Patent Application
20190022783
The present invention is directed to methods for forming a turbine component. More particularly, the present invention is directed to methods for forming a turbine component including forming a picture frame by an additive manufacturing technique.
Gas turbine unibody components may be manufactured by a complex process in which a combustion liner is formed, a transition piece is formed, a picture frame is formed, and the combustion liner, transition piece, and picture frame are joined together, but way of example, with circumferential welding by techniques such as plasma arc welding, keyhole gas tungsten arc welding, and electron beam welding. The picture frame is formed as a separate component from the transition piece or the combustion liner-transition piece assembly prior to the picture frame being joined to the transition piece or the combustion liner-transition piece assembly.
In an exemplary embodiment, a method for forming a turbine component includes applying a metal composition to a structure by an additive manufacturing technique and lengthening the structure by the additive manufacturing technique. The structure is a transition piece or a combustion liner-transition piece assembly. Lengthening the structure forms a structure extension. A picture frame is formed on an outer surface of the structure extension by the additive manufacturing technique.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.
Provided are exemplary methods for forming a turbine component. Embodiments of the present disclosure, in comparison to methods not utilizing one or more features disclosed herein, decrease costs, increase process control, simplify the fabrication, increase process efficiency, increase process speed, decrease process complexity, or combinations thereof.
Referring to
Forming the turbine component 500 may be free of circumferential welding joining the picture frame 400 to the structure 100, free of plasma arc welding joining the picture frame 400 to the structure 100, free of keyhole gas tungsten arc welding joining the picture frame 400 to the structure 100, free of electron beam welding joining the picture frame 400 to the structure 100, or combinations thereof.
Lengthening the structure 100 and forming the picture frame 400 may have any suitable duration from the commencement of applying the metal composition 200 to the structure 100 to form the structure extension through forming the picture frame 400, including, but not limited to, a duration of less than about 2 hours, alternatively a duration of less than about 1.5 hours, alternatively a duration of less than about 1 hour, alternatively a duration of less than about 0.5 hours. In one embodiment, the duration is inclusive of the finished formation of the turbine component 500.
Referring to
As used herein, “HAYNES 188” refers to an alloy including a composition, by weight, of about 22% chromium, about 22% nickel, about 0.1% carbon, about 3% iron, about 1.25% manganese, about 0.35% silicon, about 14% tungsten, about 0.03% lanthanum, and a balance of cobalt. HAYNES 188 is available from Haynes International, 1020 W, Park Avenue, Kokomo, Ind. 46904.
As used herein, “HAYNES 230” refers to an alloy including a composition, by weight, of about 22% chromium, about 2% molybdenum, about 0.5% manganese, about 0.4% silicon, about 14% tungsten, about 0.3% aluminum, about 0.1% carbon, about 0.02% lanthanum, and a balance of nickel. HAYNES 230 is available from Haynes International, 1020 W, Park Avenue, Kokomo, Ind. 46904.
As used herein, “HAYNES 263” refers to an alloy including a composition, by weight, of about 20% chromium, about 20% cobalt, about 5.9% molybdenum, about 2.2% titanium, about 0.5% aluminum. and a balance of nickel. HAYNES 263 is available from Haynes International, 1020 W, Park Avenue, Kokomo, Ind. 46904.
As used herein, “HAYNES 282” refers to an alloy including a composition, by weight, of about 20% chromium, about 10% cobalt, about 8.5% molybdenum, about 2.1% titanium, about 1.5% aluminum, about 0.06% carbon, about 0.005% boron, up to about 1.5% iron, and a balance of nickel. HAYNES 282 is available from Haynes International, 1020 W, Park Avenue, Kokomo, Ind. 46904.
As used herein, “HASTELLOY X” refers to an alloy including a composition, by weight, of about 22% chromium, about 18% iron, about 9% molybdenum, about 1.5% cobalt, about 0.1% carbon, about 0.6% tungsten, and a balance of nickel. HASTELLOY X is available from Haynes International, 1020 W, Park Avenue, Kokomo, Ind. 46904.
Referring to
The metal composition 200 may be any suitable material composition, including, but not limited to, HAYNES 188, HAYNES 230, HAYNES 263, HAYNES 282, HASTELLOY X, and combinations thereof. The metal composition 200 may be an identical material to the structure composition or may be a distinct material from the structure composition.
Referring to
Referring to
In one embodiment, the picture frame 400 is formed by the additive manufacturing technique to net shape. In another embodiment, the picture frame 400 is formed by the additive manufacturing technique to near-net shape, and is then finished to near net shape. In yet another embodiment, the picture frame 400 is formed by the additive manufacturing technique to rough shape, and is then finished to near net shape. Finishing the picture frame 400 may include any suitable finishing technique, including, but not limited to, machining, polishing, abrasive blasting, burnishing, peening, electropolishing, grinding, etching, buffing, and combinations thereof.
Forming the picture frame 400 may include forming the picture frame 400 with any suitable picture frame thickness 402, including, but not limited to, a picture frame thickness 402 between about 1.2 inches to about 1.5 inches, alternatively between about 1.2 inches to about 1.3 inches, alternatively between about 1.3 inches to about 1.4 inches, alternatively between about 1.4 inches to about 1.5 inches, alternatively about 1.35 inches.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
