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US 12,497,974 B2Granted
Cost-effective solid-state deposition of functionally graded titanium hollow fan blade sheath for improved galvanic corrosion resistance
AssigneeRtx Corporation
InventorsTahany El-Wardany, Sonia Martinez, Benjamin Bedard
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Abstract
An airfoil includes an airfoil body and a sheath. The airfoil body includes a first metallic material and the sheath includes a second metallic material. An interface connects the sheath to the airfoil body such that the sheath covers a forward edge of the airfoil body to define an airfoil leading edge. The interface includes bulk metallic glass bonding the sheath to the airfoil body.
Claims20
An airfoil comprising:
- an airfoil body comprising a first metallic material, wherein the airfoil body comprises a forward edge, a trailing edge aft of the forward edge, a pressure surface extending between the forward edge and the trailing edge, and a suction surface extending between the forward edge and the trailing edge;
- and
- a sheath comprising a second metallic material, wherein the sheath comprises:
- a head section;
- a first flank connected to the head section and extending aft from the head section;
- and
- a second flank connected to the head section and extending aft from the head section;
- and
- an interface connecting the sheath to the airfoil body such that the head section of the sheath covers the forward edge of the airfoil body to define an airfoil leading edge, wherein the interface comprises bulk metallic glass bonding the sheath to the airfoil body, and wherein the bulk metallic glass is friction bonded to the airfoil body.
6 more elements
A method of forming a fan blade comprising:
- forming an airfoil body from an aluminum alloy, wherein the airfoil body comprises a forward edge, a trailing edge aft of the forward edge, a pressure surface extending between the forward edge and the trailing edge, and a suction surface extending between the forward edge and the trailing edge;
- and
- forming a sheath on the forward edge of the airfoil body to form a leading edge of the fan blade, wherein forming the sheath comprises:
- metallurgically bonding a layer of bulk metallic glass to the forward edge of the airfoil body without phase changing the bulk metallic glass in the layer, thereby forming a friction bond between the layer of bulk metallic glass and the airfoil body;
- forming over the layer of bulk metallic glass a head section, a first flank connected to the head section and extending aft from the head section, and a second flank connected to the head section and extending aft from the head section, and wherein the layer of bulk metallic glass connects the head section, the first flank, and the second flank of the sheath to the airfoil body.
2 more elements
Dependencies are inferred from the claim text.