• 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:
    An apparatus for making a blade (40) includes a laser (72) for generating a non-focused laser beam (74) and means for providing a fluid column (76) in the beam path of the laser (72) to produce a focused laser beam (78) which is directed to the airfoil (40). A gas flowing inside the airfoil (40) interferes with the fluid column (76) inside the airfoil (40) to scatter the focused laser beam (78). A method of manufacturing a blade (40) includes the steps of: focusing a laser beam inside a fluid column (76) to produce a focused laser beam (78) and directing the focused laser beam (78) onto a surface of the blade (40) , Further, the method includes the steps of forming a hole through the surface of the airfoil (40) by means of the focused laser beam (78), and disturbing the fluid column (76) by means of a gas flowing inside the airfoil (40).
    公开号:CH706953B1
    申请号:CH01540/13
    申请日:2013-09-09
    公开日:2017-10-31
    发明作者:Hu Zhaoli；Anthony Serieno Douglas
    申请人:Gen Electric；
    IPC主号:
    专利说明:

    Description Field of the Invention The present invention relates generally to an apparatus and method for making an airfoil.
    Background of the Invention Turbines are often used in industrial and commercial operations. A typical commercially available steam or gas turbine used to generate electrical power includes alternating stages of stationary and rotating airfoils. For example, stationary vanes may be attached to a stationary component, such as a housing, that surrounds the turbine, and rotating blades may be attached to an impeller disposed along an axial centerline of the turbine. A compressed working fluid, such as, but not limited to, steam, combustion gases, or air, flows through the turbine, and the stationary vanes accelerate and direct the compressed working fluid to the subsequent stage of rotating blades to set the rotating blades in motion. so that the impeller is turned and does work.
    The efficiency of the turbine generally increases with higher temperatures of the compressed working fluid. However, too high temperatures in the turbine can reduce the life of the blades in the turbine and thereby increase repairs, maintenance and downtime associated with the turbine. As a result, a variety of designs and methods have been developed to provide cooling to the airfoils. For example, a cooling medium can be supplied to a cavity in the interior of the airfoil in order to remove heat from the airfoil by convection and / or heat conduction. In particular embodiments, the cooling medium may flow out of the cavity through cooling channels in the airfoil to enable film cooling over the outer surface of the airfoil.
    As the temperatures and / or performance standards continue to increase, the materials used for the airfoil become thinner, which makes reliable manufacture of the airfoil increasingly difficult. Specifically, the airfoil is usually cast from a high-alloy metal, and a heat-insulating layer may be attached to the outer surface of the airfoil to improve thermal protection. In order to optimize the flow of coolant across the blade, the cooling channels are often formed after casting by drilling or machining at precisely defined locations and geometries in the high alloy metal. For example, a jet of water may be used to drill the cooling channels at specific locations and angles through the high alloy metal to refine the coolant flow over the outer surface of the airfoil. Although the jet of water is used effectively for accurately drilling small diameter holes through the high alloy metal, it may also damage the thermal barrier coating and / or introduce abrasive dust byproducts into the interior of the airfoil which may be difficult to remove completely. Alternatively or moreover, the water jet may inadvertently impinge on the opposite side of the cavity on the inside of the airfoil, with the result of damaging the inside of the airfoil. The abrasive dust by-products inside the airfoil and / or damage to the inside of the airfoil are difficult to detect during the finishing steps of the airfoil. As a result, an airfoil system and method would be advantageous in that it would reduce or prevent damage to the thermal barrier coating, introduction of abrasive dust by-products into the airfoil, and / or inadvertent damage to the interior of the airfoil.
    Brief Description of the Invention Features and advantages of the invention are set forth below in the description which follows, or may be obvious from the description.
    The present invention relates to an apparatus for producing an airfoil. The apparatus includes a laser for producing an unfocused laser beam and means for providing a fluid column in a beam path of the laser such that the unfocused laser beam is focused within the fluid column to produce a focused laser beam directed at the airfoil. The apparatus further includes means for providing a gas that flows inside the airfoil, the gas interfering with the fluid column within the airfoil to scatter the focused laser beam.
    The gas may include steam.
    In addition, or alternatively, the gas may include an inert gas.
    The gas of any kind may have a pressure exceeding 172.639 kilopascals (25 pounds per square inch).
    The gas may cross the fluid column inside the airfoil.
    The gas may include a gas column in the interior of the airfoil.
    According to another aspect of the present invention, a method of making a blade includes the steps of: directing an unfocused laser beam onto a surface of the blade, and focusing the laser beam outside the blade within a fluid column to form a focused laser beam outside the blade to create. The method further includes the steps of forming a hole through the surface of the airfoil by means of the focused laser beam, and interfering with the fluid column by means of a gas inside the airfoil to scatter the focused laser beam.
    The method may further include flowing the gas inside the airfoil.
    The above-mentioned method may additionally include the step of preventing the focused laser beam from hitting an inner surface of the airfoil at the side opposite to the hole.
    The above-mentioned method may further include scattering the focused laser beam inside the airfoil.
    The above-mentioned method may further include the step of crossing the fluid column with the gas inside the airfoil.
    Again, the gas inside the airfoil may include steam and / or an inert gas inside the airfoil.
    [0018] The skilled person will understand the features and aspects of such and further embodiments after reading the description.
    BRIEF DESCRIPTION OF THE DRAWINGS A full and practical description of the present invention, which includes the best mode for carrying out the invention, will be more particularly described in the following description, taken in conjunction with the accompanying drawings, in which: FIG.
    FIG. 1 is a simplified sectional view of an exemplary turbine that may utilize different embodiments of the present invention; FIG.
    FIG. 2 is a perspective view of an exemplary airfoil according to one embodiment of the present invention; FIG. and
    Fig. 3 is a plan view of a core which may be used to cast the airfoil shown in Fig. 2;
    Fig. 4 is a perspective view showing an apparatus for producing the airfoil shown in Fig. 2; and
    Fig. 5 illustrates in a perspective view of the device shown in Fig. 4, after the focused laser beam has penetrated the airfoil.
    DETAILED DESCRIPTION OF THE INVENTION [0020] Reference will now be made in detail to the present embodiments of the invention, one or more of which examples being illustrated in the accompanying drawings. The detailed description uses alphanumeric designations to refer to features in the figures. In the figures and in the description, similar or similar terms have been used to refer to the same or similar elements of the invention. As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to denote the location or meaning of the individual components. In addition, the terms "upstream" and "downstream" refer to the relative location of the components in a flow path. For example, a component A is located upstream of a component B if a fluid flows from component A to component B. In contrast, component B is located downstream of component A if component B receives a fluid flow from component A.
    Various embodiments of the present invention include an apparatus and method for making an airfoil. The apparatus generally includes an unfocused laser beam focused through a fluid column, and the focused laser beam may be utilized to form precise holes at particular angles through a blade surface. As the focused laser beam penetrates the blade surface, gas flowing inside the airfoil interferes with the fluid column within the airfoil to prevent the focused laser beam from damaging the interior of the airfoil. As used herein, the term "gas" includes any gaseous media except air.
    Referring now to the drawings, wherein like elements are designated by like reference numerals, FIG. 1 is a simplified side sectional view of an exemplary turbine 10 according to various embodiments of the present invention. As shown in FIG. 1, the turbine 10 generally includes an impeller 12 and a housing 14 that at least partially define a gas path 16 through the turbine 10. The impeller 12 is substantially aligned with an axial centerline 18 of the turbine 10 and may be connected to a generator, compressor, or other engine to do work. The impeller 12 may include alternating portions of impellers 20 and rotor spacers 22 connected together by a bolt 24 to rotate together. The housing 14 surrounds at least a portion of the impeller 12 to receive a compressed working fluid 26 that flows through the gas path 16. The compressed working fluid 26 may include, for example, combustion gases, compressed air, saturated steam, unsaturated steam, or a combination thereof.
    As shown in FIG. 1, the turbine 10 also includes alternating stages of rotating blades 30 and stationary vanes 32 extending radially between the rotor 12 and the housing 14. The rotating blades 30 are arranged in a circle around the impeller 12 and may be connected to the impellers 20 by a variety of means. In contrast, the stationary vanes 32 may be peripherally disposed on the side opposite the rotor spacers 22 around the inside of the housing 14. As known in the art, the rotating blades 30 and the stationary vanes 32 generally have a blade profile having a concave pressure side, a convex suction side, and leading edges and trailing edges. As shown in FIG. 1, the compressed working fluid 26 flows from left to right along the gas path 16 through the turbine 10. As the compressed working fluid 26 passes over the first stage of rotating blades 30, the compressed working fluid expands, causing the rotating fluid to flow Blades 30, the wheels 20, the rotor spacers 22, the pin 24 and the impeller 12 are rotated. The compressed working fluid 26 then flows over the next stage of stationary vanes 32, which accelerate the compressed working fluid 26 and divert it to the next stage of rotating blades 30; and the process repeats for the following stages. In the embodiment shown in Figure 1, the turbine 10 has two stages of stationary vanes 32 between three stages of rotating blades 30; however, it will be readily apparent to those skilled in the art that the number of stages of rotating blades 30 and stationary vanes 32 is not limitative of the present invention unless specifically stated in the claims.
    FIG. 2 shows a perspective view of an exemplary airfoil 40 as may be integrated with the rotating blades 30 or stationary vanes 32 according to one embodiment of the present invention. As shown in FIG. 2, the airfoil 40 generally has a concave curved pressure side 42 and a convexly curved suction side 44 opposite to the pressure side 42. The pressure side and suction side 42, 44 are separated from each other to define a cavity 46 in the interior of the airfoil 40 between the pressure side and the suction side 42, 44. The cavity 46 may provide a serpentine or tortuous path for a cooling medium flowing inside the airfoil 40 to conductively and / or convectively remove heat from the airfoil 40. In addition, the pressure side and the suction side 42, 44 are combined to form a leading edge 48 at an upstream portion of the blade 40 and an outflow edge 50 downstream of the cavity 46 at a downstream portion of the blade 40. Multiple cooling channels 52 in the pressure side 42, in the suction side 44, in the leading edge 48, and / or in the trailing edge 50 may provide flow communication from the cavity 46 through the airfoil 40 to supply the cooling medium over the outer surface of the airfoil 40 spread. As shown in FIG. 2, the cooling channels 52 may be arranged, for example, at the leading edge and at the trailing edge 48, 50 and / or along the pressure side 42 and / or along the suction side 44. One skilled in the art will readily appreciate from the teachings herein that the number and / or location of the cooling channels 52 may vary depending on particular embodiments, and that the present invention is not limited to any particular number or location of cooling channels 52 unless, this is specifically mentioned in the claims.
    The exemplary airfoil 40 shown in FIG. 2 may be made by any method known in the art. For example, FIG. 3 shows a plan view of a core 60 that may be used to make the airfoil 40 shown in FIG. 2 by lost-wax casting. As illustrated in FIG. 3, the core 60 may include a serpentine portion 62 having a number of long, thin branches or protrusions 64 extending from the serpentine portion 62. The serpentine portion 62 is substantially the size and location of the cavity 46 in the airfoil 40, and the protrusions 64 are substantially the same size and location of the larger cooling channels 52 through the trailing edge 50 of the airfoil 40 any material that has sufficient strength to withstand the high temperatures of the casting melt (eg, a high alloyed metal) while maintaining the fixed positioning required for the core 60 during casting. For example, the core 60 may be cast from ceramic, ceramic composite, or other suitable materials. After casting or other manufacturing process, a laser, electric discharge machine, drill, water jet, or other suitable device may be used to refine the serpentine portion 62 and / or protrusions 64 as shown in FIG embody.
    The core 60 can then, as known from the prior art, be used in a lost wax or in another casting process. For example, the core 60 may be coated with a wax or other suitable material that readily shapes with the desired thickness and curvature of the airfoil 40. The wax-covered core 60 may then be repeatedly dipped in a liquid ceramic solution to produce a ceramic shell over the wax surface. The wax may then be heated to remove the wax between the core 60 and the ceramic shell so that a cavity is created between the core 60 and the ceramic shell which serves as a mold for the airfoil 40.
    A molten high-alloyed metal can then be poured into the mold to form the airfoil 40. The high-alloy metal may include, for example, nickel, cobalt and / or iron superalloys, e.g. GT-111, GED-222, Rene 80, Rene 41, Rene 125, Rene 77, Rene N5, Rene N6, PWA 1484, PWA 1480, 4th generation single crystal superalloys, MX-4, Hastelloy X, cobalt-based HS-188 and similar alloys. After the high-alloyed metal has cooled and solidified, the ceramic shell can be broken and removed, exposing the high-alloy metal that has taken the shape of the cavity created by the removal of the wax. The core 60 may be removed from the interior of the airfoil 40 by methods known in the art. For example, the core 60 may be dissolved by a leaching process to remove the core 60, leaving the cavity 46 and the cooling channels 52 in the airfoil 40.
    FIG. 4 shows a perspective view of a system 70 which serves to form additional cooling channels 52 through the airfoil 40. As shown in FIG. 4, the system 70 may include a laser 72 capable of producing an unfocused laser beam 74. The unfocused laser beam 72 may have a wavelength of about 532 nm, a pulse frequency of about 10 kHz, and an average power of about 40-50 W. In the particular embodiment shown in FIG. 4, the laser 72 directs the unfocused laser beam 74 into or through a fluid column 76 toward the airfoil 40. The fluid column 76 may be based on any gaseous or liquid fluid that is capable is to focus the unfocused laser beam 74 and may have a pressure in the range of about 4.826 to 10.342 megapascals (700-1500 pounds per square inch), although the present invention is not limited to any particular pressure of the fluid column 76, as it were because, this is specifically mentioned in the claims. The fluid column 76 acts as a light guide for the unfocused laser beam 74, so that a focused laser beam 78 is produced, which is directed onto the airfoil 40. The focused laser beam 78 carries off the surface of the airfoil 40, wherein finally the desired cooling channel 52 is formed through the airfoil 40.
    FIG. 5 shows a perspective view of the system 70 shown in FIG. 4 after the focused laser beam 78 has penetrated the airfoil 40. As shown in FIGS. 4 and 5, the system 70 further includes a gas 80 flowing inside the airfoil 40. As used herein, the term "gas" includes any gaseous media except air. For example, the gas 80 may be an inert gas, a vacuum, a saturated vapor, an overheated vapor, or any other gas other than air that may form a gas column 82 within the airfoil 40. The gas 80 flowing inside the airfoil 40 may have a pressure approximately equal to the pressure of the gas or liquid in the fluid column 76 and sufficient to disturb the fluid column 76 inside the airfoil 40. For example, although the present invention is not limited to a specific pressure for the gas 80, the gas 80 flowing inside the airfoil 40 may have a pressure exceeding about 172.369 kilopascals (25 pounds per square inch), unless this is specifically mentioned in the claims.
    As shown most clearly in FIG. 5, the gas 80 may be aligned to intersect the fluid column 76 and / or the focused laser beam 78 within the airfoil 40. In particular embodiments, the gas 80 may be oriented substantially perpendicular to the fluid column 76, while in other specific embodiments, the gas 80 may be aligned with the fluid column 76 and / or the focused laser beam 78 at an obtuse or acute angle. As the gas 80 intersects the fluid column 76 within the airfoil 40, the gas 80 disturbs / tears the fluid column 76 and / or scatters the focused laser beam 78 within the airfoil 40. In this manner, the gas prevents the focused laser beam 78 from flying an inner surface of the airfoil 40 meets, which is transverse to the just formed cooling channel 52.
    One skilled in the art will readily appreciate from the teachings herein that the system 70 described and illustrated with reference to FIGS. 4 and 5 may provide a method of making the airfoil 40. For example, the method may include directing the unfocused laser beam 74 onto the surface of the airfoil 40 and confining the unfocused laser beam 74 outside of the blade 40 by means of the fluid column 76 around the focused laser beam 78, as in FIGS. 4 and 5 shown outside of the blade 40 to produce. Further, the method may include the steps of forming the opening or cooling channel 52 through the surface of the airfoil 40 by means of the focused laser beam 78, and perturbing the fluid column 76 and / or the focused laser beam 78 inside the airfoil 40 by means of the gas 80 inside of the airfoil 40, as shown in Fig. 5. The method can thus scatter the focused laser beam 78 in the interior of the airfoil 40, so that an impact of the focused laser beam 78 on the inner surface of the airfoil 40 that is transverse to the cooling channel 52 is prevented.
    An apparatus for making a blade includes a laser providing an unfocused laser beam and means for providing a fluid column in the beam path of the laser to focus the unfocused laser beam directed at the airfoil. A gas flowing inside the airfoil interferes with the first fluid column inside the airfoil to scatter the focused laser beam. A method of manufacturing a blade includes the steps of: focusing a laser beam inside a fluid column to produce a focused laser beam; and directing the focused laser beam onto a surface of the blade. The method further includes the steps of forming a hole through the surface of the airfoil by means of the focused laser beam, flowing a gas inside the airfoil, and disturbing the fluid column by means of the gas flowing inside the airfoil to scatter the focused laser beam.
    REFERENCE SIGNS LIST 10 turbine 12 impeller 14 housing 16 gas path 18 axial centerline 20 impellers 22 rotor spacers 24 bolts 26 working fluid 30 rotating blades 32 stationary vanes 40 airfoil 42 pressure side 44 suction side 46 cavity 48 leading edge 50 outflow edge 52 cooling channels 60 core 62 serpentine section 64 Projections 70 System 72 Laser 74 Unfocused laser beam 76 Fluid column 78 Focused laser beam 80 Gas 82 Gas column
    权利要求:
    Claims (9)
    [1]
    Claims 1. An apparatus for making a blade (40), the apparatus comprising: a) a laser (72) for producing a non-focused laser beam (74); b) means for providing a fluid column (76) in a beam path of the laser (72) so that the unfocused laser beam (74) is focused within the fluid column (76) to produce a focused laser beam (78) which is incident on the laser beam Airfoil (40) is directed; and c) means for providing a gas (80) flowing inside the airfoil (40), the gas (80) interfering with the fluid column (76) inside the airfoil (40) to deliver the focused laser beam (78) sprinkle.
    [2]
    2. Device according to claim 1, wherein the gas (80) includes steam and / or an inert gas.
    [3]
    Apparatus according to claim 1 or 2, wherein the gas (80) intersects the fluid column (76) in the interior of the airfoil (40).
    [4]
    4. Device according to one of claims 1-3, wherein the gas (80) forms a gas column (82) in the interior of the airfoil (40).
    [5]
    A method of making a blade (40) comprising the steps of: a) directing an unfocused laser beam (74) onto a surface of the airfoil (40); b) focusing the laser beam (74) inside a fluid column (76) outside the airfoil (40) to produce a focused laser beam (78) outside the airfoil (40); c) forming a hole through the surface of the airfoil (40) by means of the focused laser beam (78); and d) interfering with the fluid column (76) by means of a gas (80) inside the airfoil (40) to scatter the focused laser beam (78).
    [6]
    The method of claim 5, further comprising the step of flowing the gas (80) inside the airfoil (40).
    [7]
    A method according to any of claims 5 or 6, including at least one of the steps of: a) preventing the focused laser beam (78) from hitting an inner surface of the airfoil (40) at the side opposite the hole; b) scattering the focused laser beam (78) inside the airfoil (40); c) aligning the gas (80) to cut the fluid column (76) inside the airfoil (40).
    [8]
    The method of any one of claims 5 to 7, further comprising the step of aligning the gas (80) within the airfoil (40) substantially perpendicular to the fluid column (76).
    [9]
    The method of any one of claims 5 to 8, wherein the flow of the gas (80) within the airfoil (40) includes a flow of steam and / or an inert gas within the airfoil (40).
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    同族专利:
    公开号 | 公开日
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    US8969760B2|2015-03-03|
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    法律状态:
    2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/617,145|US8969760B2|2012-09-14|2012-09-14|System and method for manufacturing an airfoil|
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