER OF TURBINE ROTOR BLADE

Abstract

In a manufacturing method of a turbine rotor blade using an Ni-based forged alloy, provided is a turbine rotor blade and a member of a turbine rotor blade having an excellent workability and a high degree of freedom in the design of a cooling structure. The turbine rotor blade includes at least two members, including a first member and a second member, and each member is provided with cooling structural parts acting as cooling flow passages. The turbine rotor blade has a joint that integrates the first member and the second member, wherein the joint has a forged structure and the whole turbine rotor blade including the joint has a uniform forged structure.

Claims

1. A turbine rotor blade made of a Ni-based forged material, wherein: the turbine rotor blade is composed of at least two members comprising a first member and a second member, each of the at least two members is provided with cooling structural parts acting as cooling flow passages, the turbine rotor blade has a joint integrating the first member and the second member, and the joint has a forged structure and an entirety of the turbine rotor blade including the joint has a uniform forged structure.

2. The turbine rotor blade according to claim 1, wherein the cooling structural parts include a serpentine flow passage inside the turbine rotor blade.

3. The turbine rotor blade according to claim 1, wherein the cooling structural parts include a hole at a side face of the turbine rotor blade.

4. The turbine rotor blade according to claim 1, wherein the turbine rotor blade includes 10 mol % or more and 40 mol % or less of phase at equal to or more 1050 C.

5. The turbine rotor blade according to claim 1, wherein the turbine rotor blade after solid solution and aging treatment process includes not less than 30 mol % of phase that coherent with a matrix phase at equal to or higher than 700 C.

6. The turbine rotor blade according to claim 1, wherein the at least two members act as a blade part and an apex part of the turbine rotor blade.

7. A member of a turbine rotor blade made of a Ni-based forged material, wherein: the turbine rotor blade is composed of at least two members made of a Ni-based softening material, the softening material has a dual structure comprising a phase and a incoherent phase, a raw material of the softening material includes 10 mol % or more and 40 mol % or less of phase at equal to or higher than 1050 C., and a vickers hardness of the softening material is equal to 350 Hv or less.

8. The member of a turbine rotor blade according to claim 7, wherein the at least two members of the turbine rotor blade are provided with joining parts to be joints of respective members.

9. The member of a turbine rotor blade according to claim 8, wherein the joining parts to be the joints of the respective members of the turbine rotor blade are protrusions formed at ends of members.

10. The member of a turbine rotor blade according to claim 7, wherein the at least two members of the turbine rotor blade have cooling structural parts acting as cooling flow passages.

11. The member of a turbine rotor blade according to claim 10, wherein the cooling structural parts form a serpentine flow passage inside the turbine rotor blade.

12. The member of a turbine rotor blade according to claim 10, wherein the cooling structural parts include a hole at a side face of the turbine rotor blade.

13. The member of a turbine rotor blade according to claim 10, wherein the cooling flow passages are formed by joining the at least two members.

14. The member of a turbine rotor blade according to claim 7, wherein the at least two members of the turbine rotor blade act as a blade part and an apex part of the turbine rotor blade.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0014] FIG. 1 is a sectional view schematically showing a process in a manufacturing method of a turbine rotor blade according to the present invention.

[0015] FIG. 2 is a flowchart showing a manufacturing method of a turbine rotor blade according to the present invention.

[0016] FIG. 3 is a view schematically showing temperature pro files and material structure in a softening process.

[0017] FIGS. 4A to 4D are a flowchart explaining the processes S21 to S23 in FIG. 2.

DESCRIPTION OF EMBODIMENTS

[0018] Embodiments according to the present invention are hereunder explained in detail. The present invention, however, is not limited to the embodiments addressed here and can be combined or modified appropriately in the range not changing the tenor.

[Basic Concept of the Present Invention]

[0019] FIG. 1 is a sectional view schematically showing a process in a manufacturing method of a turbine rotor blade according to the present invention. The present inventors have earnestly studied a manufacturing method of a turbine rotor blade (hereunder referred to also as an Ni-based forged blade) capable of attaining the above object. As a result, the present inventors have found that an intricate cooling structure can be formed in a blade interior through the following manufacturing process. That is, the workability of an Ni-based forged material is improved by increasing the quantity of a phase 5 incoherent with a phase 4 and then at least two members (members 1 and 2 in FIG. 1) constituting a turbine rotor blade are formed. Then, after cooling structural parts acting as cooling flow passages (cooling structures) of a cooling fluid 6 are formed in the respective members, the respective members are joined. According to the manufacturing method, an intricate cooling structure can be formed in the interior of a forged blade without generating working cracks even in the case of an Ni-based forged alloy containing a phase of not less than 10% to not more than 40% by mole at not lower than 1,050 C. and having a high high-temperature strength. The present invention is established through the findings.

[0020] FIG. 2 is a flowchart showing a manufacturing method of a turbine rotor blade according to the present invention. As stated earlier, a manufacturing method of an Ni-based forged blade according to the present invention includes a softening process (S1) of softening an Ni-based forged material (Ni-based forged alloy) that is a raw material, a first working process (S21) of manufacturing at least two members constituting the Ni-based forged blade from the raw material after softened (softened material), a second working process (S22) of forming precursors (cooling structural parts) of a cooling flow passage in the members after the first working process, and a third working process (S23) of joining and integrating a first member and a second member after the second working process and forming a turbine rotor blade (hereunder referred to also as a rotor blade or Ni-based forged blade) that is a product. The present invention includes the processes S1, S21, S22, and S23 as essential. A solid solution and aging treatment process (S3) for strengthening a rotor blade in a softened state may be applied after the process S23. The respective processes are hereunder explained in detail in reference to drawings.

(S1: Softening Process)

[0021] FIG. 3 is a view schematically showing temperature profiles and material structure in the process S1. As shown in FIG. 3, the process S1 includes a hot forging process and a cooling process. First, the hot forging process is explained. In the hot forging process, a phase incoherent with a phase precipitates over the grain boundary of the phase by hot-forging an Ni-based forged material at a temperature of not higher than a temperature at which the phase disappears (solid solution temperature Ts of a phase) and not lower than a temperature at which the recrystallization of the phase advances rapidly. Here, in the present invention, over the grain boundary of a phase means a boundary between adjacent crystal grains.

[0022] The ground of a hot-forging temperature is shown hereunder. A / phase coherent interface contributes to phase precipitation strengthening that is the major strengthening mechanism of an Ni-based alloy and strengthening capability disappears by making the / coherent interface incoherent. At the hot-forging process, hot forging is applied at a temperature of not higher than the solid solution temperature of a phase and not lower than a temperature at which the recrystallization of a phase advances rapidly in order to precipitate a incoherent phase. The solid solution temperature of a phase in a raw material used in the present invention is most desirably not lower than 1,050 C. The effects of the present invention are obtained even when the solid solution temperature of a phase is 1,000 C. to 1,050 C., but a incoherent phase hardly precipitates at not higher than 1,000 C. and cannot precipitate at not higher than 950 C., and hence the effects of the present invention cannot be obtained. Further, when the solid solution temperature of a phase comes close to the melting point of an Ni-based alloy raw material, cracking is generated during working by partial dissolution or the like and hence the solid solution temperature of a phase is desirably lower than 1,250 C.

[0023] A hot-forging temperature has to be not lower than a temperature at which the recrystallization of a phase advances rapidly as stated earlier. More specifically, a hot-forging temperature is desirably not lower than 1,000 C. and more desirably not lower than 1,050 C. When a hot-forging temperature is lower than 950 C., a incoherent phase cannot precipitate and the effects of the present invention are not obtained.

[0024] Successively, a cooling (slow cooling) process is explained. At the cooling process, a softened state is realized by: slowly cooling a raw material in which a incoherent phase 33 precipitates at a cooling rate of not higher than 50 C./h from a temperature of not lower than a hot-forging temperature; increasing (growing) the incoherent phase 33 not contributing to strength; and thus increasing the quantity of the precipitated phase 33. In a raw material immediately after hot forging, in addition to a incoherent phase 33, a coherent phase 32 also precipitates while the raw material cools from a hot-forging temperature to room temperature. At the cooling process therefore, a dual phase structure comprising a phase 31 and a incoherent phase 33 has to be formed by raising a temperature to a temperature not lower than the hot-forging temperature of a raw material and thus dissolving a coherent phase 32. A temperature before slow cooling at the cooling process therefore is desirably a temperature of not lower than the hot-forging temperature of a raw material and not higher than the solid solution temperature of a phase.

[0025] The ground of a cooling rate at a cooling process is shown hereunder. By slowly cooling a raw material from a temperature of not lower than a hot-forging temperature, the precipitation driving force of a coherent phase 32 lowers and hence a incoherent phase 33 increases. Consequently, a incoherent phase 33 can grow more as a cooling rate lowers and a cooling rate is desirably not higher than 50 C./h and more desirably not higher than 10 C./h.

[0026] The ground of a cooling end temperature is shown hereunder. By increasing a incoherent phase 33 by applying slow cooling up to a temperature of not higher than working temperatures at the working processes S21 to S23 described later, a coherent phase 32 can be inhibited from precipitating at the working temperatures. Further, the precipitation driving force of a coherent phase 32 lowers as a temperature lowers and precipitation occurs scarcely at not higher than 500 C. A slow cooling end temperature at the cooling process therefore is desirably not higher than the working temperatures of the latter steps and more desirably not higher than 500 C. Through the softening process explained above, a raw material for a rotor blade softens and comes to be in the state of good workability.

(S21: First Working Process)

[0027] Successively, an Ni-based softened material that has come to a softened state at the above softening process is processed. FIG. 4 is a flowchart explaining the processes S21 to S23 in FIG. 2. First, at the first working process (S21), Ni-based softened materials 40a and 40b ((a) in FIG. 4) are processed to form the shapes ((b) in FIG. 4) of at least two members constituting a rotor blade. In (b) of FIG. 4, a rotor blade is divided into the two members of a member 41 acting as the apex part (top end part) of the rotor blade and a member 42 constituting a blade part (part other than the apex part) of the rotor blade and the two members are processed into respective shapes. On this occasion, as shown by (d) in FIG. 4, joining parts 43 to be the joints of the respective members are formed in the members 41 and 42 at the third working process (S23) described later. The working at the first working process is not particularly limited and can be machining, hot forging (die forging), or both of them.

[0028] The joining parts 43 are formed preferably at places where a rotor blade is scarcely affected during joining. When friction stir welding described later is used for the joining of the members in particular, a large load is applied during the joining and hence the joining parts 43 are formed preferably so that a large pressure may not be applied to the parts other than the joining places of the rotor blade. As shown by (b) and (c) in FIG. 4, desirably, protrusions are formed at the ends of the members and the protrusions are used as a joint 45.

(S22: Second Working Process)

[0029] After the first working process, a second working process (S22) of forming cooling structural parts 44 that come to be the precursors of a cooling flow passage in the respective members is carried out. The working at the second working process is not particularly limited and predetermined shapes can be formed by using drilling, electrical discharge machining, or both of them. A burr formed on this occasion is removed because it can be a progress point of a crack in a rotator including a rotor blade.

[0030] By forming a structure shown by (c) in FIG. 4 as cooling structural parts 44, for example, after a third working process (S23) described later, a serpentine flow passage in which a cooling flow passage bends at an angle of 180 degrees can be formed. Further, film cooling is also possible by forming a hole at a side face of a blade by drilling.

(S23: Third Working Process)

[0031] A third working process of joining the respective members is carried out after the second working process. As the joining, various joining methods can be applied but friction stir welding is applied desirably. As shown by (d) in FIG. 4, the joining parts 43 formed at (c) in FIG. 4 are joined and form a joint 45. As a result, a desired cooling structure (cooling flow passage) is formed by combining the cooling structural parts of the members.

[0032] The ground that friction stir welding is preferred is shown hereunder. In general, an Ni-based alloy containing many alloying elements is hardly weldable but, by friction stir welding, can be joined while a joint does not dissolve and a uniform forged structure is retained. As a result, the alloy can be welded without lowering the strength of a joint.

(S3: Solid Solution and Aging Treatment Process)

[0033] A high-temperature strength can be recovered by applying solid solution and aging treatment of dissolving a incoherent phase and reprecipitating a coherent phase after the third working process. In the present invention, the conditions of solid solution treatment and aging treatment are not particularly limited and generally used conditions can be applied. A coherent phase is contained desirably by not less than 30% by mole at 700 C. after a solid solution and aging treatment process. As long as the content of a coherent phase is not less than 30% by mole, an Ni-based forged blade having an adequate high-temperature strength can be obtained.

[0034] As stated earlier, a cooling structure has heretofore been formed with one member by machining or electrical discharge machining but only a cooling structure of piercing through in one direction from the root part toward the apex part of a blade has been able to be manufactured by this method. According to the present invention, since a rotor blade is manufactured by softening an Ni-based alloy firstly, preparing a plurality of members constituting the rotor blade, forming cooling structural parts in the members, and then assembling the members, a cooling structure of an intricate shape (meandering flow passage) that has heretofore been impossible when a rotor blade is manufactured from one member can be formed. Further, since a uniform forged structure can be retained even after joining by using friction stir welding when members are joined, a rotor blade can be manufactured without lowering the strength of an Ni-based forged material.

[0035] Although a manufacturing method of a rotor blade for a gas turbine has heretofore been explained as an embodiment according to the present invention, the method is not limited to a gas turbine and can appropriately apply also to another product in the range not changing the tenor. As an example, the method can be applied also to a rotator including a rotor blade of a compressor or a steam turbine.

EXAMPLES

[0036] Examples according to the present invention are explained hereunder.

[0037] (1) Manufacturing of Turbine Rotor Blades of Examples 1 to 3 and Comparative Materials 1 to 4

[0038] Test materials (Examples 1 to 3 and Comparative materials 1 to 4) are manufactured by using raw materials having the compositions shown in Table 1 and carrying out a softening process (S1) to a solid solution and aging treatment process (S3), those being stated earlier. The test materials are evaluated by the methods shown in Table 2. Evaluation results are represented by the symbols , , and x and the evaluation criteria are described in Table 3. In the manufacturing of the test materials, the raw materials are obtained by dissolving 50 kg each of the alloys having the compositions shown in Table 1 by using vacuum induction melting, applying homogenization treatment, and successively hot-forging the alloys at 1,050 C. to 1,250 C. The evaluation results of the test materials are shown in Table 4.

TABLE-US-00001 TABLE 1 Ni Cr Co Mo W Ti Al C B Zr Nb Fe Hf Re Ta Example 1 Bal. 15.6 8.4 3.0 2.6 3.5 2.3 0.01 0.01 0.03 1.1 3.9 Example 2 Bal. 13.4 25.2 2.8 1.3 5.9 2.5 0.02 0.01 0.04 Example 3 Bal. 16.0 15.1 3.0 1.3 5.3 2.5 0.01 0.02 0.03 0.00 0.15 Comparative Bal. 19.8 19.0 5.9 2.2 0.5 0.05 0.7 material 1 Comparative Bal. 19.0 12.1 6.2 1.0 2.9 2.0 0.03 material 2 Comparative Bal. 13.1 24.8 2.9 1.2 6.0 2.4 0.02 0.02 0.05 material 3 Comparative Bal. 7.0 1.1 0.8 8.9 4.7 0.05 0.01 0.75 0.25 1.5 8.8 material 4

TABLE-US-00002 TABLE 2 Evaluation 1: y Evaluation 2: Evaluation 3: Evaluation 4: Evaluation 5: Evaluation 6: y phase quantity Hardness after Workability Workability Workability phase quantity after in raw softening during during during solid solution and material at process first working second working third working aging treatment 1,050?+0C (S1) process (S21) process (S22) process (S23) process (S3) Evaluation Calculation A raw material (1) Die forging is (1) Cooling (1) A blade part A y phase method based is heated to a carried out at structural parts and an apex quantity on thermo- forging 950 C. and are formed part are joined is calculated dynamic temperature successively at a blade by friction by observing calculation (1,050 C. pads are removed part and an stir welding. a texture 1,250 C.), by machining. apex part (2) When retained at successively (2) When die by drilling. friction 700 C. for retained for forging cannot (2) When drilling stir 16 hours after one hour, be carried out, is impossible, welding is retained successively pads are removed cooling impossible, the at 1,050 C. cooled slowly by machining. structural parts evaluation to 1,150 C. to 500 C. (3) When both die are formed finishes. for 4 hours. at 10 C./h, forging and at a blade part successively machining are and an apex part water- impossible, the by electrical cooled, and evaluation discharge extracted. finishes. machining.

TABLE-US-00003 Evaluation 1: y' Evaluation 2: Evaluation 3: Evaluation 4: Evaluation 5: Evaluation 6: y phase quantity Hardness Workability Workability Workability phase quantity in raw after softening during during during after solid solution material at process first working second working third working and aging Evaluation 1,050 C. (S1) process (S21) process (S22) process (S23) treatment (S3) 10 [mol %] Hardness not Die forging and Electrical Friction stir A y phase at or more higher than machining: discharge welding: possible 700 C. is not 350 Hv possible machining and and less than 30% drilling: possible by mole 0 to 10 [mol %] Hardness 350 Die forging: Electrical by mole to not higher impossible, discharge than 400 Hv machining: machining: possible possible, drilling: impossible Hardness Working: Working: Friction stir A y phase at 0 [mol %] not lower difficult difficult welding: 700 C. is not than 400 Hv impossible more than 30% by mole

TABLE-US-00004 Evaluation 1: Evaluation 2: Evaluation 3: Evaluation 4: Evaluation 5: Evaluation 6: y y phase Hardness Workability Workability Workability phase quantity quantity after during during during after solid in raw softening first second third solution and material at process working working working aging treatment 1,050 C. (S1) process (S21) process (S22) process (S23) process (S3) Example 1 Example 2 Example 3 Comparative material 1 Comparative material 2 Comparative Not carried out material 3 Comparative material 4

[0039] (2) Evaluation 1: Evaluation of Phase Quantity in Raw Material at 1,050 C.

[0040] A phase quantity in a raw material at 1,050 C. is calculated on the basis of thermodynamic calculation. In each of Examples 1 to 3 and Comparative materials 3 and 4, a phase of not less than 10% by mole exists thermodynamically stably at 1,050 C. In Comparative material 1, no phase exists because the solid solution temperature of a phase is not higher than 1,050 C. In Comparative material 2, a phase exists at 1,050 C. but is not more than 10% by mole. In Comparative material 4, however, a phase quantity exceeds 40% by mole at 1,050 C., a large crack is caused during the process of making a forged material by forging a raw material in the evaluation after the process S1 described later, and hence the evaluation is finished. In this way, since a raw material can hardly be forged when a phase quantity at not lower than 1,050 C. exceeds 40% by mole, a phase quantity is desirably not more than 40% by mole.

[0041] (3) Evaluation 2: Evaluation of Hardness after Softening Process (S1)

[0042] Each of the test materials is heated to a forging temperature (1,050 C. to 1,250 C.), then water-cooled after slowly cooled to 500 C. at 10 C./h, and extracted. Successively, a test piece 0.5 to 1.0 mm in size is taken out from an end of the test material and a hardness is measured with a micro Vickers hardness tester.

[0043] Examples 1 to 3 and Comparative material 1 are not higher than 350 Hv respectively. Comparative material 2 shows a hardness of 350 to 400 Hv. With respect to Comparative material 3, the softening process (S1) is not carried out and the first working process (S21) of the latter step is carried out. As a result of observing a structure on this occasion with a scanning electron microscope, it is confirmed that, in each of Examples 1 to 3, a dual phase structure comprising a phase and a incoherent phase is formed. In each of Comparative materials 1 and 2, a incoherent phase is not recognized and a coherent phase precipitates. In Comparative material 1, since a forging temperature is set at a temperature not lower than the solid solution temperature of a phase, a incoherent phase does not precipitate and the effects of the present invention are not obtained. In Comparative material 2, although a forging temperature is not lower than the solid solution temperature of a phase, the phase quantity at 1,050 C. evaluated in Evaluation 1 is small and the effects of the present invention are presumably not obtained sufficiently. In Comparative material 3, both a incoherent phase and a coherent phase precipitate. This is because a incoherent phase precipitates while a raw material is forged before the softening process (S1) and successively a coherent phase precipitates during the process of cooling the raw material to room temperature.

[0044] (4) Evaluation 3: Evaluation of Workability During First Working Process (S21)

[0045] At the first working process, firstly members acting as an apex part and a blade part of a rotor blade are manufactured by applying die forging at 950 C. A case where a load of press is insufficient during forging and a test material does not deform or a case where a defect such as a crack is generated in the interior or on the surface of a test material after forging is judged as not workable. With regard to machining, a case where a tool wears significantly or a defect is generated during working is judged as not workable.

[0046] Each of Examples 1 to 3 and Comparative material 1 can be worked by both die forging and machining. Comparative material 1 is workable because the quantity of a phase is small and strength is low although a incoherent phase does not precipitate at the softening process S1 and the softening process in the present invention does not contribute. In Comparative material 2, machining is possible but die forging is impossible. Further, in Comparative material 3, both die forging and machining are impossible. This is because Comparative material 3: is a high-strength material in which the solid solution temperature of a phase is not lower than 1,050 C.; precipitates a coherent phase during working because a softening process is not applied; and is in the state of low workability. For the reason, the softening process S1 has to be applied in order to obtain good workability when a thermodynamically stable Ni-based alloy containing a phase of not less than 10% by mole at not lower than 1,050 C. is subjected to die forging and machining.

[0047] (5) Evaluation 4: Evaluation of Workability During Second Working Process (S22)

[0048] At the second working process, firstly a cooling structural part is formed in a test material at room temperature by drilling. On this occasion, a case where a tool wears significantly or a defect is generated during working is judged as not workable, in the same manner as Evaluation 3. Electrical discharge machining can be applied because all the test materials are made of metal.

[0049] Each of Examples 1 to 3 and Comparative material 1 can be worked by both the methods of drilling and electrical discharge machining. In Comparative material 1, workability is good but the strength of the raw material itself is low as stated earlier and hence the softening process in the present invention does not contribute. In Comparative material 2, drilling is impossible but electrical discharge machining is possible.

[0050] (6) Evaluation 5: Evaluation of Workability During Third Working Process (S23)

[0051] At the third working process, an apex part and a blade part are joined by friction stir welding. A case where a tool cannot be pushed into a test material, a case where a tool wears or breaks significantly during working, or a case where a defect, a specific harmful phase, or the like is recognized in an interior at a joint is judged as joining is impossible.

[0052] In each of Examples 1 to 3 and Comparative material 1, joining is possible and, by observation with a microscope, a defect and the like are not recognized at a joint and a fine polycrystalline structure is observed. That is, a uniform forged structure is observed in a whole rotor blade including a joint. In Comparative material 2, a tool cannot be pushed in and joining is impossible.

[0053] (7) Evaluation of Phase Quantity after Solid Solution and Aging Treatment Process (S3)

[0054] Solid solution and aging treatment is carried out under a standard heat treatment condition of each test material and the quantity of a precipitated coherent phase is calculated by succeeding structure observation and image analysis. In each of Examples 1 to 3, a coherent phase of not less than 30% by mole precipitates at 700 C. and a rotor blade having an adequate high-temperature strength can be obtained. In Comparative material 1, a phase quantity is not more than 30% by mole at 700 C.

[0055] From the above results, it is verified that the present invention makes it possible, in a manufacturing method of a turbine rotor blade using an Ni-based forged alloy, to provide a manufacturing method of a turbine rotor blade having an excellent workability and a high degree of freedom in the design of a cooling structure.

[0056] Meanwhile, the above examples are explained concretely in order to help the present invention to be understood and the present invention does not necessarily have all the explained configurations. For example, a part of the configuration of a certain example can be replaced with the configuration of another example and the configuration of a certain example can be added to the configuration of another example. Further, a part of the configuration of each example can be deleted, replaced with another configuration, or added to another configuration.

TABLE-US-00005 Reference Signs List 1, 41 First member 2, 42 Second member 3, 45 Joint 4, 31 phase 5, 33 incoherent phase 32 coherent phase 43 Joining part 44 Cooling structural part S1 Softening process S21 First working process S22 Second working process S23 Third working process S3 Solid solution and aging treatment process