制作构件的方法和构件

本发明公开了制作构件的方法和构件。该方法包括将预烧结的预制件射束钎焊到构件上，从而形成射束-钎焊部分。该构件包括由预烧结的预制件形成的射束-钎焊部分。

技术领域

[0001] 本发明涉及成品构件和制作成品构件的方法。更具体地说，本发明涉及射束-钎焊构件和制作射束-钎焊构件的方法。

背景技术

[0002] 通常，涡轮叶片可联接在中心轮毂上，中心轮毂连接在从动轴上，其中叶片相对于轮毂和轴的轴线径向设置。叶片可包括翼型件，其传递使轴旋转的旋转能量。某些燃气涡轮叶片在相关联的翼型件的外端处具有护罩。叶片护罩彼此紧密地嵌套。许多涡轮叶片护罩具有呈凹口形式的机械互锁特征，其容许各个叶片在其护罩处与相邻的叶片物理地互锁

在一起。

[0003] 有各种机理可能造成机械锁紧特征的磨损。例如，在涡轮的操作期间，相邻的叶片可能存在相对彼此和相对于轮毂的振动。前述互锁特征可有利于减轻翼型件振动，使得又减轻在操作期间叶片中所引起的应力。互锁特征的紧密公差可能增加互锁特征附近的磨损，因为相邻的凹口彼此摩擦。

[0004] 此外，在起动操作期间，因为护罩、翼型件和轮毂（以及与热气体接触的所有其它构件）的温度在各个独立构件中且相对于其它相邻的构件而变化，并且涡轮被加速至操作速度，所以叶片和护罩可能扭曲，使得凹口有时彼此接触，并达到互锁条件。同样，在停止操作期间，构件温度上的变化可能与起动以及涡轮减速时相关联的变化是基本相反的，使得叶片和护罩可能扭曲，因而凹口不会彼此接触，并达到非互锁条件。

[0005] 许多护罩材料并不具有表面耐磨性特性，以抵抗接触和摩擦的长期累积效应。

[0006] 在本领域中将需要一种没有上述一个或多个缺点的构件和制作该构件的方法。

发明内容

[0007] 在一个示例性实施例中，一种制作构件的方法包括将预烧结的预制件或软带通过射束钎焊到构件上，从而形成射束-钎焊部分。

[0008] 在另一示例性实施例中，一种制造构件的方法包括制备构件的至少一部分用于接纳烧结的预制件，形成预烧结的预制件，将烧结的预制件定位在构件上，并将烧结的预制件通过射束钎焊到构件的至少一部分上。

[0009] 在另一示例性实施例中，一种构件包括非钎焊部分和由预烧结的预制件形成的射束-钎焊部分。

附图说明null实施方式

Embodiment

The disclosure provides a kind of exemplary beam-soldering member and the illustrative methods of making beam-soldering member.Embodiment of the present disclosure has alleviated the long-term accumulated effect of contact and friction, has prevented to comprise increasing wear resistance and/or hardness because the maintainability that distortion and the vibration of member cause is shut down and repaired, and reduces the susceptibility to wearing and tearing, reaches their combination.

Beam-soldering member is any suitable member that is formed by the prefab of presintering (PSP).Suitable member comprises gas turbine components (for example, guard shield surface, blade or vane surface, interlock feature or hard-facing surface) or any other suitable metal or metal composite structure.

Fig. 1 is the skeleton view of portion's section of combustion turbine 100, and it comprises member or the member part that is fit to carry out electron beam-soldering and/or laser beam-soldering.For example, turbine 100 has a plurality of turbine blades 102 that are connected on the wheel hub 104.Wheel hub 104 is connected on the turboshaft (not shown).Blade 102 comprises corresponding aerofoil profile part 106 and is connected in the corresponding turbine blade guard shield 108 on the aerofoil profile part 106 regularly.Guard shield 108 has two relative accordingly interlock feature 110.Projection 112 helps the connection of blade 102, thereby has reduced or eliminated circumferential movement and vibration.Shown that in Fig. 2 Fig. 1 is sealed and be designated as 2 part by dotted line.Fig. 2 is the top view of the guard shield that does not have hard-facing 108 that can use with combustion turbine 100.Guard shield 108 is illustrated as has interlock feature 110 on each end.Interlock feature 110 has mating surface 114.

Member comprises by for example, the substrate that the superalloy material forms.In one embodiment, substrate has and calculates by weight about 14% chromium, about 9.5% cobalt, about 3.8% tungsten, about 1.5% molybdenum, about 4.9% titanium, about 3.0% aluminium, about 0.1% carbon, about 0.01% boron, about 2.8% tantalum and the composition of balance nickel.In one embodiment, substrate has and calculates by weight about 9.75% chromium, about 7.5% cobalt, about 3.5% titanium, about 4.2% aluminium, about 6.0% tungsten, about 1.5% molybdenum, about 4.8% tantalum, about 0.08% carbon, about 0.009% zirconium, about 0.009% boron and the composition of balance nickel.In one embodiment, substrate has and calculates by weight about 7.5% cobalt, about 7.0% chromium, about 6.5% tantalum, about 6.2% aluminium, about 5.0% tungsten, about 3.0% rhenium, about 1.5% molybdenum, about 0.15% hafnium, about 0.05% carbon, about 0.004% boron, about 0.01% yttrium and the composition of balance nickel.In one embodiment, substrate has and calculates by weight about 9.75% chromium, about 7.5% cobalt, about 4.2% aluminium, about 3.5% titanium, about 1.5% molybdenum, about 6.0% tungsten, about 4.8% tantalum, about 0.5% niobium, about 0.15% hafnium, about 0.05% carbon, about 0.004% boron and the composition of balance nickel.In one embodiment, substrate has and calculates by weight about 8.35% chromium, about 9.50% cobalt, about 5.50% aluminium, about 0.75% titanium, about 9.50% tungsten, about 0.50% molybdenum, about 3.05% tantalum, 0.09% carbon, about 1.50% hafnium and the composition of balance nickel.In one embodiment, substrate has the composition of the nickel of calculating by weight about 0.06% carbon, about 9.80% chromium, about 7.50% cobalt, about 1.50% molybdenum, about 4.20% aluminium, about 3.50% titanium, about 4.80% tantalum, about 6.00% tungsten, about 0.50% niobium, about 0.15% hafnium and remaining 62%.

In one embodiment, substrate comprises and can at high temperature for example resist the superalloy of creep under the temperature in the hot gas road in gas turbine.For example; In one embodiment; The first part of substrate is kept above first temperature/comparatively high temps; The strength of for example about 1000 ° of F, about 1250 ° of F, about 1500 ° of F, about 2000 ° of F or about 3000 ° of F, and the second section of substrate tolerance is higher than second temperature/lesser temps, for example between 800 ° of F to 1250 ° of F, the heat of about 800 ° of F, about 1000 ° of F, about 1250 ° of F, about 1500 ° of F or about 2000 ° of F.In one embodiment, through for example induction heater (not shown) additional heating is provided.

Fig. 3 is the synoptic diagram that is used to make the illustrative methods 200 of beam-soldering member.Method steps 202 comprises a part (the for example surface shown in Fig. 2 of interlock feature 110 114) for preparing member.Preparation process 202 comprises any suitable substep, includes but not limited to remove any lax surface contaminant, removes the coating that lays, and removes metallurgical impurity (the for example upper layer of oxidation), removes surface irregularity or their combination.In one embodiment, preparation process 202 comprises utilizes gentle washing composition, gentle abrasive and slight mechanical workout.In another embodiment, step 202 comprises additional preparation substep, including, but not limited to removing the subsurface material deformation, alleviates surface irregularity through mechanical workout, or their combination.

Method steps 208 comprises prefab 402 (the for example prefab of the agglomerating prefab or first and second presintering) is positioned on member or the member part (for example interlock feature 110) of pending beam-soldering.In one embodiment, treat that the member of beam-soldering partly is heated to predetermined temperature, for example at about 2100 ° of F between about 2225 ° of F.As shown in Figure 4, in one embodiment, member is the guard shield 108 with hard-facing prefab 402 of connection.Prefab 402 is held in place on the mating surface 114 of interlock feature 110 through at least one discrete type spot welding 404.In one embodiment, use two spot welding 404 to promote prefab 402 is attached on the surface 114.

In one embodiment, the prefab of presintering (PSP) has the composition of calculating by weight about 27.00% to about 30.00% molybdenum, about 16.50% to about 18.50% chromium, the iron until about 1.50%, the nickel until about 1.50%, the oxygen until about 0.15%, the carbon until about 0.08%, the phosphorus until about 0.03%, the sulphur until about 0.03% and balance cobalt.In one embodiment, PSP has and calculates by weight about 0.70% to about 1.00% carbon, about 26.00% to about 30.00% chromium, about 1.00% silicon, about 4.00% to about 6.00% nickel, about 3.00% iron, about 1.25% vanadium, about 0.10% boron, about 18.00% to about 21.00% tungsten and the composition of balance cobalt.In one embodiment; PSP has and calculates by weight about 22.00% to about 24.74% chromium, about 9.00% to about 11.00% nickel, about 6.50% to about 7.60% tungsten, about 3.00% to about 4.00% tantalum, about 2.60% to about 3.16% boron, about 0.55% to about 0.65% carbon, about 0.30% to about 0.60% zirconium, about 0.15% to about 0.30% titanium, the composition of the iron until about 1.30%, the silicon until about 0.40%, the manganese until about 0.10%, the sulphur until about 0.02% and balance cobalt.In one embodiment, PSP has and calculates by weight about 17.00% nickel, about 19.00% chromium, about 4.00% tungsten, about 0.40% carbon, about 0.80% boron, about 8.00% silicon and the composition of balance cobalt.

In another embodiment; Composition comprises a kind of or more multicomponent mixture; For example about 80% first composition and about 20% second composition, about 60% first composition and about 40% second composition, about 50% first composition and about 50% second composition, or any other appropriate ingredients of selecting for the expectation attribute is provided.

PSP is a kind of suitable prespecified geometric or corresponding geometrical shape.Suitable geometrical shape comprise the geometrical shape (for example dull and stereotyped) of substantially flat, banded geometrical shape (soft band that for example can rolling, can the crooked soft band that do not have to meet at right angles under the condition of mechanical force, or have the soft band of predetermined length), the geometrical shape of substantially constant thickness (for example about 0.030 inch, about 0.160 inch or between about 0.020 inch to about 0.080 inch), the geometrical shape of rigid strip, variation in thickness (for example has about 0.010 inch thickness and has about 0.020 inch thickness at second area in the first area; Perhaps have about 0.020 inch thickness and have about 0.030 inch thickness at second area in the first area), or their combination.In having the embodiment of a PSP and the 2nd PSP, a PSP and the 2nd PSP comprise essentially identical geometrical shape.In another embodiment, a PSP and the 2nd PSP have different geometric shape (for example, a PSP has the thicker zone corresponding to the thinner region among the 2nd PSP).

In one embodiment, except PSP or as the soft band of alternative use of PSP.Through first composition and second composition and binder combination are in the same place, this mixture of rolling forms soft band to form band shape or rope-like constructed then.Soft band can bend to some kinds of geometrical shapies, comprises preset thickness, and for example about 0.020 inch to about 0.125 inch, and can be cut into predetermined length.

Method steps 210 comprises member or member is partly carried out beam soldering (for example prefab 402 beams being soldered on the mating surface 114).In one embodiment, the beam soldering of step 210 comprises heating cycle substep and refrigeration cycle substep.The heating cycle substep is included under the predetermined temperature (for example at room temperature or about 70 ° of F) guard shield 108 is placed in the electron beam welding booth (not shown), and prefab 402 is spoted weld on the interlock feature 110.In order to be beneficial to method for welding, nonoxidizing atmosphere (for example through emptying electron beam welding booth) is provided in the electron beam welding booth.In one embodiment, the electron beam welding booth of emptying is evacuated to predetermined pressure (for example 0.067Pa or lower).

The part of member is heated through the electron beam that defocuses with predetermined speed (for example about 250 ° of F of PM) by beam locally, the beam of for example locating or swinging selectively, thus heat is dispersed on the predetermined zone of combustion turbine member 100.Predetermined zone can partly be gone up predetermined path limit by member.In one embodiment, the electron beam that defocuses provides the basic uniform heating of prospective region.Extraly or alternatively, in one embodiment, compare, form the electron beam that defocuses through improving deflection with the electron beam of the focusing that can be used for the electron beam welding.When reaching predetermined temperature, predetermined temperature is held the preset time cycle (for example between about 2 minutes to about 5 minutes), and through the electron beam that defocuses predetermined zone is continued to be heated to brazing temperature subsequently.In one embodiment, predetermined zone is increased to higher temperature (for example about 1800 ° of F) with predetermined speed (for example 250 ° of F of PM), and keeps the predetermined cycle (for example 5 minutes).In this embodiment, next predetermined zone is increased to brazing temperature (for example about 2200 ° of F to 2225 ° of F) with predetermined speed (for example, 350 ° of F PMs), and keeps the preset time cycle (for example about 5 minutes).

Method steps 212 comprises mechanical workout is partly carried out in the beam-soldering of beam-soldering member or member.For example; Can carry out less mechanical workout (the for example hard-facing prefab 402 shown in Fig. 4); To alleviate surface irregularity and to obtain predetermined size (for example, the hard-facing size is substantially similar to the size that is associated of the mating surface 114 shown in Fig. 4).

Though the present invention has been described with reference to preferred embodiment, those skilled in the art should understand, can carry out various variations without departing from the scope of the invention, and substitute its element with equivalent.In addition, under the situation that does not break away from essential scope of the present invention, also can make many remodeling, make special situation or material adapt to instruction of the present invention.Therefore, the present invention is not limited to as being considered to realize optimal mode of the present invention and disclosed special embodiment, and opposite the present invention will comprise falling all embodiment within the scope of the appended claims.