Deformable rotor blade and turbine engine system including the same

Abstract

A morphing rotor blade for a turbine engine system includes a root portion and an airfoil portion, the airfoil portion having a morphing portion, the morphing portion including a morphing material that changes shape in response to a stimulus.

Description

Technical Field

[0001] This topic generally relates to components of a turbine engine system, or more specifically, to rotor blades (e.g., fan blades) that include deformable portions that allow the shape of the rotor blades to change. Background Technology

[0002] A turbine is a device that typically transfers energy between a rotor and a fluid. One type of turbine is a gas turbine engine, which generally comprises a fan section and a core engine arranged in fluid communication with each other. Furthermore, the core engine of a gas turbine engine typically includes a compressor section, a combustion section, a turbine section, and an exhaust section in a series flow sequence. In operation, air is supplied from the fan section to the inlet of the compressor section, where one or more axial compressors progressively compress the air until it reaches the combustion section. Fuel is mixed with the compressed air and burned within the combustion section to provide combustion gases. The combustion gases are then directed from the combustion section to the turbine section. The flow of combustion gases through the turbine section drives the turbine section and then through the exhaust section, for example, into the atmosphere.

[0003] One type of gas turbine engine, the turbofan engine, operates by a central gas turbine core driving a bypass fan section located radially between the engine nacelle and the engine core. The rotation of the fan blades generates airflow through the inlet to the core engine, and then onto the core engine itself. Another type of gas turbine engine, the open rotor engine, operates by placing the bypass fan section outside the engine nacelle. This typically allows for larger fan blades than turbofan engines, enabling the use of a larger volume of air and thus improving propulsive efficiency compared to conventional engine designs.

[0004] Such fan blade assemblies typically include fan blades with a root portion connected to the rotor, causing the rotor to rotate in response to gas being directed toward the fan blades. Typically, the airfoil shape used in such fan blades is designed to produce optimal performance at a single operating or flight cycle point, but may be very inefficient at other critical design points. For example, such a blade design may be more efficient at one speed relative to another.

[0005] Improvements to turbine rotor blades (e.g., fan blades in gas turbine engine systems) will be welcomed in the art. Attached Figure Description

[0006] This specification provides a full and effective disclosure of the present disclosure, including its best mode, to those skilled in the art, and references the accompanying drawings, wherein:

[0007] Figure 1This is a schematic cross-sectional view of an exemplary pipeline gas turbine engine system according to various embodiments of this subject matter.

[0008] Figure 2 These are schematic graphic views of exemplary deformable rotor blades according to various embodiments of this subject matter.

[0009] Figure 3 This is a schematic graphic view of a deformable rotor blade according to another exemplary aspect of this disclosure.

[0010] Figure 4 This is a schematic graphic view of a deformable rotor blade according to another exemplary aspect of this disclosure.

[0011] Figure 5 This is a schematic diagram of a lattice structure segment of a deformable portion according to an exemplary embodiment of the present disclosure.

[0012] Figure 6 This is a schematic diagram of a lattice structure segment of a deformable portion according to another exemplary embodiment of the present disclosure.

[0013] Figure 7 This is a graphic view of the lattice structure of a deformable portion according to another exemplary embodiment of the present disclosure.

[0014] Figure 8 These are embodiments of the present disclosure in different constructions. Figure 8 A graphical view of the crystal lattice structure.

[0015] Figure 9 This is a graphic view of the lattice structure of a deformable portion according to another exemplary embodiment of the present disclosure.

[0016] Figure 10 These are embodiments of the present disclosure in different constructions. Figure 10 A graphical view of the crystal lattice structure.

[0017] Figure 11 This is a schematic graphic view of a deformable rotor blade according to another exemplary aspect of this disclosure.

[0018] Figure 12 This is a schematic graphical view of a deformable rotor blade according to another exemplary aspect of this disclosure, particularly showing the shape change of the deformable rotor blade at the respective tip.

[0019] Figure 13 Based on exemplary aspects of this disclosure Figure 13 A view of the trailing edge of a deformable rotor blade.

[0020] Figure 14This is a schematic graphic view of a deformable rotor blade according to another exemplary aspect of this disclosure, particularly showing the shape changes of two deformable portions at the respective tips of the blade.

[0021] Reference characters are used repeatedly in this specification and accompanying drawings to indicate the same or similar features or elements of the subject matter. Detailed Implementation

[0022] Reference will now be made in detail to the present embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerals and letter reference numerals to denote features in the drawings. Similar or analogous reference numerals in the drawings and description have been used to denote similar or analogous portions of this disclosure.

[0023] The term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as superior or better than other implementations. Furthermore, unless explicitly stated otherwise, all embodiments described herein should be considered exemplary.

[0024] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the individual components.

[0025] The terms "front" and "rear" refer to relative positions within a turbine, gas turbine engine, or carrier, and to the normal operating posture of the turbine, gas turbine engine, or carrier. For example, in a gas turbine engine, "front" refers to the position closer to the engine inlet, while "rear" refers to the position closer to the engine nozzle or exhaust port.

[0026] The terms "upstream" and "downstream" refer to the relative directions of fluid flow within a fluid path. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction from which the fluid flows.

[0027] Unless otherwise stated herein, the terms “connection,” “fixed,” “attached to,” etc., refer to both direct connection, fixation, or attachment, and indirect connection, fixation, or attachment via one or more intermediate components or features.

[0028] Unless the context clearly indicates otherwise, the singular forms “a,” “a,” and “the” include plural references.

[0029] As used throughout the specification and claims, approximate language is applied to modify any quantitative expression that allows for variation without altering its underlying function. Therefore, values ​​modified by terms such as “about,” “approximate,” and “substantially” are not limited to specified exact values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the component and / or system. For example, approximate language may refer to margins of 1%, 2%, 4%, 10%, 15%, or 20%. These approximate margins may apply to a single value, to either end of a defined numerical range, or to margins between two ends, and / or between the ends.

[0030] Throughout this specification and claims, scope limitations are combined and interchanged, and unless the context or language otherwise indicates otherwise, such scopes are identified and include all subscopes contained herein. For example, all scopes disclosed herein include endpoints, and endpoints may be combined independently of each other.

[0031] In certain aspects of this disclosure, deformable rotor blades for turbine engine systems are provided. Rotor blades typically include a root portion and an airfoil portion. The airfoil portion includes a deformable portion having a lattice structure comprising a deformable material, such as a shape memory alloy or a piezoelectric material. Thus, the deformable portion is configured to change shape relative to the indeformable remainder of the airfoil portion.

[0032] The shape change of the deformable portion relative to the rest allows for adjustment of the airfoil shape at different operating cycle points, potentially improving the aerodynamic efficiency of the deformable rotor blades and / or associated rotor assemblies, thereby reducing the specific fuel consumption of the turbine engine. For example, such rotor blades can be configured to change shape in response to stimuli driven by takeoff conditions of the gas turbine engine (e.g., speed, temperature, etc.) and / or in response to cruise conditions of the gas turbine engine. Therefore, this disclosure can provide passive control over the shape of the rotor blades, such as passive control over the shape of the deformable portion located near the trailing edge and / or tip of the blade. In various other aspects of this disclosure, the deformable rotor blades can include active control to change the shape of the deformable portion, for example, by temperature control using heating elements, heat exchangers, etc., or by applying an electric current to the deformable material.

[0033] Now refer to the attached diagram, Figure 1 A front cross-sectional view is shown of an exemplary embodiment of a gas turbine engine that can be incorporated into one or more aspects of the invention disclosed herein. Figure 1 The exemplary gas turbine engine configuration is a single-rotor tubular turbine engine system 10, which defines an axial direction A, a radial direction R, and a circumferential direction (extending about the axial direction A). For example... Figure 1As shown, the turbine engine system 10 is in the form of a closed rotor propulsion system and has a rotor assembly 12 (e.g., a fan section) which includes a plurality of airfoils arranged around a central longitudinal axis 14 of the turbine engine system 10, and more specifically, a plurality of rotor blades 16 arranged around the central longitudinal axis 14 of the turbine engine system 10. Furthermore, as will be explained in more detail below, the turbine engine system 10 also includes a fixed or stationary exit guide vane assembly 18 (i.e., not rotating relative to the central longitudinal axis 14) positioned behind the rotor assembly 12, which includes a plurality of airfoils also arranged around the central longitudinal axis 14, and more specifically, a plurality of vanes 20 (e.g., exit guide vanes) arranged around the central longitudinal axis 14.

[0034] The rotor blades 16 are arranged in a typically equidistant relationship around the central longitudinal axis 14, and each blade has a root 22 and a tip 24, as well as a span defined between them. Similarly, the outlet guide vanes 20 are also arranged in a typically equidistant relationship around the central longitudinal axis 14, and each outlet guide vane 20 has a root and a tip, as well as a span defined between them. The rotor assembly 12 also includes a hub 43 located in front of the plurality of rotor blades 16.

[0035] Furthermore, the turbine engine system 10 includes a turbine core engine 30, which, in an exemplary embodiment, includes a low-speed system 31 and a high-speed system 32. The high-speed system 32 of the core engine 30 typically includes a high-speed compressor 34, a high-speed turbine 36, and a high-speed shaft 38 extending between and connecting the high-speed compressor 34 and the high-speed turbine 36. The high-speed compressor 34 (or at least its rotating components), the high-speed turbine 36 (or at least its rotating components), and the high-speed shaft 38 can be collectively referred to as the engine's high-speed spool 35. Additionally, a combustion section 40 is located between the high-speed compressor 34 and the high-speed turbine 36. The combustion section 40 may include one or more configurations for receiving a fuel-air mixture and providing a flow of combustion gases through the high-speed turbine 36 to drive the high-speed spool 35.

[0036] The low-speed system 31 similarly includes a low-speed turbine 42, a low-speed compressor 44 (or turbocharger), and a low-speed shaft 46, which extends between and connects the low-speed compressor 44 and the low-speed turbine 42. The low-speed compressor 44 (or at least its rotating parts), the low-speed turbine 42 (or at least its rotating parts), and the low-speed shaft 46 can be collectively referred to as the low-speed spool 45 of the turbine engine system 10.

[0037] Although the turbine engine system 10 is shown with the low-speed compressor 44 located in front of the high-speed compressor 34, in some embodiments, the compressors 34 and 44 may be arranged in an interdigitated manner. Furthermore, or alternatively, although the turbine engine system 10 is shown with the high-speed turbine 36 located in front of the low-speed turbine 42, in some embodiments, the turbines 36 and 42 may similarly be arranged in an interdigitated manner.

[0038] Still referencing Figure 1 The core engine 30 can be enclosed within a shroud 48. Furthermore, it is understood that the shroud 48 at least partially defines the inlet 50 and the exhaust nozzle section 52, and includes a core flow path 54 extending between the inlet 50 and the exhaust nozzle section 52. In the illustrated embodiment, the inlet 50 is an annular or axisymmetric 360-degree inlet located between the rotor assembly 12 and the stationary or stationary outlet guide vane assembly 18, and provides a path for incoming atmospheric air to enter the core flow path 54 (and the compressors 44, 34, combustion section 40, and turbines 36, 42) radially in the direction R inside the outlet guide vane 20. This location may be advantageous for various reasons, including icing performance management and protecting the inlet 50 from various objects and materials that may be encountered during operation. However, in other embodiments, the inlet 50 can be located in any other suitable location, such as behind the vane assembly 18, arranged in a non-axisymmetric manner, etc.

[0039] As described above, the turbine engine system 10 includes a blade assembly 18. The blade assembly 18 extends from the shroud 48 and is located behind the rotor assembly 12. The outlet guide blade 20 of the blade assembly 18 can be mounted to a stationary frame or other mounting structure and does not rotate relative to the central longitudinal axis 14. For ease of reference, Figure 1 The arrow F further describes the forward direction, which in turn defines the front and rear parts of the system. For example... Figure 1As shown, rotor assembly 12 is configured as a "puller" positioned in front of core engine 30, and exhaust nozzle section 52 is positioned behind exit guide vane 20. As will be understood, the exit guide vane 20 of vane assembly 18 may be configured to straighten the airflow from rotor assembly 12 (e.g., reduce swirl in the airflow) to improve the efficiency of turbine engine system 10. For example, the size, shape, and configuration of exit guide vane 20 may impose counteracting swirl on the airflow from rotor blades 16 so that the airflow has a significantly reduced degree of swirl in the downstream direction behind both airfoils (e.g., rotor blades 16, exit guide vane 20), which can translate into an increased level of induced efficiency. Furthermore, exit guide vane 20 may support one or more of the core engine 30, cowling 48, or nacelle 80 (currently described), or a frame or other fixed structure supporting the turbine engine system 10 or associated foundation, vehicle, etc.

[0040] Still referencing Figure 1 The rotor blades 16, the exit guide vanes 20, or both may include a pitch mechanism so that the airfoil (e.g., rotor blades 16, exit guide vanes 20, etc.) can rotate independently or in combination with each other relative to the pitch rotation axis. This pitch can be used to change thrust and / or vortex effects under various operating conditions, including adjusting the magnitude or direction of thrust generated at rotor blades 16, or providing thrust reversal functionality, which may be useful under certain operating conditions, such as during aircraft landing, or desirably adjusting acoustic noise at least partially generated by rotor blades 16, exit guide vanes 20, or the aerodynamic interaction of rotor blades 16 with respect to exit guide vanes 20. More specifically, for Figure 1 In one embodiment, rotor assembly 12 is depicted having pitch mechanism 58 for rotating rotor blades 16 about their respective pitch axes 60, and blade assembly 18 is depicted having pitch mechanism 26 for rotating outlet guide blades 20 about their respective pitch axes 64.

[0041] As shown in the figure, the rotor assembly 12 is driven by the core engine 30, and more specifically, by the low-speed spool 45. More specifically, Figure 1 The turbine engine system 10 in the illustrated embodiment includes a power gearbox 56, and the rotor assembly 12 is driven across the power gearbox 56 by a low-speed spool 45 of the core engine 30. The power gearbox 56 may include a set of gears for reducing the rotational speed of the low-speed spool 45 relative to the low-speed turbine 42, so that the rotor assembly 12 can rotate at a slower speed than the low-speed spool 45. In this way, the rotating rotor blades 16 of the rotor assembly 12 can rotate about a central longitudinal axis 14 and generate thrust to propel the turbine engine system 10 in the forward direction F, and thus propel the associated aircraft. Figure 1As further shown, the exemplary turbine engine system 10 includes a nacelle 80 that at least partially surrounds the rotor assembly 12 and the core engine 30 circumferentially, forming a bypass airflow passage 82 between the two.

[0042] During operation of the tubular turbine engine system 10, a certain amount of air 59 enters the turbine engine system 10 through the nacelle 80 and / or the associated inlet 51 of the rotor assembly 12. As the certain amount of air 59 passes through the rotor blades 16, a first portion of the air 59, indicated by arrow 62, is directed or directed to the bypass airflow passage 82, and a second portion of the air 59, indicated by arrow 65, is directed or directed to the core flow path 54, or more specifically, to the low-speed compressor 44. The ratio between the first portion 62 and the second portion 65 of the air is commonly referred to as the bypass ratio. The pressure of the second portion 65 of the air then increases as it is directed through the high-speed compressor 34 and into the combustion section 40, where it mixes with fuel and burns to provide combustion gases 66.

[0043] Combustion gas 66 is directed through high-speed turbine 36, where a portion of the thermal and / or kinetic energy from the combustion gas 66 is extracted via a continuous stage of high-speed turbine stator blades and high-speed turbine rotor blades connected to high-speed shaft 35, thereby rotating high-speed shaft 35 to support the operation of high-speed compressor 34. Combustion gas 66 is then directed through low-speed turbine 42, where a second portion of the thermal and kinetic energy is extracted from the combustion gas 66 via a continuous stage of low-pressure turbine stator blades and low-speed turbine rotor blades connected to low-speed shaft 45, thereby rotating low-speed shaft 45 to support the operation of low-speed compressor 44 and / or rotation of rotor assembly 12.

[0044] Combustion gas 66 is then directed through the injection exhaust nozzle section 52 of the core engine 30 to provide propulsive thrust. Simultaneously, as a first portion of air 62 is directed through a bypass airflow passage 82 before exiting from the nozzle exhaust section 76 of the tubular turbine engine system 10, the pressure of the first portion of air 62 increases significantly, also providing propulsive thrust. The high-speed turbine 36, the low-speed turbine 42, and the injection exhaust nozzle section 52 at least partially define a hot gas path 55 for directing combustion gas 66 through the core engine 30.

[0045] However, it should be recognized that, Figure 1The exemplary single-rotor pipe engine shown is merely an example, and in other exemplary embodiments, the turbine engine system 10 may have any other suitable configuration, including, for example, any other suitable number of shafts or spindles, turbines, compressors, etc. Furthermore, or alternatively, in other exemplary embodiments, any other suitable gas turbine engine may be provided. For example, in other exemplary embodiments, the gas turbine engine may be a non-pipeline engine, a turbofan engine, a turboshaft engine, a turboprop engine, a turbojet engine, etc.

[0046] Now for reference Figure 2-4 According to various aspects of this disclosure, graphic views of exemplary rotor blades configured as deformable rotor blades 100 are illustrated. For example, in various embodiments, Figure 2-4 The deformable rotor blades 100 can be configured for use in gas turbine engines, such as pipeline gas turbine engines, which are configured to be compatible with... Figure 1 The pipeline turbine engine system 10 is the same as or similar to that in the pipeline turbine engine system, such as a turbofan engine. In various embodiments, the deformable rotor blades 100 may be configured as fan blades of a pipeline gas turbine engine. It should be understood that the following description also applies to other suitably configured stage and associated rotor assemblies. For example, in additional or alternative embodiments, Figure 2-4 Each of the exemplary deformable rotor blades shown can be configured for use in a non-pipeline gas turbine engine. Therefore, in various embodiments, each of the deformable rotor blades 100 can be configured as a fan blade for a piped gas turbine engine.

[0047] It should be recognized that this disclosure is equally applicable to any rotor blade within a suitably constructed rotor stage of a turbine. For example, such deformable rotor blades 100 may include, but are not limited to, fan blades, compressor rotor blades, turbine rotor blades, etc. Therefore, the illustrated deformable rotor blade 100 can generally be used in any suitably constructed rotor assembly for any suitably constructed turbine engine system or turbine, such as an open propeller engine, turbojet engine, power generation gas turbine engine, marine engine, etc. Furthermore, at least one deformable rotor blade 100 can generally be constructed to be included within a rotor stage of a turbine rotor assembly. Typically, rotor assemblies (e.g., such as...) Figure 1 The rotor assembly 12) is driven by the rotating spindle of the turbine, such as reference Figure 1 The described low-speed spool 45 or a similar rotating spool.

[0048] More specifically, any deformable rotor blade 100 depicted can be configured as a fan blade for the fan section of a gas turbine engine, such as... Figure 1The fan blades are fan blades of the fan section of a pipe-driven turbine engine system 10 or a similarly constructed pipe-driven gas turbine engine. Alternatively, the deformable rotor blades 100 shown may be configured as rotor blades of a rotor assembly of a non-pipe-driven gas turbine engine or a similarly constructed non-pipe-driven gas turbine engine. Furthermore, it should be recognized that one or more rotor blades within a stage of any suitable rotor assembly may be configured as... Figure 2-4 Any deformable rotor blade 100 is the same as or similar to it. For example, all rotor blades within a stage of the rotor assembly can be configured to be the same as... Figure 2-4 Any deformable rotor blade 100 is identical or similar. Furthermore, or alternatively, the rotor stage of the rotor assembly may include two or more rotor blades with different suitable configurations of the deformable rotor blade 100.

[0049] Still largely referencing Figure 2-4 According to an exemplary aspect of this disclosure, a plurality of deformable rotor blades 100 are illustrated. Each deformable rotor blade 100 generally includes a leading edge 102 and a trailing edge 104. As will be understood by those skilled in the art, the leading edge 102 is located at the foremost portion of the blade during rotation, while the trailing edge 104 is located at the rearmost point. Each deformable rotor blade 100 may also include a root portion 106 and an airfoil portion 108. The root portion 106 may be configured (e.g., shaped and sized to) be received in a cavity of a suitable rotor disk to allow the respective deformable rotor blades 100 to be connected to a rotor. A mid-chord region 111 may be located approximately midway between the root portion 106 and the tip 112, as depicted for each illustrated embodiment.

[0050] Each exemplary embodiment includes a deformable portion 114 of an airfoil and a non-deformable remainder (remains portion 116), the deformable portion 114 being configured to change shape in response to a stimulus. The shape change of the deformable portion 114 relative to the remainder 116 allows adjustment of the airfoil shape at two or more operating cycle points, thereby improving the aerodynamic efficiency of the deformable rotor blade 100 and / or associated rotor assemblies (e.g., multiple rotor blades in a rotor assembly stage, or all rotor blades in a rotor assembly stage), which in turn can reduce the specific fuel consumption of the gas turbine engine. For example, the deformable portion 114 may be configured to have an initial shape at low speeds or cruising speeds and a changed shape at higher speeds. For example, in a chordal cross-section, the initial shape may be a single curved shape with relatively high curvature, while the deformed shape is a single curved shape with relatively low curvature.

[0051] In some embodiments, the corresponding deformable portion 114 may typically include one or more lattice structures formed of a deformable material, as described below. Figure 5-10More specifically, in one embodiment, the deformable region 114 may include a lattice structure that extends within the deformable portion 114 over the entire thickness, span, and / or chord defined by the deformable rotor blade 100. For example, the deformable region 114 may be formed of such a lattice structure. Alternatively, a suitable lattice structure may be embedded within the deformable region. In additional or alternative embodiments, the deformable region 114 according to this disclosure may include one or more sheets comprising such a lattice structure. For example, one or more such sheets may be embedded within the deformable region. Alternatively, during the composite lamination process, one or more such sheets may be placed between fiber layups or fiber layers. Thus, in several embodiments, it should be appreciated that such sheets may be oriented such that the plane of the sheet is substantially aligned with the span and chord of the deformable rotor blade 100. In additional or alternative embodiments, the deformable portion 114 may include a sheet that wraps around, is coupled to, or is formed together with the outer surface of the airfoil portion 108 within the deformable region 114.

[0052] Now for special reference Figure 2 The illustrated deformable rotor blade 100 includes a deformable portion 114 located at or near the tip 112 on the trailing edge 104 of the airfoil portion 108. Furthermore, or alternatively, the deformable portion 114 may extend partially or entirely from the trailing edge 104 to the leading edge 102 (e.g., along the chord of the illustrated deformable rotor blade 100). For example, the deformable portion 114 may extend along at least 10% of the chord, such as at least 20% of the chord, such as at least 40% of the chord, such as at least 75% of the chord. In one or more embodiments, the deformable portion 114 may extend along the full length of the chord at the tip 112 of the airfoil portion 108. Furthermore, or alternatively, the deformable portion 114 may extend partially or entirely from the tip 112 to the root portion 106 (e.g., along the span of the illustrated deformable rotor blade 100). For example, the deformable portion 114 may extend along at least 10% of the span, such as along at least 20% of the span, such as along at least 40% of the span, such as along at least 75% of the span.

[0053] Furthermore, or alternatively, in order to cause a change in shape, such as from a more curved C-shape to a less curved C-shape in the trailing edge region, the deformable portion 114 may extend in the chord direction from the trailing edge 104 at the tip 112 toward the middle chord region, but not reaching the middle chord region. In such an embodiment, the deformable portion 114 may extend in the span direction along the trailing edge 104 from the tip 112 toward the middle span region, but not reaching the middle span region.

[0054] Now for reference Figure 3The illustrated deformable rotor blade 100 includes a deformable portion 114 located at or near a tip 112 on the leading edge 102 of the airfoil portion 108. Alternatively, the deformable portion 114 may extend partially or entirely from the leading edge 102 to the trailing edge 104 (e.g., along a chord of the illustrated deformable rotor blade 100). For example, the deformable portion 114 may extend along at least 10% of the chord, such as at least 20% of the chord, such as at least 40% of the chord, such as at least 75% of the chord. Alternatively, the deformable portion 114 may extend partially or entirely from the tip 112 to the root portion 106 (e.g., along the span of the illustrated deformable rotor blade 100). For example, the deformable portion 114 may extend along at least 10% of the span, such as at least 20% of the span, such as at least 40% of the span, such as at least 75% of the span.

[0055] Now for reference Figure 4 The illustrated deformable rotor blade 100 includes a deformable portion 114 located at or near the tip 112 in the midchord region of the airfoil portion 108. Additionally, or alternatively, the deformable portion 114 may extend partially to the leading edge 102, trailing edge 104, or both (e.g., along the chord of the illustrated deformable rotor blade 100). For example, the deformable portion 114 may extend along at least 10% of the chord, such as at least 20% of the chord, such as at least 40% of the chord, such as at least 75% of the chord. Additionally, or alternatively, the deformable portion 114 may extend partially or entirely from the tip 112 to the root portion 106 (e.g., along the span of the illustrated deformable rotor blade 100). For example, the deformable portion 114 may extend along at least 10% of the span, such as at least 20% of the span, such as at least 40% of the span, such as at least 75% of the span.

[0056] Those skilled in the art will understand that the deformable rotor blade 100 may include deformable portions (e.g., deformable portion 114) at various locations, including the leading and trailing edges of the blade, at various radial locations relative to the root of the rotor to which it can be connected to the rotor assembly. In additional or alternative embodiments, the deformable rotor blade 100 may include deformable portions (e.g., deformable portion 114) located at various locations within the body of the rotor blade and displaced from each of the trailing edge 104, leading edge 102, and tip 112 at various radial locations and / or at various chordally locations.

[0057] Now for reference Figure 5According to an exemplary embodiment of the present disclosure, a schematic diagram of a segment of the lattice structure 118 (constructed as a two-dimensional lattice structure) of the deformable portion 114 is shown. Figure 5 The lattice structure 118 in the rotor blade can be configured to accommodate any suitable configuration including the deformable portion 114 (e.g., Figure 2-4 It can be used with any deformable rotor blade 100 or similarly constructed rotor blade. The illustrated lattice structure 118 includes a plurality of interconnecting members 120. Members 120 (e.g., two or more members 120) can typically be connected or formed together at multiple nodes 122.

[0058] For ease of discussion, Figure 5 The lattice structure 118 in the embodiment is defined with respect to the local x-axis and y-axis of the plane defining the exemplary two-dimensional lattice structure. In one embodiment, the x-axis and / or y-axis may be oriented to align with the axial and / or radial directions of the associated rotor assembly. Furthermore, or alternatively, the x-axis and / or y-axis may be oriented to align along the chord and / or span of the associated deformable rotor blade. However, it should be appreciated that the local x-axis, y-axis, or both may define different orientations relative to such axial, radial, chord, and / or span directions. Furthermore, although... Figure 5 The exemplary lattice structure 118 is constructed as a grid, but those skilled in the art will understand that additional or alternative two-dimensional lattice structures may include defining two or more members 120 of different lengths. Furthermore, members 120 may extend at different angles relative to the y-axis and / or x-axis. Additionally, or alternatively, one or more members 120 may be bent, or define one or more segments with different orientations, thicknesses, radii of curvature, etc. For example, Figure 5 Exemplary embodiments include straight or near-straight members 120, each member defining the same or near-the same length. More specifically, the depicted embodiments include a plurality of first members 124 oriented to extend along a local x-axis and a plurality of second members 126 oriented to extend along a local y-axis. Therefore, those skilled in the art will understand that this disclosure is equally applicable to lattice structures with alternative constructions.

[0059] According to various aspects of this disclosure, Figure 5 The lattice structure 118 shown may include deformable materials, such as shape memory alloy (SMA) materials, piezoelectric materials, etc.

[0060] Shape memory alloys (SMAs) are typically alloys that can recover their original shape after deformation. For example, SMAs can define hysteresis effects, where the loading path on a stress-strain diagram differs from the unloading path. Therefore, SMAs can provide improved hysteresis damping compared to conventional elastic materials. Furthermore, SMAs can serve as lightweight solid-state alternatives to conventional actuators. For instance, certain SMAs can be heated to allow a deformed SMA to recover its pre-deformed shape. SMAs can also provide different stiffnesses in a predetermined manner in response to specific temperature ranges (i.e., temperature stimuli). The change in stiffness of a shape memory alloy is a response to a temperature-induced solid-state microstructure phase transition, which allows the alloy to change from one physical shape to another. The change in stiffness of an SMA can be achieved by machining and annealing alloy preforms at temperatures equal to or higher than the temperature at which the solid-state microstructure phase transition occurs in the shape memory alloy. The temperature at which this phase transition occurs is often referred to as the alloy's critical temperature or transformation temperature. In the fabrication of a lattice structure of an SMA material intended to change stiffness during operation of the deformable rotor blade 100, the SMA material may be formed to have an operating stiffness (e.g., a first stiffness) below the transition temperature and another stiffness (e.g., a second stiffness) at or above the transition temperature.

[0061] Some shape memory alloys used in this article are characterized by temperature-dependent phase transformations. These phases include martensitic and austenitic phases. Martensitic phases generally refer to the phase at lower temperatures, while austenitic phases generally refer to the phase at higher temperatures. Martensitic phases are generally more easily deformable, while austenitic phases are generally less easily deformable. When a shape memory alloy is in the martensitic phase and is heated above a certain temperature, it begins to transform into the austenitic phase. The temperature at which this phenomenon begins is called the austenitic initiation temperature (As). The temperature at which this phenomenon completes is called the austenitic termination temperature (Af). When a shape memory alloy in the austenitic phase cools, it begins to transform into the martensitic phase. The temperature at which this transformation begins is called the martensitic initiation temperature (Ms). The temperature at which the transformation to the martensitic phase is completed is called the martensitic termination temperature (Mf). As used herein, the term "transformation temperature" without further qualifiers can refer to either the martensitic transformation temperature or the austenitic transformation temperature. In addition, "below the transformation temperature" without the qualifiers "start temperature" or "end temperature" usually refers to a temperature below the martensite end temperature, and "above the transformation temperature" without the qualifiers "start temperature" or "end temperature" usually refers to a temperature above the austenite end temperature.

[0062] In some embodiments, the SMA material may be defined with a first stiffness at a first temperature and a second stiffness at a second temperature, wherein the second temperature is different from the first temperature. Furthermore, in some embodiments, one of the first or second temperature is below the transformation temperature, and the other may be equal to or higher than the transformation temperature. Thus, in some embodiments, the first temperature may be below the transformation temperature and the second temperature may be equal to or higher than the transformation temperature. In other embodiments, the first temperature may be equal to or higher than the transformation temperature and the second temperature may be below the transformation temperature. Moreover, the various SMA materials described herein may be configured to have different first stiffnesses and different second stiffnesses at the same first and second temperatures.

[0063] Non-limiting examples of SMA materials suitable for forming the lattice structure 118 described herein may include nickel-titanium (NiTi) and other nickel-titanium-based alloys, such as nickel-titanium hydrogen fluoride (NiTiHf) and nickel-titanium palladium (NiTiPd). However, it should be understood that other SMA materials may be equally applicable to the present disclosure. For example, in some embodiments, the SMA material may include nickel-aluminum-based alloys, copper-aluminum-nickel alloys, or alloys containing zinc, zirconium, copper, gold, platinum, and / or iron. The alloy composition can be selected to provide the desired stiffness effects for this application, such as, but not limited to, damping capacity, transformation temperature and strain, strain hysteresis, yield strength (of martensitic and austenitic phases), oxidation resistance and hot corrosion resistance, the ability to change shape through repeated cycling, the ability to exhibit unidirectional or bidirectional shape memory effects, and / or many other engineering design criteria. Suitable shape memory alloy compositions that can be used with the embodiments of this disclosure may include, but are not limited to, NiTi, NiTiHf, NiTiPt, NiTiPd, NiTiCu, NiTiNb, NiTiVd, TiNb, CuAlBe, CuZnAl, and some iron-based alloys. In some embodiments, a NiTi alloy with a transformation temperature between 5°C and 150°C is used. The NiTi alloy can transform from austenite to martensite upon cooling.

[0064] Furthermore, SMA materials can also exhibit superelasticity. Superelasticity is typically characterized by recovery from large strains and may involve some dissipation. For example, the martensite and austenite phases of SMA materials can respond to mechanical stress as well as temperature-induced phase transformations. For instance, SMA can be loaded in the austenite phase (i.e., above a certain temperature). Therefore, when a critical stress is reached, the material can begin to transform into the (twinned) martensite phase. With continued loading and assuming isothermal conditions, the (twinned) martensite can begin to detwin, allowing the material to undergo plastic deformation. If unloading occurs before plastic deformation, the martensite can typically transform back into austenite, and the material can recover its original shape by inducing hysteresis.

[0065] Piezoelectric materials can typically be used as piezoelectric actuators, configured to extend or contract based on signals of a defined charge. Therefore, as described herein, a component 120 comprising a lattice structure 118 of a piezoelectric material can typically define an actuator or spring that applies a force or load to change the shape of the deformable portion 114 and / or the deformable rotor blade 100. In various embodiments, the piezoelectric material can include, but is not limited to, piezoelectric crystals, piezoelectric ceramics, or piezoelectric polymers. In various embodiments, the piezoelectric material can include, but is not limited to, lanthanum gallium silicate, gallium orthophosphate, lithium niobate, lithium tantalate, barium titanate, lead titanate, lead zirconate, lead zirconate titanate, potassium niobate, sodium tungstate, Ba₂NaNb₅O₅, and Pb₂KNb₅O₅. 15 Zinc oxide, polyvinylidene fluoride, polyvinylidene fluoride, porous polypropylene, fluoroethylene propylene, polytetrafluoroethylene, porous cyclic olefins, porous polyethylene terephthalate, or combinations thereof.

[0066] Refer again Figure 5 In one embodiment, all components 120 may include one or more deformable materials. For example, all components 120 may be formed from a single deformable material, a combination of deformable materials, or the components may include different deformable materials and / or combinations of deformable materials. In additional or alternative embodiments, a portion of component 120 may include a deformable material, while the remainder of component 120 may not include a deformable material, different deformable materials, or different combinations of deformable materials. As an example, each of the first components 124 may include a deformable material, while the second component 126 may not include a deformable material, and vice versa. In additional or alternative embodiments, a portion or all of each of the first components 124 may include a deformable material, while a portion or all of the second component 126 may include a deformable material.

[0067] Now for reference Figure 6 According to alternative or additional exemplary embodiments of the present disclosure, a schematic diagram of a segment of the lattice structure 118 (constructed as a three-dimensional lattice structure) of the deformable portion 114 is shown. Figure 6 The crystal lattice structure 118 can be constructed in a manner similar to... Figure 5 A two-dimensional lattice structure 118. For example, the lattice structure includes components 120 (e.g., first component 124 and second component 126) interconnected at multiple nodes 122. However, Figure 6 The exemplary lattice structure 118 includes one or more third members 128 oriented to extend along a local z-axis defined perpendicular to the local x-axis and y-axis. Although Figure 6 The exemplary lattice structure 118 is constructed as a grid, but those skilled in the art will understand that this disclosure is equally applicable to additional or alternative three-dimensional lattice structures, including components 120 with similar or different orientations and constructions.

[0068] According to various aspects of this disclosure, Figure 6 The lattice structure 118 shown may include a deformable material. In one embodiment, all components 120 may include a deformable material. For example, all components may be formed of a deformable material. In additional or alternative embodiments, a portion of component 120 may include a deformable material, while the remainder of component 120 may not include a deformable material, including different deformable materials and / or different combinations of deformable materials. As an example, only the first component 120 may include a deformable material, only the second component 126 may include a deformable material, or only the third component 128 may include a deformable material. In additional or alternative embodiments, a portion or all of the first component 120 may include a deformable material, a portion or all of the second component 126 may include a deformable material, and / or a portion or all of the third component 128 may include a deformable material.

[0069] Furthermore, or alternatively, all or a portion of the member 120 contained within the desired plane of the lattice structure 118 may comprise a deformable material. For example, all or a portion of the member 120 within the plane defined by the x and y axes at a location along the z-axis may comprise a deformable material (as described above regarding...). Figure 5 (Generally described). Furthermore, or alternatively, the lattice structure 118 may include a plurality of desired planes of the lattice structure 118, the plurality of desired planes including members 120 having deformable material. For example, all or part of the member 120 within a selected plane defined along the x and y axes at a selected location along the z-axis may include deformable material (as described above regarding...). Figure 5 (General description).

[0070] Although Figure 5 and Figure 6 The embodiments described and illustrated have been referenced to the corresponding lattice structure 118, but those skilled in the art will understand that this disclosure is equally applicable to other suitable two-dimensional and / or three-dimensional structures. For example, in additional or alternative embodiments, the deformable portion of a deformable turbine blade may include a two-dimensional braid comprising elements (e.g., fibers or toes) of deformable material. More specifically, one or more (e.g., some, all) of the elements within such a deformable portion may comprise or be formed of deformable material or a combination of deformable materials. In several embodiments, some or all of the elements aligned in one or more orientations may comprise deformable material, similar to the above description. Figure 5Various embodiments of the described lattice structure 118. In additional or alternative embodiments, the deformable portion of the deformable turbine blade may include a 2.5-dimensional or three-dimensional braid comprising elements (e.g., fibers or toes) of deformable material. More specifically, one or more (e.g., some, all) of the elements within such a deformable portion may comprise or be formed of deformable material. In several embodiments, some or all of the elements aligned in one or more orientations may comprise one or more deformable materials and / or elements within a desired plane of the braid, similar to those described above. Figure 6 Various embodiments of the described lattice structure 118.

[0071] Now for reference Figure 7-10 Embodiments of exemplary lattice structures 118, each comprising a deformable material, are partially illustrated according to various aspects of this disclosure. For example, the illustrated lattice structure 118 may be configured for rotor blades with suitable construction including deformable portions, such as with reference to... Figure 2-4 The deformable rotor blades described are rotor blades constructed in the same or similar manner as the deformable rotor blades 100 described herein. While exemplary lattice structures 118 have been illustrated and described herein, those skilled in the art will understand that this disclosure is equally applicable to alternating orientation lattice structures, such as those described above. Figure 5 and Figure 6 The lattice structure 118 is constructed in the same or similar manner as the lattice structure described above. More specifically, Figure 7 and Figure 9 An embodiment of the corresponding lattice structure 118 in the corresponding first configuration 130 is shown. Figure 8 The second construction 132 is shown. Figure 7 An embodiment of the crystal lattice structure 118, and Figure 10 The second construction 132 is shown. Figure 9 An embodiment of the crystal lattice structure 119.

[0072] Now for special reference Figure 7 and Figure 9 The lattice structures 118 each define a corresponding first configuration 130 (e.g., the length of member 120, the orientation of member 120, the shape of member 120, etc.). Furthermore, at least a portion of the corresponding member 120 includes deformable material in the first configuration 130. Typically, the deformable material of each lattice structure 118 is configured to have the first configuration 130 (e.g., the initial configuration) when not subjected to a specific stimulus (e.g., not subjected to high temperature, electrical signals, specific stress / strain, etc.).

[0073] In some embodiments, the stimulus may include the operating conditions of the associated turbine engine system. Figure 7 and Figure 9The corresponding lattice structure 118 can be configured to have the first configuration 130 shown under conditions at a first point within the corresponding cruise and / or design envelope. In several embodiments, the deformable material of the corresponding lattice structure 118 can, for example, define a corresponding first value of the material properties in the first configuration 130 under the first operating conditions. For example, the material properties can be Young's modulus, stiffness, elasticity, etc. In additional or alternative embodiments, the stimulus can include a first temperature of the corresponding deformable portion 114 and / or the deformable material. For example, the first temperature can be the temperature of the deformable portion 114 of the associated deformable rotor blade 100 at a first point within the cruise and / or design envelope.

[0074] Now for special reference Figure 8 and Figure 10 The lattice structure 118 defines the corresponding second structure 132 (e.g., the length of the member 120, the orientation of the member 120, the shape of the member 120, etc.). Specifically, Figure 8 and Figure 10 The second construction 132 shown is different from Figure 7 and Figure 9 The corresponding first configuration is described above. Furthermore, the deformable material of each lattice structure 118 is configured to change shape in response to a stimulus, for example, to become the second configuration 132. Generally, deformable materials may change shape in response to certain stimuli, as described in more detail above.

[0075] In some embodiments, the stimulus may include the operating conditions of the associated turbine engine system. Figure 8 and Figure 10 The corresponding lattice structure 118 can be configured to have the second configuration 132 shown at a second point within the design envelope at takeoff and / or accordingly. The deformable material of the corresponding lattice structure 118 typically defines a corresponding second value of the material properties in the second configuration 132, for example, under operating conditions. In several embodiments, under operating conditions, the corresponding deformable material may define at least one second value of a material property different from the first material property, e.g., different Young's modulus, stiffness, elasticity, etc. In additional or alternative embodiments, the stimulus may include a second temperature of the corresponding deformable portion 114 and / or the deformable material. For example, the second temperature may be the temperature of the deformable portion 114 of the associated deformable rotor blade 100 at a second point within the design envelope at takeoff and / or accordingly.

[0076] Now for reference Figure 11 According to various aspects of this disclosure, additional or alternative embodiments of the deformable rotor blade 100 are shown. Specifically, Figure 11 An embodiment of a deformable rotor blade 100 for active control is shown. Although Figure 11The embodiment illustrated is a deformable rotor blade 100, wherein the deformable portion 114 is positioned at the tip 112 along the trailing edge 104, but those skilled in the art will understand that the deformable rotor blade 100 may include the deformable portion 144 at various locations, for example, regarding Figure 2-4 At the same or similar locations mentioned above.

[0077] In the depicted embodiment, the deformable rotor blade 100 includes a heating element 134, which is generally configured to change the temperature of the deformable portion 114. For example, the heating element 134 may be configured to set the temperature of the deformable material to a first temperature, a second temperature, or to shift the temperature towards a first temperature, a second temperature, transition between the first and second temperatures, and / or allow temperature regulation of the deformable material at a temperature between the first and second temperatures. Figure 11 In one embodiment, the heating element 134 is positioned within the deformable portion 114. In additional or alternative embodiments, the heating element 134 may be positioned within the remaining portion 116, immediately adjacent to the deformable portion 114, for example, immediately adjacent to the tip 112 and / or trailing edge 104 of the airfoil portion 108. In several embodiments, the heating element 134 may be energized, electrically connected to a power source, or controlled via one or more power lines, connections, links, etc., included in the deformable rotor blade 100; these are omitted for clarity.

[0078] In additional or alternative embodiments, the deformable rotor blades 100 may define one or more fluid channels 136, such as a first fluid channel 138 and a second fluid channel 140, forming a heat exchanger 142 (both within...). Figure 11 (Drawn in dashed lines). Heat exchanger 142 can typically be configured to alter the temperature of deformable section 114. Typically, air from a section of the associated turbine engine system at a pressure higher than that of the deformable rotor blades 100 (e.g., from high-speed compressor 34 and / or later stages of such compressors) can be discharged and used to raise the temperature of deformable section 114. Alternatively, cooler air can be mixed with such higher-pressure air and used to raise, lower, or stabilize the temperature of deformable section 114. Alternatively, such higher-pressure air can be cooled via an auxiliary heat exchanger and used to lower the temperature of deformable section 114. Alternatively, another fluid (e.g., lubricant, fuel, etc.), or a combination thereof, can be pumped, compressed, cooled, expanded to lower the temperature of deformable section 114.

[0079] The heat exchanger 142 may be configured to set the temperature of the deformable material to a first temperature, a second temperature, or to shift the temperature to or from the first temperature to the second temperature, to transition between the first temperature and the second temperature, and / or to allow temperature regulation of the deformable material at a temperature between the first temperature and the second temperature. Each fluid passage 136 includes a fluid inlet 144 for receiving exchanged fluid. Each fluid passage includes an exhaust outlet 146, a fluid return 148, or both.

[0080] exist Figure 11 In an exemplary embodiment, the deformable rotor blade 100 may define a first fluid passage 138. More specifically, the first fluid passage 138 is at least partially defined through the deformable portion 114. In additional or alternative embodiments, the deformable rotor blade 100 may define a second fluid passage 140 within the remaining portion 116, adjacent to the deformable portion 114, such as adjacent to the tip 112 and / or trailing edge 104 of the airfoil portion 108.

[0081] In additional or alternative embodiments, the deformable portion 114 may be configured to change shape based on electrical signals transmitted to the deformable material of the deformable portion 144. For example... Figure 11 As schematically shown in dashed lines, a turbine engine system associated with deformable rotor blade 100 may include a power source 150 electrically connected to deformable portion 114, such as deformable material electrically connected to deformable portion 114. In several embodiments, the deformable material may receive electrical signals via one or more electrical lines, connections, links, etc. (dashed line 152) included in the schematically shown deformable rotor blade 100. For example, stimuli and / or operating conditions may include a first electrical signal, such as a first current transmitted from power source 150. Furthermore, or alternatively, stimuli and / or operating conditions may include a second electrical signal, such as a second current transmitted from power source 150.

[0082] In additional or alternative embodiments, the deformable portion 114 may be configured to change shape based on the blade's movement speed during operation and thus the surface pressure exerted by its immediate environment (e.g., the gas within the region of rotor assembly 12) and in response to centrifugal forces of rotation. For example, the stimulus and / or operating conditions may include a first rotational speed associated with the turbine engine system, such as the rotational speed of the deformable portion of the deformable rotor blade at a first point within the cruise and / or design envelope. Furthermore, or alternatively, the stimulus and / or operating conditions may include a second rotational speed associated with the turbine engine system, such as the rotational speed of the deformable portion of the deformable rotor blade at a second point within the takeoff and / or design envelope.

[0083] Figure 12An example of a shape change at the tip 112 of a deformable portion 114 of a deformable rotor blade 100 according to an exemplary aspect of this disclosure is described. Specifically, dashed lines indicate a first shape, while solid lines indicate changes in shape in response to stimuli and / or changes in the deformable material within the lattice structure included in the deformable portion 114 from a first configuration to a second configuration (e.g., reference to...). Figure 7-10 The second shape (similar variations described in the corresponding first construction 130 and second construction 132).

[0084] Figure 13 yes Figure 12 A close-up view of the trailing edge 104 of the deformable rotor blade 100 shows the shape of the deformable portion 114 varying with an outboard angle θ. For example, in some embodiments, the outboard angle θ of the trailing edge 104 changes as the deformable material changes shape. In these embodiments, the outboard angle θ can vary from about 2 degrees to about 15 degrees. In some embodiments, the outboard angle θ can vary from about 10 degrees. For example, for an aircraft using a turbine engine system employing the deformable rotor blades disclosed herein, a lower outboard angle can provide a greater climb benefit, while a higher outboard angle can provide a greater cruise benefit. The variation in the outboard angle can be generated via one or more stimulus conditions occurring under the corresponding operating conditions.

[0085] In addition, or alternatively, the ratio of the surface area and / or volume of the deformable portion 114 and the remaining portion 116 may be controlled to provide the desired performance of the deformable rotor blade 100 in response to changes in stimuli, as described herein.

[0086] Before changing shape, the initial shape of the airfoil (e.g., airfoil portion 108) can be configured, or even optimized, such that bending loads (or moments) favor inducing deformation of the rotor blade 16 (e.g., a fan blade). For example, the configuration of the lattice structure of the deformable material described herein can be optimized such that in-plane loads from centrifugal forces in response to blade rotation and induced bending moments drive a change in the initial airfoil shape of the airfoil portion and / or deformable portion 114. In the chordal cross-section, the initial shape of the airfoil portion 108 can be a relatively high-curvature monocurved shape, while the deformed shape is a relatively low-curvature monocurved shape.

[0087] Furthermore, as described herein in various embodiments, the deformable rotor blade can respond to stimuli by changing its shape from a more curved C-shape to a less curved C-shape. The shape change occurs in the trailing edge region of the blade or in the leading and trailing edge regions of the blade, and is generally not located in the mid-chord region of the blade. For example, now referring to… Figure 14Top views of exemplary additional or alternative embodiments of the deformable rotor blade 100 are illustrated in accordance with various aspects of this subject matter. As shown, the deformable rotor blade 100 may include deformable portions 114 (e.g., lattice structures comprising deformable materials as described herein) at the leading edge 102 and trailing edge 104.

[0088] In various embodiments, the deformable rotor blade 100, root portion 106, deformable portion 114, and / or remaining portion 116 may comprise at least one of a metallic material (e.g., a metal or metal alloy), a polymeric material, and / or a composite material. In additional or alternative embodiments, Figure 2-4 Each deformable rotor blade 100 can be configured as a composite rotor blade such that at least the remaining portion 116 substantially comprises one or more composite materials. In one or more embodiments, a suitable deformable rotor blade 100 may be configured as a solid having a hollow cavity or having a filled cavity (e.g., filled with a low-density material). Furthermore, or alternatively, each deformable rotor blade 100 may be at least partially formed of a ceramic matrix composite. More specifically, in some embodiments, the corresponding remaining portion 116 and / or deformable portion 114 may be formed of one or more ceramic matrix composite prepreg layers. In additional or alternative embodiments, the corresponding remaining portion 116 and / or deformable portion 114 may be at least partially formed of a ceramic matrix composite braided structure (e.g., a 2D, 3D, or 2.5D braided structure). The composite material may include, but is not limited to, metal matrix composites (MMC), polymer matrix composites (PMC), or ceramic matrix composites (CMC). The composite material, for example, used in the exemplary deformable rotor blade 100, typically comprises a fiber reinforcement embedded in a matrix material, such as a polymer, ceramic, or metallic material. The reinforcing material serves as the load-bearing component of the composite material, while the matrix of the composite material is used to bind the fibers together and acts as a medium through which externally applied stress is transmitted and distributed to the fibers.

[0089] Exemplary CMC materials may include silicon carbide (SiC), silicon, silica, or alumina matrix materials and combinations thereof. Ceramic fibers may be embedded within the matrix, such as oxide-stabilized reinforcing fibers comprising monofilamentary sapphire and silicon carbide (e.g., Textron's SCS-6), and silicon carbide (e.g., Nippon Carbon's...). UbeIndustries and Dow Corning Aluminosilicates (e.g., Nextel's 440 and 480), and chopped whiskers and fibers (e.g., Nextel's 440 and 480). The preform contains rovings and yarns, and optionally ceramic microparticles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite). For example, in some embodiments, fiber bundles that may include a ceramic refractory coating are formed as reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes may be laid together (e.g., as a layup) to form a preform component. The fiber bundles may be impregnated with a slurry composition before or after the preform is formed. The preform may then be subjected to heat treatment, such as curing or burnout, to produce a high coke residue in the preform, and subsequently subjected to chemical treatment, such as infiltration with a silicon melt, to achieve a component formed from a CMC material having the desired chemical composition. In other embodiments, the CMC material may be formed, for example, as carbon fiber cloth instead of tapes.

[0090] Similarly, in various embodiments, the PMC material can be manufactured by impregnating a fabric or unidirectional tape with resin (prepreg) and then curing it. For example, multiple layers of prepreg can be stacked to the appropriate thickness and orientation of the part, and then the resin can be cured and solidified to present a fiber-reinforced composite part. As another example, a mold can be used, on which uncured layers of prepreg can be stacked to form at least a portion of the composite part. The mold can be a closed construction (e.g., compression molding) or an open construction utilizing a vacuum bag. For example, in an open construction, the mold forms one side of the blade (e.g., the pressure side or suction side). The PMC material is placed inside the bag, and the vacuum is used to hold the PMC material on the mold during curing. In other embodiments, the corresponding deformable rotor blade 100 can be at least partially formed via resin transfer molding (RTM), light resin transfer molding (LRTM), vacuum-assisted resin transfer molding (VARTM), molding processes (e.g., thermoforming), or similar methods.

[0091] Before impregnation, the fabric may be referred to as a "dry" fabric and typically comprises a stack of two or more fiber layers (layouts). The fiber layers can be formed from a variety of materials, and non-limiting examples of these materials include carbon (e.g., graphite), glass (e.g., glass fiber), and polymers (e.g., polymers). Fibers and metal fibers. Fiber reinforcement materials can be used in the form of relatively short chopped fibers, typically less than 2 inches in length, more preferably less than 1 inch, or they can be used in the form of long continuous fibers, the latter typically used to produce woven fabrics or unidirectional tapes. Other embodiments may include other textile forms, such as plain weave, twill, or satin.

[0092] In several embodiments, PMC materials can be produced by dispersing dry fibers into a mold and then flowing a matrix material around reinforcing fibers. Resins used for PMC matrix materials are generally classified as thermosetting or thermoplastic resins. Thermoplastic resins are generally classified as polymers that can repeatedly soften and flow when heated and hardened in response to physical rather than chemical changes, upon sufficient cooling. Notable examples of thermoplastic resins include nylon, thermoplastic polyesters, polyaryletherketones (PAEs), and polycarbonate resins. Specific examples of high-performance thermoplastic resins intended for aerospace applications include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), and polyphenylene sulfide (PPS). In contrast, thermosetting resins, once fully cured into a rigid solid, do not soften significantly upon heating but undergo thermal decomposition upon sufficient heating. Notable examples of thermosetting resins include epoxy resins, bismaleimide (BMI), and polyimide resins.

[0093] In additional or alternative embodiments Figure 2-4 Each deformable rotor blade 100 can be configured as a composite rotor blade such that at least the remaining portion 116 substantially comprises one or more metallic materials, such as, but not limited to, steel, titanium, aluminum, nickel, or alloys thereof. For example, in some embodiments, the deformable rotor blade may substantially comprise an aluminum material with one or more titanium additives, such as titanium edge guards. In one or more embodiments, a suitable deformable rotor blade 100, including embodiments in which the deformable rotor blade 100 comprises one or more metallic materials, can be configured as a solid having a hollow cavity or a filled cavity (e.g., filled with a low-density material). Furthermore, in some embodiments, the deformable rotor blade 100 may include a remaining portion comprising multiple materials, may include a substantially monolithic remaining portion, or may include any other combination or construction of materials suitable for the rotor blade application. For example, in some embodiments, the remaining portion 116 may be cast.

[0094] In various embodiments, the corresponding remainder 116 and / or deformable portion 114 may be at least partially made of a polymer (e.g., thermoplastic or thermosetting). However, it should be appreciated that the corresponding remainder 116 and / or deformable portion 114 may be formed of a variety of materials, such as deformable materials, metals, metal alloys, polymers, and / or combinations of composite materials. Furthermore, the corresponding root portion 106 may comprise any of these materials or components thereof.

[0095] In additional or alternative embodiments, the corresponding remaining portion 116 and / or deformable portion 114 may include additive structures. More specifically, in various embodiments, the corresponding deformable portion 114 and associated features and structures described herein can be formed via additive manufacturing (e.g., a 3D printing process). Using such a process allows the deformable rotor blade 100 to be integrally formed as a single integral part or any suitable number of sub-parts. For example, at least one of the deformable portion 114 or the remaining portion 116 can be formed using an additive manufacturing process. Specifically, at least one lattice structure 118 comprising a deformable material can be formed in the corresponding deformable portion 114 via an additive manufacturing process. Forming the corresponding lattice structure comprising a deformable material via additive manufacturing allows the lattice structure to be integrally formed and includes various features that would not be possible using prior manufacturing methods. For example, the additive manufacturing methods described herein are capable of manufacturing the deformable portion 114 and / or the lattice structure 118 comprising one or more deformable materials having any suitable size and shape and one or more configurations, some of which are described herein.

[0096] As used herein, the terms “additive manufacturing,” “additive fabrication,” “additive manufacturing technology or process,” etc., generally refer to a manufacturing process in which consecutive layers of material are provided on one another to “stack” a three-dimensional part layer by layer. Consecutive layers are often fused together to form a monolithic part, which may have multiple integral sub-parts. Although additive manufacturing technology is described herein as the manufacture of complex objects by typically building objects point-by-point, layer-by-layer in a vertical direction, other manufacturing methods are possible and within the scope of this subject matter. For example, although the discussion herein involves adding material to form consecutive layers, those skilled in the art will understand that the methods and structures disclosed herein can be implemented with any additive manufacturing technology or manufacturing process. For example, embodiments of this disclosure may use additive, subtractive, or hybrid processes.

[0097] Suitable additive manufacturing techniques according to this disclosure include, for example, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing (e.g., by inkjet and laser jetting), stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net-shape (LENS), laser net-shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM), and other known processes.

[0098] In addition to using direct metal laser sintering (DMLS) or direct metal laser melting (DMLM) processes (where an energy source is used to selectively sinter or melt portions of the powder layer), it should be recognized that, according to alternative embodiments, the additive manufacturing process can be a "binder jetting" process. In this respect, binder jetting involves the continuous deposition of additive powder layers in a manner similar to that described above. However, instead of using an energy source to generate an energy beam to selectively melt or fuse the additive powder, binder jetting involves selectively depositing a liquid binder onto each powder layer. The liquid binder can be, for example, a photocurable polymer or other liquid binder. Other suitable additive manufacturing methods and variations are intended to be within the scope of this subject matter.

[0099] The additive manufacturing process described herein can be used to form parts using any suitable material. For example, the material can be the deformable material described herein, plastic, metal, concrete, ceramic, polymer, epoxy resin, photopolymer resin, or any other suitable material that can be solid, liquid, powder, sheet, wire, or any other suitable form. More specifically, according to exemplary embodiments of this subject matter, the additively manufactured parts described herein can be formed in part, in whole, or in certain combinations of materials, including but not limited to pure metals, nickel alloys, chromium alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, ferroalloys, stainless steel, and nickel or cobalt-based superalloys (e.g., those provided by Special Metals Corporation). (Those that are named). These materials are examples of materials applicable to the additive manufacturing process described herein and may generally be referred to as "additive materials".

[0100] Furthermore, those skilled in the art will recognize that a variety of materials and methods for bonding these materials can be used and are contemplated within the scope of this disclosure. As used herein, reference to “fusion” can refer to any suitable process used to create a bonded layer of any of the aforementioned materials. For example, if the object is made of a polymer, fusion can refer to the formation of a thermosetting bond between polymeric materials. If the object is an epoxy resin, the bond can be formed through a crosslinking process. If the material is ceramic, the bond can be formed through a sintering process. If the material is a powdered metal, the bond can be formed through a melting or sintering process. Those skilled in the art will understand that other methods are possible for manufacturing parts by additive manufacturing of fused materials, and these methods can be used to practice the subject matter of this disclosure.

[0101] Furthermore, the additive manufacturing processes disclosed herein allow for the formation of a single part from multiple materials. Therefore, the parts described herein can be formed from any suitable mixture of the aforementioned materials. For example, a part may comprise multiple layers, segments, or parts formed using different materials, processes, and / or on different additive manufacturing machines. In this way, parts with different materials and material properties can be constructed to meet the needs of any particular application. Moreover, although the parts described herein can be constructed entirely by additive manufacturing processes, it should be recognized that, in alternative embodiments, all or part of these parts may be formed via casting, machining, and / or any other suitable manufacturing process. In fact, any suitable combination of materials and manufacturing methods can be used to form these parts.

[0102] An exemplary additive manufacturing process will now be described. The additive manufacturing process uses three-dimensional (3D) information about a part, such as a 3D computer model, to manufacture the part. Therefore, a 3D design model of the part can be defined prior to manufacturing. In this regard, a model or prototype of the part can be scanned to determine the 3D information of the part. As another example, a model of the part can be constructed using a suitable computer-aided design (CAD) program to define the 3D design model of the part.

[0103] The design model may include 3D digital coordinates of the entire construction of a component, including its outer and inner surfaces. For example, the design model may define a corresponding deformable rotor blade 100, airfoil portion 108, deformable portion 114, remaining portion 116, lattice structure 118 including deformable material, and / or internal channels, openings, support structures, etc. In one exemplary embodiment, the three-dimensional design model is converted into multiple slices or segments, for example, along the component's central (e.g., vertical) axis or any other suitable axis. Each slice may define a thin cross-section of the component for a predetermined slice height. Multiple consecutive cross-sectional slices together form a 3D component. The component is then "stacked" slice by slice or layer by layer until completion.

[0104] In this way, the parts described herein can be manufactured using additive manufacturing processes, or more specifically, by fusing or polymerizing plastics using laser energy or heat, or by sintering or melting metal powders, forming each layer sequentially. For example, certain types of additive manufacturing processes may use energy beams, such as electron beams, or electromagnetic radiation (e.g., laser beams), to sinter or melt powder materials. Any suitable laser and laser parameters can be used, including considerations regarding power, laser beam spot size, and scanning speed. The building material can be formed from any suitable powder or material selected to enhance strength, durability, and service life (especially at high temperatures).

[0105] For example, each continuous layer can be between approximately 10 μm and 200 μm, but the thickness can be selected based on any number of parameters and, according to alternative embodiments, can be any suitable size. Thus, using the additive forming method described above, the component described herein can have a cross-section as thin as the associated powder layer used during the additive forming process (e.g., 10 μm).

[0106] While this disclosure is generally not limited to using additive manufacturing to form these components, additive manufacturing does offer several manufacturing advantages, including ease of manufacture, reduced costs, and increased precision. In this regard, even multi-part components can be formed as a single piece of continuous metal using additive manufacturing methods, and therefore can contain fewer sub-parts and / or joints compared to previous designs. Forming these multi-part components integrally using additive manufacturing can advantageously improve the overall assembly process. For example, integral formation reduces the number of individual parts that must be assembled, thereby reducing associated time and overall assembly costs. Furthermore, existing problems such as leakage, joint quality between individual parts, and overall performance may be advantageously reduced.

[0107] Furthermore, the additive manufacturing method described above enables more complex and intricate shapes and profiles of the example deformable rotor blade 100 described herein. For example, such components may include thin additively manufactured layers and unique internal structures, such as lattice structures, for instance, lattice structures formed from deformable materials. Moreover, the additive manufacturing process can produce individual components with different materials, allowing different parts of the component to exhibit different performance characteristics. The continuity and additive nature of the manufacturing process enable the construction of these novel features. Therefore, the various deformable rotor blades 100 described herein can exhibit improved performance and reliability.

[0108] This written description uses examples to illustrate various embodiments, including best practices, and also enables any person skilled in the art to practice this disclosure, including making and using any device or system and methods of making any combination. The patent scope of this disclosure is defined by the claims, but may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

[0109] Further details are provided by the following topics:

[0110] A deformable rotor blade for a turbine engine system includes: a root portion; and an airfoil portion comprising a deformable part comprising a deformable material that changes shape in response to a stimulus.

[0111] The deformable rotor blade according to any clause herein, wherein the deformable material includes shape memory alloys.

[0112] The deformable rotor blade according to any clause herein, wherein the deformable material includes a piezoelectric material.

[0113] The deformable rotor blade as described in any of the clauses herein, wherein the stimulus includes a temperature stimulus.

[0114] The deformable rotor blade according to any of the clauses herein further includes a heating element configured to change the temperature of the deformable portion.

[0115] The deformable rotor blade according to any item herein includes a fluid channel located within the deformable rotor blade, such that fluid flowing through the fluid channel can change the temperature of the deformable portion.

[0116] The deformable rotor blade according to any clause herein, wherein the fluid passage extends through the root portion.

[0117] The deformable rotor blade as described in any of the clauses herein, wherein the stimulus comprises an electrical signal.

[0118] The deformable rotor blade according to any clause herein, wherein at least a portion of the trailing edge comprises the deformable portion.

[0119] The deformable rotor blade according to any clause herein, wherein the deformable portion comprises a lattice structure containing the deformable material, and wherein the lattice structure changes shape in response to the stimulus.

[0120] According to any of the clauses herein, the deformable rotor blades, wherein the trailing edge inclination changes in a manner as the deformable material changes shape.

[0121] According to any of the clauses herein, the deformable rotor blades, wherein the outward tilt angle varies from about 2 degrees to about 15 degrees.

[0122] The deformable rotor blade according to any item herein comprises a composite material.

[0123] The deformable rotor blade described in any of the clauses herein is a fan blade.

[0124] A turbine engine system includes: a compressor section, a combustion section, and a turbine section, an axially extending shaft through the compressor section, the combustion section, and the turbine section, and a rotor assembly including a plurality of rotor blades, at least one of the plurality of rotor blades including: a root portion; and an airfoil portion including a deformable portion comprising a deformable material that changes shape in response to a stimulus.

[0125] According to any item in this document, the turbine engine system wherein the stimulus includes the rotational speed of the rotor assembly.

[0126] According to any item herein, in a turbine engine system, at least one of the plurality of rotor blades includes a fluid passage located within the at least one of the plurality of rotor blades, such that fluid flowing through the fluid passage can change the temperature of the deformable portion.

[0127] According to any item in this document, the turbine engine system wherein the fluid passage extends through the root portion and is fluidly connected to the compressor section.

[0128] According to any item in this document, the turbine engine system, wherein the stimulus includes an electrical signal.

[0129] The turbine engine system described in any of the clauses herein includes a power source configured to generate the electrical signal.

Claims

1. A morphing rotor blade for a turbine engine system, characterized by, including: a root portion; and an airfoil portion extending from the root portion to a tip of the transformable rotor blade, the tip being an edge furthest in a spanwise direction from the root portion, the airfoil portion including a transformable portion disposed at the tip and a remaining portion free of transformable material, the transformable portion including the transformable material, the transformable material changing shape in response to a stimulus to change a shape of the airfoil portion; wherein the remaining portion extends from the root portion to the tip.

2. A morphing rotor blade according to claim 1, wherein, wherein, the transformable material includes a shape memory alloy.

3. The morphing rotor blade of claim 1, wherein, wherein, the transformable material includes a piezoelectric material.

4. The morphing rotor blade of claim 1, wherein, wherein, the stimulus includes a temperature stimulus.

5. A morphing rotor blade according to claim 4, wherein, further comprising a heating element configured to change a temperature of the transformable portion.

6. The morphing rotor blade of claim 4, wherein, wherein, the transformable rotor blade includes a fluid passage within the transformable rotor blade such that a fluid flowing through the fluid passage is capable of changing the temperature of the transformable portion.

7. A morphing rotor blade according to claim 6, wherein, wherein, the fluid passage extends through the root portion.

8. The morphing rotor blade of claim 1, wherein, wherein, the stimulus includes an electrical signal.

9. The morphing rotor blade of claim 1, wherein, wherein, at least a portion of a trailing edge includes the transformable portion.

10. The morphing rotor blade of claim 1, wherein, wherein, the transformable portion includes a lattice structure including the transformable material, and wherein the lattice structure changes shape in response to the stimulus.

11. The morphing rotor blade of claim 1, wherein, wherein, a dihedral angle of a trailing edge changes when the transformable material changes shape.

12. A morphing rotor blade according to claim 11, wherein, wherein, the dihedral angle changes by 2 degrees to 15 degrees.

13. The morphing rotor blade of claim 1, wherein, wherein, the transformable rotor blade includes a composite material.

14. The morphing rotor blade of claim 1, wherein, wherein, the transformable rotor blade is a fan blade.

15. A turbine engine system characterized by, including: a compressor section, a combustion section, and a turbine section, a shaft extending axially through the compressor section, the combustion section, and the turbine section, and a rotor assembly including a plurality of rotor blades, at least one rotor blade of the plurality of rotor blades including: a root portion; and an airfoil portion extending from the root portion to a tip of the at least one rotor blade of the plurality of rotor blades, the tip being an edge furthest in a spanwise direction from the root portion, the airfoil portion including a transformable portion disposed at the tip and a remaining portion free of transformable material, the transformable portion including the transformable material, the transformable material changing shape in response to a stimulus to change a shape of the airfoil portion; wherein the remaining portion extends from the root portion to the tip.

16. The turbine engine system of claim 15, wherein, wherein, the stimulus includes a rotational speed of the rotor assembly.

17. The turbine engine system of claim 15, wherein, wherein, the at least one rotor blade of the plurality of rotor blades includes a fluid passage within the at least one rotor blade of the plurality of rotor blades such that a fluid flowing through the fluid passage is capable of changing a temperature of the transformable portion.

18. The turbine engine system of claim 17, wherein, wherein, the fluid passage extends through the root portion and is in fluid connection with the compressor section.

19. The turbine engine system of claim 15, wherein, wherein, the stimulus includes an electrical signal.

20. The turbine engine system of claim 19, wherein, wherein, the turbine engine system includes a power source configured to generate the electrical signal.

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