WO2018147875A1 - Schémas d'étanchéité pour structures stratifiées empilées composites à matrice céramique - Google Patents
Schémas d'étanchéité pour structures stratifiées empilées composites à matrice céramique Download PDFInfo
- Publication number
- WO2018147875A1 WO2018147875A1 PCT/US2017/017547 US2017017547W WO2018147875A1 WO 2018147875 A1 WO2018147875 A1 WO 2018147875A1 US 2017017547 W US2017017547 W US 2017017547W WO 2018147875 A1 WO2018147875 A1 WO 2018147875A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- laminates
- sealing
- stacked
- laminate structure
- component
- Prior art date
Links
- 239000011153 ceramic matrix composite Substances 0.000 title claims abstract description 57
- 238000007789 sealing Methods 0.000 title claims description 94
- 239000000463 material Substances 0.000 claims abstract description 73
- 239000007769 metal material Substances 0.000 claims abstract description 45
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 9
- 239000010949 copper Substances 0.000 claims abstract description 9
- 229910001316 Ag alloy Inorganic materials 0.000 claims abstract 2
- 229910000881 Cu alloy Inorganic materials 0.000 claims abstract 2
- 238000001816 cooling Methods 0.000 claims description 64
- 229910052751 metal Inorganic materials 0.000 claims description 48
- 239000002184 metal Substances 0.000 claims description 48
- 238000000034 method Methods 0.000 claims description 28
- 239000012530 fluid Substances 0.000 claims description 14
- 238000004891 communication Methods 0.000 claims description 12
- 229910045601 alloy Inorganic materials 0.000 claims description 10
- 239000000956 alloy Substances 0.000 claims description 10
- 229910052802 copper Inorganic materials 0.000 claims description 7
- 229910052709 silver Inorganic materials 0.000 claims description 5
- 239000004332 silver Substances 0.000 claims description 5
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 3
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052787 antimony Inorganic materials 0.000 claims description 3
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 claims description 3
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052737 gold Inorganic materials 0.000 claims description 3
- 239000010931 gold Substances 0.000 claims description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 239000010937 tungsten Substances 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
- 238000011049 filling Methods 0.000 claims description 2
- 239000000835 fiber Substances 0.000 description 17
- 239000007789 gas Substances 0.000 description 16
- 239000012809 cooling fluid Substances 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 9
- 229910000601 superalloy Inorganic materials 0.000 description 9
- 239000000919 ceramic Substances 0.000 description 7
- 238000002485 combustion reaction Methods 0.000 description 6
- 239000011159 matrix material Substances 0.000 description 5
- 239000002826 coolant Substances 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000005245 sintering Methods 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 229920006240 drawn fiber Polymers 0.000 description 2
- -1 e.g. Substances 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 230000008595 infiltration Effects 0.000 description 2
- 238000001764 infiltration Methods 0.000 description 2
- 238000011068 loading method Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 239000012783 reinforcing fiber Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229910000995 CMSX-10 Inorganic materials 0.000 description 1
- 229910001011 CMSX-4 Inorganic materials 0.000 description 1
- OQPDWFJSZHWILH-UHFFFAOYSA-N [Al].[Al].[Al].[Ti] Chemical compound [Al].[Al].[Al].[Ti] OQPDWFJSZHWILH-UHFFFAOYSA-N 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 229910000856 hastalloy Inorganic materials 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 238000003698 laser cutting Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 230000036316 preload Effects 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 229910001173 rene N5 Inorganic materials 0.000 description 1
- 229910001088 rené 41 Inorganic materials 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 230000003685 thermal hair damage Effects 0.000 description 1
- 229910021324 titanium aluminide Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
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- B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
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- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
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- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
- F01D5/187—Convection cooling
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/284—Selection of ceramic materials
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01D9/00—Stators
- F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
- F01D9/04—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector
- F01D9/041—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector using blades
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- F01D9/00—Stators
- F01D9/06—Fluid supply conduits to nozzles or the like
- F01D9/065—Fluid supply or removal conduits traversing the working fluid flow, e.g. for lubrication-, cooling-, or sealing fluids
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- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
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- B32B2260/023—Two or more layers
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
- C04B2237/34—Oxidic
- C04B2237/343—Alumina or aluminates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
- C04B2237/38—Fiber or whisker reinforced
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
- C04B2237/62—Forming laminates or joined articles comprising holes, channels or other types of openings
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
- C04B2237/68—Forming laminates or joining articles wherein at least one substrate contains at least two different parts of macro-size, e.g. one ceramic substrate layer containing an embedded conductor or electrode
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
- F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
- F05D2230/237—Brazing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
- F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
- F05D2230/238—Soldering
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/50—Building or constructing in particular ways
- F05D2230/51—Building or constructing in particular ways in a modular way, e.g. using several identical or complementary parts or features
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/603—Composites; e.g. fibre-reinforced
- F05D2300/6033—Ceramic matrix composites [CMC]
Definitions
- the present invention relates to high temperature components, and more particularly to structures and processes for sealing ceramic matrix composite (CMC) stacked laminate structures.
- CMC ceramic matrix composite
- Gas turbines comprise a casing or cylinder for housing a compressor section, a combustion section, and a turbine section.
- a supply of air is compressed in the compressor section and directed into the combustion section.
- the compressed air enters the combustion inlet and is mixed with fuel.
- the air/fuel mixture is then combusted to produce high temperature and high pressure gas. This working gas then travels past the combustor transition and into the turbine section of the turbine.
- the turbine section comprises rows of vanes which direct the working gas to the airfoil portions of the turbine blades.
- the working gas travels through the turbine section, causing the turbine blades to rotate, thereby turning the rotor.
- the rotor is also attached to the compressor section, thereby turning the compressor and also an electrical generator for producing electricity.
- High efficiency of a combustion turbine is achieved by heating the gas flowing through the combustion section to as high a temperature as is practical.
- the hot gas may degrade the various metal turbine components, such as the combustor, transition ducts, vanes, ring segments, and turbine blades that it passes when flowing through the turbine.
- CMC ceramic matrix composite
- Such CMC materials may include a ceramic or a ceramic matrix material, either of which hosts a plurality of reinforcing fibers.
- the fibers may have a predetermined orientation to provide the CMC materials with additional mechanical strength. It has been found, however, that forming turbine components from CMC materials may be challenging due to, amongst other things, the difficulty in orientating fibers at edges of the component in the complex shapes typical of many turbine components.
- the stacked CMC laminates comprise a plurality of laminates formed from a CMC material with fibers in a desired orientation.
- the overall composition and shape of the component may be better controlled with increased options.
- oxide and non- oxide CMC materials can survive high temperatures, they can only do so for limited time periods in a combustion environment without being cooled since external surfaces are typically exposed to gas path combustion gases that are substantially hotter than 1200° C.
- cooling schemes have been developed within stacked laminates structures, wherein a cooling air flow is introduced into one or more cavities extending radially through the stack of laminates and into cooling channels formed in the individual laminates.
- the cooling air carries heat away from the CMC material by convection and is flowed out from the cooling channels. Because of the temperatures and pressures involved, however, even the slightest gap between adjacent laminates may result in separation of the adjacent laminates and substantial leakage of the cooling air between adjacent laminates.
- a retaining ring placed on top of the laminate stack which is tightened to place a compressive load on the stack
- Such solutions have been to be not fully effective in eliminating the separation of adjacent airfoils and substantial leakage of cooling fluid during operation.
- One issue is that the further away a given laminate is from the compressive load and the source thereof, the less effect the compressive load has on that distant area. Accordingly, improved solutions for sealing a stacked laminate structure are desired.
- a stacked laminate structure such as one made from ceramic matrix composite (CMC) fillets or laminates.
- CMC ceramic matrix composite
- aspects of the present invention infiltrate a thermally conductive and ductile metal (“seal") material, such as a copper material, between the laminates in the stacked laminate structure in order to produce a seal between the laminates.
- the seal prevents cooling fluid (e.g., air) leakage and improves cooling efficiency in high temperature environments.
- the seal material may be one that is highly malleable under high temperature conditions, thereby allowing it to maintain an effective seal under high temperature conditions, e.g. , > 1200° C.
- the described sealing structures and processes may also aid in reducing a degree of necessary (compressive) pre- loading on the stacked laminates since the metal material used for the seal will actually pull the laminates together in its cooled state.
- the metal (seal) material will expand and re-anneal during operational cycles, thereby avoiding load transmission between laminates under high temperature conditions and relieving stresses that might otherwise induce cracks.
- the seal formed by the metal material may also aid in removing heat from CMC laminates, which is particularly useful since CMC materials are typically insulators.
- the seal may be positioned throughout the stacked laminate structure to allow heat to be transferred via conduction to interior areas of the structure where heat can be carried away via convection to a cooling fluid traveling through the component.
- a component comprising a plurality of stacked laminates, a portion or all of which comprise a ceramic matrix composite material.
- the plurality of stacked laminates define a stacked laminate structure.
- the component further includes a seal formed from a metal material disposed between adjacent stacked laminates in the stacked laminate structure.
- the seal comprises a column of the resolidifiable ductile and conductive material which extends through corresponding openings in the stacked laminates between a top end and a bottom end of the stacked laminate structure.
- the seal may be disposed within a plurality of sealing passages inboard of an exterior of the stacked laminate structure and between a leading edge and trailing edge thereof. The sealing passages are in fluid communication with the column such that the metal material forming the seal may also be disposed within the sealing passages.
- a process for sealing a stacked laminate structure comprising: stacking a plurality of laminates comprising a ceramic matrix composite material on one another to form the stacked laminate structure; forming a plurality of sealing passages within an interior of the stacked laminate structure; filling the plurality of sealing passages with a molten metal material; and cooling the molten metal material within the sealing passages to form a seal for the stacked laminate structure in the sealing passages.
- FIG. 1 illustrates a turbine component comprising a plurality of stacked laminates having a seal between the laminates in accordance with an aspect of the present invention.
- FIG. 2 illustrates a laminate having a sealing channel formed therein in accordance with an aspect of the present invention.
- FIG. 3 illustrates a seal passage formed between two laminates in accordance with an aspect of the present invention.
- FIG. 4 illustrates another seal passage formed between two laminates in accordance with another aspect of the present invention.
- FIG. 5 illustrates a laminate having a seal passage and a cooling passage in accordance with an aspect of the present invention.
- FIG. 7 illustrates a metal support formed through the sealed stack of laminates in accordance with an aspect of the present invention.
- FIG. 8 illustrates the formation of a laminate plate having a sealing channel and a cooling channel formed therein in accordance with an aspect of the present invention.
- FIG. 9 illustrates the addition of a metal material to a laminate in accordance with an aspect of the present invention.
- FIG. 10 illustrates the stacking of laminates to form the stacked laminate structure in accordance with an aspect of the present invention.
- FIG. 1 1 illustrates the addition of seal material to the seal passages in accordance with an aspect of the present invention.
- FIG. 1 illustrates an exemplary
- the component 10 formed by a plurality of stacked laminates 12 stacked on top of one another to form a stacked laminate structure 14 in accordance with an aspect of the present invention.
- the component 10 comprises a gas turbine component (e.g. , blade 16); however, it is understood that the present invention is not so limited.
- the component 10 of FIG. 1 comprises an airfoil shape 18 having a top end 20, a bottom end 22, a leading edge 24, and a trailing edge 26.
- the laminates 12 comprise a seal 28 formed from a metal (seal) material 25 that is infiltrated between the stacked laminates 12 and/or radially (R) through the stacked laminate structure 14.
- the seal 28 is effective to prevent air leakage between adjacent laminates 12, as well as carry away heat from the laminates 12 in the stacked structure 14.
- a portion of the seal 28 is illustrated within a sealing passage 30 extending radially (R) toward the top end 20 of the component 20 from the bottom end 22. It is understood that the seal 28 is typically also located within further internal sealing passages 30 between adjacent laminates 12 as will be described below and illustrated in additional figures.
- the illustrated embodiment shows the sealing channel 38 with a uniform distance between the sealing channel 38 and an exterior 44 of laminate 12.
- the present invention is not so limited. In other embodiments, the distance between the sealing channel 38 and an exterior 44 or outer perimeter of the laminate 12 may vary depending on the particular application.
- the body 32 of the laminate 12 may comprise at least one opening 46 through the body 32 for the introduction of the molten metal (seal) material 25 therein (as will be explained below).
- the opening 46 may be within the sealing channel 38, or may be located adjacent thereto as shown, such that material which is flowed into the opening 46 is also able to flow into the sealing channel 38.
- the opening 46 may be sized such that the opening 46 on one laminate 12 at least partially overlaps a similar opening 46 on an abutting laminate 12 in the stack to form a sealing passage 30 in the form of a column 48 (shown by the dotted lines in FIG. 1 ) extending radially through the component 10.
- the metal (seal) material 25 can be introduced into the column 48 and distributed to the other sealing channels 38 throughout the stacked laminate structure 14 to form the seal 28.
- the column 48 and the sealing channels 38 collectively define sealing passages 30 for the component 10.
- Each sealing channel 38 may be of any suitable dimension (e.g., depth and width) suitable for providing the desired degree of sealing for the laminates 12 and desired degree of thermal conductivity for the component 10.
- each channel 38 may comprise a depth of from about 0.25 to about 5 mm and a width of from about 0.25 mm to about 5 mm.
- the term "about” refers to a value which may be ⁇ 5% of the stated value.
- each channel 38 may have any desired shape in cross-section, such as a polygonal shape or a curved (e.g. , a semicircle or a half-ellipse) shape.
- a surface of each sealing channel 38 may have varying degrees of roughness or smoothness as desired.
- each laminate 12 is formed wholly or partially formed from a CMC material 47 as is known in the art.
- the CMC material 47 may include a ceramic or a ceramic matrix material, each of which hosts a plurality of reinforcing fibers.
- the CMC material 47 may be anisotropic, at least in the sense that it can have different strength
- a plurality of the laminates 12 are stacked on top of one another to form a component 10 having a plurality of seal passages 30 formed therein.
- the component 10 formed from a stack of laminates 12 may comprise a rotating component for a gas turbine, such as a blade, which may be mounted on a platform 50 as shown in FIG. 1 .
- the component 10 may comprise a stationary component for a gas turbine, such as a blade, which may be mounted on a platform 50 as shown in FIG. 1 .
- the component 10 may comprise a stationary
- the present invention is not so limited to gas turbine components and it is understood that any desired component may be formed by the processes described herein.
- a sealing channel 38 in one laminate 12 may overlap with a sealing channel 38 in an abutting laminate 12 to form a sealing passage 30 as shown in FIG. 3.
- selected ones of the laminates 12 comprise a channel 38 in only one of the top surface 34 and the bottom surface 36.
- the channel 38 is formed in only one of the laminates 12, but the other laminate 12 is utilized to close the sealing passage 30 as is shown in FIG. 4.
- the formed sealing passages 30 (via channels 38) may be in fluid communication with the radial sealing passage 30 (column 48) (FIG. 1 ) such that metal (seal) material 25 may flow from the column 48 into the sealing passages 30 defined between the laminates 12 during assembly of the component 10.
- the laminates 12 utilized in forming the desired component 10 may be substantially identical to one another.
- at least one laminate 12 may be different from another laminate 12 in terms of size, shape, density, fiber orientation, cooling channel dimensions, porosity, or the like.
- a portion or all of the laminates 12 may be in the form of a flat plate, and may have an airfoil shape, for example.
- selected ones or pairs of the laminates 12 may have substantially non-planar abutting surfaces.
- the metal material (seal) material 25 may be any metal which can be heated and flowed into the passageways 30 between laminates 12 as described herein during assembly of the component 10, allowed to cool and solidify, and act a seal between and for the laminates 12.
- the metal material 25 may be one which has a greater thermal conductivity than the CMC material 47 of the laminates 12. In this way, when the CMC material 47 of the laminates 12 is subjected to a high temperature environment (e.g. , > 1200° C), heat may be transferred to the metal material 25 from the "hot" CMC material and aid in cooling the CMC material 47 to prevent thermal damage thereto.
- the metal material 25 may comprise a metal selected from the group consisting of aluminum, antimony, copper, silver, gold, tungsten, and zirconium. In certain embodiments, the metal material 25 may comprise an alloy formed from two or more of these elements (and optionally other additional components). In a particular embodiment, the metal material 25 comprises copper, which is highly advantageous as the material melts and resolidifies easily, is thermally conductive, and highly ductile. In an embodiment, the metal material 25 may comprise an alloy comprising both copper and silver. The addition of silver will raise both the melting point and thermal conductivity of the alloy relative to copper alone. In accordance with another aspect, the component 10 further comprises a plurality of cooling passages formed within an interior of the component 10 such that a cooling fluid may be flowed through the cooling passages to further draw heat from the component 10 during high
- selected ones of the laminates 12 may further comprise a cooling channel 52 (distinct from sealing channel 38) formed on a top surface 34 and/or a bottom surface 36 of the laminate 12.
- any suitable number of the cooling channels 52 and cooling passages 54 may be provided in a given laminate 12 or in the component 10 as a whole, and in any desired shape or pattern.
- the opening(s) 60 of one laminate 12 may overlap with the opening(s) of another laminate 12 such that a radial cooling passage 54 is defined through the stacked laminate structure 14 in fluid communication with the cooling passages 54 defined between the laminates 12.
- the component 10 may further comprise at least one metal support 64 which extends radially through the stacked laminate structure 14 through additional respective openings in the laminates 12.
- more than one metal support 64 may be provided extending radially through the structure.
- the metal support 64 may be pre-formed and the laminates 12 may be stacked over the metal support 64 akin to rings on a pole.
- the metal support 64 may be formed by an additive
- the metal support 64 may comprise an optimal interface between the CMC material of the laminates 12 and the metal along an entire radial length of the component 10.
- additively manufacturing the metal support as the laminates are added also allows for the possibility of varying a thickness of the support 14 along its radial length to account for differences in thermal exposure (if so desired).
- Exemplary additive manufacturing processes for producing a support 64 through the stacked laminate structure 14 are described in PCT Application No. PCT/US2015/023017, entitled "Hybrid Ceramic Matrix
- the processes may manufacture a gas turbine component as is known in the art, which may be a rotating or stationary component, such as a blade or vane.
- a stationary vane is formed by the illustrated process, although it is understood that the present invention is not so limited to the processes described herein or the manufacture of stationary vanes or gas turbine components altogether.
- the component formed may comprise any other suitable structure.
- a substantially flat plate 66 comprising a CMC material may be provided. From the flat plate 66, a laminate 12 may be cut (e.g.
- a given laminate 12 may be provided with a sealing channel 38, a cooling channel 52, an opening 46 in fluid communication with the sealing channel 38 (FIG. 2), an opening 60 in fluid communication with the cooling channel 52 (FIG. 5), and an outlet 62 for the cooling channel 52 (FIG. 5).
- the laminate 12 may include one or more openings (not shown) to accommodate a metal support 64 as described above.
- the formation of the laminate 12 and the desired features therein may be accomplished by any suitable method, such as machining, water jet cutting, and/or laser cutting, or the like.
- a flat plate provides a strong, reliable, and statistically consistent form of the CMC material.
- the flat plate approach may avoid manufacturing difficulties that have arisen when fabricating tightly curved configurations.
- flat plates may be unconstrained during curing, and thus do not suffer from anisotropic shrinkage strains.
- utilizing flat plates reduces the criticality of delamination-type flaws, which are difficult to identify.
- dimensional control is more easily achieved as flat plates may be accurately formed and machined to shape using cost- effective cutting methods.
- a flat plate construction also enables scaleable and automated manufacturing processes. Exemplary resulting laminates 12 from this process step are shown in FIGS. 2 and 5 as discussed previously.
- the laminates 12 may initially be provided by first forming a substantially flat skeleton of a desired shape instead of in the form of a substantially flat plate, while still retaining a strong, reliable, and statistically consistent form of the CMC material.
- the flat skeleton technique involves drawing out or purchasing commercially drawn out fiber material such as Nextel 610, 720 and 650.
- the drawn fiber may have one or more certain intended thickness, size, shape, density, fiber orientation, fiber architecture, and the like.
- the elongated drawn fiber is worked in any of a variety of ways, such as by laying up, rolling, tacking, injecting, spraying and the like, to shape out a substantially flat skeleton of a desired shape.
- the produced laminate 12 may be provided with a sealing channel 38, a cooling channel 52, an opening 46 in fluid
- the laminates 12 may be provided with their desired features and obtained from a suitable commercial source.
- a base member 68 may be provided on which to stack the plurality of laminates 12.
- the base member 68 may comprise any suitable substrate, such as a first laminate 12 in the stack, a plain laminate with no features incorporated therein, or an element of the
- one or more metal supports 64 are also provided, each of which extends radially from the base member 68 as was shown in FIG. 7.
- the individual laminates 12 or laminate groups are stacked sequentially over the metal support 64 until the completed stacked laminate structure 14 is formed.
- the metal support structure 64 may thus be pre-fabricated and dimensioned so as to accommodate placement of the laminates 12 thereon.
- the metal support 64 may instead be built in situ via additive manufacturing as the laminates 12 are stacked to form the complete stacked laminate structure 14.
- a metal source material 70 may be added within corresponding openings of one or more laminates 12 from a suitable metal source 72.
- the metal material 70 is provided from a suitable metal source, such as a hopper or the like, in powdered form at a predetermined volume and feed rate.
- an energy source 74 such as a laser source, focuses an amount of energy 76 on the metal material 70 to form molten metal within the respective opening.
- the energy source 74 may be moved with respect to the subject laminate(s) 12, or vice-versa, to position the energy source 74 at a desired location over the subject laminate(s) 12 to melt the metal material 70.
- the molten metal will be allowed to cool actively or passively to provide a corresponding segment of the metal support 64.
- one or more additional laminates 12 may be added to the laminate stack, and an additional portion of the metal support 64 formed.
- the process of building segments of the metal support(s) 64 may be repeated several times until the stacked laminate structure 14 is fully formed with the desired metal support(s) 64 therein.
- the laminates 12 may undergo heat treatment, e.g. , a sintering process, in order to sinter/fuse the laminates together.
- heat treatment e.g. , a sintering process
- two or more laminates 12 forming a respective internal sealing passage 30 or cooling passage 54 may be sintered in a separate location (away from the stack) so as to fuse the laminates together as a laminate group having two or more laminates. Thereafter, the sintered group of laminates 12 may then be placed on the stack.
- sintering may be done at any suitable temperature and a for a suitable duration to join two or more adjacent laminates to one another, and in one embodiment, may be done at a temperature of about 500 to 1000° C for a period of 1 to 24 hours.
- the stacking of the laminates 12 also facilitates the formation of the sealing passages 30, including a passage 30 in the form of a column 48 extending radially through the stacked laminate structure 14.
- This column 48 will be utilized as a "fill port” to distribute molten seal material 25 to other corresponding interior sealing passages 30 which extend longitudinally through the body 32 of the stacked laminate structure 14 as is shown by arrows 78.
- a suitable amount of the metal (seal) material 25 may be delivered from a suitable source to the column 48 in order to fill the column 48 with the molten metal material 25.
- the metal material 25 prior to addition to the sealing passages 30, the metal material 25 is heated to such an extent as to give the metal material 25 a degree of viscosity and allow flow of the metal material 25 into the passages 30, including column 48.
- the base member 68 may be outfitted with a plug 80 or the like to provide for sealed closure of the passages 30 as shown in FIG. 12.
- FIG. 12 represents an underside of the base member (inner shroud) 68 shown in FIG. 1 1 .
- a laminate 12 or other structure which closes off the column 48 at a bottom or top portion thereof may also be provided.
- an additional platform e.g.
- outer shroud 82 may be fixed to the laminate stacked structure 14 as is conventional in the art and as is shown in FIG. 13 to complete production of the component 10.
- one column 48 is illustrated, it is appreciated that multiple fill ports (radial sealing passages 30 or columns 48) may be provided through the stacked laminate structure 14 to distribute the molten metal material 25 to the sealing passages 30 formed between adjacent laminates 12.
- the molten seal material 25 is allowed to cool within the passages 30 in order to form the seal 28 for the stacked laminates 12.
- cooling passages 54 are provided as described herein, the seal 28 will act to prevent leakage of cooling fluid from the component (typically between the laminates 12 in the stack), thereby improving cooling efficiency and high temperature capabilities of the
- the seal material 25 may, in fact, become molten to at least an extent. In this way, the seal material 25 is able to reform (at least to an extent) during and following operational cycles, thereby relieving stresses that otherwise might induce cracks. In this way also, the integrity of the seal 28 may remain intact even after several operational cycles.
- the laminates 12 may also be retained/compressed via a retaining structure or other structure that compresses the stack of laminates 12 and maintains the laminates in a compressed state.
- a metal plate (not shown) may be disposed as a top member in the stacked laminate structure 14.
- a threaded bolt or the like may be driven down into the metal plate and/or metal support 64 (when present) in order to provide a desired degree of
- the amount of compressive force is determined by the materials present, the size and number of laminates in the stack, the presence of a metal support or not, and the like.
- the metal will likely have a significantly greater coefficient of thermal expansion relative to the CMC material 47 of the laminates 12.
- the metal support 64 will expand and the compressive force on the laminates 12 will be reduced.
- this significant preload was often too great for the laminates 12, which are prone to cracking and breaking with significant compressive loads.
- the disclosed sealing structures and sealing processes allow for reduced compression or preloading on the top of the stacked laminates and/or the metal support 64, and thus a reduced cold crushing load on the laminates 12 since the metal (seal) material 25 will conform to the laminates 12 when hot.
- the CMC laminates 12 are also heated to prevent premature solidification of the molten metal material 25.
- the sealing passages 30 are filled with the molten metal material 25, and the molten metal material 25 is allowed to cool.
- the infiltrated metal material 25 may pull the laminates 12 together, thereby reducing the compressive force needed on the laminates 12 in a cold state.
- the formed seal 28 from the cooled metal material 25 is thus in tension throughout the stacked laminate structure 14, but that tension may be reduced or eliminated as the associated component 10 is heated back to operating temperature (e.g., > 1200° C).
- operating temperature e.g., > 1200° C.
- the latter is of benefit since it is preferred that the seal does not transfer any load to the laminates 12 during operation, but rather solely acts to seal the laminates 12 and prevent cooling fluid (e.g., air) from escaping between the laminates 12.
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Abstract
L'invention concerne un composant (10) ayant une pluralité de stratifiés (12) formés à partir d'un matériau composite à matrice céramique empilés les uns sur les autres pour former une structure stratifiée empilée (14). Un joint d'étanchéité (28) formé d'un matériau ductile resolidifiable et d'un matériau métallique thermoconducteur (25) est disposé de manière adjacente aux stratifiés empilés (12) de façon à réduire et/ou éliminer toue fuite d'air entre eux. Le joint d'étanchéité (28) comprend une colonne (48) du matériau métallique (25) s'étendant à travers des ouvertures correspondantes (46) dans les stratifiés (12) entre une extrémité supérieure (20) et une extrémité inférieure (22) de la structure stratifiée empilée (14). Le matériau métallique (25) comprend un alliage d'argent et de cuivre.
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CN114502819A (zh) * | 2019-10-07 | 2022-05-13 | 赛峰飞机发动机公司 | 金属通风回路所穿过的具有由陶瓷基复合材料制成的叶片装置的涡轮喷嘴 |
CN114502819B (zh) * | 2019-10-07 | 2024-03-08 | 赛峰飞机发动机公司 | 金属通风回路所穿过的具有由陶瓷基复合材料制成的叶片装置的涡轮喷嘴 |
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