• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method of manufacturing a centrifugal paddle wheel (1), said paddle wheel (1) comprising a base (7) with a hub (8), the paddle wheel (1) further comprising a plurality of projecting paddles (4) resting on the surface ( 6) of the hub (8), characterized in that the method comprises the following steps: providing a metal paddle wheel base (7) with a hub surface (6); - building up the blades (4) layer by layer on the hub surface (6) of the metal paddle wheel base (7) with layers (10) of a metal using an additive manufacturing method, the metal used for the layers ( 10) is compatible with the metal paddle wheel base (7).
    公开号:BE1023131B1
    申请号:E2015/5774
    申请日:2015-11-27
    公开日:2016-11-25
    发明作者:Aleksandr Pulnikov
    申请人:Atlas Copco Airpower, Naamloze Vennootschap；
    IPC主号:
    专利说明:

    Method for manufacturing a centrifugal paddle wheel and centrifugal paddle wheel obtained with such a method.
    The present invention relates to a method for manufacturing a centrifugal blade wheel.
    The centrifugal blade wheel can be used in a centrifugal machine such as a turbocharger, turbine or the like.
    A centrifugal compressor element as used in turbo-compressors consists, as is known, of a paddle wheel that is rotatably mounted in a housing with an axial inlet and a radial outlet, the paddle wheel being formed by a kind of trumpet-shaped hub about the sucked gas from the axial direction to the axial direction. inlet to bend in the radial direction at the outlet and through vanes mounted on the hub and defining narrowing channels together with the hub and housing through which the gas is passed to compress it.
    The paddle wheel is provided with a central bore for attaching the paddle wheel to a drive shaft.
    Centrifugal paddle wheels are traditionally manufactured using so-called subtractive manufacturing methods, such as turning and milling.
    This is based on a workpiece that is brought to the outer casing of the centrifugal blade wheel, the so-called 'shroud surface', by turning.
    Subsequently, the aforementioned channels and vanes are milled out.
    The depth of the channels is typically determined by the so-called hub surface.
    In order to increase efficiency, the blades are preferably made as thin as possible.
    As a result, 90% to 95% of the material located between the 'shroud surface' and the hub surface is removed.
    This is of course a major waste and an inefficient use of material.
    Thus, it would be better to add the blades to a workpiece formed by the hub surface, thus adding additional material to the workpiece rather than removing material.
    The material to be added in the form of blades would be about 10 to 20 times less than the material to be removed when a subtractive manufacturing method is used.
    In this way costs and material are saved.
    There are a number of complications. For example, the height of the blades in a centrifugal blade wheel is not constant. The inlet diameter is typically smaller and the height of the blades at the inlet is larger compared to the height of the blades at the outlet.
    This means that the chosen method for applying the blades to the hub surface must leave sufficient space to reach the construction site.
    Attempts have already been made to manufacture a centrifugal blade wheel with an additive manufacturing method instead of a subtractive manufacturing method. For example, in WO 2014/128169 a method is described for manufacturing a paddle wheel using separate segments. This document describes how to weld these segments together against a hub or to connect the segments to the hub by means of a mechanical connection. The aforementioned segments are made by means of an additive manufacturing method.
    However, a major disadvantage of this approach is that there is no continuous connection between the segments and the hub as with a subtractive manufacturing method, making them unsuitable for paddle wheels used in high-speed machines.
    After all, such a paddle wheel is driven at high speeds of several tens of thousands of revolutions per minute, whereby the linear peripheral speed at the outlet of the paddle wheel can reach several hundred meters per second.
    Due to the large centrifugal forces that occur at such high speeds, very large stresses are generated, which act on the connection between the segments and the hub.
    As a result, there is a real risk of this aforementioned connection failing, as a result of which not only the centrifugal blade wheel, but also the machine, can be irreparably damaged.
    Moreover, applying the last blades to the hub will be difficult, since accessibility is limited by the blades already present.
    The present invention has for its object to provide a solution to at least one of the aforementioned and other disadvantages.
    The present invention has a method as object for manufacturing a centrifugal paddle wheel, which paddle wheel comprises a base with a hub, the paddle wheel further comprising a number of protruding paddles mounted on the surface of the hub, the method comprising the following steps comprises: - providing a metal blade wheel base with a hub surface; - building the blades layer by layer on the hub surface of the metal blade wheel base with layers of a metal using an additive manufacturing method, the metal used for the layers being compatible with the metal of the metal blade wheel base.
    The aforementioned metal impeller base comprises a trumpet-shaped hub whose diameter increases in the direction from one end to the other end, the hub being provided with a central bore for attaching the impeller to a drive shaft. The outer surface of the hub is called the hub surface.
    The blades are mounted on the aforementioned paddle wheel base, in particular on the hub surface.
    The additive manufacturing method is, for example, laser coating or 'laser cladding'. Hereby material to be added is supplied to the melting zone, i.e. the zone to which material is to be added. The material can be applied in the form of powder or a wire or a combination of both. The melting zone is locally heated by means of a laser, whereby the powder and / or the wire and the part of the underlying material are melted.
    An advantage of a method according to the invention is that there is no or virtually no loss of material.
    Moreover, by building up the blades layer by layer, it will be possible to go to a subsequent blade after having applied one or more layers of one blade. In this way it will always be possible to guarantee the necessary space and accessibility during the following phases of the manufacturing process.
    Yet another advantage is that by building up the blades layer by layer, the tension in the blades is distributed. Building up layer by layer with the aid of an additive manufacturing method will also ensure that, as it were, a continuous connection is formed between the hub and the blades. As a result, the centrifugal paddle wheel can be used in high-speed machines, since it can withstand the large centrifugal forces that accompany this.
    The invention also relates to a centrifugal paddle wheel manufactured according to a method according to the invention and a compressor or expander provided with such a centrifugal paddle wheel.
    With the insight to better demonstrate the characteristics of the invention, a few preferred variants of the method according to the invention for manufacturing a centrifugal paddle wheel and a centrifugal paddle wheel are obtained hereafter, as an example without any limiting character, with reference to the accompanying drawings, in which: figure 1 schematically shows a traditional method for manufacturing a centrifugal blade wheel; figure 2 schematically represents a method according to the invention for manufacturing a centrifugal blade wheel; Figures 3 and 4 show variants of a method according to the invention.
    Figure 1 schematically shows a traditional method for manufacturing a centrifugal blade wheel 1.
    This is based on a rough workpiece 2 that is turned to the surface of the jacket 3, or the 'shroud surfsce'. This is a geometric surface that surrounds the blades 4 of the blade wheel 2.
    Channels 5 are then milled in the workpiece 2 to form the blades 4 by removing material.
    The bottom of the channels are formed by the hub surface 6, this is the surface of the blade wheel 1 on which the blades 4 are planned.
    In a method according to the invention, as shown in figure 2, a workpiece is assumed which is bounded by the hub surface 6.
    Thus, a first step of the method is to provide a paddle wheel base 7 with a hub 8 with a hub surface 6, as shown in Figure 2A. This hub 8 is provided with a central bore 9 for attaching the paddle wheel 1 to a drive shaft.
    This paddle wheel base 7 is made of metal.
    The paddle wheel base 7 or the hub 8 can be manufactured by rotating the workpiece to the hub surface 6, by casting a workpiece or by another manufacturing method that gives a desired quality of the hub surface 6. Thus, the paddle wheel base 7 or the hub 8 can also be manufactured using an additive manufacturing method.
    The blades are then built up layer by layer on the hub surface 6 with layers 10 of metal, using an additive manufacturing method. This is shown in Figures 2B-2D. .
    The metal of the layers 10 used is compatible with the blade wheel base metal and thus the hub surface.
    A possible additive manufacturing method is laser coating or 'laser cladding'.
    For this purpose, a metal that is compatible with the metal of the paddle wheel base 7 and thus the hub surface 6 is supplied and locally melted with the aid of a heat source. This creates a kind of welding process, as it were.
    Due to the compatibility between the two metals, it is ensured that a connection is possible between the hub surface 6 and the aforementioned layer 10.
    However, this means that the composition of the metal supplied may be different than the composition of the metal of the hub surface 6.
    The material supplied to the melting zone can be in the form of powder or of a wire or a combination of powder and wire.
    A laser or a plasma torch can be used for the heat source. But any heat source that can supply heat at a localized point is suitable.
    For the first layer 10, the hub surface 6 serves as a substrate on which this first layer 10 is applied. For each subsequent layer 10, the underlying layer 10 will serve as a substrate to melt the next layer 10.
    If the material is supplied as a powder, the supply of this powder can be interrupted, so that work can be carried out in discrete steps so that material can be built up at discrete locations.
    Moreover, with a powder, it is possible to change the composition of the powder, for example per layer 10.
    In this case, but not necessarily for the invention, the metal used for building up the vanes 4 layer by layer may have a different composition per layer 10.
    In this way the composition of the powder of the vane 4 can be changed or varied during the construction of the vane 4.
    It is also possible that the composition does not vary over the entire vane 4, but that, for example, only at the location of the edge 11 of the vanes 4 on the inlet side 12, where the vane 4 is exposed to erosion by incident dust particles and water drops, the composition of the powder is changed, for example by adding Carbide particles.
    The powder can be supplied by means of one or more nozzles which are arranged for example around the laser source and which spray the powder on the surface at the desired location. By working with different nozzles, the composition of the powder can be adjusted by providing each nozzle with a different type of powder and adjusting the flow rate of each nozzle.
    Preferably, but not necessarily, the substrate, i.e. the hub surface 6 or a previous layer 10, is heated or preheated to provide a next layer 10. This will make it possible to reduce the internal stresses in the centrifugal blade wheel 1.
    An additive manufacturing method is preferably carried out in a protective atmosphere, for example an inert atmosphere or in vacuum, to avoid excessive oxidation of the added metal.
    Various ways can be used to build up the vanes 4, layer by layer, via the laser coating principle or another additive manufacturing method described above.
    Figure 2 shows a possible way in which each layer 10 extends in a direction parallel to the hub surface 6. This is clearly seen in Figures 2B, 2C.
    This means that the direction of construction of the blades 4 extends perpendicularly or almost perpendicularly to the hub surface 6.
    In this case, one, two, three or more layers 10 are provided for each vane 4, before one, two, three or more layers 10 of the following vane 4 are applied.
    For example, all first layers 10 of all blades 4 could first be applied, whereafter the second layer 10 is applied to each of these first layers 10.
    By ensuring that two or more consecutive layers 10 of a vane 4 have a different length, the height of the vane 4 can be varied along the length.
    This means that one end 10a of the layer 10 is situated on the edge of the hub surface 6 on the inlet side 12, while the other end 10b of the layer 10 is either situated on the edge of the hub surface 6 on the outlet side 13 or at a location between the inlet side 12 and the outlet side 13, depending on the height at which the relevant layer 10 is located.
    At the transition from a vane 4 to the next, the application direction of the layer 10 can be changed from: from the inlet side 12 to the outlet side 13, to: from the outlet side 13 to the inlet side 12. This will shorten the time required to move from one vane 4 to the next. It is of course also possible to maintain the application direction and, for example, to apply each layer 10 from the inlet side 12 to the outlet side 13, or vice versa.
    By successively applying the layers 10, it is possible to obtain and maintain good accessibility to apply the following layers 10.
    If enough space is available for the tools used for the additive manufacturing method, two or three layers 10 could be applied for each blade 4 before moving to the next blade 4.
    When all the layers 10 of the vanes 4 have been applied, one or more additional layers can optionally be applied to smooth out the stepped transitions of the successive layers 10.
    It is also possible for the stepped transitions to be melted again, for example with the laser without powder being supplied, so that a smooth transition is obtained in this way.
    The side surfaces of the blades 4 can also be melted again, in order to reduce the surface roughness.
    It is also possible to apply an extra layer to the edges 11 of the vanes 4 at the inlet side 12. This edge 11 of the vanes 4 is, as already mentioned, exposed to the incident dust particles and water particles, making it sensitive to erosion. By appropriately choosing the composition of this extra layer 10, the erosion resistance can be increased.
    In a further optional step of a method according to the invention, the centrifugal blade wheel 1 can be subjected to a heat treatment.
    By applying such heat treatment, such as, for example, tempering, curing, discharging or annealing, any internal stresses in the vane 4 that have arisen during the build-up can be reduced.
    For finishing, the method may optionally comprise the step of machining the edges and side surfaces of the blades 4 by means of tensioning.
    The upper edge of the vane 4, this is the edge that coincides with the jacket surface 3 and is therefore also called 'shroud line', can be machined by turning or milling. The side faces of the blades 4 are preferably machined by milling.
    The paddle wheel 1 thus formed can be used in a compressor or expander. Since the stresses in the vanes 4 are distributed and a continuous connection is formed between the hub surface 6 and the vanes 4, the vane wheel 1 can also be used in a compressor or expander that has a high speed.
    The example in figure 2, the method focused on the use of (metal) powder for laser coating. This has the advantage that the material supply can be interrupted. A disadvantage is that the laser coating must be done in an inert atmosphere.
    As already stated, it is also possible to provide the material supply for laser coating with the aid of a (metal) wire.
    In this case, it is not necessary to provide an inert environment since the oxidation of a wire will occur more slowly.
    The process will also be faster if a wire is used.
    In this case it is not possible, or very difficult, to interrupt the material supply.
    In this case, continuous layers 14 will have to be used, i.e. a first continuous layer 14 for all vanes 4, whereby a further continuous layer 14 can be applied to this first layer 14.
    Figure 3 shows an example of such a method, where the first continuous, continuous layer 14 is applied to the hub surface 6 of a paddle wheel base 7.
    With such a method it will be necessary, after manufacturing the blades 4, to remove certain parts of the added material by means of milling in order to thus create the individual blades 4.
    Figure 4 shows yet another variant of a method according to the invention. In this example, the successive layers 10 extend in a direction that deviates from the direction of the hub surface 6.
    This means that the direction of construction of the blades 4 deviates from the direction perpendicular to the hub surface 6.
    In most cases this means that more layers 10 are needed to fully build up a vane 4, which ensures that building up of the vanes 4 takes longer, also due to a longer transition time from one vane 4 to the other blade 4.
    However, as a result, the composition of the blades 4 can be better manipulated.
    As can be seen from Figures 4B-4D, the layers 10 are built up from the outlet side 13 of the paddle wheel 1 towards the inlet side 12.
    This means that the first layers 10 are applied at the location of the outlet side 13, whereafter the layers 10 shift more and more in the direction of the inlet side 12.
    Such a method will also ensure that there is always sufficient space to be able to apply the following layers.
    Although in the variants shown above, the application of after one, two or three layers 10 was always transferred to the next vane 4, it is also possible that only after all the layers 10 of a first vane 4 have been applied, the layers 10 of a following vane 4 are fitted.
    It is clear that the various optional steps and ways of building up the vanes 4 layer 10 per layer 10 as discussed in the variant of Figure 2 are also applicable to the other variants of Figures 3 and 4.
    The present invention is by no means limited to the embodiments described as examples and shown in the figures, but such a method and centrifugal paddle wheel obtained therewith can be realized according to different variants without departing from the scope of the invention.
    权利要求:
    Claims (13)
    [1]
    Conclusions. Method for manufacturing a centrifugal paddle wheel (1), which paddle wheel (1) comprises a base (7) with a hub {8), the paddle wheel (1) further comprising a number of protruding paddles (4) mounted on the surface {6) of the hub (8) is arranged, characterized in that the method comprises the following steps: - providing a metal blade wheel base (7) with a hub surface (6); - building up the blades (4) layer by layer on the hub surface (6) of the metal blade base (7) with layers (10) of a metal using an additive manufacturing method, the metal used for the layers ( 10) is compatible with the metal of the metal impeller base (7).
    [2]
    Method according to claim 1, characterized in that the method also comprises the step of applying a heat treatment after building up the aforementioned blades (4).
    [3]
    Method according to claim 1 or 2, characterized in that the method also comprises the step of machining by machining the edges or the side faces of the aforementioned blades (4).
    [4]
    Method according to one of the aforementioned claims, characterized in that the hub surface (6) and the layers (10) already applied to the hub surface (6) are heated before the next layer (10) is applied.
    [5]
    Method according to one of the preceding claims, characterized in that after one, two, three or more layers (10) of a first vane (4) have been applied, one, two, three or more layers (10) of a following blade (4). Method according to one of the preceding claims, characterized in that two or more consecutive layers (10) of a vane (4) have a different length, so that the height of the vane (4) varies along the length of the vane ( 4). Method according to one of the preceding claims, characterized in that for layer-by-layer building of the blades (4) use is made of layers (14) which form one continuous layer (14) for all blades (4).
    [8]
    Method according to one of the preceding claims, characterized in that the successive layers (10) extend in a direction parallel to the hub surface (6).
    [9]
    Method according to one of the preceding claims 1 to 7, characterized in that the successive layers (10) extend in a direction that deviates from the direction of the hub surface (6).
    [10]
    Method according to claim 9, characterized in that the layers (10) are built up from the outlet side {13} of the centrifugal paddle wheel (1) towards the inlet side (12).
    [11]
    Method according to one of the preceding claims, characterized in that the metal used for layer-by-layer building of the blades (4) has a different composition per layer (10).
    [12]
    Method according to any one of the preceding claims, characterized in that the hub (8) or impeller base (7) is manufactured using an additive manufacturing method.
    [13]
    13. Centrifugal paddle wheel, characterized in that the centrifugal paddle wheel (1) is manufactured according to a method according to one of the preceding claims.
    [14]
    Compressor, characterized in that the compressor is provided with a centrifugal blade wheel (1) according to claim 13.
    [15]
    Expander, characterized in that the expander is provided with a centrifugal blade wheel (1) according to claim 13.
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    同族专利:
    公开号 | 公开日
    BE1023131A1|2016-11-25|
    引用文献:
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    US3159106A|1962-03-21|1964-12-01|Allis Chalmers Mfg Co|Impeller and method of making same|
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    WO2014128169A1|2013-02-20|2014-08-28|Nuovo Pignone Srl|Method for making an impeller from sector segments|
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    US20150044048A1|2013-08-07|2015-02-12|Samsung Techwin Co., Ltd.|Impeller assembly of fluid rotary machine and manufacturing method thereof|
    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    US201562138589P| true| 2015-03-26|2015-03-26|
    US62/138,589|2015-03-26|PCT/BE2016/000014| WO2016149774A1|2015-03-26|2016-03-17|Method for manufacturing a centrifugal metal impeller and a centrifugal impeller obtained with such a method|
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