Method of producing blades or blade arrangements of a turbomachine with erosion protection layers and correspondingly produced component

Patent metadata

Field	Value
Publication number	US-10400613-B2
Application number	US-201715599567-A
Country	US
Kind code	B2
Filing date	May 19, 2017
Priority date	May 20, 2016
Publication date	Sep 3, 2019
Grant date	Sep 3, 2019

Abstract

The present invention relates to a method for producing a blade or blade arrangement of a turbomachine, which features the following steps:
producing a blade ( 4 ) from at least one blade material, machining the blade in at least one region of the blade by a surface machining process, cleaning the surface of the blade depositing an erosion protection coating ( 10 ) of at least two layers of different hardness by physical vapor deposition in the at least one region, machining the erosion protection coating ( 10 ) by a coating smoothing process in order to establish a defined surface roughness.

Furthermore, the invention relates to correspondingly produced blades or blade arrangements.

First claim

What is claimed is:

1. A method for producing a blade or blade arrangement of a turbomachine, wherein the method comprises:
subjecting a blade made of at least one blade material to a surface machining process in at least one region of the blade;
cleaning the surface of the blade which has been subjected to the surface machining process in the at least one region;
depositing on the at least one region of the blade which has been cleaned an erosion protection coating comprising at least two layers of different hardness by physical vapor deposition; and
machining the deposited erosion protection coating by a coating smoothing process.

2. The method of claim 1 , wherein the blade is a part of a blisk.

3. The method of claim 1 , wherein the at least one blade material is selected from one or more of titanium alloys, nickel alloys, steel, composite materials, ceramic-matrix composite materials.

4. The method of claim 1 , wherein the surface machining process is selected from one or more of grinding, slide grinding, polishing, electropolishing, shot peening, shot blasting.

5. The method of claim 1 , wherein the erosion protection coating comprises a sequence of layers which are selected from one or more of metal layers, metal alloy layers, ceramic layers, metal-ceramic layers, graded metal-ceramic layers.

6. The method of claim 5 , wherein the sequence of layers has a total thickness of less than 50 μm and/or each layer of the sequence of layers has a thickness of from 0.2 μm to 10 μm.

7. The method of claim 5 , wherein the sequence of layers comprises a layer which is nanostructured and deposited in a plurality of sub-layers.

8. The method of claim 7 , wherein the plurality of sub-layers is a plurality of alternately repeating sub-layers of which an individual sub-layer has a thickness of from 10 nm to 200 nm.

9. The method of claim 5 , wherein the layers of the sequence of layers comprise layers of one or more of chromium, chromium alloys, CrAlN, CrN.

10. The method of claim 1 , wherein prior to deposition of the erosion protection coating a diffusion barrier layer and/or an adhesion promoting layer is deposited.

11. The method of claim 1 , wherein the coating smoothing process comprises at least one of grinding, slide grinding, polishing, electropolishing.

12. The method of claim 1 , wherein before or after the coating smoothing process, shot peening is carried out.

13. The method of claim 1 , wherein after the machining of the blade by a surface machining process and prior to deposition of the erosion protection coating a deposition of a tip armor plating is carried out.

14. The method of claim 13 , wherein the blade-tip armor plating comprises a nickel matrix with embedded cubic boron nitride particles.

15. The method of claim 1 , wherein after the coating smoothing process one or more functional layers are applied.

16. The method of claim 1 , wherein the erosion protection coating is deposited on the blade as partial coating with decreasing layer thickness toward edges of the erosion protection coating and/or is deposited on a flow leading edge and/or flow trailing edge of the blade with a different layer thickness compared to that on a blade airfoil.

17. The method of claim 16 , wherein the erosion protection coating is deposited on a flow leading edge and/or flow trailing edge of the blade with a thickness of from 20% to 200% of a layer thickness on the blade airfoil.

18. The method of claim 16 , wherein the erosion protection coating is deposited on a flow leading edge and/or flow trailing edge of the blade with a continuous transition from the blade airfoil to the flow leading edge or trailing edge.

19. The method of claim 1 , wherein after the machining of the blade by a surface machining process and prior to deposition of the erosion protection coating a cutting of the blade to length is carried out.

20. A blade or blade arrangement of a turbomachine, produced by the method of claim 1 .

Assignees

• MTU Aero Engines AG

Inventors

• Windprechtinger Joerg
• Stolle Ralf
• Utz Philipp
• Uihlein Thomas
• Gether Markus

Classifications

• F05D2250/621

  polished · CPC title

• C23C28/36

  including layers graded in composition or physical properties · CPC title

• C23C28/34

  including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates · CPC title

• C23C28/321

  with at least one metal alloy layer · CPC title

• C23C14/5886

  Mechanical treatment (involving removal of material C23C14/588) · CPC title