Method for making a double-wall airfoil
First Claim
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1. A method of making a double-wall airfoil, comprising the steps of:
- forming a partially-hollow airfoil support wall that is attached to and extends longitudinally from an airfoil base and has an airfoil-shaped outer surface, said support wall formed from a first material and having at least one longitudinally-extending recessed channel formed in the airfoil-shaped outer surface;
filling the at least one longitudinally-extending recessed channel with a channel filling means so as to make an upper surface of the channel filling means substantially continuous with the airfoil-shaped outer surface;
depositing an airfoil skin of a second material, the second material comprising a material selected from the group consisting of;
an IS /M composite in the form of a micro-laminate having a plurality of alternating layers of IS and M and an IS /IM composite in the form of a micro-laminate having a plurality of alternating layers of IS and IM, onto the airfoil-shaped outer surface of the airfoil support wall such that the airfoil skin conforms to the airfoil-shaped outer surface of the support wall and covers the at least one longitudinally-extending recessed channel and the channel filling means, and such that the airfoil skin is metallurgically bonded to the airfoil-shaped outer surface of the airfoil support wall, wherein the combination of the airfoil skin and airfoil support wall form a double-wall airfoil structure; and
removing the channel filling means, thereby creating an integral internal channel within the double-wall airfoil structure.
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Abstract
A method for making double-wall airfoil for applications such as the blades and vanes of gas turbine engines by depositing an airfoil skin over an inner support wall which is separately formed and contains channels filled by a channel filling means. The channel filling means is removed thereby forming integral channels within the double-wall for circulating a cooling gas adjacent to the airfoil skin. The airfoil skin deposited may be a metal alloy skin or a microlaminate structure, including microlaminate composite structures.
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19 Claims
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1. A method of making a double-wall airfoil, comprising the steps of:
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forming a partially-hollow airfoil support wall that is attached to and extends longitudinally from an airfoil base and has an airfoil-shaped outer surface, said support wall formed from a first material and having at least one longitudinally-extending recessed channel formed in the airfoil-shaped outer surface; filling the at least one longitudinally-extending recessed channel with a channel filling means so as to make an upper surface of the channel filling means substantially continuous with the airfoil-shaped outer surface; depositing an airfoil skin of a second material, the second material comprising a material selected from the group consisting of;
an IS /M composite in the form of a micro-laminate having a plurality of alternating layers of IS and M and an IS /IM composite in the form of a micro-laminate having a plurality of alternating layers of IS and IM, onto the airfoil-shaped outer surface of the airfoil support wall such that the airfoil skin conforms to the airfoil-shaped outer surface of the support wall and covers the at least one longitudinally-extending recessed channel and the channel filling means, and such that the airfoil skin is metallurgically bonded to the airfoil-shaped outer surface of the airfoil support wall, wherein the combination of the airfoil skin and airfoil support wall form a double-wall airfoil structure; andremoving the channel filling means, thereby creating an integral internal channel within the double-wall airfoil structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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Specification