MANUFACTURING OF SINGLE OR MULTIPLE PANELS
20170009600 ยท 2017-01-12
Assignee
Inventors
- Piero-Daniele GRASSO (Niederweningen, CH)
- Alexander STANKOWSKI (Wurenlingen, CH)
- Sabrina PUIDOKAS (ENNETBADEN, CH)
Cpc classification
F01D5/147
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C04B35/00
CHEMISTRY; METALLURGY
F05D2260/204
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B23P15/02
PERFORMING OPERATIONS; TRANSPORTING
C04B2235/616
CHEMISTRY; METALLURGY
F05D2220/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2240/11
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D9/041
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D9/065
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C04B38/10
CHEMISTRY; METALLURGY
F05D2300/6033
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2230/50
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C04B38/10
CHEMISTRY; METALLURGY
F05D2260/231
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C04B2237/62
CHEMISTRY; METALLURGY
F05D2260/201
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C04B2237/597
CHEMISTRY; METALLURGY
C04B2235/6028
CHEMISTRY; METALLURGY
C04B2237/84
CHEMISTRY; METALLURGY
F01D5/282
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B18/00
PERFORMING OPERATIONS; TRANSPORTING
F05D2230/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C04B2235/5272
CHEMISTRY; METALLURGY
C04B35/80
CHEMISTRY; METALLURGY
F05D2300/613
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/6012
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C04B35/80
CHEMISTRY; METALLURGY
F05D2300/6034
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/284
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D25/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D9/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A method of manufacturing of a structured cooling panel includes cutting of desized 2D ceramic into tissues; slurry infiltration in the tissues by at least one knife blade coating method; laminating the tissues in a multi-layer panel, with slurry impregnation after each layer, wherein the tissue has combined fibres and/or pre-build cooling holes; drying; de-moulding; sintering the multi-layer panel, wherein part of the combined fibres burns out during the sintering process leaving a negative architecture forming the cooling structure and/or the pre-build cooling holes define the cooling structure; finishing, using of i) post-machine, and/or ii) surface smoothening/rework, and/or iii) coating application, and/or other procedures.
Claims
1. Method of manufacturing of a structured cooling panel for applying on a component to adapt the final component to a specific cooling function, which is manufactured by the following operations: a) Cutting of desized 2D ceramic into tissues in the right size and shape for the application; b) Slurry infiltration in the tissues by at least one knife blade coating method; c) Laminating the tissues in a multi-layer panel, with slurry impregnation after each layer, wherein the tissue has combined fibres and/or pre-build cooling holes; d) Drying; e) De-moulding; g) Sintering the multi-layer panel, wherein part of the combined fibres burns out during the sintering process leaving a negative architecture forming the cooling structure and/or the pre-build cooling holes define the cooling structure; h) Finishing, using of i) post-machine, and/or ii) surface smoothening/rework, and/or iii) coating application, and/or other procedures.
2. The method according to claim 1, including a pin application with a plurality of pins in order to generate straight cooling paths referring to cooling air holes, through a part of the thickness or through the full thickness of the panel structure comprising at least one of the following steps: namely pins can be: i) metallic pins with a ceramic layer on top to avoid attachment of matrix to the pin and too strong oxidation of the pin during sintering; ii) permanent ceramic pins, that can be easily removed after sintering; iii) pin that will be eliminated during the sintering process via a heat treatment.
3. The method according to claim 2, wherein the eliminated pins are made of a carbon material.
4. The method according to claim 1, wherein the pins are applied by sliding them through a part of thickness or through the panel structure, wherein in order to facilitate the positioning of the pins, a mould underneath can be provided with positioning hole in which the pins are fit into with the appropriated position and angle.
5. The method according to claim 1, wherein the pins are inserted in-between the tissue fibre bundles in order to avoid any damages of the ceramic fibres during the processing and later removal of the pins.
6. The method of claim 1, comprising: combining a supplemental panel structure made of CMC to the multiple panel structure.
7. The method according to claim 6, wherein the combining of the supplemental panel structure comprises one or more of following manufacturing steps: i) the structure is manufactured separately using the same manufacturing route as the standard CMC tissues and an appropriated mould including the drying and de-moulding steps; ii) the structure is slipped in the internal cavity of the multiple panel structure obtained from operations a) to g); iii) both structures are glued using the same ceramic slurry used for the infiltration of the ceramic tissues, or only punctually bound in order to allow a larger lateral movement/expansion of the supplemental structure; iv) the binding between both structures is made by a different joining method, such as a ceramic glue or a brazing technique using metallised surfaces on both ceramic structures.
8. The method according to claim 7, wherein a subsequent drying operation is made, when step iii) is carried out.
9. The method according to claim 7, wherein the supplemental panel structure is an undulated or quasi-undulated configuration.
10. The method according to claim 1, wherein laminating comprises: laminating one to n-layers of ceramic felt, with a slurry infiltration in the felt.
11. The method of claim 10, wherein infiltration of the felt comprises: only outer surface infiltration of the felt in order to bind it to the CMC multiplies panels, or fully impregnation by knife blade coating, after each single layer.
12. Method according to claim 1, comprising: forming the panel structure form as at least one of the constructive elements of a guide vane or rotor blade or liner of a turbomachine, wherein the elements for the purpose of a thermal protection include at least an airfoil, having of at least one CMC shell, at least one intermediate layer, at least one flexible joint with respect to airfoil platform and/or metallic foot, at least one inner platform and outer platform.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0105] The present invention is going now to be explained more closely by means of different embodiments and with reference to the attached drawings.
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DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION
[0129] Figures of this description show various embodiment of single and/or multi-plies CMC panels provided for system arrangements. Fundamentally, the CMC panel can be designed with individualized fibre structure in accordance with the operational requirements. A certain percentage of the fibres may have differentiated diameters, which are intended to mainly carry the mechanical load (in the case of the larger diameters) and thermal stresses during the flow-applied operation.
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[0133] Other combinations can be realised depending on the specific application. The layer-up order of the panels can also be different. The panels can be made of complex 3D geometries such as a gas turbine rotor blade/vane airfoil (see the examples under
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[0135] The mentioned CMC zones 20, 40 can consist of a laminate structure, such that an appropriate bond between the single intermediate layers (different tissue plies) is achieved. Furthermore, the zones can be formed by a multiple sandwich structure. Laminate structure means the technique of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, appearance or other properties from the use of differing materials. A laminate structure is usually permanently assembled by heat, pressure, welding, or adhesives
[0136] Moreover, the mentioned ceramic felt 30 between the CMC zones 20, 40, likewise build-up of 2D/3D tissue structure with thinner fibres, serves to fix the ceramic matrix to the overall fibre substructure. The fibres of the ceramic felt can be differently woven using the same or different materials, within the ceramic felt and on each side of the panels comprises both first and second fibre materials. Any stacking-sequence of different woven fibres within the thickness of the panel arrangement is also possible.
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[0140] Additionally, the cooling holes being actively connected to the structured cooling or chaotic running channels within the panel body are designated for convective and/or impingement and/or effusion cooling effects. Furthermore, in some specific configurations or using a specific type of pins, the introduced pins (see
[0141] One additional point to mention is the fact that the pins can be inserted through the full thickness of a single panel or of a panel combination. However, it can also be the case that the pins are inserted only partially through the thickness of the panel combination, not passing through the whole thickness.
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[0146] Complementary fibres 60 (black) consist of carbon fibres. The black fibres are sacrificial fibres that will burn out during the sintering process leaving a negative architecture forming the cooling structure. Both fibres can be differently woven using the same or different materials. The resulting architecture having a rectangular or quasirectangular weaving, or an oblique or quasi-oblique, or non-rectangular angulation weaving. Furthermore, the architecture can be designated as a sinusoidal or quasisinusoidal interdigitated weaving. Any stacking-sequence of different woven fibres within the thickness of the panel arrangement is also possible.
[0147] A practical result of a manufacturing according to
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[0149] In this context using a special fabric (see definition under summery of the invention) where the cooling structure (CAHs) is directly woven in within a ceramic fabric and applying as a layer. The performing are as follows: [0150] 1) Cut a stripe or pre-defined geometry tissue from a special fabric. [0151] 2) Integrated stripe or pre-defined geometry tissue into ceramic fabric, e.g., by cutting out the corresponding geometry from the ceramic fabric.
[0152] Referring to
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[0154] The additional use of a heat and oxidation resistant flexible layer (
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[0156] Two ceramic tissues interwoven at one extremity in order to enable a connection at, e.g., the TE, which is not only relying on gluing/brazing methods.
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[0162] Accordingly, each guide vane provides a radial outer platform 200, an airfoil 100 and a radial inner platform 300. The radial outer platform contains mounting hooks 201, 202 that are inserted into mounting grooves of the stator component of the first turbine stage (not shown). The inner platform 300 of the guide vane, typically, encloses a gap with the rotor liner through which a purge flow of cooling medium can be injected into the hot gas flow within the gas turbine. In the same way, a purge flow of cooling medium is injected through a gap, which is enclosed by parts of the stator component, the upstream edge of the outer platform 200 of the guide vane and the outer combustor liner, also called stator liner. Generally, downstream of the outer platform 200a heat shield (not shown) is mounted inside of the stator component which prevents overheating of the inner faced areas of the stator component in the same way as in case of the outer platform 200.
[0163] Generally, the means for the purpose of an interchangeable connection of the guide vane elements, namely between airfoil, inner platform, outer platform and optionally flow carrier comprising reciprocal lugs or recesses based on a friction-locked bonding or permanent connection or fixing.
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[0165] The flow-applied shell module encases integrally or partially the outer contour of the based guide vane airfoil of the guide vane according to aerodynamic requirements. The partial shell structure is actively connected to the leading edge of the based airfoil of the guide vane, wherein the outer contour of the based airfoil consists of an independent flow-charged part, being actively connected to the leading edge of the airfoil of the guide vane. The flow-charged shell structure encases integrally the outer contour of the based guide vane airfoil, complying with aerodynamic final aims of the vane, or the flow-charged shell structure encases partially the outer contour of the based airfoil in the flow direction of the working medium of the gas turbine, complying with aerodynamic final aims of the guide vane. According to an additional embodiment the based guide vane airfoil comprises inside a supplementary body formed by the configuration of a spar. In place of the based guide vane airfoil can be made a spar as substructure. The shell structure may be formed by the form of an integrally or segmented body. The first shell structure comprises internally a second or intermediate non-flow-charged or partially flow-charged shell structure, complying with aerodynamic final aims of the vane. The two shell liners are adjacent or have an intermediate distance from one another. When the first flow-charged shell structure encases integrally the outer contour of the guide vane airfoil, this shell structure comprises at least two bodies forming completely or partially the outer contour of the based guide vane airfoil. The mentioned bodies, forming completely or partially the outer shell structure, are brazed or welded along their radial interface, and they have radial or quasi-radial gaps, which are filled with a seal and/or ceramic material. The outer shell is inter-changeable, consumable, pre-fabricated, single or multi-piece with radial or circumferential patches or uses with respect to the sub-structure of the guide vane airfoil a shrinking joint.
[0166] Furthermore, the intermediate shell or shells are parts of an optional assembly. The mentioned shell(s) are inter-changeable, pre-fabricated, arranged as single or multi multi-piece with radial or circumferential patches, uncooled or cooled (convective, film, effusion, impingement cooling), fabricated as compensator for different thermal expansion of outer shell and spar, and with a cooling shirt with respect to different cooling configurations for optimization operational requirements. The spar as sub-structure of the guide vane airfoil or of the shell assembly is interchangeable, pre-fab heated or various manufactured, single or multi-piece, uncooled or cooled using convective, film, effusion, impingement cooling, having a web structure for cooling or stiffness improvement.
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[0168] Normally, the platforms 200, 300 and the guide vane airfoil are no consumable parts. In contrast, the mentioned sealing and liners are consumable parts. The airfoil carrier may be consumable, depending on costs. The airfoil carrier 220 is cast, machined or forged comprising additionally additive features with internal local web structure for cooling or stiffness improvements. Furthermore, the airfoil carrier comprises flexible cooling configurations for adjustment to operational requirements, like base-load, peak-mode, partial load of the gas turbine.
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[0170] The outer platform 200 is cast, forged or manufactured in metal sheet or plate. The outer platform is consumable in relation to predetermined cycles, and frequently replaced at specified maintenance periods, and may be mechanically decoupled from the guide vane airfoil, wherein the outer platform may be supplementary mechanically connected to the airfoil carrier, using force closure elements, namely bolts. The outer platform may be coated with CMC or ceramic materials or may be manufactured by an isolation panel according to the attached claims.
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[0172] The inner platform 300 is cast, forged or manufactured in metal sheet or plate. The outer platform is consumable, is replaced at specified maintenance periods, and may be mechanically decoupled from the guide vane airfoil, wherein the inner platform may be supplementary mechanically connected to the airfoil carrier, using force closure elements, namely bolts. The inner platform may be coated with CMC or ceramic materials or may be manufactured by an isolation panel according to the attached claims.
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