Dual alloy turbine rotors and methods for manufacturing the same

Patent metadata

Field	Value
Publication number	US-10399176-B2
Application number	US-201715648577-A
Country	US
Kind code	B2
Filing date	Jul 13, 2017
Priority date	Jun 5, 2014
Publication date	Sep 3, 2019
Grant date	Sep 3, 2019

Abstract

Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.

First claim

What is claimed is:

1. A dual alloy turbine rotor comprising:
an assembled blade ring comprising a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy, the assembled blade ring has a ring portion with an inner annular surface and a plurality of blades coupled to the ring portion opposite the inner annular surface;
a hub comprising a second alloy and bonded to the assembled blade ring, the hub has a centrally formed bore and an outer peripheral surface spaced radially apart from the centrally formed bore and the outer peripheral surface has opposed exterior surfaces and the outer peripheral surface of the hub is positioned within the inner annular surface to define an interface therebetween; and
a pair of diaphragms coupled to the assembled blade ring and hub, respectively, to define opposing braze gaps spaced away from the interface and configured to receive a braze material.

2. The dual alloy turbine rotor of claim 1 , wherein the assembled blade ring includes an inner annular surface and the hub is disposed within the assembled blade ring and has an outer peripheral surface flush against the assembled blade ring inner annular surface.

3. The dual alloy turbine rotor of claim 1 , wherein the inner annular surface of the assembled blade ring has opposed exterior surfaces.

4. The dual alloy turbine rotor of claim 3 , wherein the interface comprises a non-contacting interface if the coefficient of thermal expansion of the hub is greater than that of the assembled blade ring and a contacting interface if the coefficient of thermal expansion of the hub is less than that of the assembled blade ring.

5. The dual alloy turbine rotor of claim 3 , wherein the pair of diaphragms are directly bonded to the exterior surfaces of the ring portion of the assembled blade ring and the exterior surfaces of the outer peripheral surface of the hub so that the pair of diaphragms bridge the interface on opposing sides.

6. The dual alloy turbine rotor of claim 5 , wherein each of the exterior surfaces of the ring portion has a raised external surface portion that extends outwardly from the respective exterior surface of the ring portion and each of the exterior surfaces of the outer peripheral surface have a raised hub external surface portion that extends outwardly from the respective exterior surface of the outer peripheral surface, and the pair of diaphragms are bonded to the raised exterior portions of the ring portion and the raised hub external surface portions of the outer peripheral surface to define opposing gaps that are spaced away from the interface.

7. The dual alloy turbine rotor of claim 6 , wherein the braze material is received within each of the gaps.

8. The dual alloy turbine rotor of claim 5 , wherein the exterior surfaces of the ring portion each define a first groove and the exterior surfaces of the outer peripheral surface each define a second groove, and the pair of diaphragms are coupled to the first groove and the second groove to bridge the interface on opposing sides.

9. The dual alloy turbine rotor of claim 5 , wherein each of the pair of diaphragms include an outer spring portion and an inner spring portion, the respective outer spring portion is bonded to the ring portion of the blade ring and the respective inner spring portion is bonded to the outer peripheral surface of the hub.

10. A dual alloy turbine rotor comprising:
a blade ring comprising a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy, the blade ring including an inner annular surface;
a hub comprising a second alloy different from the first alloy, the hub disposed within the blade ring to define an interface between the hub and the blade ring, the hub having an outer peripheral surface flush against the blade ring inner annular surface, and the hub is bonded to the blade ring; and
a pair of diaphragms coupled to the assembled blade ring and hub, respectively, to define opposing braze gaps spaced away from the interface and configured to receive a braze material.

11. The dual alloy turbine rotor of claim 10 , wherein the blade ring comprises a plurality of individually cast airfoil blades coupled to a ring portion to define an assembled blade ring.

12. The dual alloy turbine rotor of claim 10 , wherein the blade ring is a unitary blade ring integrally cast from an equi-axed alloy.

13. The dual alloy turbine rotor of claim 10 , wherein the hub has a centrally formed bore and an outer peripheral surface spaced radially apart from the centrally formed bore and the outer peripheral surface has opposed exterior surfaces, and the blade ring has a ring portion with an inner annular surface and a plurality of blades coupled to the ring portion opposite the inner annular surface, the inner annular surface having opposed exterior surfaces, and the outer peripheral surface of the hub is positioned within the inner annular surface to define the interface therebetween.

14. The dual alloy turbine rotor of claim 13 , wherein the interface comprises a non-contacting interface if the coefficient of thermal expansion of the hub is greater than that of the blade ring and a contacting interface if the coefficient of thermal expansion of the hub is less than that of the blade ring.

15. The dual alloy turbine rotor of claim 13 , wherein the pair of diaphragms are directly bonded to the exterior surfaces of the ring portion of the blade ring and the exterior surfaces of the outer peripheral surface of the hub so that the pair of diaphragms bridge the interface on opposing sides.

16. The dual alloy turbine rotor of claim 15 , wherein each of the exterior surfaces of the ring portion has a raised external surface portion that extends outwardly from the respective exterior surface of the ring portion and each of the exterior surfaces of the outer peripheral surface have a raised hub external surface portion that extends outwardly from the respective exterior surface of the outer peripheral surface, and the pair of diaphragms are bonded to the raised exterior portions of the ring portion and the raised hub external surface portions of the outer peripheral surface to define opposing gaps that are spaced away from the interface.

17. The dual alloy turbine rotor of claim 16 , wherein the braze material is received within each of the gaps.

18. The dual alloy turbine rotor of claim 15 , wherein the exterior surfaces of the ring portion each define a first groove and the exterior surfaces of the outer peripheral surface each define a second groove, and the pair of diaphragms are coupled to the first groove and the second groove to bridge the interface on opposing sides.

19. The dual alloy turbine rotor of claim 15 , wherein each of the pair of diaphragms include an outer spring portion and an inner spring portion, the respective outer spring portion is bonded to the ring portion of the blade ring and the respective inner spring portion is bonded to the outer peripheral surface of the hub.

Assignees

• Honeywell Int Inc

Inventors

• Miner Amandine
• Jan David K
• Mittendorf Don
• Smoke Jason

Classifications

• F01D5/3061

  by welding, brazing · CPC title

• F01D5/34

  Rotor-blade aggregates of unitary construction {, e.g. formed of sheet laminae; (discs formed of sheet laminae F01D5/028; ceramic materials F01D5/284, composite materials F01D5/282)} · CPC title

• Y10T29/49323

  Assembling fluid flow directing devices, e.g., stators, diaphragms, nozzles · CPC title

• F05D2220/323

  for aircraft propulsion, e.g. jet engines · CPC title

• B23K1/00

  Soldering, e.g. brazing, or unsoldering (B23K3/00 takes precedence) · CPC title