Open-cell reticulated foam
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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Abstract
A foam for use in a lost-foam casting process utilized in the manufacture of a component for a gas turbine engine, the foam having a void fraction less than or equal to ninety five percent, is disclosed. The foam may include a first layer comprising polymer foam having an open-cell structure and a void fraction greater than ninety five percent. A second layer, comprising adhesive, may be adhered to the first layer. A third layer comprising particulate material may be adhered to the second layer.
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Citations
12 Claims
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1. A method of manufacturing a fan blade for a gas turbine engine, comprising:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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Specification