Multi-zone blade fabrication
AssigneeRtx Corporation
InventorsJohn R. Farris, John A. Sharon, Alan D. Cetel, Dilip M. Shah
Life of this patent
Estimating the term…
Abstract
In a method for manufacturing a turbine engine element such as a blade or vane, the element has an airfoil. The method includes: applying a load across an assembly of a first cast portion of the airfoil and a second cast portion of the airfoil; and applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion.
Claims19
A method for manufacturing a plurality of turbine engine elements, each element having an airfoil, the method comprising:
- casting a first cast portion of the airfoil of each element and a second cast portion of the airfoil of each element;
- and
- for each element:
- assembling the first cast portion and second cast portion to each other;
- applying a load across the assembly of the first cast portion and the second cast portion;
- and
- applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion,
- wherein:
- the casting comprises:
- casting a plurality of precursors having cast passageways;
- and
- from each cast precursor, cutting the first cast portion and the second cast portion or precursors thereof from the cast precursor;
- the casting of each precursor leaves:
- a first alloy in a region for forming the first portion;
- a second alloy in a region for forming the second portion;
- and
- a transition region between the first alloy and the second alloy;
- and
- the cutting at least partially removes the transition region to leave at the junction at most 10% said second alloy in the first portion and 10% said first alloy in the second portion.
A method for manufacturing a plurality of turbine engine elements, each element having an airfoil, the method comprising:
- casting a first cast portion of the airfoil of each element and a second cast portion of the airfoil of each element;
- and
- for each element:
- assembling the first cast portion and second cast portion to each other;
- applying a load across the assembly of the first cast portion and the second cast portion;
- and
- applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion,
- wherein:
- the casting comprises:
- casting a plurality of precursors;
- and
- from each cast precursor, cutting the first cast portion and the second cast portion or precursors thereof from the cast precursor;
- the cutting comprises a pair of spaced-apart cuts;
- the pair of spaced-apart cuts are electrodischarge machined (EDM);
- the pair of spaced-apart cuts remove a twist or a kink;
- and
- the assembling assembles the first cast portion and second cast portion with corresponding crystalline axes 20° to 90° out of registry.
A method for manufacturing a plurality of turbine engine elements, each element having an airfoil, the method comprising:
- casting a first cast portion of the airfoil of each element and a second cast portion of the airfoil of each element;
- and
- for each element:
- assembling the first cast portion and second cast portion to each other;
- applying a load across the assembly of the first cast portion and the second cast portion;
- and
- applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion,
- wherein:
- the casting comprises:
- casting a plurality of precursors;
- and
- from each cast precursor, cutting the first cast portion and the second cast portion or precursors thereof from the cast precursor;
- the cutting comprises a pair of spaced-apart cuts;
- the pair of spaced-apart cuts are electrodischarge machined (EDM);
- the pair of spaced apart cuts are two of a plurality of spaced apart cuts;
- the plurality of spaced apart cuts divide the first cast portion into a blade tip piece and a plurality of other pieces and the second portion as a rootward piece;
- the method includes machining cooling channels into cut surfaces of the plurality of other pieces;
- the fusing is of a stack of the tip piece, the plurality of other pieces, and the rootward piece;
- and
- the machined cooling channels form outlet passageways from cast passageways upon the fusing.
Dependencies are inferred from the claim text.