Hollow component manufacture

• US 5,611,944 A
• Filed: 04/28/1995
• Issued: 03/18/1997
• Est. Priority Date: 05/10/1994
• Status: Expired due to Term

• Current Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Inventors: Richardson, Brian, Gilkinson, John J.
• Primary Examiner(s): Walberg, Teresa J.
• Assistant Examiner(s): Pelham, J.
• Application Number:
  US08/430,617
• Time in Patent Office: 690 Days
• Field of Search: 219/86.1, 219/91.2, 219/91.23, 219/117.1, 219/121.12, 219/121.13, 219/121.14, 219/121.36, 219/121.45, 219/121.46, 219/121.59 , 219/121.63, 219/121.64, 228/60, 228/173.3, 228/186, 29/889.7, 29/889.72, 415/115, 415/119, 416/97 R, 416/241 R
• US Class Current: 219/117.1
• CPC Class Codes: B21D 26/055 Blanks having super-plastic properties
• CPC Class Codes: B21D 53/045 by inflating partially united plates
• CPC Class Codes: B21D 53/78 propeller blades; turbine blades
• CPC Class Codes: B23K 20/18 Zonal welding by interposing weld-preventing substances between zones not to be welded
• CPC Class Codes: F01D 5/147 Construction, i.e. structural features, e.g. of weight-saving hollow blades F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18
• CPC Class Codes: F05D 2220/36 specially adapted for the fan of turbofan engines
• CPC Class Codes: F05D 2230/236 Diffusion bonding

Abstract

In a method of manufacturing a hollow component metallic sheets are diffusion bonded together except where a stop off pattern is applied to the surfaces of the sheets. A gas channel is accommodated in the thickness of the sheets for the entry of pressurised gas under superplastic forming conditions to produce the hollow component. The material defining the gas channel is locally deformed by forging to reduce the height of the gas channel in order that a subsequent fusion welding pass over the deformed area defining the gas channel hermetically seals the gas channel.

Claims

1. A hollow component manufacturing method including the steps of:

(a) forming at least two metallic sheets by a process of diffusion bonding them together in selected places, at least one of the sheeets being capable of superplastic deformation and at least one of the sheets accommodating in the thickness thereof gas channel means for entry of pressurized gas into the interior of the component after diffusion bonding,

(b) where the sheets are not diffusion bonded together, expanding at least one of said sheets away from at least one other sheet by means of inflation by supplying pressurized gas under superplastic forming conditions through the gas channel means into the interior of the component to produce the desired interior structure for the component,

(c) locally deforming the material of at least one of the sheets at least in the area defining the gas channel means to reduce the height of said gas channel means,

(d) making at least one fusion weld pass over the deformed area defining the gas channel means thereby to obturate the gas channel means with weld material such that the gas channel means is hermetically sealed.

2. A method as claimed in claim 1 comprising deforming the material defining the gas channel means on both sides of the component.

3. A method as claimed in claim 1 or claim 2 wherein the local deformation of the material defining the gas channel means is by locally forging the material by application of heat and pressure.

4. A method as claimed in claim 3 wherein a plurality of forging operations are performed over immediately adjacent areas of the material.

5. A method as claimed in claim 3 wherein the material defining the gas channel means is locally deformed by the use of a resistance spot welding apparatus, the welding electrodes being applied to the material defining the channel means, or to a wider area.

6. A method as claimed in claim 1 wherein the fusion weld is caused to penetrate into the material on both sides of the channel means.

7. A method as claimed in claim 6 wherein the fusion welding is performed by laser welding, electron beam welding or plasma welding.

8. A hermetically sealed hollow component comprises at least two metallic sheets at least one of which is capable of superplastic deformation, the metallic sheets having been joined by diffusion bonding in selected places and where not diffusion bonded, the at least one superplastically deformable sheet having been expanded away from the at least one other sheet by means of inflation by pressurised gas under superplastic forming conditions to define a hollow interior structure, gas connection to the hollow interior having been achieved by means of at least one gas entry passage whose height is accommodated in the thickness of at least one sheet, wherein subsequent to superplastic forming the material defining said passage has been locally deformed to reduce the height of said passage, said passage subsequently having been hermetically sealed by at least one fusion weld.

9. A hollow component as claimed in claim 8 wherein the component is a gas turbine engine blade or vane.

10. A hollow component as claimed in claim 9 wherein the component is a fan blade.

11. A hollow component as claimed in claim 8 wherein the component is heat exchanger.