Rotor blades with removable tips

Abstract

A rotor blade for a gas turbine engine is provided. The rotor blade includes a blade body formed of a first material and a tip component removably connected to the blade body, the tip component being formed of a second material different from the first material.

Description

Technical Field

[0001] The present subject matter relates generally to gas turbine engines, or more particularly, to rotor blades for gas turbine engines. Background Art

[0002] A gas turbine engine generally comprises a turbine that includes, in serial flow order, a fan section, a compressor section, a combustion section, a turbine section, and an exhaust section. During operation of the turbine, the gas turbine engine drives the rotor blades of these sections or otherwise rotates the rotor blades of these sections relative to the nacelle. The rotation of the rotor blades, in turn, generates a pressurized airflow that can support the operation of the gas turbine engine and / or be used as propulsive thrust to propel an aircraft.

[0003] However, friction between the tips of the rotor blades and parts of the engine may result in the need to replace the entire rotor blade. Summary of the Invention

[0004] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0005] In one exemplary embodiment of the present disclosure, a rotor blade for a gas turbine engine is provided, comprising: a blade body formed of a first material; and a tip component removably connected to the blade body, the tip component formed of a second material different from the first material.

[0006] In certain exemplary embodiments, the tip component defines an abradable outer surface.

[0007] In certain exemplary embodiments, the rotor blade includes a lock connected to the tip member and the blade body, the lock being operable to selectively lock the tip member to the blade body.

[0008] In certain exemplary embodiments, the lock is operable to selectively lock the tip member to the blade body, thereby preventing the tip member from moving in radial and axial directions relative to the blade body.

[0009] In certain exemplary embodiments, the tip member is removably connected to the blade body via the lock.

[0010] In certain exemplary embodiments, the lock comprises: a protrusion extending from the tip member; and a slot in the blade body, wherein the slot is sized to receive the protrusion to selectively lock the tip member to the blade body.

[0011] In certain exemplary embodiments, the tip member is formed of a shape memory alloy.

[0012] In certain exemplary embodiments, the span dimension of the tip member is 10% or less of the span dimension of the blade body.

[0013] In certain exemplary embodiments, the span dimension of the tip member is 20% or less of the span dimension of the blade body.

[0014] In certain exemplary embodiments, the second material of the tip component is a less rigid material than the first material of the blade body.

[0015] In another exemplary embodiment of the present disclosure, a gas turbine engine is provided. The gas turbine engine includes: a fan; and a rotor blade positioned within the fan, the rotor blade including: a blade body formed of a first material; and a tip component removably connected to the blade body, the tip component formed of a second material different from the first material.

[0016] In certain exemplary embodiments, the tip component defines an abradable outer surface.

[0017] In certain exemplary embodiments, the rotor blade includes a lock connected to the tip member and the blade body, the lock being operable to selectively lock the tip member to the blade body.

[0018] In certain exemplary embodiments, the lock is operable to selectively lock the tip member to the blade body, thereby preventing the tip member from moving in radial and axial directions relative to the blade body.

[0019] In certain exemplary embodiments, the tip member is removably connected to the blade body via the lock.

[0020] In certain exemplary embodiments, the lock comprises: a protrusion extending from the tip member; and a slot in the blade body, wherein the slot is sized to receive the protrusion to selectively lock the tip member to the blade body.

[0021] In certain exemplary embodiments, the tip member is formed of a shape memory alloy.

[0022] In certain exemplary embodiments, the span dimension of the tip member is 20% or less of the span dimension of the blade body.

[0023] In certain exemplary embodiments, the second material of the tip component is a less rigid material than the first material of the blade body.

[0024] In an exemplary aspect of the present disclosure, a method for repairing a rotor blade having a blade body for a gas turbine engine is provided, wherein the method comprises: removing a first tip component from the blade body when the first tip component is damaged; and connecting a second tip component to the blade body.

[0025] These and other features, aspects and advantages of the present invention will become more readily understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In the specification with reference to the accompanying drawings, a complete and enabling disclosure of the present invention including the best mode thereof is set forth for those skilled in the art, wherein:

[0027] Figure 1 is a schematic cross-sectional view of an exemplary gas turbine engine according to an exemplary embodiment of the present disclosure.

[0028] Figure 2 is a side cross-sectional view of a rotor blade of a gas turbine engine according to an exemplary embodiment of the present disclosure.

[0029] Figure 3 is a cross-sectional exploded view of a tip component and a blade body of a rotor blade according to an exemplary embodiment of the present disclosure.

[0030] Figure 4 is a cross-sectional connection view of a tip component and a blade body of a rotor blade according to an exemplary embodiment of the present disclosure.

[0031] Figure 5 is a cross-sectional exploded view of a tip component and a blade body of a rotor blade according to another exemplary embodiment of the present disclosure.

[0032] Figure 6 is a cross-sectional connection view of a tip component and a blade body of a rotor blade according to another exemplary embodiment of the present disclosure.

[0033] Figure 7 is a cross-sectional view of a first configuration of a groove of a lock portion according to an exemplary embodiment of the present disclosure.

[0034] Figure 8 is a cross-sectional view of a second configuration of a groove of a locking portion according to another exemplary embodiment of the present disclosure.

[0035] Figure 9 is a cross-sectional view of a third configuration of a groove of a lock portion according to another exemplary embodiment of the present disclosure.

[0036] Corresponding reference characters indicate corresponding parts throughout the several views.The examples set out herein illustrate exemplary embodiments of the present disclosure, and these examples should not be construed as limiting the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0037] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and the description have been used to refer to like or similar parts of the invention.

[0038] The following description is provided to enable those skilled in the art to make and use the embodiments contemplated for implementation of the present invention. However, various modifications, equivalents, variations, and substitutions will be apparent to those skilled in the art. Any and all such modifications, variations, equivalents, and substitutions are intended to fall within the scope of the present invention.

[0039] For the purposes of the following description, the terms "upper," "lower," "right," "left," "vertical," "horizontal," "top," "bottom," "lateral," "longitudinal," and their derivatives shall relate to the present invention as it is oriented in the accompanying drawings. However, it should be understood that the present invention contemplates various alternative variations unless expressly specified to the contrary. It should also be understood that the specific devices shown in the drawings and described in the following specification are merely exemplary embodiments of the present invention. Accordingly, specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting.

[0040] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of each component.

[0041] The terms "fore" and "aft" refer to relative positions within a gas turbine engine, with front referring to a position closer to the engine inlet and aft referring to a position closer to the engine nozzle or exhaust.

[0042] The terms "upstream" and "downstream" refer to relative directions of fluid flow in a fluid path. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction toward which the fluid flows.

[0043] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0044] Furthermore, unless otherwise specified, the terms "low," "high," or their respective comparatives (e.g., lower, higher, where applicable) each refer to a relative speed within the engine. For example, a "low-pressure turbine" operates at a substantially lower pressure than a "high-pressure turbine." Alternatively, unless otherwise specified, the above terms may be understood as referring to the highest order. For example, a "low-pressure turbine" may refer to the turbine with the lowest maximum pressure within a turbine section, and a "high-pressure turbine" may refer to the turbine with the highest maximum pressure within a turbine section.

[0045] As used herein throughout the specification and claims, approximate language is applied to modify any quantitative representation that may be permissibly varied without resulting in a change in the basic function to which it is associated. Therefore, a value modified by one or more terms such as "approximately," "approximately," and "substantially" is not limited to the precise value specified. In at least some cases, approximate language may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximate language may refer to within a margin of ten percent. Here and throughout the specification and claims, range limitations are combined and interchanged, and unless the context or language indicates otherwise, these ranges are identified and include all subranges contained therein.

[0046] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, these ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0047] The rotor blade of the present disclosure includes a blade body formed from a first material and a tip component removably connected to the blade body, the tip component being formed from a second material different from the first material. As described above, friction between the tip of the rotor blade and portions of the engine can necessitate replacement of the entire rotor blade. Advantageously, the rotor blade of the present disclosure only requires replacement of the worn tip, rather than the entire rotor blade. For example, once the tip component is worn, the tip component can be removed from the blade body, and a new, second tip component can then be connected to the same blade body.

[0048] The tip component of the present disclosure can be made of a wear-resistant material. For example, the tip component defines a wear-resistant outer surface formed of the wear-resistant material. In this way, any friction between the tip component and the engine portion will not wear the engine component, but will wear the tip component, which can then be replaced with a new tip component.

[0049] In other exemplary embodiments, the tip component of the present disclosure may be made of a shape memory alloy that can deform during any friction between the tip component and a portion of the engine, but will return to its pre-deformed shape, for example, upon heating. It is also contemplated that other materials may be used to form the tip component.

[0050] It is contemplated that the tip components of the present disclosure may have any desired geometric configuration or shape to support a variety of aerodynamic features and designs. It is contemplated that a first tip component having a first geometric shape may be removably connected to a blade body. When the first tip component having the first geometric shape is removed, a second tip component having a second geometric shape different from the first geometric shape may then be removably connected to the blade body.

[0051] It is also contemplated that the tip component can have any desired tip hardness, i.e., tip fragility, to support a variety of features and designs. It is contemplated that a first tip component having a first tip hardness can be removably connected to the blade body. When the first tip component having the first tip hardness is removed, a second tip component having a second tip hardness that is the same as the first tip hardness can then be removably connected to the blade body. It is also contemplated that in other exemplary embodiments, the second tip component can have a second tip hardness that is different from the first tip hardness.

[0052] Referring now to the drawings, in which like numerals refer to like elements throughout, Figure 1 is a schematic cross-sectional view of a gas turbine engine according to an exemplary embodiment of the present disclosure. More specifically, Figure 1 In the embodiment of the present invention, the gas turbine engine is a high bypass turbofan jet engine 10, referred to herein as "turbofan engine 10". Figure 1 As shown, the turbofan engine 10 defines an axial direction A (extending parallel to a longitudinal centerline or axis 12 provided for reference) and a radial direction R. Generally, the turbofan 10 includes a fan section 14 and a turbine 16 disposed downstream of the fan section 14 .

[0053] The depicted exemplary turbine 16 generally includes a substantially tubular casing 18 defining an annular inlet 20. Casing 18 encloses, in serial flow relationship, a compressor section comprising a supercharger or low-pressure (LP) compressor 22 and a high-pressure (HP) compressor 24; a combustion section 26; a turbine section comprising a high-pressure (HP) turbine 28 and a low-pressure (LP) turbine 30; and an exhaust nozzle section 32. A high-pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low-pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22. Furthermore, the compressor section, combustion section 26, and turbine section together at least partially define a core air flow path 37 extending therethrough. Each compressor 22, 24 may further include one or more rows of stator vanes interleaved with one or more rows of compressor rotor blades. Furthermore, each turbine 28, 30 may further include one or more rows of stator vanes interleaved with one or more rows of turbine rotor blades. In the exemplary embodiment, LP compressor 22 includes sequential stages of LP compressor stator blades 23 and LP compressor rotor blades 25, and HP compressor 24 includes sequential stages of HP compressor stator blades 27 and HP compressor rotor blades 29. Furthermore, LP turbine 30 includes sequential stages of LP turbine stator blades 72 and LP turbine rotor blades 74, and HP turbine 28 includes sequential stages of HP turbine stator blades 68 and HP turbine rotor blades 70.

[0054] For the depicted embodiment, the fan section 14 includes a variable pitch fan 38 having a plurality of fan blades 40 coupled to a disk 42 in a spaced-apart manner. As shown, the fan blades 40 extend generally outwardly from the disk 42 in a radial direction R. Each fan blade 40 is rotatable relative to the disk 42 about a pitch axis P due to the fan blade 40 being operably coupled to a suitable actuating member 44, which is configured to collectively and uniformly change the pitch of the fan blades 40. The fan blades 40, disk 42, and actuating member 44 are rotatable together about the longitudinal axis 12 via the LP shaft 36 across a power gearbox 46. The power gearbox 46 includes a plurality of gears for gradually reducing the rotational speed of the LP shaft 36 to a more efficient rotational fan speed. In an exemplary embodiment of the present disclosure, the fan 14 may include a plurality of rotor stages, each rotor stage including a row of fan blades or rotor airfoils mounted to a rotor having a rotatable disk. The fan 14 may also include at least one stator stage including a row of stationary or stator airfoils for turning airflow therethrough. As used herein, the term "fan" refers to any device in a turbine engine having a rotor with airfoils operable to generate fluid flow. It is contemplated that the principles of the present invention are equally applicable to multi-stage fans, single-stage fans, and other fan configurations; as well as low-bypass turbofan engines, high-bypass turbofan engines, and other engine configurations.

[0055] Still refer to Figure 1 In the exemplary embodiment, the disk 42 is covered by a rotatable forward nacelle 48 having an aerodynamic profile to facilitate airflow over the plurality of fan blades 40. In addition, the exemplary fan section 14 includes an annular fan casing or outer nacelle 50 that circumferentially surrounds the fan 38 and / or at least a portion of the turbine 16. For the illustrated embodiment, the nacelle 50 is supported relative to the turbine 16 by a plurality of circumferentially spaced outlet guide vanes 52. In addition, a downstream section 54 of the nacelle 50 extends over an outer portion of the turbine 16 to define a bypass airflow passage 56 therebetween.

[0056] During operation of the turbofan engine 10, a volume of air 58 enters the turbofan engine 10 through the nacelle 50 and / or associated inlet 60 of the fan section 14. As the volume of air 58 passes through the fan blades 40, a first portion of the air 58, as indicated by arrow 62, is directed or routed into the bypass airflow passage 56, and a second portion of the air 58, as indicated by arrow 64, is directed or routed into the LP compressor 22. The ratio between the first portion of air 62 and the second portion of air 64 is generally referred to as the bypass ratio. The pressure of the second portion of air 64 is then increased as it is directed through the high pressure (HP) compressor 24 and into the combustion section 26, where it is mixed with fuel and combusted to provide combustion gases 66.

[0057] The combustion gases 66 are directed through the HP turbine 28 where a portion of the thermal and / or kinetic energy from the combustion gases 66 is extracted via sequential stages of HP turbine stator blades 68 coupled to the casing 18 and HP turbine rotor blades 70 coupled to the HP shaft or spool 34, thereby rotating the HP shaft or spool 34 to support operation of the HP compressor 24. The combustion gases 66 are then directed through the LP turbine 30 where a second portion of the thermal and / or kinetic energy is extracted from the combustion gases 66 via sequential stages of LP turbine stator blades 72 coupled to the casing 18 and LP turbine rotor blades 74 coupled to the LP shaft or spool 36, thereby rotating the LP shaft or spool 36 to support operation of the LP compressor 22 and / or rotation of the fan 38.

[0058] The combustion gases 66 are then directed through the exhaust nozzle section 32 of the turbine 16 to provide propulsive thrust. Simultaneously, the pressure of the first portion of air 62 is significantly increased as the first portion of air 62 is directed through the bypass airflow passage 56 before being discharged from the fan nozzle exhaust section 76 of the turbofan engine 10, also providing propulsive thrust. The HP turbine 28, the LP turbine 30, and the exhaust nozzle section 32 at least partially define a hot gas path 78 for directing the combustion gases 66 through the turbine 16.

[0059] However, it should be understood that Figure 1The exemplary turbofan engine 10 depicted in FIG is for example only, and in other exemplary embodiments, the turbofan engine 10 may have any other suitable configuration. For example, in other exemplary embodiments, the turbofan engine 10 may be a direct drive turbofan engine (i.e., not including a power gearbox 46), may include a fixed pitch fan 38, etc. Additionally or alternatively, aspects of the present disclosure may be incorporated into any other suitable gas turbine engine, such as a turboshaft engine, a turboprop engine, a turbojet engine, an open rotor or unducted turbofan engine, a land-based gas turbine engine for power generation, an aeroderivative gas turbine engine, etc.

[0060] Figure 2-9 Exemplary embodiments of the present disclosure are shown. Figure 2 is a side cross-sectional view of a rotor blade 100 according to an exemplary embodiment of the present disclosure, which may be incorporated into the engine 10 in place of any of the fan rotor blades 40, compressor rotor blades 25, 29 ( Figure 1 ) and / or turbine rotor blades 70, 74 ( Figure 1 As shown, the rotor blade 100 defines a longitudinal direction L, a radial direction R, and a circumferential direction C. Generally, the longitudinal direction L extends parallel to the axial centerline 12 of the engine 10, the radial direction R extends generally orthogonal to the axial centerline 12, and the circumferential direction C extends generally concentrically about the axial centerline 12.

[0061] refer to Figure 2-6 In the exemplary embodiment, rotor blade 100 includes a blade body 102 and a tip member 120 that is detachably or removably connected to blade body 102. Rotor blade 100 extends along a radial direction R from a root section 104 to a tip 106. As described herein, tip member 120 forms a portion of tip 106 of rotor blade 100. Furthermore, rotor blade 100 includes a pressure side surface 108 and an opposing suction side surface 110. In this regard, pressure side surface 108 and suction side surface 110 are joined together or interconnected at a leading edge 112 of blade body 102 and a trailing edge 114 of blade body 102. Rotor blade 100 defines a peripheral edge 116.

[0062] refer to Figure 2 Each rotor blade 100 has a span or span dimension "S1," defined as the radial distance from the root 104 to the tip 106, and a chord or chord dimension "C1," defined as the length of an imaginary straight line connecting the leading edge 112 and the trailing edge 114. Depending on the specific design of the rotor blade 100, its chord C1 may be different at different locations along the span S1. In one embodiment, the relevant measurement is the chord C1 at the root 104 of the rotor blade 100.

[0063] Additionally, as described below, root section 104 secures rotor blade 100 to a rotor disk (not shown), which is coupled to LP shaft 36 ( Figure 1 ) or HP shaft 34( Figure 1 However, in alternative exemplary embodiments, the rotor blade 100 may have any other suitable configuration. For example, in one embodiment, the rotor blade 100 may include a platform positioned along the radial direction R between the blade body 102 and the root section 104 .

[0064] In an exemplary embodiment, the rotor blade 100 may further include a cover portion 118 disposed on a portion of the blade body 102 and a portion of the tip member 120 . Figure 2 In one embodiment, the cover portion 118 may be formed from a metallic material, although it is contemplated that the cover portion 118 may be formed from other protective materials.

[0065] refer to Figure 2-6 In the exemplary embodiment, blade body 102 is formed from a first material, and tip member 120 , which is removably connected to blade body 102 , is formed from a second material that is different from the first material.

[0066] In an exemplary embodiment, the blade body 102 is made of a material that is stronger, harder, and more rigid than the material from which the tip component 120 is formed. The blade body 102 is made of a material having a higher modulus than the material from which the tip component 120 is formed. For example, the blade body 102 may be formed of a woven or fabric composite material, a material such as an intermediate modulus fiber and a standard modulus fiber, or any material that is stronger and harder than the tip component 120, although it is contemplated that other materials may be used. In this way, while the tip component 120 may wear or become damaged, the blade body 102 is stronger and more resistant to any damage. As described herein, a worn tip component 120 can be removed from the blade body 102 and then replaced with a new tip component 120.

[0067] In exemplary embodiments, a portion of blade body 102 and / or a portion of tip component 120 may be formed from any suitable composite material, such as a suitable material for forming the matrix of, and / or comprising, the final blade body 102 and / or tip component 120. For example, the composite material may be selected from the group consisting of, but not limited to, ceramic matrix composites (CMCs), polymer matrix composites (PMCs), metal matrix composites (MMCs), or combinations thereof. Suitable examples of matrix materials for CMCs include, but are not limited to, silicon carbide, aluminum oxide, silicon oxide, and combinations thereof. Suitable examples of matrix materials for PMCs include, but are not limited to, epoxy-based matrices, polyester-based matrices, and combinations thereof. Suitable examples of matrix materials for MMCs include, but are not limited to, aluminum, titanium, and combinations thereof. For example, the MMC may be formed from powdered metal, such as, but not limited to, aluminum powder or titanium powder, which can be melted into a continuous molten liquid metal that can encapsulate the fibers present in the assembly before cooling into a solid ingot with coated fibers. The resulting MMC is a metal article having increased hardness, with the metal portion (matrix) being the primary load-bearing element.

[0068] In an exemplary embodiment, tip component 120 is made of a material that is less hard or softer than the material forming blade body 102. Tip component 120 is made of a material having a lower modulus than the material forming blade body 102. In an exemplary embodiment, tip component 120 may be formed of a friction-resistant material, a shape memory alloy such as a TiNi alloy, or any material that is less hard than blade body 102, although it is contemplated that other materials may be used.

[0069] In addition, the tip component 120 can be made of a wearable material. For example, the tip component 120 defines a wearable outer surface 122 formed of a wearable material. In this way, the tip component 120 and the engine 10 ( Figure 1 ) will not wear the engine components, but will wear the tip component 120, which can then be replaced with a new tip component.

[0070] In other exemplary embodiments, the tip member 120 may be made of a shape memory alloy that is formed between the tip member 120 and the engine 10 ( Figure 1 ) may deform during any friction between parts thereof, but will recover to its pre-deformed shape, for example, upon heating. It is also contemplated that other materials may be used to form the tip component 120.

[0071] It is contemplated that the tip component 120 can have any desired geometric configuration or shape to support various aerodynamic features and designs. It is contemplated that a first tip component 120 having a first geometric shape can be removably connected to the blade body 102. When the first tip component 120 having the first geometric shape is removed, a second tip component 120 having a second geometric shape different from the first geometric shape can then be removably connected to the blade body 102.

[0072] It is also contemplated that the tip component 120 can have any desired tip hardness, i.e., tip fragility, to support various features and designs. It is contemplated that a first tip component 120 having a first tip hardness can be removably connected to the blade body 102. When the first tip component 120 having the first tip hardness is removed, a second tip component 120 having a second tip hardness different from the first tip hardness can then be removably connected to the blade body 102.

[0073] like Figure 3 and 4 As shown, in a first exemplary embodiment, rotor blade 100 includes a lock 140 connected to tip member 120 and blade body 102, and lock 140 is operable to selectively lock tip member 120 to blade body 102. In this manner, lock 140 is operable to selectively lock tip member 120 to blade body 102, thereby preventing tip member 120 from moving in radial and axial directions relative to blade body 102. In the exemplary embodiment, tip member 120 is removably connected to blade body 102 via lock 140.

[0074] refer to Figure 3 and 4 In one exemplary embodiment, the lock 140 includes a protrusion 142 extending from the tip member 120 and a slot 144 defined in the blade body 102. In this embodiment, the slot 144 defined in the blade body 102 is sized to receive the protrusion 142 extending from the tip member 120, thereby selectively locking the tip member 120 to the blade body 102.

[0075] In the exemplary embodiment, the protrusion 142 extending from the tip member 120 and the slot 144 defined in the blade body 102 have an interlocking dovetail shape. However, it is contemplated that other interlocking shapes, such as any interlocking geometric features, may be used. Furthermore, it is contemplated that any other connection system may be used between the blade body 102 and the tip member 120 that allows the tip member 120 to be removably connected to the blade body 102.

[0076] Another exemplary connection system between the tip component 120 and the blade body 102 of the present disclosure will now be discussed. Figure 5 and 6 As shown, in another exemplary embodiment, rotor blade 100 includes a lock 150 connected to tip member 120 and blade body 102, and lock 150 is operable to selectively lock tip member 120 to blade body 102. In this manner, lock 150 is operable to selectively lock tip member 120 to blade body 102, thereby preventing tip member 120 from moving in radial and axial directions relative to blade body 102. In the exemplary embodiment, tip member 120 is removably connected to blade body 102 via lock 150.

[0077] refer to Figure 5 and 6 In one exemplary embodiment, the lock 150 includes a protrusion 152 extending from the blade body 102 and a slot 154 defined in the tip member 120. In this embodiment, the slot 154 defined in the tip member 120 is sized to receive the protrusion 152 extending from the blade body 102, thereby selectively locking the tip member 120 to the blade body 102.

[0078] In the exemplary embodiment, the protrusion 152 extending from the blade body 102 and the slot 154 defined in the tip member 120 have interlocking dovetail shapes. However, it is contemplated that other interlocking shapes, such as any interlocking geometric features, may be used. Furthermore, it is contemplated that any other connection system may be used between the blade body 102 and the tip member 120 that allows the tip member 120 to be removably connected to the blade body 102.

[0079] An exemplary configuration of the slot of the lock portion of the present disclosure will now be discussed. Figure 7 In one exemplary embodiment, a slot 144 ( Figure 3 and 4 ) or the groove 154 ( Figure 5 and 6 ) may include a linear axial groove 160.

[0080] refer to Figure 8 In another exemplary embodiment, a slot 144 ( Figure 3 and 4 ) or the groove 154 ( Figure 5 and 6 ) may include a spherical axial groove 170.

[0081] refer to Figure 9In yet another exemplary embodiment, the slot 144 ( Figure 3 and 4 ) or the groove 154 ( Figure 5 and 6 ) may include a linear circumferential groove 180. Furthermore, it is contemplated that any other configuration of grooves and / or geometric interlocking designs of the present disclosure may be used.

[0082] refer to Figure 2 , the tip component 120 has a span dimension STC, and the blade body 102 has a span dimension SBB. In one exemplary embodiment, the span dimension STC of the tip component 120 is 20% or less of the span dimension SBB of the blade body 102. In another exemplary embodiment, the span dimension STC of the tip component 120 is 15% or less of the span dimension SBB of the blade body 102. In another exemplary embodiment, the span dimension STC of the tip component 120 is 10% or less of the span dimension SBB of the blade body 102. In another exemplary embodiment, the span dimension STC of the tip component 120 is 5% or less of the span dimension SBB of the blade body 102. It is also contemplated that other shapes and sizes of the tip component 120 relative to the blade body 102 may be used.

[0083] In an exemplary aspect of the present disclosure, a method for repairing a rotor blade having a blade body for a gas turbine engine is provided. The method includes removing a first tip component from the blade body when the first tip component is damaged; and connecting a second tip component to the blade body.

[0084] Further aspects of the invention are provided by the subject matter of the following clauses:

[0085] 1. A rotor blade for a gas turbine engine, the rotor blade comprising: a blade body formed of a first material; and a tip component removably connected to the blade body, the tip component formed of a second material different from the first material.

[0086] 2. The rotor blade according to any of the preceding clauses, wherein the tip component defines an abradable outer surface.

[0087] 3. The rotor blade according to any of the preceding clauses, further comprising a lock connected to the tip member and the blade body, the lock being operable to selectively lock the tip member to the blade body.

[0088] 4. Rotor blade according to any of the preceding clauses, wherein the lock is operable to selectively lock the tip member to the blade body, thereby preventing movement of the tip member in radial and axial directions relative to the blade body.

[0089] 5. Rotor blade according to any of the preceding clauses, wherein the tip member is removably connected to the blade body via the lock.

[0090] 6. A rotor blade according to any of the preceding clauses, wherein the lock comprises: a protrusion extending from the tip member; and a slot in the blade body, wherein the slot is dimensioned to receive the protrusion to selectively lock the tip member to the blade body.

[0091] 7. A rotor blade according to any of the preceding clauses, wherein the tip component is formed from a shape memory alloy.

[0092] 8. A rotor blade according to any of the preceding clauses, wherein the span dimension of the tip component is 10% or less of the span dimension of the blade body.

[0093] 9. A rotor blade according to any of the preceding clauses, wherein the span dimension of the tip component is 20% or less of the span dimension of the blade body.

[0094] 10. Rotor blade according to any of the preceding clauses, wherein the second material of the tip component is a less hard material than the first material of the blade body.

[0095] 11. A gas turbine engine comprising: a fan; and a rotor blade positioned within the fan, the rotor blade comprising: a blade body formed of a first material; and a tip component removably connected to the blade body, the tip component formed of a second material different from the first material.

[0096] 12. The gas turbine engine according to any of the preceding clauses, wherein the tip component defines an abradable outer surface.

[0097] 13. The gas turbine engine according to any of the preceding clauses, further comprising a lock connected to the tip member and the blade body, the lock being operable to selectively lock the tip member to the blade body.

[0098] 14. A gas turbine engine according to any of the preceding clauses, wherein the lock is operable to selectively lock the tip member to the blade body, thereby preventing movement of the tip member in radial and axial directions relative to the blade body.

[0099] 15. The gas turbine engine according to any of the preceding clauses, wherein the tip component is removably connected to the blade body via the lock.

[0100] 16. A gas turbine engine according to any of the preceding clauses, wherein the lock comprises: a protrusion extending from the tip member; and a slot in the blade body, wherein the slot is sized to receive the protrusion to selectively lock the tip member to the blade body.

[0101] 17. A gas turbine engine according to any of the preceding clauses, wherein the tip component is formed from a shape memory alloy.

[0102] 18. The gas turbine engine according to any of the preceding clauses, wherein the span dimension of the tip component is 20% or less of the span dimension of the blade body.

[0103] 19. A gas turbine engine according to any of the preceding clauses, wherein the second material of the tip component is a material that is less hard than the first material of the blade body.

[0104] 20. A method for repairing a rotor blade having a blade body for a gas turbine engine, the method comprising: removing a first tip component from the blade body when the first tip component is damaged; and connecting a second tip component to the blade body.

[0105] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims, they are intended to be within the scope of the claims.

[0106] Although the present disclosure has been described as having an exemplary design, the present disclosure may be further modified within the scope of the present disclosure. Therefore, this application is intended to cover any variation, use, or adaptation of the present disclosure using its general principles. Further, this application is intended to cover such deviations from the present disclosure as come within known or customary practice in the art to which the present disclosure pertains and which fall within the limits of the appended claims.

Claims

1. A rotor blade for a gas turbine engine, characterized in that: The rotor blade comprises: a blade body formed from a first material, wherein the blade body defines a leading edge, a trailing edge, a root, a tip, a pressure side surface, a suction side surface, and a slot extending between the pressure side surface and the suction side surface between the leading edge and the trailing edge of the blade body; a cover portion disposed over a portion of the leading edge; and a tip member defining an abradable outer surface at a radial extremity of the rotor blade relative to the root portion of the blade body, wherein the tip member is positioned within the slot and is removably connected to the blade body, the tip member being formed of a second material different from the first material, wherein the cover portion extends radially through the tip member to the radial extremity.

2. The rotor blade according to claim 1, characterized in that Further included is a lock connected to the tip member and the blade body, the lock operable to selectively lock the tip member to the blade body.

3. The rotor blade according to claim 2, characterized in that The lock portion is operable to selectively lock the tip member to the blade body, thereby preventing the tip member from moving in radial and axial directions relative to the blade body.

4. The rotor blade according to claim 2, wherein: wherein the tip member is removably connected to the blade body via the lock.

5. The rotor blade according to claim 2, wherein: The locking portion includes: a protrusion extending from the tip member, wherein the slot is sized to receive the projection to selectively lock the tip member to the blade body.

6. The rotor blade according to claim 1, wherein: The tip component is formed of a shape memory alloy.

7. The rotor blade according to claim 1, wherein: The tip member has a span dimension that is 10% or less of a span dimension of the blade body.

8. The rotor blade according to claim 1, wherein: The tip member has a span dimension that is 20% or less of a span dimension of the blade body.

9. The rotor blade according to claim 1, wherein: The second material of the tip component is less hard than the first material of the blade body.

10. A gas turbine engine, characterized in that: include: fan; and a rotor blade positioned within the fan, the rotor blade comprising: a blade body formed from a first material, wherein the blade body defines a leading edge, a trailing edge, a root, a tip, a pressure side surface, a suction side surface, and a slot extending between the pressure side surface and the suction side surface between the leading edge and the trailing edge of the blade body; a cover portion disposed over a portion of the leading edge; and a tip member defining an abradable outer surface at a radial extremity of the rotor blade relative to the root portion of the blade body, wherein the tip member is positioned within the slot and is removably connected to the blade body, the tip member being formed of a second material different from the first material, wherein the cover portion extends radially through the tip member to the radial extremity.

11. The gas turbine engine according to claim 10, wherein: Further included is a lock connected to the tip member and the blade body, the lock operable to selectively lock the tip member to the blade body.

12. The gas turbine engine according to claim 11, wherein The lock portion is operable to selectively lock the tip member to the blade body, thereby preventing the tip member from moving in radial and axial directions relative to the blade body.

13. The gas turbine engine according to claim 11, wherein: wherein the tip member is removably connected to the blade body via the lock.

14. The gas turbine engine according to claim 11, wherein: The locking portion includes: a protrusion extending from the tip member, wherein the slot is sized to receive the projection to selectively lock the tip member to the blade body.

15. The gas turbine engine according to claim 10, wherein: The tip component is formed of a shape memory alloy.

16. The gas turbine engine according to claim 10, wherein: The tip member has a span dimension that is 20% or less of a span dimension of the blade body.

17. The gas turbine engine according to claim 10, wherein: The second material of the tip component is less hard than the first material of the blade body.

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