METHOD OF MANUFACTURING A TURBOMACHINE COMPONENT, AN AIRFOIL AND A GAS TURBINE ENGINE

• US 20140311163A1
• Filed: 06/27/2014
• Published: 10/23/2014
• Est. Priority Date: 12/30/2011
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce North American Technologies, Inc. (Rolls-Royce Holdings Plc)
• Inventors: Uskert, Richard Christopher, Freeman, Ted Joseph, Thomas, David John, Lane, Jay E., Chamberlain, Adam Lee, Weaver, John Alan
• Granted Patent: US 9,920,634 B2
• Time in Patent Office: Days
• US Class Current: 60/806
• CPC Class Codes: B29C 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• CPC Class Codes: B29D 99/0025 Producing blades or the like, e.g. blades for turbines, propellers, or wings
• CPC Class Codes: B29L 2031/085 Wind turbine blades
• CPC Class Codes: F01D 5/18 Hollow blades, i.e. blades with cooling or heating channels or cavities structure of hollow blades in general F01D5/147; Heating, heat-insulating or cooling means on blades
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F05D 2230/60 Assembly methods
• CPC Class Codes: F05D 2300/612 Foam
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

One embodiment of the present invention is a unique method of manufacturing a component for a turbomachine, such as an airfoil. Another embodiment is a unique airfoil. Yet another embodiment is a unique gas turbine engine. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for cooled gas turbine engine components. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.

Claims

1. A method of manufacturing a component for a turbomachine, comprising:

forming an internal portion of the component, including forming a first composite foam structure to a desired shape, wherein the first composite foam structure is configured to pass a cooling fluid therethrough;

enveloping the internal portion of the component with composite wrap plies to form a body, without using a removable core support pin to support the internal portion of the component; and

rigidizing the body.

2. The method of claim 1, wherein the enveloping includes forming the body as an airfoil shape using the composite wrap plies.

3. The method of claim 1, further comprising stacking one or both of a composite filler tape and a composite filler fabric onto the first composite foam structure to form the internal portion of the component, without using a removable core support pin to support the first composite foam structure.

4. The method of claim 3, wherein the stacking of the one or both of the composite filler tape and the composite filler fabric onto the first composite foam structure includes applying the one or both of the composite filler tape and the composite filler fabric along a length of the first composite foam structure.

5. The method of claim 3, further comprising:

forming a second composite foam structure to a desired shape, wherein the second composite foam structure is configured to pass at least some the cooling fluid therethrough; and

stacking the one or both of the composite filler tape and the composite filler fabric onto the second composite foam structure in addition to the first composite foam structure to form the internal portion of the component.

6. The method of claim 5, wherein the stacking of the one or both of the composite filler tape and the composite filler fabric onto the second composite foam structure in addition to the first composite foam structure includes applying the one or both of the composite filler tape and the composite filler fabric along a length of the first composite foam structure and of the second composite foam structure.

7. The method of claim 5, wherein the stacking of the one or both of the composite filler tape and the composite filler fabric onto the second composite foam structure in addition to the first composite foam structure includes applying the one or both of the composite filler tape and the composite filler fabric between the first composite foam structure and of the second composite foam structure.

8. The method of claim 5, further comprising:

forming a third composite foam structure to a desired shape;

wherein the second composite foam structure is configured to pass at least some of the cooling fluid therethrough; and

wherein the third composite foam structure is configured to bridge between the first composite foam structure and the second composite foam structure and allow the at least some of the cooling fluid to flow between the first composite foam structure and the second composite foam structure; and

stacking the one or both of the composite filler tape and the composite filler fabric onto the third composite foam structure in addition to the first composite foam structure and the second composite foam structure to form the internal portion of the component.

9. The method of claim 8, further comprising varying the density in at least one of the first composite foam structure, the second composite foam structure and the third composite foam structure to generate an increased pressure drop at a desired location in the at least one of the first composite foam structure, the second composite foam structure and the third composite foam structure.

10. The method of claim 1, further comprising varying the density in the first composite foam structure to generate an increased pressure drop at a desired location in the first composite foam structure.

11. The method of claim 1, wherein the first composite foam structure forms at least part of a serpentine structure;

and wherein the forming of the first composite foam structure to the desired shape includes forming the first composite foam structure into a serpentine shape.

12. The method of claim 1, further comprising incorporating a metallic spar into the internal portion of the component.

13. An airfoil for a turbomachine, comprising:

a body having an airfoil shape, wherein the body includes;

an internal portion of the airfoil having a composite foam cooling passage configured to pass a cooling fluid therethrough; and

a plurality of composite wrap plies enveloping the internal portion of the airfoil.

14. The airfoil of claim 13, further comprising one or both of a composite filler tape and a composite filler fabric surrounding at least a portion of the composite foam cooling passage, wherein the one or both of the composite filler tape and the composite filler fabric form a part of the internal portion of the airfoil.

15. The airfoil of claim 13, wherein the plurality of composite wrap plies form an airfoil shape around the internal portion of the airfoil.

16. The airfoil of claim 13, wherein the composite foam cooling passage includes a controlled density variation configured to generate an increased pressure drop at a desired location.

17. The airfoil of claim 13, wherein the composite foam cooling passage is formed of a unitary composite foam structure.

18. The airfoil of claim 13, wherein the composite foam cooling passage is formed of a plurality of composite foam structures arranged together to form the composite foam cooling passage.

19. The method of claim 13, further comprising a metallic spar in the internal portion of the airfoil.

20. The airfoil of claim 13, further comprising a composite filler surrounding at least a portion of the composite foam cooling passage, wherein the composite filler forms a part of the internal portion of the airfoil.

21. A gas turbine engine, comprising:

a compressor;

a combustor in fluid communication with the compressor; and

a turbine in fluid communication with the combustor,

wherein at least one of the compressor, the combustor and the turbine includes a component having means for cooling the component with a cooling fluid.

22. The gas turbine engine of claim 21, wherein the means for cooling the component does not employ a removable core support pin to support the internal portion of the component.

23. The gas turbine engine of claim 21, wherein the means for cooling the component includes a composite foam cooling passage.

24. The gas turbine engine of claim 23, wherein the composite foam cooling passage includes a controlled density variation configured to generate an increased pressure drop at a desired location.