METHOD OF FORMING A TURBINE ENGINE COMPONENT
First Claim
1. A method of forming a turbine engine component having a plurality of airfoils disposed in an annular array between inner and outer shroud rings, said method comprising the steps of forming an inner shroud ring pattern by sequentially forming cross sectional layers of the inner shroud ring pattern and interconnecting the cross sectional layers of the inner shroud ring pattern, forming an outer shroud ring pattern by sequentially forming cross sectional layers of the outer shroud ring pattern and interconnecting the cross sectional layers of the outer shroud ring pattern, positioning a plurality of airfoils in an annular array with radially inner end portions of the airfoils adjacent the inner shroud ring pattern and radially outer end portions of the airfoils adjacent the outer shroud ring pattern, covering the inner and outer shroud ring patterns with ceramic mold material, removing the inner and outer shroud ring patterns from the covering of ceramic mold material to leave inner and outer shroud ring mold cavities having configurations corresponding to the configurations of the inner and outer shroud ring patterns, filling the inner and outer shroud ring mold cavities with molten metal, and solidifying the molten metal in the inner and outer shroud ring mold cavities to form inner and outer shroud rings which are connected to the radially inner and outer end portions of the airfoils.
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Accused Products
Abstract
The present invention provides a new and improved method of forming a turbine engine component having a plurality of airfoils disposed in an annular array between inner and outer shroud rings. The method includes forming inner and outer shroud ring patterns. The inner and outer shroud ring patterns may advantageously be formed by solid freeform fabrication techniques, such as stereolithography. An assembly fixture may be utilized to position the inner and outer shroud rings and an array of airfoils in a coaxial relationship. When the inner and outer shroud rings are to be assembled, axially inner and outer shroud ring patterns may be interconnected by providing relative rotation between annular sections of the shroud ring patterns. In addition, adhesive may be utilized to interconnect the sections of the shroud ring patterns.
11 Citations
37 Claims
- 1. A method of forming a turbine engine component having a plurality of airfoils disposed in an annular array between inner and outer shroud rings, said method comprising the steps of forming an inner shroud ring pattern by sequentially forming cross sectional layers of the inner shroud ring pattern and interconnecting the cross sectional layers of the inner shroud ring pattern, forming an outer shroud ring pattern by sequentially forming cross sectional layers of the outer shroud ring pattern and interconnecting the cross sectional layers of the outer shroud ring pattern, positioning a plurality of airfoils in an annular array with radially inner end portions of the airfoils adjacent the inner shroud ring pattern and radially outer end portions of the airfoils adjacent the outer shroud ring pattern, covering the inner and outer shroud ring patterns with ceramic mold material, removing the inner and outer shroud ring patterns from the covering of ceramic mold material to leave inner and outer shroud ring mold cavities having configurations corresponding to the configurations of the inner and outer shroud ring patterns, filling the inner and outer shroud ring mold cavities with molten metal, and solidifying the molten metal in the inner and outer shroud ring mold cavities to form inner and outer shroud rings which are connected to the radially inner and outer end portions of the airfoils.
- 5. A method as set forth in 4 further including the steps of positioning the second annular inner shroud ring pattern section adjacent to the annular array of airfoils in a coaxial relationship with the first annular inner shroud ring pattern section, positioning the second annular outer shroud ring pattern section adjacent to the annular array of airfoils in a coaxial relationship with the first annular outer shroud ring pattern section, interconnecting the first and second annular inner shroud ring pattern sections, and interconnecting the first and second annular outer shroud ring pattern sections.
- 20. A method of forming a turbine engine component having a plurality of airfoils disposed in an annular array between inner and outer shroud rings, said method comprising the steps of positioning a first annular section of an inner shroud ring pattern on an assembly fixture, positioning a first annular section of an outer shroud ring pattern on the assembly fixture, said first annular section of an inner shroud ring pattern and said first annular section of an outer shroud ring pattern being positioned on the assembly fixture in a coaxial relationship, positioning a plurality of airfoils in an annular array on the assembly fixture with the annular array of airfoils at least partially disposed between the first annular section of the inner shroud ring pattern and the first annular section of the outer shroud ring pattern, said step of positioning a plurality of airfoils in an annular array on the assembly fixture includes positioning the annular array of airfoils in a coaxial relationship with the first annular section of the inner shroud ring pattern and in a coaxial relationship with the first annular section of the outer shroud ring pattern, positioning a second annular section of the inner shroud ring pattern on the assembly fixture in a coaxial relationship with the first annular section of the inner shroud ring pattern, said step of positioning a second annular section of the inner shroud ring pattern on the assembly fixture includes providing relative rotation between the first and second annular sections of the inner shroud ring pattern, and positioning the second annular section of the outer shroud ring pattern on the assembly fixture in a coaxial relationship with the first annular section of the outer shroud ring pattern, said step of positioning a second annular section of the outer shroud ring pattern on the assembly fixture includes providing relative rotation between the first and second annular sections of the outer shroud ring pattern.
- 30. A method of forming a turbine engine component having a plurality of airfoils disposed in an annular array between inner and outer shroud rings, said method comprising the steps of positioning a first section of an inner shroud ring pattern and a first section of an outer shroud ring pattern in a coaxial relationship with the first section of the outer shroud ring pattern extending around the first section of the inner shroud ring pattern, thereafter, positioning a plurality of airfoils in an annular array which is in a coaxial relationship with the first sections of the inner and outer shroud ring patterns, thereafter, positioning a second section of the inner shroud ring pattern in a coaxial relationship with the first section of the inner shroud ring pattern, positioning a second section of the outer shroud ring pattern in a coaxial relationship with the first section of the outer shroud ring pattern, thereafter, covering the first and second sections of the inner and outer shroud ring patterns with ceramic mold material, removing the first and second sections of the inner and outer shroud ring patterns from the covering of ceramic mold material to leave inner and outer shroud ring mold cavities, filling the inner and outer shroud ring mold cavities with molten metal, and solidifying the molten metal to form inner and outer shroud rings which are connected with radially inner and outer end portions of the airfoils.
- 35. A method of forming a turbine engine component having a plurality of a plurality of airfoils disposed in an annular array, said method comprising the steps of forming a first annular section of an inner shroud ring pattern by sequentially forming cross sectional layers of the first section of the inner shroud ring pattern and interconnecting the cross sectional layers of the first section of the inner shroud ring pattern, forming a first annular section of an outer shroud ring pattern by sequentially forming cross sectional layers of the first section of the outer shroud ring pattern and interconnecting the cross sectional layers of the first section of the outer shroud ring pattern, positioning the first section of the inner shroud ring pattern on an assembly fixture, positioning the first section of the outer shroud ring pattern on the assembly fixture, said steps of positioning the first section of the inner shroud ring pattern on the assembly fixture and positioning the first section of outer shroud ring pattern on the assembly fixture include positioning the first sections of the inner and outer shroud ring patterns in a coaxial relationship, gripping the first sections of the inner and outer shroud ring patterns with the assembly fixture to retain the first sections of the inner and outer shroud ring patterns in a coaxial relationship, positioning a plurality of airfoils in an annular array on the assembly fixture in a coaxial relationship with the first sections of the inner and outer shroud ring patterns, forming a second annular section of the inner shroud ring pattern by sequentially forming cross sectional layers of the second section of the inner shroud ring pattern and interconnecting the cross sectional layers of the second section of the inner shroud ring pattern, forming a second annular section of an outer shroud ring pattern by sequentially forming cross sectional layers of the second section of the outer shroud ring pattern and interconnecting the cross sectional layers of the second section of the outer shroud ring pattern, positioning the second section of the inner shroud ring pattern in a coaxial relationship with the first section of the inner shroud ring pattern while the first section of the inner shroud ring pattern is disposed on the assembly fixture in a coaxial relationship with the annular array of airfoils, and positioning the second section of the outer shroud ring pattern in a coaxial relationship with the first section of the outer shroud ring pattern while the first section of the outer shroud ring pattern is disposed on the assembly fixture in a coaxial relationship with the annular array of airfoils.
Specification