THICKENED RADIALLY OUTER ANNULAR PORTION OF A SEALING FIN

Abstract

A blisk 10 for a gas turbine includes a rotor blade row 12 extending around a central axis X and, axially spaced therefrom and extending coaxially therewith, at least one annular sealing fin 11. The sealing fin has a radially outer annular portion 111 that is thickened as compared to a radially more inward annular portion 113. A compressor 1 includes a rotor and a casing 30. The casing includes at least one stator vane row having at least one abradable liner. The rotor includes at least one blisk 10, whose at least one sealing fin 11 at least partly engages in the abradable liner. A turbine is constructed analogously. A method for manufacturing a blisk 10 for a gas turbine includes producing a blisk 10 having least one annular sealing fin 11, as well as applying a coating 116 to a radially outer surface 115 of a thickened annular portion 111 of sealing fin 11.

Description

This claims the benefit of German Patent Application DE 102016211337.2, filed Jun. 24, 2016 and hereby incorporated by reference herein.

The present invention relates to a blisk for a gas turbine, and further to a compressor and a turbine having such a blisk, and to a method for manufacturing a blisk.

BACKGROUND

Compressors are used in gas turbines, such as, for example, in aircraft engines, to compress the air passing therethrough and thereby bring it to a higher energy state. A mixture of the air and a fuel is then ignited in a combustor and subsequently expanded in actual turbines (expanders) respectively associated therewith. Generally, one part of the energy produced in this manner is used to further drive the compressor, and the other part is used, as useful energy, for driving the respective unit or for generating thrust.

Compressors, just as turbines, generally include a rotor having a plurality of rows of rotor blades which are connected to a rotor shaft and externally surrounded by a casing, so that a flow duct is formed between the rotor shaft and the casing. Stator vanes attached to the casing are adapted to suitably direct gas flowing through the flow duct onto the rotor blades. The rotor blades may be manufactured separately and inserted into receiving grooves of the rotor shaft. Alternatively, it is possible to use one-piece blisks (blades disks) which each include a disk or a ring having a plurality of rotor blades integrally formed therewith or joined (e.g., welded) thereto. Such blisks have the advantage over the rotor blade rows composed of separate blades that they have greater mechanical strength and lower weight.

In order to avoid losses, it is in particular required that passages formed between moving and stationary components be kept as small as possible. For instance, in order to seal such passages between the rotor shaft and the radially inner tips of the stator vanes, it is known to use so-called “sealing fins.” These are generally configured as an annular radial projection and adapted to engage, with a radially outer section (herein also called “rub-in portion” of the respective sealing fin), in abradable liners provided on the tips of the stator vanes. As used herein and unless otherwise stated, the terms “radial” and “axial” always relate to an (intended) axis of rotation of the rotor shaft.

In order for the sealing fins to resist the mechanical and thermal stresses occurring during engagement in the abradable liners, the correspondingly stressed surfaces there are generally coated. However, selective application of a coating in the desired regions requires that the intended regions be accessible for the respective coating tool. In the case of the advantageous one-piece blisks, due to a rotor blade row disposed at a short distance or because another, proximate sealing fin, it may be impossible or at least very difficult to apply a coating in an axial direction because coating may be feasible in a radial direction only (from the outside inwards). Thus, flanks of a sealing fin which extend substantially radially (perpendicularly to the axis of rotation) are not adequately reached and are therefore insufficiently protected from friction resulting from deep penetration and simultaneous axial movements of the rotor and the casing relative to each other. As a result, metal-to-metal contact may occur at these flanks. This may cause damage to the sealing fins, which may result in premature failure of the rotor and severe damage to the engine.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a technology which will overcome the above-mentioned disadvantages.

The present invention provides a blisk, a compressor, a turbine, and a method for manufacturing a blisk.

A blisk according to the present invention is intended for installation in a gas turbine (e.g., an aircraft engine) or already installed in a gas turbine, in particular in a compressor or in a turbine (an expander). The blisk has a rotor blade row extending around an (abstract) central axis and, axially spaced therefrom, at least one annular sealing fin extending coaxially with the rotor blade row, the central axis being the (intended) axis of rotation of the gas turbine.

The at least one sealing fin has a radially outer annular portion (i.e., a ring-like portion) that is thickened (in the axial direction) as compared to a radially more inward annular portion of the sealing fin; i.e., has a greater axial thickness than the radially more inward annular portion. As used herein, the terms “axial thickness” or simply “thickness” of an annular portion refer to its maximum extent (extension) in the axial direction.

The exact boundaries of the aforementioned annular portions are not necessarily defined physically. Rather, they may be defined on the sealing fin as respective annular portions having the required properties.

Due to the greater thickness of the radially outer annular portion, this portion axially overhangs radially more inward annular portion in at least one section. Thus, the radially more inward annular portion forms an undercut with respect to this section. In particular, the thickened annular portion may have at least one surface facing the central axis. Therefore, when an axial movement of the rotor relative to the stator or stator vanes occurs during operation, contact may occur only at the overhang of the respective flank of the sealing fin; i.e., at the overhanging section of the thickened annular portion. Therefore, coating of the thickened annular portion alone may already avoid the above-mentioned disadvantages resulting from contact. Since this thickened radially outer annular portion is relatively well accessible from radially outside, a blisk according to the present invention advantageously facilitates and improves the application of a coating, thus providing an efficient way of improving a seal.

An inventive compressor and an inventive turbine for a gas turbine each include a rotor and a casing having at least one row of stator vanes. The stator vanes extend radially inwards, and their (radially inner) tips are provided with an abradable liner, which may in particular include honeycomb seal cells. The abradable liner may be a single piece or include a plurality of (connected or separate) components.

In particular, different components of the abradable liner may be disposed at different tips and may be connected to one another (thus forming, for example, a ring).

The rotor of an inventive compressor or an inventive turbine includes at least one blisk according to any of the embodiments disclosed herein, whose at least one sealing fin at least partly engages in the abradable liner.

In an advantageous embodiment of a blisk according to the present invention, the thickened annular portion of the at least one sealing fin is provided with a protective coating on a radially outer surface. Preferably, the coating extends to an axial overhang of the thickened annular portion over the radially more inward annular portion. As mentioned, contact may occur at this overhang during axial movement of the rotor and the stator relative to each other, and the coating in this region can avoid or at least reduce the resulting disadvantages, in particular wear or damage to the material (e.g., due to metal-to-metal contact).

It should be noted that the coating may itself be composed of a plurality of separate layers and therefore does not necessarily have to exhibit the same material properties across the entire cross-sectional area. Thus, the coating (in the case of a blisk according to the present invention or a blisk produced using a method according to the present invention) may, for example, include an adhesion layer of a nickel-based alloy, preferably NiAl, and an overlayer of ceramic, preferably Al₂O₃—TiO₂. The coating is preferably applied by plasma spraying.

A method according to the present invention is used for manufacturing a blisk, in particular an inventive blisk according to any of the embodiments disclosed herein. The method includes producing a (one-piece) blisk having a rotor blade row extending around a central axis and at least one annular sealing fin which is axially spaced from the rotor blade row and extends coaxially therewith and which has a radially outer annular portion that is thickened (in the axial direction) as compared to a radially more inward annular portion of the sealing fin. The production of the blisk may include, for example, milling, friction welding, precise electrochemical machining and/or additive manufacturing (e.g., selective laser melting, electron beam melting).

The method further includes applying a coating at least to a radially outer surface of the thickened annular portion. The application may be performed in particular solely or partially radially from the outside. This facilitates coating.

In accordance with a preferred embodiment, the application process includes providing the coating over at least part of a surface of an axial overhang of the thickened annular portion over the radially more inward annular portion. As mentioned, this makes it possible to protect a potential contact region between the sealing fin and the abradable liner during use of the blisk.

Preferably, the thickened annular portion (or even the entire sealing fin) of a blisk according to the present invention or a blisk produced using a method according to the present invention is composed of a uniform or homogeneous material. Thus, any coating that may be present on the thickened annular portion will be considered as not forming part thereof inasmuch as the thickness of the annular portions is determined without considering such a coating, and the thickened annular portion is thicker than the radially more inward portion even without the coating.

In an advantageous embodiment of the present invention, the thickened annular portion is provided, on a side facing the rotor blade row and/or on a side facing away therefrom, with an edge that runs along a circular path around the central axis and along which the thickened annular portion has its greatest axial thickness. Thus, during coating of the thickened annular portion radially from the outside, a protective layer can be built up on the edge, which may extend beyond the edge in the axial direction (due to the viscosity of coating material). This makes it possible to prevent contact of the thickened annular portion with the abradable liner during use of the blisk.

Preferably, the thickened annular portion includes a radially outermost section in which the thickened annular portion tapers (continuously and strictly monotonically) radially outwardly (i.e., becomes increasingly thinner with increasing distance from the central axis). An embodiment that is particularly advantageous is one in which the axial thickness of the thickened annular portion is assumed to be in such a radially outermost section. Thus, in this case, the thickened annular portion becomes increasingly thinner radially outwardly from its thickest region. If, as mentioned above, the thickened annular portion has edges on its side facing the rotor blade row and on its side facing away from the rotor blade row, the radially outermost section may, for example, be radially inwardly bounded by an abstract plane connecting the edges and taper radially outwardly.

Such a taper allows the thickened annular portion to have a particularly large surface that is accessible radially from the outside, thus allowing a coating to be applied over a particularly large area in this direction.

Preferably, the entire surface of the radially outermost section is provided with a (or the) coating. In particular, the surface that is coated using a method according to the present invention may include a surface of a radially outermost section in which the thickened annular portion has its maximum thickness and which tapers radially outwardly.

In an advantageous embodiment, the thickened annular portion (i.e., the radially outer section thereof) is chamfered or curved on its side facing the rotor blade row and/or on its side facing away therefrom, so that it preferably has a radially outermost surface (facing away from the central axis) which spans the thickened annular portion also laterally, at least partially, but nevertheless faces away from the central axis.

This allows a suitable coating to be applied radially from the outside also over parts of the lateral surfaces of the thickened annular portion. As mentioned, contact may occur at these lateral surfaces during axial oscillations of the rotor and the casing relative to each other.

On a side facing the rotor blade row and/or on a side facing away therefrom, the thickened annular portion may, for example, extend substantially along the lateral surface of an (abstract; i.e., imaginary, and preferably straight) circular cone about the central axis (which thus coincides with the axis of the cone). In an advantageous embodiment, the cone angle of such a circular cone is no more than 120°, more preferably no more than 100° and/or at least 60°, more preferably at least 80°.

Such opening angles advantageously enable the respective lateral surfaces of the thickened annular portions to be reached when applying a coating (substantially) radially from the outside; i.e., they enable an advantageously large extent of the thus reached inclined surfaces in the radial direction.

In an advantageous variant, the radially more inward annular portion has an extent in the radial direction that is at least twice the extent of the thickened annular portion in the radial direction. Thus, even when the thickened portion penetrates deeply into the abradable liner, the sealing fin can be protected from axial contact with the abradable liner, namely along the full radial extent of the radially more inward, less thick annular portion.

Preferably, the radially more inward annular portion and/or the thickened annular portion are/is configured substantially symmetrically to a plane extending perpendicular to the axis of rotation. Such an embodiment advantageously provides substantially the same protection on both axial sides of the sealing fin.

In an advantageous embodiment, the radially more inward annular portion and the thickened annular portion are sections of an intended rub-in portion of the sealing fin, which is thus adapted to engage in an abradable liner (possibly after a rub-in process during initial use of the blisk). Preferably, the rub-in portion is disposed on a sealing fin base, whose thickness in the axial direction is greater than the thickness of the thickened annular portion. This increases the stability of the sealing fin in a radially innermost portion that is not intended for engagement in an abradable liner, i.e., which remains spaced from the abradable liner during operation.

In the present patent application, the term “abradable liner” includes also honeycomb structures.

Analogously, the radially more inward annular portion may advantageously thicken radially inwardly, which improves the stability of the sealing fin, in particular of the rub-in portion thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred exemplary embodiments of the present invention will be described in greater detail below with reference to the drawings. It is understood that individual elements and components may be combined in other ways than those described. Corresponding elements are identified by the same reference characters throughout the figures and may not be described again for each figure.

In the schematic drawings,

FIG. 1 shows a perspective view of the configuration of an exemplary blisk according to the present invention;

FIG. 2 shows part of a meridional section through an exemplary compressor according to the present invention; and

FIG. 3 shows a meridional cross-sectional detail view of a sealing fin according to the present invention.

DETAILED DESCRIPTION

FIG. 1 shows an exemplary blisk 10 having a ring section 13, a rotor blade row 12 (having rotor blades 12a), and a plurality of annular sealing fins 11 which, although not discernible in this figure, preferably have a radially outer annular portion and a radially more inward annular portion, as described herein. Rotor blade row 12 and sealing fins 11 extend coaxially about a common central axis X which forms the axis of rotation during use of the blisk. Sealing fins 11 are spaced apart (i.e., offset) from rotor blade row 12 in the axial direction.

FIG. 2 shows part of a schematic meridional section through a compressor 1 according to the present invention. This partial view shows a portion of a blisk 10 with a central axis X, as well as a casing 30 of the compressor, to which are attached stator vane rows having stator vanes 20a. A flow duct 40 is formed between casing 30 and a ring section 13 of the blisk which, together with other components, forms a rotor shaft. During normal operational use, air is passed through flow duct 40 in the direction indicated by the arrow.

The radially inner tips of stator vanes 20a are provided with abradable liners 21 which engage sealing fins 11, thereby minimizing the passage of air between abradable liners 21 and sealing fins 11.

FIG. 3 presents a detail view of a sealing fin according to an embodiment of the present invention. This figure, too, shows part of a schematic meridional section taken along central axis X.

Sealing fin 11 (in particular its thickened annular portion 111 and its radially more inward annular portion 113) is configured symmetrically to a plane E which is perpendicular to the plane of the drawing of FIG. 3 and pierced orthogonally by central axis X. Sealing fin 11 includes a radially outer annular portion 111 and a radially more inward annular portion 113. Radially outer annular portion 111 is thickened as compared to radially more inward annular portion 113, because its axial thickness d₁ is greater than the axial thickness d₂ of radially more inward annular portion 113. The axial thicknesses of the annular portions are their respective greatest extent in the axial direction. In the meridional cross-sectional view shown in the figure, such a maximum thickness is thus a maximum width of the representation of the respective annular portion (parallel to the central axis).

In the example shown, radially outer annular portion 111 and radially more inward annular portion 113 adjoin each other and form part of a rub-in portion 117 of the sealing fin which may engage in an abradable liner 21 (such as is shown in FIG. 2) during normal operational use. Radially more inward annular portion 113 thickens toward central axis X, which improves the stability thereof.

In radial direction R, radially more inward annular portion 113 has an extent a₂ which, in the example shown, is more than twice the radial extent a₁ of radially outer annular portion 111 in the radial direction. Thus, detrimental lateral contact of the sealing fin with an abradable liner may occur only in a relatively small section of rub-in portion 117, and this small section is protected by the coating.

Rub-in portion 117 of the illustrated sealing fin 11 is disposed on a sealing fin base 118, which is intended to remain spaced from abradable liner 21, in particular not to engage therein.

Sealing fin base 118 has a greater axial thickness than rub-in portion 117 of the sealing fin, in particular than the thickened radially outer annular portion 111 thereof, which serves to advantageously stabilize the sealing fin.

In the example shown, thickened radially outer annular portion 111 has a surface 119 on both sides (i.e., on the side facing the rotor blade row not shown in FIG. 3 and on the side facing away therefrom), which surface 119 faces the central axis and radially inwardly bounds an overhang of thickened annular portion 111 over radially more inward annular portion 113.

Thickened radially outer annular portion 111 is provided with a coating 116 on a radially outer surface 115. The coating spans thickened radially outer annular portion 111 over the entire thickness thereof and thus acts as a protective layer also for the thinner, radially more inward annular portion during axial movement of the sealing fin (and, respectively, of the blisk of which it forms part) relative to an abradable liner.

Thickened radially outer annular portion 111 assumes its maximum axial thickness d₁ along edges 114a, 114b. The applied coating 116 extends slightly beyond the edges in the axial direction (due to the viscosity of coating material and/or a minimal inclination of a coating direction), thereby forming a possible contact surface at which sealing fin 11 may contact an abradable liner, and thus protecting the sealing fin laterally.

A radially outermost section 112 of thickened annular portion 111 tapers strictly monotonically radially outwardly. In the example shown, the base of radially outermost section 112 lies in an imaginary plane connecting the edges 114a, 114b, so that the full axial thickness of the thickened annular portion, which is from where the radially outermost section tapers strictly monotonically radially outwardly, is reached in this section 112.

In particular, thickened annular portion 111 is chamfered on both of its sides (which each may face or face away from a rotor blade row not shown). Hence, radially outer surface 115 of the thickened annular portion spans the thickened annular portion partially also laterally and faces away from the central axis at these sides as well. This made it possible to reach also the sloped lateral surfaces during the application of the coating radially from the outside.

The sloped sides of the thickened annular portion each extend substantially along the lateral surface of an (abstract; i.e., imaginary, and preferably straight) circular cone about central axis X. In the figure, for the sake of clarity, this is only shown for one of the sloped sides. The associated cone has a cone angle α of preferably no more than 120°, more preferably no more than 100° and/or at least 60°, more preferably at least 80°.

An inventive blisk 10 for a gas turbine includes a rotor blade row 12 extending around a central axis X and, axially spaced therefrom and extending coaxially therewith, at least one annular sealing fin 11. The sealing fin has a radially outer annular portion 111 that is thickened as compared to a radially more inward annular portion 113.

A turbine according to the present invention includes a rotor and a casing. The casing includes at least one stator vane row having at least one abradable liner 21. The rotor includes at least one blisk according to an embodiment of the invention disclosed herein, whose at least one sealing fin 11 at least partly engages in the abradable liner.

Analogously, a compressor 1 according to the present invention includes a rotor and a casing 30. The casing includes at least one stator vane row having at least one abradable liner. The rotor includes at least one blisk 10 according to an embodiment of the invention disclosed herein, whose at least one sealing fin 11 at least partly engages in the abradable liner.

A method according to the present invention for manufacturing a blisk 10 for a gas turbine includes producing a blisk 10 having least one annular sealing fin 11, as well as applying a coating 116 to a radially outer surface 115 of a thickened annular portion 111 of sealing fin 11.

LIST OF REFERENCE NUMERALS

• 1 compressor
• 10 blisk
• 11 sealing fin
• 12 rotor blade row
• 12a rotor blade
• 13 ring
• 20a stator vane
• 21 abradable liner
• 30 casing
• 40 flow duct
• 111 thickened annular portion
• 112 radially outermost section of the thickened annular portion
• 113 radially more inward annular portion
• 111a, 114b edge along which thickened annular portion 111 has its greatest axial thickness
• 115 radially outer surface
• 116 coating
• 117 rub-in portion
• 118 sealing fin base
• 119 surface facing the central axis
• a₁ extent of the thickened annular portion in the radial direction
• a₂ extent of the radially more inward annular portion in the radial direction
• d₁ thickness of the thickened annular portion
• d₂ thickness of the radially more inward annular portion
• E plane
• R radial direction
• X central axis
• α cone angle

Claims

1. A blisk for a gas turbine, the blisk comprising:

a rotor blade row extending around a central axis; and

at least one annular sealing fin axially spaced from the rotor blade row and extending coaxially with the rotor blade row, the annular sealing fin having a radially outer annular portion thickened as compared to a radially more inward annular portion of the sealing fin.

2. The blisk as recited in claim 1 wherein the thickened annular portion is provided with a coating on a radially outer surface.

3. The blisk as recited in claim 1 wherein the thickened annular portion includes a radially outermost section, the thickened annular portion tapering radially outwardly in the radially outermost section.

4. The blisk as recited in claim 1 wherein the radially more inward annular portion thickens radially inwardly.

5. The blisk as recited in claim 1 wherein an extent (a2) of the radially more inward annular portion in the radial direction is at least twice an extent (a1) of the thickened annular portion in the radial direction.

6. The blisk as recited in claim 1 wherein the radially more inward annular portion or the thickened annular portion is configured symmetrically to a plane extending perpendicular to the central axis.

7. The blisk as recited claim 1 wherein the radially more inward annular portion and the thickened annular portion are sections of a rub-in portion of the sealing fin, the rub-in portion being disposed on a sealing fin base, the sealing fin base having an axial thickness greater than an axial thickness of the thickened annular portion.

8. A compressor for a gas turbine, the compressor comprising:

a rotor; and

a casing, the casing including at least one stator vane row having radially inwardly extending stator vanes with stator vane tips provided with an abradable liner,

the rotor includes at least one blisk as recited in claim 1, the annular sealing fin at least partly engaging in the abradable liner.

9. A turbine for a gas turbine, the turbine comprising:

a rotor; and

a casing, the casing including at least one stator vane row having stator vanes with stator vane tips each provided with an abradable liner,

the rotor including at least one blisk as recited in claim 1, the annular sealing fin at least partly engaging in the abradable liner.

10. A method for manufacturing a blisk for a gas turbine, the method comprising:

producing a blisk having a rotor blade row extending around a central axis and at least one annular sealing fin axially spaced from the rotor blade row and extending coaxially with the rotor blade row, the annular sealing fin having a radially outer annular portion thickened as compared to a radially more inward annular portion; and

applying a coating to a radially outer surface of the thickened annular portion.

11. The method as recited in claim 10 wherein the surface provided with the coating includes a surface of a radially outermost section where the thickened annular portion tapers radially outwardly from a maximum thickness.