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Open-cell reticulated foam

  • US 10,035,174 B2
  • Filed: 02/09/2015
  • Issued: 07/31/2018
  • Est. Priority Date: 02/09/2015
  • Status: Active Grant
First Claim
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1. A method of manufacturing a fan blade for a gas turbine engine, comprising:

  • providing a polymer foam having an open-cell structure and a void fraction greater than ninety five percent;

    coating the polymer foam with an adhesive to create an adhesive coated foam;

    applying a particulate material to the adhesive coated foam to make a modified foam having a void fraction less than or equal to ninety five percent;

    covering the modified foam having a void fraction less than or equal to ninety five percent with a refractory material;

    curing the refractory material until it hardens to form an investment;

    heating the investment to a temperature above the boiling point of the modified foam having a void fraction less than or equal to ninety five percent to form a negative of the modified foam;

    adding molten metal or metal alloy to the negative, followed by cooling the negative to a temperature below the melting temperature of the metal or metal alloy to form a positive of the modified foam;

    removing the refractory material to form an open-cell metal foam having a void fraction less than or equal to ninety five percent; and

    enveloping the open-cell metal foam having a void fraction less than or equal to ninety five percent with an outer shell of a first material, the outer shell having the shape of an airfoil, to form a fan blade for a gas turbine engine.

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