• 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 rotary article and a rotary article The present invention relates to a method of manufacturing a rotary article, comprising: providing a cold metal transfer welding apparatus (200) comprising a welding torch (202, 300); provide a rotating substrate; providing a digital representation of the spinning article having at least one internal fluid passageway; define a welding path on the rotating substrate based on the digital representation; rotating the rotating substrate while depositing layer by layer of a filler metal on the welding path of the rotating substrate to form the rotating article; and separating the rotating substrate from the rotating article.
    公开号:BR112015009368B1
    申请号:R112015009368-0
    申请日:2013-10-31
    公开日:2019-09-24
    发明作者:Wen Tan；Guoshuang Cai；Hongyuan Shen；Lei Yang；Renwei Yuan；Yanmin Li；Yong Liu；Zhixue Peng
    申请人:General Electric Company；
    IPC主号:
    专利说明:

    "METHOD FOR MANUFACTURING A ROTATING ARTICLE AND ROTATING ARTICLE"
    Field of the Invention [001] The present invention relates in general to a method for manufacturing a rotating article, and, more specifically, to a method for manufacturing a rotating article, such as an impeller, by means of welding transfer deposition. cold metal as well as the rotating article as manufactured.
    Background of the Invention [002] Rotating articles that have internal passages, such as impellers with a plurality of internal fluid passages, are not easy to manufacture using traditional manufacturing techniques, such as casting or forging. Impellers are widely used inside tubes or pipes of equipment such as pumps, compressors and gas turbine engines to increase or decrease a pressure and the flow of a fluid. For example, an impeller can be used in a centrifugal pump to transfer energy from a motor that drives the pump to the fluid that is pumped, by accelerating the fluid out from the center of rotation. The speed reached by the impeller turns into pressure when the movement out of the fluid is confined by the pump casing. A typical impeller includes an orifice to receive a drive rod rotated by a motor or other drive mechanism and vanes that have empty spaces formed inside them to push the fluid radially, and it is difficult to manufacture using traditional techniques. manufacturing due to its complicated structure.
    [003] A conventional method for manufacturing impellers is to split and shape the impeller into several members and then join the molded members separately by welding or other joining methods. However, compared to integrally formed impellers, impellers manufactured
    Petition 870190056924, of 6/19/2019, p. 11/28
    2/13 by joining molded parts separately from the impeller have relatively weak mechanical properties.
    [004] Currently, there is a method in which impellers are manufactured by a process that includes pre-milling, electric discharge machining (EDM) roughing and EDM finishing. But the cycle time for this process is usually longer than 5 weeks. In addition, a high investment in installation and equipment (P&E) is required for a milling center and EDM machine. This is neither efficient nor economical, due to the long time of click and a high demand for investment in P&E.
    [005] Therefore, it is desirable to provide a new method for manufacturing rotating articles, such as impellers, on an efficient and economical basis.
    Description of the Invention [006] The present invention relates to a method for making a rotating article. The method comprises: providing a cold metal transfer welding apparatus comprising a welding torch; provide a rotating substrate; providing a digital representation of the rotating article that has at least one internal fluid passage; define a welding path on the rotating substrate, based on the digital representation; rotating the rotating substrate while depositing layer by layer of a filler metal on the welding path of the rotating substrate to form the rotating article; and separating the rotating substrate from the rotating article.
    [007] The present invention also relates to a method for manufacturing a rotating article which comprises: providing a cold metal transfer welding apparatus comprising a welding torch; provide a rotating substrate; supply the rotating article using the cold metal transfer welding machine to deposit a
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    3/13 filler metal on the rotating substrate, rotating or moving the rotating substrate at the same time and / or simultaneously moving the welding torch; and separating the rotating substrate from the rotating article.
    [008] The present invention also relates to a rotating article that has at least one internal fluid passage that is manufactured, depositing layer by layer of a filler metal by means of cold metal transfer welding.
    Brief Description of the Drawings [009] The aspects and resources above, among others, of the realizations of the present invention become more evident in the light of the following detailed description, when done together with the attached drawings, in which:
    Figure 1 is a schematic view showing the movement of wire in a typical cold metal transfer (CMT) welding process;
    Figure 2 shows a CMT system adapted to manufacture a rotating article;
    Figure 3 is a schematic view showing a welding torch for a CMT apparatus;
    Figure 4 shows a CMT deposition scheme for making a one-piece impeller;
    Figure 5A is a perspective view of an impeller to be manufactured;
    Figure 5B is an image showing an article that is manufactured by additive deposition of CMT based on a digital representation of the impeller, as shown in Figure 5A; and Figure 5C is an image showing a CMT additive deposition product based on a digital representation of the as impeller, as shown in Figure 5A.
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    4/13
    Description of Embodiments of the Invention [010] Embodiments of the present invention are described in relation to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present invention by unnecessary details.
    [011] The approximate language, as used in this document during specification and claims, can be applied to modify any quantitative representation that may vary permissibly without resulting in a change in the basic function to which it is related. Consequently, a value modified by a term or terms, such as "approximately", should not be limited to the precise value specified. In certain embodiments, the term "approximately" means about ten percent (10%) of a value. For example, "approximately 100" refers to any number between 90 and 110. In addition, when using the expression "approximately a first value - a second value", approximately is intended to modify both values. In some instances, the approximate language may correspond to the accuracy of an instrument for measuring value or values.
    [012] Any numerical values cited in this document include all values from the lowest value to the highest value in increments of one unit, as long as there is a separation of at least 2 units between any lower value and any higher value. As an example, it is stated that the dosage of a component or a variable process value such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expressly listed in that specification. For values that are less than one, a unit is considered to be
    Petition 870190056924, of 6/19/2019, p. 14/28
    5/13
    0.0001, 0.001, 0.01 or 0.1, as appropriate. These are just examples of what is specifically intended and all possible combinations of numerical values between the lowest and the highest listed values should be considered as expressly stated in the present application in a similar manner.
    [013] Unless otherwise stated, the technical and scientific terms used in this document have the same meaning, as is commonly understood by the person skilled in the art, to whom the present invention is intended. The terms "first", "second" and the like, as used in this document, do not denote any order, quantity or importance, but are used instead to distinguish one element from another. In addition, the terms "one" and "one" do not denote a quantity limitation, but instead denote the presence of at least one of the items referred to.
    [014] The embodiments of the present invention relate to a method for making a rotating article that has at least one internal fluid passage by cold metal transfer welding deposition, as well as the rotating article, as manufactured. Since the method of the present invention is particularly applicable to manufacturing impellers, the description is directed to impellers, but can be used in the manufacture of other rotating articles.
    [015] Cold metal transfer welding, commonly referred to as CMT, is a modified electric arc welding process with shielding gas (GMAW) with short-circuit transfer, which is characterized by cyclic one-phase alternation electrical arc and a short-circuit phase. In a CMT Process, the wire feed system is synchronized with a digital control system and is able to change the directions of movement of the wire in response to
    Petition 870190056924, of 6/19/2019, p. 15/28
    6/13 cyclic alternation. During the electric arc phase, a welding wire is moved towards an object to be welded / substrate until it contacts the object to be welded / substrate and the welding current and / or the welding voltage are controlled so that the wire welding material is rapidly melted at a high transfer arc current to form a droplet. Once the short circuit occurs, the digital control system detects the voltage drop and then reduces the current to a significantly lower level, while the wire transport is reversed and the welding wire is moved to away from the object to be welded / substrate until the short circuit is opened.
    [016] Therefore, CMT incorporates a welding current control with wire movement and physically collects the welding wire from the melt pool at a certain rate and standard. In relation to Figure 1, a typical CMT process may comprise the following steps: (1) moving a welding wire in the direction of a weld puddle on an object to be welded / substrate; (2) lower the electric current, while feeding the welding wire in the weld pool; (3) retract the welding wire; and (4) repeat steps (1) to (3).
    [017] Such a cyclic alternation based on the systematic discontinuation of the arc has the capacity to greatly reduce the thermal power transferred to the object to be welded / substrate, because the arc only introduces heat to the object to be welded / substrate for a very short time, during the period sparking. In comparison to the conventional GMAW process, the object to be welded / substrate and the weld zones remain much "cooler" during a CMT process. The reduced thermal power offers the possibility for the additive layer to manufacture components on a large scale using CMT. In addition, the reduced thermal power offers advantages such as low distortion and greater precision, which also benefits the manufacturing process of the additive layer.
    Petition 870190056924, of 6/19/2019, p. 16/28
    7/13 [018] In a method for manufacturing a rotating article by additive deposition of CMT, a rotating substrate is provided and a CMT apparatus comprising a welding torch is used to deposit layer by layer of a filler metal (wire welding path) on a predetermined welding path of the rotating substrate to form the rotating article.
    [019] As used in this document, the filler metal can be various metals or alloys that have a melting point and can be melted during the additive deposition of CMT. Some non-limiting examples of applicable metals or alloys include carbon steel, steel alloy, nickel alloys, titanium alloys and combinations thereof. The rotating substrate can have an outer circumference surface so that a molten filler metal is deposited to form the rotating article and can be driven to rotate around a central geometric axis during the deposition process. In certain embodiments, the rotating substrate may have a hole in it to allow a cooling fluid to pass during the additive deposition of CMT, so that the substrate and the deposit on it can be controlled at a relatively low temperature. In a specific embodiment, the rotating substrate is an empty cylinder that has a central hole along its axial direction, the central hole being able to function as the cooling hole for the passage of a cooling fluid, such as water.
    [020] In certain embodiments, as shown in Figure 2, a system 200 applicable for manufacturing a rotary article by additive deposition of CMT comprises a welding torch 202, a welding robot 204 to drive welding torch 202 to move along a predetermined welding path, a welding power supply 208 to supply power to the welding torch
    Petition 870190056924, of 6/19/2019, p. 17/28
    8/13
    202, a wire unit 209 for feeding a filler wire to the welding torch 202, a tilting table 210 adapted to retain and move a substrate to be deposited, as well as the deposit on the substrate and a robot controller 206 to control the welding robot 204 and tilting table 210. In certain embodiments, as shown in Figure 3, a welding torch 300 comprises a contact tip 302 to accommodate a welding wire 304 so that the welding wire 304 protrudes from a tip end of the contact tip 302, a nozzle guard 306 that surrounds the contact tip 302 and that defines an annular channel 308 that surrounds the contact tip 302 for a shield gas to pass through.
    [021] Before performing additive deposition, a digital representation of the rotating article to be manufactured can be provided and, thus, a welding path can be predetermined based on the digital representation. In certain embodiments, the welding path can be determined by a process that comprises: (1) correlating the CMT deposition process parameters with deposit properties; (2) develop and identify the ideal process window (scope) for deposition of CMT; (3) modulate the CMT deposition database; and (4) to develop a welding path generation and compensation algorithm for part distortion.
    [022] By depositing layer by layer of the filler metal on the rotating substrate along the predetermined welding path, rotating the rotating substrate continuously or discontinuously at the same time, it is possible to build a rotating article close to the final shape.
    [023] An impeller deposition scheme is shown in Figure 4. As shown, a process for making a CMT additive deposition impeller comprises: (1) providing a rotating substrate that
    Petition 870190056924, of 6/19/2019, p. 18/28
    9/13 can be driven to rotate around a central geometric axis and has an outer circumference surface so that a molten welding wire is deposited; (2) depositing a first layer of the welding wire material on the outer circumference surface of the rotating substrate along a predetermined welding path, while rotating the rotating substrate at the same time; and (3) continuously depositing a new layer on the previous layer until the impeller with a shape close to the final one is completed.
    [024] In certain embodiments, each layer may comprise at least one circular or nearly circular structure that extends along or approximately parallel to a circumferential direction of the rotating substrate, similar to a 402 structure, as shown in Figure 4, and at least at least one lamina structure that intersects at least one circular or quasi-circular structure, similar to one 404 structure, as shown in Figure 4. Therefore, the step of depositing each layer can comprise: at least one deposition step of a circular or almost circular structure on the substrate, while rotating the substrate, and at least one step of depositing a blade structure, moving the welding torch relative to the substrate along a direction of intersection with the circular or almost circular structure (which intersects the circumferential direction), whether or not the substrate is rotated at the same time.
    [025] In the illustrated embodiment, the impeller to be manufactured comprises two rounded end plates and a plurality of blades between the two end plates and defines a plurality of fluid passages between them. The deposition step of each layer comprises: (i) depositing a circular or almost circular structure, while rotating the substrate; (ii) move the welding torch and / or the substrate
    Petition 870190056924, of 6/19/2019, p. 19/28
    10/13 along or parallel to an axial direction of the substrate; (iii) depositing another circular or almost circular structure, while rotating the substrate; (iv) depositing a blade structure, moving the welding torch to trace the welding wire through the substrate along or parallel to an axial direction of the substrate, while maintaining the substrate in a non rotated; (v) rotate the substrate; and (vi) repeat steps (iv) and (v) until the layer of all blade structures is deposited.
    [026] In step (v), the substrate can be rotated at an angle, so that it deposits a blade structure adjacent to the previous one. In some other specific embodiments, in step (v), the substrate can be rotated at a relatively greater angle, in order to deposit a blade structure opposite or almost opposite to the previous one, in order to reduce the distortion of the protective layer that can occur to the article that is manufactured. By optimizing the sequence to deposit different blade structures on a rotating article, in particular a rotating symmetrical article, the distortion of the protective layer that can occur to the article being manufactured can be greatly reduced.
    [027] During deposition, the welding wire can be fed continuously to the welding torch. In certain embodiments, the yarn feed rate ranges from approximately 3 m / min to approximately 10 m / min or, preferably, from approximately 4.5 m / min to approximately 10 m / min.
    [028] After the article is constructed in a format close to the final one, the rotating substrate can be separated from the article before the article is further processed. In this way, a hole is formed in the rotating article at the point where it is previously occupied by the rotating substrate. The orifice is capable of receiving a rotating rod. In
    Petition 870190056924, of 6/19/2019, p. 20/28
    11/13 certain achievements, the article made by additive deposition of CTM is further processed by EDM finishing.
    [029] The achievements of this document offer benefits over conventional manufacturing technologies. The additive deposition of CMT allows a rotating article that has internal fluid passages to be constructed in a format close to the definitive one and this can significantly reduce the forging time and thereby increase productivity. More particularly, the additive deposition of CMT allows articles to be constructed in a format close to the definitive one, thereby reducing material input, material waste and total manufacturing time. Applying only the amount of material necessary to complete the article conserves raw materials and the needs for material removal and finishing are greatly reduced. For example, compared to manufacturing impellers by a process that includes pre-milling, EDM forging and EDM finishing, manufacturing impellers of a shape close to the definitive by additive deposition of CMT are able to increase productivity by approximately twice and reduce material usage by 15%. In addition, the additive deposition of CMT allows flexibility to change or update the impeller design quickly and at a lower cost when compared to conventional machining methods.
    Example
    To demonstrate the suitability of manufacturing rotating articles by additive deposition of CMT, an experiment was conducted to manufacture an impeller, as shown in Figure 5A. During the experiment, a 304 stainless steel substrate and a CMT system including a robot (Motoman UP50N), a tilting table (YASKAWA Motopos) and a CMT welder (Fronius TPS4000 CMT (up to 400A)). The tip end of the CMT welder contact tip was spaced
    Petition 870190056924, of 6/19/2019, p. 21/28
    12/13 of the substrate over a distance ranging from approximately 14 mm to 15 mm. Argon (Ar) mixed with 5% CO2 by volume was used as the shielding gas. A welding wire made of a low-alloy steel material ER90S-B3 and having a diameter of approximately 1.2 mm was used. The composition of ER90S-B3 by weight is shown in the following table.
    Composition (% by weight) Ç Si Mn P s Cr Mo ER90S-B3 0.10 0.45 0.60 0.01 0.01 2.55 1.05
    [030] Experiment conditions and detailed process parameters are described below.
    - Welding current: 130 A
    - Welding voltage: 14.5 V
    - Wire feed rate: 4.5 m / min
    - Welding speed: 0.3 m / min
    - Torch weaving: 5 Hz, 3 mm amplitude
    - Protective gas flow: 18 l / min
    - Layer thickness: 2 mm [031] In relation to Figure 5B, fixing the rotating substrate to the tilting table and rotating the rotating substrate, while depositing the wire material layer by layer in the welding path of the rotating substrate, using the welding torch, an impeller of a shape close to the definitive one without crack and porosity, as shown in Figure 5C, was the result in 1 day for the first attempt. During the process, welding was regularly interrupted8 to allow heat dissipation.
    [032] Although the present invention illustrates and describes with typical embodiments, it is not intended to be limited to the details shown, since various modifications and substitutions can be made without departing from the scope of the present invention in any way. Like this,
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    13/13 Additional and equivalent modifications of the invention made in this document may occur to those skilled in the art who use no more than the routine of experiments, and it is believed that all such modifications and equivalents are within the character and scope of the present invention, as defined by the following claims.
    权利要求:
    Claims (15)
    [1]
    1. METHOD FOR MANUFACTURING A ROTARY ARTICLE, characterized by the fact that it comprises:
    - providing a cold metal transfer welding apparatus (200) comprising a welding torch (202, 300);
    - provide a rotating substrate;
    - providing a digital representation of the rotating article that has at least one internal fluid passage;
    - define a welding path on the rotating substrate based on the digital representation;
    - rotating the rotating substrate, while depositing layer by layer of a filler metal on the welding path of the rotating substrate to form the rotating article; and
    - separate the rotating substrate from the rotating article.
    [2]
    2. METHOD, according to claim 1, characterized by the fact that depositing each layer comprises:
    - deposit a circular or quasi-circular structure (402) on the rotating substrate, while rotating the rotating substrate at the same time; and
    - deposit a blade structure (404), moving the welding torch (202, 300) in relation to the substrate along a direction of intersection with the circular or quasi-circular structure (402), while remaining at the same time the rotating substrate in an un-rotated state.
    [3]
    3. METHOD, according to claim 1, characterized by the fact that depositing each layer comprises:
    (i) deposit a circular or almost circular structure (402), while rotating the substrate;
    (ii) moving the welding torch (202, 300) and / or the substrate along or parallel to an axial direction of the substrate;
    Petition 870190056924, of 6/19/2019, p. 24/28
    2/4 (iii) deposit another circular or almost circular structure (402), while rotating the substrate;
    (iv) deposit a blade structure (404), moving the welding torch (202, 300) to trace the welding wire (304) through the substrate along or parallel to an axial direction of the substrate, maintaining at the same time the rotating substrate is in an un-rotated state;
    (v) rotate the substrate; and (vi) repeat steps (iv) and (v) until the layer of all blade structures is deposited.
    [4]
    4. METHOD according to claim 3, characterized in that in step (v), the substrate is rotated at an angle in order to deposit a next blade structure (404) adjacent to the previous blade structure (404) .
    [5]
    5. METHOD, according to claim 3, characterized in that in step (v), the substrate is rotated at an angle in order to deposit a blade structure (404) opposite or almost opposite to the blade structure (404 ) previous.
    [6]
    6. METHOD, according to claim 1, characterized by the fact that depositing each layer comprises:
    - deposit a circular or quasi-circular structure (402) on the rotating substrate, while rotating the rotating substrate at the same time; and
    - deposit a blade structure (404), moving the welding torch (202, 300) in relation to the substrate along a direction of intersection with the circular or quasi-circular structure (402), while rotating the substrate rotating.
    [7]
    7. METHOD, according to claim 1, characterized by the fact that it additionally comprises finishing the rotating article by means of electrical discharge machining.
    Petition 870190056924, of 6/19/2019, p. 25/28
    3/4
    [8]
    8. METHOD, according to claim 1, characterized by the fact that it additionally comprises cooling the rotating substrate and depositing on it, passing a cooling fluid through a hole in the rotating substrate.
    [9]
    9. METHOD, according to claim 1, characterized by the fact that the filler metal is selected from the group consisting of carbon steel, steel alloy, nickel alloy, titanium alloy and combinations thereof.
    [10]
    10. METHOD, according to claim 1, characterized by the fact that the filler metal is fed at a rate ranging from 3 m / min to 10 m / min during deposition.
    [11]
    11. METHOD FOR MANUFACTURING A ROTARY ARTICLE, characterized by the fact that it comprises:
    - providing a cold metal transfer welding apparatus (200) comprising a welding torch (202, 300);
    - provide a rotating substrate;
    - producing the rotating article, using the welding torch (202, 300) to deposit a filler metal on the rotating substrate, while rotating or moving the rotating substrate and / or simultaneously moving the torch welding (202, 300); and
    - separate the rotating substrate from the rotating article.
    [12]
    12. METHOD, according to claim 11, characterized by the fact that it additionally comprises finishing the rotating article by means of electrical discharge machining.
    [13]
    13. METHOD, according to claim 11, characterized by the fact that it additionally comprises cooling the rotating substrate and depositing on it, passing a cooling fluid through a hole in the rotating substrate.
    Petition 870190056924, of 6/19/2019, p. 26/28
    ΑΙΑ
    [14]
    14. METHOD, according to claim 11, characterized by the fact that the filler metal is selected from the group consisting of carbon steel, steel alloy, nickel alloy, titanium alloy and combinations thereof.
    [15]
    15. ROTARY ARTICLE, manufactured according to the method defined in any one of claims 1 to 14, characterized by the fact that it has at least one internal fluid passage, the rotating article being obtained by depositing layer by layer of a filler metal by means of welding by cold metal transfer (200).
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    同族专利:
    公开号 | 公开日
    CN103801799A|2014-05-21|
    EP2919940A1|2015-09-23|
    KR20150082607A|2015-07-15|
    CN103801799B|2017-11-21|
    JP2016504194A|2016-02-12|
    RU2663914C9|2018-10-04|
    US9981333B2|2018-05-29|
    JP6340008B2|2018-06-06|
    CN104797370A|2015-07-22|
    WO2014074379A1|2014-05-15|
    RU2015115957A|2017-01-10|
    RU2663914C2|2018-08-13|
    US20160297024A1|2016-10-13|
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    法律状态:
    2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-04-09| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application according art. 36 industrial patent law|
    2019-07-23| B09A| Decision: intention to grant|
    优先权:
    申请号 | 申请日 | 专利标题
    CN201210452167.2|2012-11-12|
    CN201210452167.2A|CN103801799B|2012-11-12|2012-11-12|The revolving meber for manufacturing the method for revolving meber and being manufactured with this method|
    PCT/US2013/067675|WO2014074379A1|2012-11-12|2013-10-31|Method for manufacturing rotary article by cold metal transfer welding deposition and rotary article as manufactured|
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