Method of manufacturing a blade

• US 8,382,441 B2
• Filed: 02/03/2010
• Issued: 02/26/2013
• Est. Priority Date: 02/27/2009
• Status: Expired due to Fees

• Current Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Inventors: Brennand, Phillip, Jones, Richard M
• Primary Examiner(s): Nguyen, Ninh H
• Assistant Examiner(s): GRIGOS, WILLIAM G
• Application Number:
  US12/699,507
• Publication Number:
  US 20100221117A1
• Time in Patent Office: 1,119 Days
• Field of Search: 416/229.R, 416/229.A, 416/232, 416/233, 228/193, 228/157, 298/891, 298/892, 298/892.1, 298/897.21
• US Class Current: 416/229.R
• CPC Class Codes: B21D 26/059 Layered blanks
• CPC Class Codes: B21D 53/78 propeller blades; turbine blades
• CPC Class Codes: B23K 20/023 Thermo-compression bonding
• CPC Class Codes: B23K 20/18 Zonal welding by interposing weld-preventing substances between zones not to be welded
• CPC Class Codes: B23K 2101/001 Turbines
• 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 2230/236 Diffusion bonding
• CPC Class Codes: F05D 2230/31 Layer deposition
• CPC Class Codes: F05D 2250/18 patterned
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

A method of manufacturing a blade (20) for a turbomachine by superplastic forming and diffusion bonding a first layer (18), a second layer (16) and a membrane (2), the membrane (2) being disposed between the first and second layers (18, 16), the method comprising: applying a stop-off material in a first predetermined pattern between the first layer (18) and the membrane (2) so as to prevent a diffusion bond from forming between the first layer and the membrane across said first predetermined pattern; and applying the stop-off material in a second predetermined pattern between the second layer (16) and the membrane (2) so as to prevent a diffusion bond from forming between the second layer and the membrane across said second predetermined pattern.

Claims

1. A method of manufacturing a blade for a turbomachine by superplastic forming and diffusion bonding a first layer, a second layer and a membrane, the membrane being disposed between the first and second layers, the method comprising:

applying a stop-off material in a first predetermined pattern between the first layer and the membrane so as to prevent a diffusion bond from forming between the first layer and the membrane across said first predetermined pattern;

wherein the first pattern is applied such that it defines one or more first strips and one or more first dots, the first strips and first dots being void of the stop-off material, and wherein the first strips are arranged in a span-wise direction, and the first dots are located between the first strips and the blade tip edge, the first dots being offset from a longitudinal axis of the first strips in a chord-wise direction; and

applying the stop-off material in a second predetermined pattern between the second layer and the membrane so as to prevent a diffusion bond from forming between the second layer and the membrane across said second predetermined pattern;

wherein the second pattern is applied such that it defines one or more second strips and one or more second dots, the second strips and second dots being void of the stop-off material, and wherein the second strips are arranged in a span-wise direction and the second dots are located between the second strips and the blade tip edge, the second dots being offset from a longitudinal axis of the second strips in a chord-wise direction;

wherein the first and second predetermined patterns are applied such that the second strips are spaced apart from the first strips and the first dots are spaced apart from the second dots on opposite sides of the membrane.

2. The method of manufacture according to claim 1, wherein the method comprises applying the first and second predetermined patterns such that the second dots are in line with the longitudinal axes of the first strips.

3. The method of manufacture according to claim 1, wherein the method comprises applying the first and second predetermined patterns such that the first dots are in line with the longitudinal axes of the second strips.

4. The method of manufacture according to claim 1, wherein the method comprises applying the first and second predetermined patterns such that the spacing between the first strip and the neighbouring second dot is a function of the spacing between the first strip and the neighbouring second strip.

5. The method of manufacture according to claim 4, wherein the spacing between the first strip and the neighbouring second dot is equal to the spacing between the first strip and the neighbouring second strip multiplied by a strain ratio of the blade.

6. The method of manufacture according to claim 1, wherein the size of the first or second dots is a function of one or more of:

(a) the spacing between neighbouring strips adjacent to the first or second dot;

(b) the width of the strip adjacent to the first or second dot;

(c) the spacing between the longitudinal axes of the strips adjacent to the first or second dot; and

(d) a strain ratio of the blade.

7. The method of manufacture according to claim 6, wherein the size of the first or second dot decreases with the distance of the first or second dot from the blade tip.

8. The method of manufacture according to claim 1, wherein the first and second strips are substantially obround.

9. The method of manufacture according to claim 1, wherein the first and second dots are substantially circular.

10. The method of manufacture according to claim 1, wherein the first and second predetermined patterns are arranged so as to allow a diffusion bond to be formed along the blade edges.

11. The method of manufacture according to claim 1, wherein the first layer forms a pressure surface or a suction surface of the turbomachine blade and the second layer forms the other of the pressure surface or suction surface.

12. The method of manufacture according to claim 1, wherein the blade is a compressor fan blade.

13. The method of manufacture according to claim 1, wherein the method further comprises heating and pressing the first and second layers and the membrane to diffusion bond the first and second layers and the membrane together to form an integral structure.

14. The method of manufacture according to claim 1, wherein the method further comprises placing the first and second layers and the membrane between appropriately shaped dies;

heating the first and second layers, the membrane and dies; and

supplying a pressurised fluid between the first and second layers to cause at least one of the first and second layers to be superplastically formed.

15. A blade for a turbomachine comprising a first layer, a second layer and a membrane therebetween, wherein

the membrane is joined to the first layer across one or more first strips and one or more first dots, the first strips being arranged in a span-wise direction, and the first dots being located between the first strips and the blade tip edge, the first dots being offset from a longitudinal axis of the first strips in a chord-wise direction;

and

the membrane is joined to the second layer across one or more second strips and one or more second dots, the second strips being arranged in a span-wise direction and the second dots being located between the second strips and the blade tip edge, the second dots being offset from a longitudinal axis of the second strips in a chord-wise direction;

wherein the second strips are spaced apart from the first strips and the first dots are spaced apart from the second dots on opposite sides of the membrane.