METHOD FOR PRODUCING A COMPONENT, AND DEVICE

Abstract

A method for producing a component for a turbomachine, having the additive build-up of the component by an additive production method from a base material for the component and the introduction of material fibers into a construction for the component during the additive build-up in such a way that the material fibers are oriented in a circumferential direction of the component around a component axis and in such a way that a fiber composite material is produced, including the material fibers and a base material that is solidified by the additive build-up. A corresponding component is produced by the method and a corresponding device is used for producing the component.

Claims

1. A method for producing a component for a turbomachine, the method comprising: additive build up of the component by means of an additive production method from a base material for the component and introduction of material fibers into a construction for the component during the additive build up in such a way that the material fibers are oriented along a circumferential axis of the component around a component axis and in such a way that a fiber composite material is created, the fiber composite material comprising the material fibers and a base material which is solidified as a result of the additive build up, wherein the material fibers comprise ceramic material.

2. The method as claimed in claim 1, wherein the material fibers are introduced by means of a robot-controlled appliance.

3. The method as claimed in claim 1, wherein the material fibers are introduced only in a central region of the component, as seen along a build-up direction of the component.

4. The method as claimed in claim 1, wherein the additive production method is selective laser melting, selective laser sintering, electron beam melting or laser deposition welding.

5. The method as claimed in claim 1, wherein the base material is arranged at least partially between the material fibers.

6. The method as claimed in claim 1, wherein the material fibers are provided with a coating before introduction.

7. A component for a turbomachine, wherein the component is produced, by means of the method according to claim 1, wherein the component is a rotor part of a turbomachine, or of a gas turbine.

8. The component as claimed in claim 7, wherein the component is a turbine disk for the mounting of a rotating part of a turbomachine, or a compressor blade, during operation.

9. A turbine disk for a turbomachine, comprising: a fiber composite material comprising material fibers which comprise ceramic material, wherein the material fibers are oriented along a circumferential direction or the turbine disk around a rotation axis thereof during operation.

10. The turbine disk as claimed in claim 9, wherein the material fibers comprise one or more of the following materials: carbon, boron and/or basalt.

11. A device for producing a component for a turbomachine, wherein the device is designed for additively building up the component from a base material, the device comprising: an appliance which is designed for introducing material fibers into a construction for the component in such a way that the material fibers are oriented along a circumferential direction of the component around a component axis and in such a way that a fiber composite material is created, which fiber composite material comprises the material fiber and a solidified base material.

12. The method as claimed in claim 1, wherein the material fibers comprise ceramic material, consisting of aluminum oxide, mullite, SiBCN, SiCN or SiC.

13. The turbine disk as claimed in claim 9, wherein the material fibers comprise ceramic material, consisting of aluminum oxide, mullite, SiBCN, SiCN or SiC.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Further details of the invention are described below with reference to the drawing.

[0041] FIG. 1 schematically shows a top view of a device for the additive production of a component for a turbomachine.

[0042] FIG. 2 schematically shows a sectional or side view of a device for the additive production of a component for a turbomachine.

[0043] FIG. 3 schematically shows a cross section through a turbine disk.

DETAILED DESCRIPTION OF INVENTION

[0044] FIG. 1 schematically shows a top view of a device 10. The device 10 is a device for the additive production of a component 1. The device 1 is advantageously a device for the layered build up of a component from a powder bed, for example a device for selective laser melting, as shown in FIG. 1. Alternatively, the device 10 can be a device for selective laser sintering and/or for electron beam melting.

[0045] A method according to the invention for producing the component 1 is described based on the device 10 and with reference to FIGS. 1 and 2.

[0046] The component 1 is especially a rotor part of a turbomachine, such as a gas turbine. The component 1 especially refers to a turbine disk, a turbine ring or a rotor disk of a compressor of the turbine.

[0047] The device 10 has a construction platform 8 (cf. FIG. 2) on which is arranged a advantageously powder-form source or base material 2 for the component 1. The base material 2 can for example be a nickel-based, a cobalt-based or an iron-based material.

[0048] Shown on the construction platform 8 is a build up of the component. In this case, it can be a partially built-up component and/or can be the component during its additive production. The component 1 is expediently of rotationally symmetrical design, or in the main of rotationally symmetrical design. As the rotor part of a turbomachine or of a compressor thereof, the component is also advantageously rotatable, e.g. rotatable relative to stator components of the turbomachine. The component advantageously rotates during the designated operation of the turbine.

[0049] For the additive build up, the device 10 has a solidification device 9. In this case, it can be a solidification device of the prior art. The solidification device 9 is advantageously a computer-controlled or computer-controllable unit which for solidifying the base material 2 is equipped with a laser or an electron beam device (not explicitly identified). For the solidification, the base material 2 is advantageously first of all melted and then solidified.

[0050] For applying the base material 2, the device 10 has a coating or deposition device 7. In this case, it can be a doctor blade with which the advantageously powder-form base material 2 can be distributed or deposited on the build platform 8. This can be carried out for example along a coating direction B.

[0051] As an element according to the invention, the device 10 is also an appliance 5. The appliance 5 is designed for introducing material fibers 3 into the build up for the component 1, specifically in such a way that the material fibers 3 are oriented at least in the main along a circumferential direction or rotation direction, identified by the designation A, of the component 1 during operation.

[0052] The dashed (concentric) circles, which are shown inside the component 1 in FIG. 1, advantageously indicate a region in which the material fibers 3 are arranged and/or introduced. The material fibers are also shown only in sections. With reference to the depicted sections, it is to be seen that the direction of orientation or alignment corresponds to the circumferential direction A.

[0053] The appliance 5 is advantageously also designed in such a way that the introduction of the material fibers 3 creates a fiber composite material 4 comprising the material fibers 3 and a solidified base material or matrix material (for the sake of simplicity this is identified by the designation 2 in the same way as the base material. The fiber composite material 4 can be formed by the material fibers 3 and the matrix material.

[0054] The appliance 5 is advantageously robot-controlled. As shown in FIG. 1, the appliance 5 can comprise a robot arm which is shown only schematically in the illustration. This robot arm is pivotable for example across the production area of the construction platform 8 or the component 1 in such a way that the material fibers 3 can be built into the component, as described above, during the additive build up of the base material. Said robot arm can also be for example of telescopically extendable design.

[0055] Within the scope of the present method, the material fibers 3with the aid of the appliance 5are introduced into the construction advantageously during the additive build up or the additive production of the component 1 so that the fiber composite material 4 is created and the fibers are oriented in the same way as described above. One fiber layer (cf. FIG. 1) can be introduced per additively built-up and/or solidified layer of base material. This takes place advantageously before the base material 2 is deposited or distributed by means of the coating device 7 so that a corresponding layer can be formed or produced for the fiber composite material. The base material 2 is advantageously deposited in such a way and/or the material fibers are introduced in such a way that base material 2 is at least partially arranged between the material fibers 3.

[0056] The material fibers 3 can especially also be interwoven.

[0057] It is also provided within the scope of the described method that the material fibers, for example before introduction into the construction by means of the appliance 5, are provided or coated with a coating (not explicitly identified). The coating can be a sliding or lubricant coating, especially in order to enable a sliding movement of the material fibers 3 relative to the matrix material 2, which movement in turn has an effect upon the specific mechanical properties of the fiber composite material 4.

[0058] FIG. 2 shows a schematic side view of a device 10. A build-up direction is identified by the designation C. As an alternative to the embodiment of the device of FIG. 1, the device 10as shown in FIG. 2can for example also be a device for laser deposition welding, especially laser powder deposition welding. Accordingly, the solidification device 9 in this case advantageously comprises both a laser (not explicitly identified) for solidification of the base material 2 and a powder nozzle (not explicitly identified) by means of which the base material 2 is made available.

[0059] FIG. 3 shows, in a simplified cross section, a finished component 1. The component 1in comparison to the remaining sectionshas a narrowed or waisted central, or inner radial region 6. In this region, particularly high mechanical loads can occur during operation of the component 1. An upper, not identified, widening region of the turbine disk 1 is especially provided both in order to keep turbine blades in place, for example during operation of a gas turbine, and to make the turbine blades exchangeable, advantageously by axial sliding into or out of the formed cavities.

[0060] The central region 6 comprises the described fiber composite material 4. The central region 6 can consist of the fiber composite material 4. In particular, the material fibers 3 are shown in circular form in the region 6 in the cross-sectional view of FIG. 4. The fiber composite material 4 and/or the component which is provided therewithin comparison to a turbine disk of the prior artespecially has improved mechanical properties, especially a higher fracture elongation or fracture-elongation loadability, e.g. by up to one percent. By the same token, the component 1 according to the invention, which is produced by the described method, advantageously has a significantly increased crack resistance, an improved thermal shock resistance, and for example improved thermo-mechanical properties.

[0061] Furthermore, an extensibility or extension loadability of the component 1 relative to a conventional rotor part of a turbine can be increased by 2%.

[0062] The fiber composite material 4due to the specification of the fiber directionscan have anisotropic and therefore especially mechanical properties.

[0063] The component 1 can especially be a rotor disk of a compressor or of a compressor stage of a gas turbine (advantageously upstream of the combustion chamber of the turbine as seen in the flow direction). The component 1 can especially be a compressor rotor disk of the material grade 26NiCrMoV 14-5 or Cost-E (X 1 2CrMoWVNbN 10-1-1.

[0064] The described material fibers 3 can also comprise one or more of the following materials: carbon, boron, basalt and/or ceramic material, especially aluminum oxide, for example Al.sub.2O.sub.3, mullite, SiBCN, SiCN and SiC.

[0065] By the description based on the exemplary embodiments, the invention is not limited to these but covers each new feature and each combination of features. This especially contains each combination of features in the patent claims, even if this feature or this combination itself is not explicitly disclosed in the patent claims or exemplary embodiments.