Hybrid blade for turbomachines

Patent metadata

Field	Value
Publication number	US-10544689-B2
Application number	US-201615280653-A
Country	US
Kind code	B2
Filing date	Sep 29, 2016
Priority date	Oct 6, 2015
Publication date	Jan 28, 2020
Grant date	Jan 28, 2020

Abstract

A blade for a turbomachine comprising an outer shell and an inner core which is at least partially enclosed by the outer shell and has a higher porosity than the outer shell. The outer shell is formed by a ceramic body or a body made of a ceramic matrix composite material, and the inner core is formed by a fiber-reinforced ceramic or a fiber-reinforced ceramic matrix composite material.

First claim

What is claimed is:

1. A blade for a turbomachine, wherein the blade comprises an outer shell and an inner core which is at least partially enclosed by the outer shell and has a higher porosity than the outer shell, the outer shell being formed by a body of ceramic material (A) or a body of a ceramic matrix composite material (B), and the inner core being formed by a fiber-reinforced ceramic material (C) or a fiber-reinforced ceramic matrix composite material (D), and wherein
(i) the ceramic material (A) or the ceramic matrix composite material (B) comprises at least one material which is selected from HfB 2 , ZrB 2 , HfN, TiC, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC or comprises ZrN in combination with one or more of HfB 2 , ZrB 2 , HfN, TiC, TiN, ThO 2 , TaC, and SiC; and/or
(ii) the ceramic material (C) or the ceramic matrix composite material (D) which is reinforced with fibers comprises at least one material which is selected from HfB 2 , ZrB 2 , HfN, ZrN, TiC, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC; and/or
(iii) the fibers which reinforce the ceramic material (C) or the matrix composite material (D) comprise at least one material which is selected from HfB 2 , ZrB 2 , HfN, ZrN, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC or comprise TiC in combination with one or more of HfB 2 , ZrB 2 , HfN, ZrN, TiN, ThO 2 , and TaC.

2. The blade of claim 1 , wherein the outer shell is formed by a compact ceramic body and the inner core is formed by a porous fiber-reinforced ceramic.

3. The blade of claim 1 , wherein the ceramic matrix composite material (B) is a ceramic/ceramic composite material or a composite of a ceramic and one or more intermetallic compounds.

4. The blade of claim 1 , wherein the ceramic matrix composite material (D) is a ceramic/ceramic composite material or a composite of a ceramic and one or more intermetallic compounds.

5. The blade of claim 1 , wherein the porosity of the outer shell is not higher than 5 vol %, and/or the porosity of the inner core is between 10 and 30 vol %.

6. The blade of claim 1 , wherein the porosity of the outer shell is not higher than 1 vol %.

7. The blade of claim 1 , wherein the porosity of the inner core is between 15 and 23 vol %.

8. The blade of claim 1 , wherein the ceramic material (A) or the ceramic matrix composite material (B) comprises at least one material which is selected from HfB 2 , ZrB 2 , HfN, TiC, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC or comprises ZrN in combination with one or more of HfB 2 , ZrB 2 , HfN, TiC, TiN, ThO 2 , TaC, and SiC.

9. The blade of claim 1 , wherein the ceramic material (C) or the ceramic matrix composite material (D) which is reinforced with fibers comprises at least one material which is selected from HfB 2 , ZrB 2 , HfN, ZrN, TiC, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC.

10. The blade of claim 1 , wherein the fibers which reinforce the ceramic material (C) or the matrix composite material (D) comprise at least one material which is selected from HfB 2 , ZrB 2 , HfN, ZrN, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC or comprise TiC in combination with one or more of HfB 2 , ZrB 2 , HfN, ZrN, TiN, ThO 2 , and TaC.

11. A blade for a turbomachine, wherein the blade comprises an outer shell and an inner core which is at least partially enclosed by the outer shell and has a higher porosity than the outer shell, the outer shell being formed by a body of ceramic material (A) or a body of a ceramic matrix composite material (B), and the inner core being formed by a fiber-reinforced ceramic material (C) or a fiber-reinforced ceramic matrix composite material (D), and wherein the inner core has been produced by introducing a flowable mixture comprising reinforcing fibers and one or more pore-forming agents into a cavity of the outer shell and subsequent heat treatment to burn the one or more pore-forming agents and/or convert the one or more pore-forming agents to a gaseous state to form pores in the inner core of the blade.

12. The blade of claim 11 , wherein the one or more pore-forming agents comprise one or more of nylon, polyester, acrylic compounds, and epoxy resins.

13. The blade of claim 11 , wherein the flowable mixture comprises from 20 to 30 vol % of the one or more pore-forming agents and from 10 to 30 vol % of the fibers, remainder ceramic material and/or intermetallic compounds.

14. The blade of claim 13 , wherein the flowable mixture comprises from 15 to 25 vol % of the fibers.

15. The blade of claim 11 , wherein the outer shell has been produced by a generative method or a three-dimensional printing method.

16. The blade of claim 11 , wherein a ceramic slurry formed into a green body has been used for producing the outer shell.

17. The blade of claim 11 , wherein the porosity of the outer shell is not higher than 5 vol %, and/or the porosity of the inner core is between 10 and 30 vol %.

18. The blade of claim 11 , wherein the porosity of the outer shell is not higher than 1 vol %.

19. The blade of claim 11 , wherein the porosity of the inner core is between 15 and 23 vol %.

20. The blade of claim 11 , wherein
(i) the ceramic material (A) or the ceramic matrix composite material (B) comprises at least one material which is selected from HfB 2 , ZrB 2 , HfN, ZrN, TiC, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC; and/or
(ii) the ceramic material (C) or the ceramic matrix composite material (D) which is reinforced with fibers comprises at least one material which is selected from HfB 2 , ZrB 2 , HfN, ZrN, TiC, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC; and/or
(iii) the fibers which reinforce the ceramic material (C) or the matrix composite material (D) comprise at least one material which is selected from HfB 2 , ZrB 2 , HfN, ZrN, TiC, TiN, ThO 2 , TaC and mixtures of at least one of the aforementioned materials with SiC.

Assignees

• MTU Aero Engines AG

Inventors

• Borto Artur
• Kapusta Piotr
• Luczyniec Dawid

Classifications

• B28B1/52

  specially adapted for producing articles from mixtures containing fibres, {e.g. asbestos cement}(by wrapping on to mandrels B28B1/42) · CPC title

• F01D5/282 Primary

  Selecting composite materials, e.g. blades with reinforcing filaments · CPC title

• F01D5/147

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title

• B22F7/08

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title