CN-122014359-A - Composite wall cooling structure of turbine blade and manufacturing method thereof

CN122014359ACN 122014359 ACN122014359 ACN 122014359ACN-122014359-A

Abstract

The invention provides a composite wall cooling structure of a turbine blade and a manufacturing method thereof, belonging to the technical field of design and manufacturing of hot end components of a gas turbine. The composite wall cooling structure comprises a blade substrate, a functional layer, a thermal barrier coating and blade surface air film holes, wherein a blade inner cooling channel is arranged in the blade substrate, a near-surface outer cooling channel is arranged on the surface layer of the blade substrate, the near-surface outer cooling channel is communicated with the blade inner cooling channel, the functional layer is made of a heat-conducting, oxidation-resistant and heat-corrosion-resistant material and is arranged on the surface of the blade substrate, the thermal barrier coating is arranged on the surface of the functional layer, and the functional layer and the thermal barrier coating are provided with the blade surface air film holes penetrating through the functional layer and the thermal barrier coating, and the blade surface air film holes are communicated with the near-surface outer cooling channel. The composite wall cooling structure can remarkably improve the cooling efficiency and service life of the turbine blade, and in addition, the manufacturing method is simple and convenient for industrialized popularization.

Inventors

XU GUOBIAO
SHEN MINGZHONG
XIE FAN
WANG CHAO
JIN LIANLIAN
HUANG GUANGBIN

Assignees

华电燃气轮机技术(上海)有限公司

Dates

Publication Date: 20260512
Application Date: 20260413

Claims (10)

1. A composite wall cooling structure for a turbine blade, said composite wall cooling structure comprising: the blade comprises a blade substrate, wherein a blade inner cooling channel is arranged in the blade substrate, a near-surface outer cooling channel is arranged on the surface layer of the blade substrate, and the near-surface outer cooling channel is communicated with the blade inner cooling channel; The functional layer is made of a heat-conducting, oxidation-resistant and heat-corrosion-resistant material, the heat-conducting, oxidation-resistant and heat-corrosion-resistant material is at least one of a nickel-based superalloy, a cobalt-based superalloy and a ceramic particle dispersion-strengthened metal matrix, the metal matrix is at least one of a nickel-based superalloy, a cobalt-based superalloy and an iron-based superalloy, and the functional layer is arranged on the surface of the blade matrix; the thermal barrier coating is arranged on the surface of the functional layer; The functional layer and the thermal barrier coating are provided with blade surface air film holes penetrating through the functional layer and the thermal barrier coating, and the blade surface air film holes are communicated with the near-surface external cooling channel.
2. The composite wall cooling structure of claim 1, wherein the cross-sectional shape of the near-surface external cooling passage is T-shaped in a direction from the thermal barrier coating to the blade matrix.
3. The composite wall cooling structure of claim 1, wherein the blade surface film holes are disposed obliquely with respect to the blade substrate in a direction from the thermal barrier coating to the blade substrate.
4. The composite wall cooling structure according to claim 1, wherein the ceramic particles are at least one of fully stabilized zirconia, yttria partially stabilized zirconia, and GaYbYZrO 2 .
5. The composite wall cooling structure according to claim 1, wherein the ceramic particles have a volume fraction of 5% -30% based on 100% of the total volume of the ceramic particle dispersion-strengthened metal matrix.
6. The composite wall cooling structure according to claim 5, wherein in the functional layer, the volume fraction gradient of the ceramic particles increases from a side closer to the blade base to a side farther from the blade base.
7. The composite wall cooling structure according to claim 1, wherein the functional layer has a thickness of 30 to 1000 μm.
8. The composite wall cooling structure of claim 1, wherein the thermal barrier coating comprises an adhesive layer and a ceramic layer, the adhesive layer being disposed on a side of the functional layer remote from the blade substrate, the ceramic layer being disposed on a side of the adhesive layer remote from the functional layer.
9. The method for manufacturing a composite wall cooling structure of a turbine blade according to any one of claims 1 to 8, characterized in that the method for manufacturing comprises the steps of: s1, providing a blade matrix, wherein an inner cooling channel of the blade is arranged in the blade matrix; s2, machining a near-surface external cooling channel communicated with the blade internal cooling channel at a position of the surface layer of the blade matrix corresponding to the blade internal cooling channel by adopting a precision machining technology; s3, depositing the heat-conducting, oxidation-resistant and hot corrosion-resistant material layer by layer on the surface of the blade matrix by adopting a 3D printing technology to obtain a functional layer; s4, machining a thermal barrier coating on the surface of the functional layer; S5, processing blade surface air film holes penetrating through the functional layer and the thermal barrier coating at positions, corresponding to the near-surface external cooling channels, on the functional layer and the thermal barrier coating by adopting a punching technology, so that the blade surface air film holes are communicated with the near-surface external cooling channels, and the composite wall cooling structure is obtained.
10. The method of claim 9, wherein the precision machining technique is a micro milling technique, a laser engraving technique, or an electric spark machining technique, and/or the 3D printing technique is a laser directed energy deposition technique or a laser selective melting technique.

Description

Composite wall cooling structure of turbine blade and manufacturing method thereof Technical Field The invention belongs to the technical field of design and manufacture of hot end components of a gas turbine, and particularly relates to a composite wall cooling structure of a turbine blade and a manufacturing method thereof. Background Gas turbines are the core equipment of modern energy and aviation propulsion systems, the efficiency of which is closely related to the pre-turbine temperature. The turbine blade works in the extreme environment of high temperature, high pressure and high speed rotation for a long time, and the temperature bearing capacity directly determines the efficiency and reliability of the whole machine. In order to break through the limit of the melting point of the nickel-based superalloy material, modern advanced turbine blades commonly adopt complex internal cooling channels and air film hole structures, and Thermal Barrier Coatings (TBCs) are prepared on the surface of the nickel-based superalloy to realize heat protection. Currently, one of the most advanced cooling techniques is a double-wall cooling structure, i.e. a dense micro-channel and impingement cooling structure built into the blade wall, achieving near-wall cooling. However, the fabrication of such structures faces the following significant challenges. The casting difficulty is that the traditional investment casting process is difficult to form a double-wall cooling structure with complex, fine and closed internal channels, the yield is low, and the design freedom is limited. The welding problem is that by adopting a scheme of welding two plates with channels respectively, the welding seam becomes a weak link at high temperature, the welding deformation, the micro-channels can be blocked by the welding seam, and the reliability is difficult to ensure. The material limitation is that the base body of the blade is usually nickel-based superalloy, the heat conduction capacity is limited, even if the interior is cooled, the heat still needs to be conducted to a cooling medium through the base body material, and the thermal resistance is large. Although 3D printing (additive manufacturing) technology provides new possibilities for forming complex structures of turbine blades, manufacturing the whole turbine blade by using 3D printing only faces challenges that material properties (such as fatigue properties) are difficult to meet, high in cost, poor in surface finish and the like. Therefore, there is a strong need in the art for new turbine blade cooling solutions that break through the existing manufacturing bottlenecks, with high performance, high reliability and good process feasibility. Disclosure of Invention The invention aims to overcome the defects of difficult casting and welding of a double-wall cooling structure of the existing turbine blade and insufficient heat conduction performance of a matrix material, and provides a composite wall cooling structure of the turbine blade and a manufacturing method thereof. The composite wall cooling structure has novel design, simple and feasible processing and good cooling effect, and the manufacturing method aims at: 1. Reliable manufacture of complex, efficient near wall cooling channels is achieved. 2. An intermediate functional layer with high heat conductivity and high temperature resistance is introduced between the turbine blade matrix and the thermal barrier coating, so that the thermal resistance is reduced. 3. Finally, the working temperature of the turbine blade matrix is obviously reduced, so that the creep life and the thermal fatigue life of the turbine blade are greatly improved. The present invention aims to solve at least one of the technical problems in the related art to some extent. To this end, embodiments of the present invention provide a composite wall cooling structure for a turbine blade and a method of manufacturing the same. In a first aspect, embodiments of the present invention provide a composite wall cooling structure for a turbine blade, the composite wall cooling structure comprising: the blade comprises a blade substrate, wherein a blade inner cooling channel is arranged in the blade substrate, a near-surface outer cooling channel is arranged on the surface layer of the blade substrate, and the near-surface outer cooling channel is communicated with the blade inner cooling channel; The functional layer is made of a heat-conducting, oxidation-resistant and heat-corrosion-resistant material, the heat-conducting, oxidation-resistant and heat-corrosion-resistant material is at least one of a nickel-based superalloy, a cobalt-based superalloy and a ceramic particle dispersion-strengthened metal matrix, the metal matrix is at least one of a nickel-based superalloy, a cobalt-based superalloy and an iron-based superalloy, and the functional layer is arranged on the surface of the blade matrix; the thermal barrier coating is arranged on the surfac