Composite airfoils having leading edge protection made using high temperature additive manufacturing methods

Abstract

Composite airfoils including a leading edge, and a near net shape metal leading edge protective strip operably connected to the leading edge, the protective strip made by providing a high temperature additive manufacturing device; providing a tooling system including a mandrel; a metallic cladding; and at least one cooling channel applying a metallic deposit to the mandrel having the metallic cladding using the high temperature additive manufacturing device; and concurrently removing heat from the mandrel using the at least one cooling channel.

Description

TECHNICAL FIELD[0001]Embodiments described herein generally relate to composite airfoils having leading edge protection made using high temperature additive manufacturing methods.BACKGROUND OF THE INVENTION[0002]Many modern turbine engine airfoils, such as blades and vanes, are constructed of a composite laminate or molded fiber. Airfoil metal leading edge (herein “MLE”) protective strips can be used to protect composite airfoils from impact and erosion damage that can often occur in the engine environment. In conventional practices, a v-shaped protective metallic strip is often wrapped around the leading edge and sides of the airfoil to provide such protection.[0003]While MLE protective strips can be made from a variety of materials, titanium and titanium alloys are often utilized due to their favorable weight and mechanical properties. However, hot forming methods must be used to fabricate these titanium components. Hot forming typically involves multiple steps with intermediate c...

AI Technical Summary

Benefits of technology

[0008]Embodiments herein generally relate to composite airfoils comprising: a leading edge; and a near net shape metal leading edge protective strip operably connected to the leading edge, the protective strip made by providing a high temperature additive manufacturing device; providing a tooling s

Problems solved by technology

This can lead to high tooling costs, high yield losses, and environmentally unfriendly processing.

These drawbacks are especially true when fabricating thin, complex geometries, such as MLE protective strips.

Additionally, the tool must not cause any contamination of the metallic deposit, as contamination can have a disastrous affect on the physical and mechanical properties of the component.

More specifically, when titanium or titanium alloy is deposited, the risk of contamination of the deposit by the tooling is high due to the high melting point and reactive nature of titanium.

While this approach helps mitigate the issue of contamination, it results in a very narrow process window for making a sound deposit without fusion of the deposit to the tool.

This is because titanium is a relatively poor heat conductor when compared to other heat sink materials (e.g. refractory metals, mild steel, copper).

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