Engine component with abradable material and handling portion

Abstract

An engine component having a wearable material and a treatment portion is disclosed herein. An example engine component includes a base having a first thickness and defining at least a first base surface, the base extending in an axial direction; a wearable material on the first base surface, the wearable material defining a first wear material surface, a second wear material radially spaced apart from the first wear material surface and defining a second thickness; and a treatment portion extending from the first wear material surface through at least a portion of the first thickness of the base.

Description

Technical Field

[0001] This disclosure generally relates to turbine engines, and more specifically, to an engine component having abrasive material and a processing section. Background Technology

[0002] Turbine engines are one of the most widely used power generation technologies, commonly used in aircraft and power generation applications. A turbine engine typically comprises a fan and a core arranged in a flow-through manner. The turbine engine core typically includes a compressor section, a combustion section, a turbine section located on the same axis as the compressor section, and an exhaust section, all in series flow. A casing or outer shell usually surrounds the turbine engine core. Similarly, the same or separate casing or outer shell typically surrounds the fan. Turbine engines operate by drawing in air through the front of the turbine engine, which has a fan, and forcing the air through the various sections of the core. Attached Figure Description

[0003] Figure 1 This is a schematic cross-sectional view of an example gas turbine engine in which the examples disclosed herein may be implemented.

[0004] Figure 2 This is a schematic cross-sectional view of an example high-pressure compressor section of another example turbine engine.

[0005] Figure 3 This is a partial circumferential view of an example hybrid housing having abrasive material and a processing section, in accordance with the teachings of this disclosure.

[0006] Figure 4 yes Figure 3 A partial side view of an example hybrid housing.

[0007] Figure 5 This is a partial side view of another example of a hybrid housing having abrasive material and a processing section in accordance with the teachings of this disclosure.

[0008] Figure 6 This is a flowchart of an example method for manufacturing a hybrid engine component having abrasive material and a processing section according to the teachings of this disclosure.

[0009] These figures are not drawn to scale. Instead, the thickness of layers or regions may be enlarged in the figures. While the figures show layers and regions with sharp lines and boundaries, these lines and / or boundaries, in part or all, may be idealized. In reality, boundaries and / or lines may be imperceptible, mixed, and / or irregular. Generally, the same reference numerals will be used throughout the figures and the accompanying written description to refer to the same or similar parts. As used herein, unless otherwise stated, the term “above” refers to the relationship between two parts relative to the ground. If at least part of the second part is between the ground and the first part, then the first part is above the second part. Similarly, as used herein, when the first part is closer to the ground than the second part, the first part is “below” the second part. As stated above, the first part may be above or below the second part, with one or more of the following in between: there are other parts between them, there are no other parts between them, the first part and the second part are in contact, or the first part and the second part are not in direct contact with each other. As used herein, a statement that any part (e.g., layer, film, region, area, or plate) is located on (e.g., positioned on, situated on, arranged on, or formed on, etc.) another part in any manner indicates that the referenced part is either in contact with the other part or is above the other part, and one or more intermediate parts are located between them. As used herein, a connection reference (e.g., attachment, coupling, connection, and joining) can include intermediate members between sets of elements and relative movement between elements, unless otherwise stated. Therefore, a connection reference does not necessarily imply that two elements are directly connected and have a fixed relationship with each other. As used herein, a statement that any part is “in contact” with another part means that there is no intermediate part between the two parts.

[0010] Unless otherwise expressly stated, this document uses descriptors such as “first,” “second,” and “third” without assigning or otherwise indicating any meaning of priority, physical order, arrangement in a list, and / or any order, but only as labels and / or arbitrary names to distinguish elements for the purpose of understanding the disclosed examples. In some examples, the descriptor “first” may be used to refer to an element in the detailed description, while different descriptors (e.g., “second” or “third”) may be used in the claims to refer to the same element. In such cases, it should be understood that the use of such descriptors is merely for the purpose of distinguishing elements that, for example, otherwise share the same name.

[0011] As used herein, approximate language is applied to modify any quantitative expressions that may allow for variation without altering the underlying functionality associated with them. Therefore, values ​​modified by one or more terms such as “approximately,” “about,” and “substantially” are not limited to the specified precise values. In some examples used herein, the term “substantially” is used to describe a relationship between two parts that is within three degrees of said relationship (e.g., a substantially collinear relationship within three degrees of linearity, a substantially perpendicular relationship within three degrees of verticality, a substantially parallel relationship within three degrees of parallelism, etc.). As used herein, dimensions (e.g., thickness, depth, etc.) are substantially equal if they have measurements that vary within 10% of the average measured value of the dimension.

[0012] The terms "upstream" and "downstream" refer to the relative directions of fluid flow within a fluid flow path. For example, "upstream" refers to the direction from which fluid flows, and "downstream" refers to the direction towards which fluid flows. Various terms are used herein to describe the curves of the features. Typically, figures are annotated with reference to the axial, radial, and circumferential directions of the vehicle associated with the features, forces, and moments. Typically, figures are annotated with a set of axes, including axial axis A, radial axis R, and circumferential axis C.

[0013] In the following detailed description, reference is made to the accompanying drawings, which form a part thereof, in which specific examples that may be implemented are shown by way of illustration. These examples are described in sufficient detail to enable those skilled in the art to practice the subject matter, and it should be understood that other examples may be used. Therefore, the following detailed description is provided to describe exemplary embodiments and should not be construed as limiting the scope of the subject matter described in this disclosure. Certain features from different aspects of the following description may be combined to form new aspects of the subject matter discussed below. Detailed Implementation

[0014] A turbine engine, also referred to herein as a gas turbine engine, is an internal combustion engine that uses the atmosphere as the moving fluid. In operation, the atmosphere enters through the front of the turbine engine, which has a fan, and is fed into the compressor. The compressor section of the turbine engine is responsible for efficiently supplying a sufficient amount of compressed air to the downstream section of the core. As atmospheric air flows through the compressor section, one or more compressors (e.g., axial compressors, centrifugal compressors, etc.) gradually compress the air until it reaches the combustion section.

[0015] Turbine engine compressors typically consist of a series of continuously flowing compressor stages. However, some turbine engine compressors comprise a single compressor stage. A compressor stage comprises a rotor hub (e.g., also referred to as a rotor, hub, etc.) with arrayed rotor blades and a stator with corresponding stator blades. As disclosed herein, blades may refer to rotor blades and / or stator blades. For example, the hub may be concentrically positioned about a longitudinal axis and coaxially positioned along the longitudinal axis. As the rotor hub rotates at high speed, the rotor blades rotate and drive air downstream through the individual compressor stages. As the air flows through the compressor, the successive compressor stages further compress the air. Because the compressor does work on the airflow against a pressure gradient (e.g., the air is forced to flow towards a high-pressure region), the compressor is prone to instability problems.

[0016] As described above, at least one housing typically surrounds a section of the turbine engine. The area between the housing and the hub defines the flow path of airflow through the turbine engine. The housing is subjected to various loads, such as thermal loads, pressure loads, and mechanical loads, all of which affect the tip clearance. As disclosed herein, tip clearance refers to the distance between the tip of a blade (e.g., rotating blades such as compressor rotor blades, fan rotor blades, etc., and / or stator blades) and another engine component located at the blade tip (e.g., housing, hub, etc.). Over a period of engine operation, the tip clearance changes due to rotor and housing growth, for example, by the rotational speed of the rotor and the thermal expansion of the rotating components and housing. During turbine engine operation, the tip clearance transitions between relatively large and relatively small clearances, which negatively impacts compressor operability and stability, increases transient losses in component efficiency, and increases the tendency for tip friction. In some cases, for example, the tip clearance between the blade and engine component is essentially nonexistent. In such examples, the blade may rub against the engine component, thereby damaging the engine component and / or damaging the blade tip. In some cases, a relatively large tip clearance can lead to tip leakage flow. As disclosed herein, tip leakage flow refers to airflow loss in the housing region associated with rotor blades and / or in the hub region associated with stator blades.

[0017] Due to the interaction of tip leakage flow with the mainstream flow and other secondary flows, the airflow field in the tip regions of a compressor (e.g., rotor blade tip regions and / or stator blade tip regions) is relatively complex. These interactions can lead to reduced efficiency and negatively impact compressor stability. For example, tip leakage can cause compressor instability, such as stall and surge. Compressor stall is an abnormal airflow condition caused by aerodynamic stall of the rotor blades within the compressor. Compressor stall causes the air flowing through the compressor to slow down or stagnate. In some cases, interruption of airflow through each stage of the compressor can lead to compressor surge. Compressor surge refers to a stall that results in a complete interruption of airflow through the compressor. The operating range of a compressor can be characterized by its stall margin. The compressor stall margin is defined as the difference between the operating revolutions per minute (RPM) of the compressor rotor blades and the RPM at which the compressor rotor blades stall at a given height. The determinants of the stall margin, more generally, are the aerodynamic performance of the compressor contained in the region of the compressor at the blade tips (e.g., the tip region).

[0018] Geometric modifications to engine components (e.g., housings, hubs, etc.), such as treatment sections (e.g., housing treatment sections), can be integrated to improve airflow quality through a turbine engine while minimizing the impact on efficiency. As disclosed herein, a treatment section is a groove (e.g., slot, cavity, etc.) manufactured into the surface of a component (e.g., the inner surface of a rotor housing (e.g., compressor housing, fan housing, etc.) and / or the outer surface of a hub (e.g., compressor hub, fan hub, etc.)). In some examples, the treatment section is manufactured in the inner surface of the housing near the tip region. In some examples, the treatment section is manufactured in the outer surface of the hub near the stator blade tip. This treatment section can reduce airflow obstruction in the tip region and can allow airflow to recirculate within the treatment section before being reinjected into the main flow path.

[0019] The processing unit can be integrated into the compressor housing, fan housing, and / or hub to improve the compressor's operating range and stability. Specifically, the processing unit can increase the compressor's aerodynamic operability by increasing the stall margin. However, the processing unit cannot manage tip clearance. When the tip clearance is large, tip flow leakage may continue. Furthermore, the processing unit does not prevent rotor blade tips and / or stator blade tips from rubbing against corresponding engine components (e.g., housing and / or hub), thereby damaging engine components and / or blades. Therefore, a new engine component is needed for turbine engines.

[0020] The examples disclosed herein enable the manufacture of example hybrid engine components having abrasive material and a processing section. In the examples disclosed herein, the hybrid engine component includes a substrate having at least a first surface. In some examples, the substrate is manufactured using die casting. However, other suitable techniques, such as additive manufacturing techniques, can be used. In the examples disclosed herein, the hybrid engine component includes an abrasive material coated on the first surface of the substrate and a processing section manufactured into the first surface of the substrate having the abrasive material.

[0021] In some examples disclosed herein, the hybrid engine component is a housing and may surround a portion of a turbine engine having a rotor hub and rotor blades, such as a compressor section, fan section, and / or turbine section. In such examples, the substrate has a second surface radially spaced from an inner surface. The first surface is the inner surface of the substrate, which is radially spaced inward from a second (e.g., outer) surface of the substrate. The rotor blades may have a leading edge and a trailing edge, the leading edge being the upstream edge of the blade where it first encounters the oncoming airflow, and the trailing edge being the downstream edge of the blade. In some examples, the abrasive material is thicker near the leading edge of the rotor blade. For example, the abrasive material may be thicker near a region of the housing where it interacts with the leading edge of the rotor blade to help minimize tip clearance near the leading edge. In some examples, a treatment section is fabricated at the leading edge of the rotor blade. In some examples, the treatment section extends upstream of the leading edge of the rotor.

[0022] In some examples disclosed herein, the hybrid engine component is a hub and may be surrounded by a portion of a turbine engine (such as a compressor section) having a stator and stator blades. In such examples, the first surface is the outermost surface of the substrate. In some such examples, the abrasive material has a constant thickness. In some examples, the thickness of the abrasive material may vary along the region of the hub where the stator blades are located.

[0023] In the examples disclosed herein, an abrasive material is applied to a first surface of an engine component. In some examples, the abrasive material is thermally sprayed onto the first surface of the engine component. However, any suitable technique can be used to additionally or optionally apply the abrasive material, including electron beam physical vapor deposition (EBPVD), etc. In some examples, the abrasive material is made of nickel-graphite. However, the abrasive material can be any suitable abrasive material, including cobalt-nickel-chromium-aluminum-yttrium (CoNiCrAlY), etc. In the examples disclosed herein, blades can rub against the abrasive material, thereby abrading the abrasive material coating. In some examples, the abrasive material helps minimize or otherwise reduce tip clearance by allowing the blade tip to rub against the abrasive material coating. In some examples, the abrasive material prevents damage to the blade tip when it rubs against the abrasive material coating. Therefore, the hybrid engine component disclosed herein can help minimize or otherwise reduce tip clearance and / or prevent damage to the blade tip.

[0024] In the examples disclosed herein, the treatment portion is machined and / or otherwise manufactured into the abrasive material and engine component. The treatment portion may include one or more recesses that are radially recessed into the abrasive material and engine component. In some examples, the treatment portion manufactured into the abrasive material and the substrate are aligned and collinear. In some examples, the treatment portion may be manufactured simultaneously in the abrasive material and the engine component. Any suitable method for manufacturing the treatment portion can be used, including subtractive manufacturing processes such as milling, drilling, chemical treatment, etc.

[0025] Some examples disclosed herein improve the efficiency and operability of turbine engines by integrating hybrid engine components with wearable portions (e.g., wearable coatings) and treatment portions (e.g., treatment portions, casing treatment portions, etc.). Some examples improve tip clearance management between the first surface of an engine component and the blade tip by applying a wearable material coating to the first surface of the engine component. In some examples, the wearable material reduces the tip clearance, thereby improving airflow through the turbine engine. In some examples, if the tip rubs against the engine component, the wearable material protects the blade tip from damage because the wearable material coating would be worn away. Some examples improve the aerodynamic performance of turbine engines by fabricating treatment portions on engine components with wearable material coatings. For example, fabricating treatment portions can improve the stall margin of a turbine engine, thus providing aerodynamic benefits. Therefore, some examples disclosed herein improve tip clearance management and extend stall margin with minimal efficiency loss.

[0026] The examples disclosed below are described with reference to a hybrid engine component as a housing (e.g., a hybrid housing). It should be understood that the examples of hybrid housings with abrasive material and treatment sections disclosed herein can be additionally or optionally applied to a turbine engine hub (e.g., a hybrid hub). For example, the hub may include an abrasive material coated on a first surface of the hub. The abrasive material may be applied to the first (e.g., outermost) surface of the hub in a region near the stator blades. The examples of abrasive material disclosed herein with respect to the hybrid housing may be additionally or optionally applied to the first surface of the hub. Furthermore, treatment sections may be machined onto the first surface of the hub having an abrasive material coating. The examples of treatment sections disclosed herein with respect to the hybrid housing may be additionally or optionally applied to the first surface of the hub. Similarly, the benefits and / or advantages of a hybrid housing may also be the benefits and / or advantages of a hybrid hub.

[0027] The examples disclosed herein are discussed in conjunction with hybrid engine components (e.g., hybrid housings) having abrasive materials and handling sections for the various stages of the compressor. Additionally or alternatively, hybrid engine components with abrasive materials and handling sections as disclosed herein can be applied to other sections of a turbofan engine, including fan sections (e.g., single-stage fans, multi-stage fans, open rotor / ductless fans, etc.) and turbine sections. Although the examples disclosed herein are discussed in conjunction with turbofan jet engines, it should be understood that the examples disclosed herein can be implemented in conjunction with turbojet engines, turboprop jet engines, gas turbines for power generation, or any other suitable application. Furthermore, it should be understood that the examples disclosed herein can be implemented with turbofan engines having gear structures, having more than two shafts, including multiple spools, etc.

[0028] Referring now to the accompanying drawings, where the same numbers throughout the drawings denote the same elements. Figure 1 This is a schematic cross-sectional view of an example high-bypass turbofan gas turbine engine 110 (“turbofan engine 110”). Although the example shown is a high-bypass turbofan engine, the principles of this disclosure are also applicable to other types of engines, such as low-bypass turbofan engines, turbojet engines, turboprop engines, etc. Figure 1 As shown, the turbofan engine 110 defines a longitudinal or axial centerline axis 112 extending through it for reference. Figure 1 It also includes annotated direction diagrams for the axial direction A, radial direction R, and circumferential direction C. Generally, as used herein, the axial direction A is a direction extending approximately parallel to the centerline axis 112, the radial direction R is a direction extending orthogonally outward from the centerline axis 112, and the circumferential direction C is a direction extending concentrically around the centerline axis 112.

[0029] Generally, the turbofan engine 110 includes a core turbine 114 located downstream of the fan section 116. The core turbine 114 includes a generally tubular housing 118 defining an annular inlet 120. The housing 118 may be formed from a single housing or multiple housings. The housing 118 surrounds, in series flow relationship, a compressor section having a supercharger or low-pressure compressor 122 (“LP compressor 122”) and a high-pressure compressor 124 (“HP compressor 124”), a combustion section 126, a turbine section having a high-pressure turbine 128 (“HP turbine 128”) and a low-pressure turbine 130 (“LP turbine 130”), and an exhaust section 132. A high-pressure shaft or spool 134 (“HP shaft 134”) drives the HP turbine 128 and the HP compressor 124. A low-pressure shaft or spool 136 (“LP shaft 136”) drives the LP turbine 130 and the LP compressor 122. The LP shaft 136 can also be coupled to the fan spool or fan shaft 138 of the fan section 116. In some examples, the LP shaft 136 is directly coupled to the fan shaft 138 (e.g., direct drive configuration). In an optional configuration, the LP shaft 136 may be coupled to the fan shaft 138 via a reduction gearbox 139 (e.g., indirect drive or gear drive configuration).

[0030] like Figure 1 As shown, fan section 116 includes a plurality of fan blades 140 coupled to and extending radially outward from fan shaft 138. An annular fan housing or nacelle 142 circumferentially surrounds at least a portion of fan section 116 and / or nacelle 142. Nacelle 142 may be supported relative to core turbine 114 by a plurality of circumferentially spaced outlet guide vanes 144. Furthermore, a downstream section 146 of nacelle 142 may surround an external portion of core turbine 114 to define a bypass airflow passage 148 therebetween.

[0031] like Figure 1 As shown, air 150 enters its inlet section 152 during operation of the turbofan engine 110. A first portion 154 of the air 150 flows into a bypass airflow passage 148, while a second portion 156 of the air 150 flows into the annular inlet 120 of the LP compressor 122. One or more successive stages of the LP compressor stator blades 170 and LP compressor rotor blades 172, coupled to the LP shaft 136, progressively compress the second portion 156 of the air 150 flowing through the LP compressor 122 and reaching the HP compressor 124. Subsequently, one or more successive stages of the HP compressor stator blades 174 and HP compressor rotor blades 176, coupled to the HP shaft 134, further compress the second portion 156 of the air 150 flowing through the HP compressor 124. This provides compressed air 158 to the combustion section 126, where it mixes with fuel and burns to provide combustion gases 160.

[0032] Combustion gas 160 flows through HP turbine 128, where one or more sequential stages of HP turbine stator blades 166 and HP turbine rotor blades 168, coupled to HP shaft 134, extract a first portion of kinetic and / or thermal energy. This energy extraction supports the operation of HP compressor 124. Combustion gas 160 then flows through LP turbine 130, where one or more successive stages of LP turbine stator blades 162 and LP turbine rotor blades 164, coupled to LP shaft 136, extract a second portion of thermal and / or kinetic energy. This energy extraction causes LP shaft 136 to rotate, thereby supporting the operation of LP compressor 122 and / or the rotation of fan shaft 138. Combustion gas 160 then exits core turbine 114 through its exhaust section 132. Turbine frame 161 with a cowling assembly is located between HP turbine 128 and LP turbine 130. Turbine frame 161 serves as a support structure, connecting the rear bearing of the high-pressure shaft to the turbine housing and forming an aerodynamic transition duct between HP turbine 128 and LP turbine 130. The fairing forms the flow path between the high-pressure and low-pressure turbines and can be formed using metal castings (e.g., nickel-based cast metal alloys).

[0033] Together with turbofan engine 110, core turbine 114 serves a similar purpose and is exposed to a similar environment to that of land-based gas turbines and turbojet engines, wherein the ratio of the first portion 154 of air 150 to the second portion 156 of air 150 is less than that in turbofan and ductless fan engines (where fan section 116 has no nacelle 142). In each turbofan, turbojet, and ductless engine, a reduction gear (e.g., reduction gearbox 139) may be included between any shaft and spool. For example, reduction gearbox 139 is disposed between LP shaft 136 and fan shaft 138 of fan section 116.

[0034] As mentioned above Figure 1 The turbine frame 161 is located between the HP turbine 128 and the LP turbine 130 to connect the rear bearing of the high-pressure shaft to the turbine housing and to form an aerodynamic transition duct between the high-pressure turbine 128 and the low-pressure turbine 130. Therefore, air flows through the turbine frame 161 between the HP turbine 128 and the LP turbine 130.

[0035] Figure 2This is a schematic cross-sectional view of an example high-pressure compressor (e.g., an HP compressor) 200 of another example turbine engine above an axial centerline (e.g., centerline axis 112). In some examples, the turbine engine may include additional compressor sections, such as another high-pressure compressor section, a low-pressure compressor section, etc. As mentioned above, the task of the compressor is to compress a sufficient amount of atmosphere for the downstream section of the turbine engine. Therefore, the HP compressor 200 should operate as efficiently as possible to provide sufficient compressed air for the operation of the turbine engine.

[0036] Figure 2 The HP compressor 200 includes example rotor blades 202, example stator blades 204, example HP compressor housing 206, and example HP compressor hub (e.g., wheel hub) 207. The rotor blades 202 are circumferentially spaced around the hub 207 and extend radially outward toward the HP compressor housing 206. In operation, the rotor blades 202 rotate in the circumferential direction. Figure 2 An example HP compressor housing (e.g., housing) 206 includes an annular base having an outer annular base surface and an inner annular base surface (e.g., an inner surface). In the illustrated example, the inner surface is an example first surface 208 that varies in radius along the axial direction and is radially inwardly inclined along the axial direction. In additional or optional examples, housing 206 may be radially outwardly inclined along the axial direction and / or may maintain a constant radius along the axial direction. In the illustrated example, hub 207 is defined by an annular base having an outer annular surface (e.g., an outer surface). In the illustrated example, the outer surface is an example first surface 209.

[0037] Example rotor blade tip region 210 is shown at example rotor blade tip 212 in the region of housing 206. Example stator blade tip region 211 is shown at example stator blade tip 213 in the region of hub 207. In operation, housing 206 experiences significant loads affecting the tip clearance via the affected tip regions 210, 211, and more specifically. Figure 2As shown, the tip clearance is the distance between the rotor tip 212 and the first surface 208 of the housing 206 and / or between the stator tip 213 and the first surface 209 of the hub 207. In operation, the clearance between the blade tips 212, 213 and the first surfaces 208, 209 can transition between relatively large and relatively small clearances. For example, a larger clearance may be between 4% and 10% of the axis of rotation. In some cases, the blade tips 212, 213 may rub against the first surfaces 208, 209. Furthermore, variations in the tip clearance can affect the airflow through the HP compressor 200, leading to instability. Therefore, the example hybrid engine component would be beneficial to the HP compressor 200. Additionally or optionally, the example hybrid engine component would be beneficial to other compressor sections and additional sections of the turbine engine, such as the fan section and / or turbine section.

[0038] Figure 3 An example hybrid housing 300 formed in accordance with the teachings of this disclosure is shown. Figure 3 A partial circumferential view of an example compressor (e.g., HP compressor 200) above an axial centerline (e.g., centerline axis 112) at the tip region of the rotor blades (e.g., tip region 210). For simplicity, Figure 3 The examples shown do not include an example hub (e.g., hub 207) or an example stator blade (e.g., stator blade 204). However, it should be understood that the disclosed examples with respect to the hybrid housing may be additionally or optionally applied to the example hybrid hub.

[0039] The hybrid housing 300 includes an example substrate 302, an example abrasive material 304, and an example processing unit 306. Figure 3 An example partial view of a compressor rotor blade (e.g., rotor blade 202) is also shown. An example tip gap 308 is shown between rotor blade 202 and mixing housing 300.

[0040] Figure 3 The example matrix 302 is made of ductile iron. However, any suitable material can be additionally or optionally used to form the matrix 302, such as Kevlar. TM The substrate 302 extends in the axial direction. The substrate 302 has an example first surface 310 and an example substrate thickness 312. The substrate thickness 312 is defined by the distance between the first surface 310 and an exemplary second surface 314 extending radially outward from the substrate 302. The first surface 310 of the substrate 302 surrounds the rotor blade 202. In the illustrated example, the first surface 310 of the substrate 302 maintains a constant radius in the axial direction. As described above, in additional or optional examples, the first surface 310 of the substrate 302 may vary its radius in the axial direction.

[0041] An example abrasive material 304 is applied to the first surface 310 of the substrate 302. The thickness of the abrasive material (also referred to as the abrasive material thickness) 316 is defined by a distance from an example first abrasive surface 318, which is located at the same position as the first surface 310 of the substrate 302 and extends radially toward an example second abrasive surface 320. The thickness of the hybrid housing 300 is defined by the substrate thickness 312 and the abrasive material thickness 316. The abrasive material thickness 316 is relatively thin compared to the substrate thickness 312. The abrasive material thickness 316 can vary during operation of the turbine engine. For example, the tips of the rotor blades 202 may abrade the abrasive material 304, thereby rubbing off the abrasive material 304 coating. In some examples, the abrasive material thickness 316 is approximately 30-40 mils. However, the abrasive material thickness 316 can be any thickness suitable for withstanding wear during operation. In some examples, the thickness 316 of the abrasive material is such that if the abrasive material 304 is rubbed away, the thickness of the hybrid housing 300 remains relatively constant. In some examples, the thickness 316 of the abrasive material is such that if the abrasive material 304 is rubbed away, the depth 322 of the processing section 306 remains relatively constant.

[0042] Example processing section 306 includes a plurality of recesses recessed into a substrate 302 having abrasive material 304. Processing section 306 is manufactured by creating recesses in the abrasive material 304 and a first surface 310 of the substrate 302. Example processing section 306 extends from a second wear-resistant surface 320 of the abrasive material 304 to a surface of the substrate 302 beyond the first surface 310 (e.g., between the first surface 310 and the outer surface 314). Example processing section depth 322 can be any suitable depth to achieve aerodynamic benefits. In some examples, the ratio of processing section depth 322 to abrasive material thickness 316 is such that wear of the abrasive material 304 does not affect the aerodynamic benefits of processing section 306.

[0043] As described below, the processing unit 306 of the mixing housing 300 can have any suitable configuration. Figure 3 In the example, processing unit 306 includes a quadrilateral-shaped groove. However, the shape of processing unit 306 may include one or more grooves. Furthermore, processing unit 306 can be any suitable shape, including circumferential grooves, axial grooves, semi-circular grooves, U-shaped grooves, S-shaped grooves, etc. In some examples, processing unit 306 includes multiple grooves that are substantially similar. However, in some examples, the grooves may differ. Figure 3In the example shown, the processing section 306 extends along the axial direction of the mixing housing 300. Further, the processing section 306 includes recessed grooves evenly spaced in both the radial and circumferential directions. However, the processing section 306 can extend in any suitable direction. For example, the processing section 306 can be annular and extend continuously around the axis of the compressor (e.g., circumferential grooves).

[0044] Figure 4 yes Figure 3 Example of a hybrid housing 300 along Figure 3 The side view is taken from line AA. The hybrid housing 300 includes an example base 302, an example abrasive material 304, and an example treatment 306. Figure 4 It also shows Figure 3 A side view of an example rotor blade 202. In operation, the rotor blade 202 rotates at high speed in the circumferential direction. Therefore, the rotor blade 202 has an example leading edge 402 (the upstream edge of the blade) and an example trailing edge 404 (the downstream edge of the blade). As shown, a processing unit 306 is manufactured at the section of the mixing housing 300 operating at the leading edge 402 of the rotor blade 202. In some examples, the processing unit 306 may occupy a portion of the mixing housing 300 at the trailing edge 404 and / or a portion of the mixing housing 300 between the leading edge 402 and the trailing edge 404. In some examples, the processing unit 306 extends upstream of the leading edge 402. In additional or optional examples, the processing unit 306 extends downstream of the trailing edge 404.

[0045] exist Figure 4 In the example, the thickness 316 of the abrasive material 304 is constant. However, as combined with the following... Figure 5 As shown, the thickness 316 of the abrasive material 304 can vary in some examples. For example, the leading edge 402 of the rotor blade 202 may have the highest performance derivative of the compressor. Therefore, in some examples, the thickness 316 of the abrasive material 304 may be greater near the leading edge 402 of the rotor blade 202 compared to the trailing edge 404.

[0046] Figure 5 This is another example of a hybrid housing 500 illustrated in accordance with the teachings of this disclosure. Figure 5 This includes an example substrate (e.g., substrate 302), an example abrasive material (e.g., abrasive material 304), an example processing section (e.g., processing section 306), and an example rotor blade (e.g., rotor blade 202). The rotor blade 202 has a leading edge (e.g., leading edge 402) and a trailing edge (e.g., trailing edge 404). The example mixing housing 500 is similar to... Figure 3 and 4 The hybrid housing 300. However, Figure 5The example mixing housing 500 has an abrasive material 304 that is thicker near the leading edge 402 of the rotor blades 202 operating within the portion of the mixing housing 500. As shown, the leading edge thickness 502 of the abrasive material 304 is greater than the trailing edge thickness 504 of the abrasive material 304. The abrasive material 304 is thicker near the leading edge 402 and gradually changes its radius axially towards the trailing edge 404 portion of the mixing housing 500 (e.g., tilting, skewing, etc.).

[0047] Figure 6 This is a flowchart representing example method 600, which is used to manufacture a hybrid engine component having abrasive material and a processing section (including...). Figure 3-5 (The hybrid housing). In some examples, method 600 begins at block 602, where an example substrate (e.g., example substrate 302) is fabricated for hybrid engine components (e.g., hybrid housings 300, 500). Hybrid housings 300, 500 may include, for example, an example first surface (e.g., first surface 310) and an example second surface (e.g., second surface 314). Substrate 302 may be fabricated using a die-casting process. In some examples, method 600 begins at block 604 (e.g., in an example where a substrate has already been provided). At block 604, an example abrasive material (e.g., abrasive material 304) is applied to the first surface 310 of substrate 302. For example, abrasive material 304 may be thermally sprayed, sprayed by electron beam physical vapor deposition (EBPVD), etc. The method then inquires whether to add an additional layer of abrasive material 304 at a location where an example leading edge (e.g., leading edge 402) of rotor blade 202 interacts with the first surface 310 of substrate 302 (block 606). If the answer to box 606 is negative, the method moves to box 608. If the answer to box 606 is positive, box 604 is repeated to spray an additional layer of abrasive material 304 at the section of the hybrid housing 300, 500 that interacts with the leading edge 402 of the rotor blade 202. Boxes 604 and 606 are repeated until the desired amount of abrasive material 304 has been applied. In an additional or optional example, a smart spray is used to spray a thicker layer of abrasive material 304 at the leading edge 402. In such an example, box 606 can be skipped. At box 608, a treatment section 306 is manufactured onto the substrate 302, extending from an example second abrasive surface of the abrasive material 304 (e.g., second abrasive surface 320) toward a third surface of the substrate 302 beyond the first surface 310 (e.g., between the first surface 310 and the second surface 314 of the substrate 302). The processing section 306 can be manufactured using any suitable method, including subtractive manufacturing processes such as milling and drilling, and / or other suitable methods such as chemical etching.

[0048] Although each of the above-disclosed example hybrid housings 300, 500 has certain features, it should be understood that specific features of the example hybrid housings 300, 500 are not necessarily specific to that example. Additionally or optionally, although each of the above-disclosed exemplary abrasive materials 304 has certain features, it should be understood that specific features of the example abrasive material 304 are not necessarily specific to that example. Additionally or optionally, although each of the above-disclosed example processing units 306 has certain features, it should be understood that specific features of the example processing unit 306 are not necessarily specific to that example. Rather, any feature depicted in the foregoing and / or figures may be combined with any example to complement or substitute for any other feature of those examples. Features of one example are not mutually exclusive with features of another example. Rather, the scope of this disclosure includes any combination of any features. Furthermore, the example features disclosed for hybrid housings 300, 500 may be additionally or optionally applied to another example hybrid engine component, such as a hybrid hub.

[0049] "Comprising" and "including" (and all their forms and tenses) are used herein as open-ended terms. Therefore, whenever a claim uses "comprising" or "including" in any form (e.g., including, comprising, having, etc.) in the preamble or in any type of claim statement, it should be understood that additional elements, terms, etc., may be present without exceeding the scope of the corresponding claim or reference. As used herein, when the phrase "at least" is used as a transitional term, for example, in the preamble of a claim, it is open-ended in the same way as the terms "comprising" and "including". The term "and / or", when used in the form of, for example, A, B, and / or C, refers to any combination or subset of A, B, C, such as (1) only A, (2) only B, (3) only C, (4) A and B, (5) A and C, (6) B and C, and (7) A and B and C. As used herein in the context of describing structures, components, items, objects, and / or things, the phrase "at least one of A and B" is intended to refer to an implementation including any one of the following: (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, as used herein in the context of describing structures, components, items, objects, and / or things, the phrase "at least one of A or B" is intended to refer to an implementation including any one of the following: (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. As used herein in the context of describing the performance or execution of processes, instructions, actions, activities, and / or steps, the phrase "at least one of A and B" is intended to refer to an implementation including any one of the following: (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, as used herein in the context of describing the performance or execution of processes, instructions, actions, activities and / or steps, the phrase “at least one of A or B” is intended to refer to an implementation that includes any one of the following: (1) at least one A, (2) at least one B, or (3) at least one A and at least one B.

[0050] As used herein, singular references (e.g., "a," "one," "first," "second," etc.) do not exclude plurals. As used herein, the term "a" or "one" refers to one or more of those objects. The term "a"

[0051] The terms “one”, “one or more”, and “at least one” are used interchangeably in this document. Furthermore, although individually…

[0052] Listed, but multiple devices, elements, or methods may be performed by, for example, the same entity or object. Additionally, while individual features may be included in different examples or claims, these may be combined and included in different...

[0053] The examples or claims do not imply that the combination of features is not feasible and / or advantageous.

[0054] As can be understood from the foregoing, exemplary methods, apparatus, and articles of manufacture for hybrid engine components having abrasive materials and processing sections have been disclosed. In the examples disclosed herein, the matrix is ​​in the blades (e.g., rotor blades and / or stator wheels).

[0055] A first surface is present in the region near the leaf. In the examples disclosed herein, an abrasive material is applied to the first surface of the substrate. In the examples disclosed herein, a processing section is applied to an engine component having an abrasive material. Partly due to the abrasive...

[0056] The material coatings disclosed herein provide improved tip clearance management. The examples disclosed herein can improve aerodynamic performance in part due to the treatment. The examples disclosed herein protect blade tips from damage by allowing the tips to abrade abrasive material when the tip clearance is minimal. Therefore, the examples disclosed herein can improve the operability and efficiency of turbine engines, achieve aerodynamic benefits, improve stall margin, and control tip clearance.

[0057] The other aspects of the 5 published articles are provided by the following terms:

[0058] Example 1 includes an engine component comprising: a substrate having a first thickness and at least defining a first substrate surface, the substrate extending in an axial direction; and an abrasive material on the first substrate surface, the abrasive material defining a first abrasive material surface, a second abrasive material surface and defining a second thickness, the second abrasive material surface being adjacent to the first substrate surface.

[0059] The surfaces of the abrasive material are radially spaced apart; the processing section extends from the first abrasive material surface through at least a portion of the first zero thickness of the substrate.

[0060] Example 2 includes an engine component of any of the preceding clauses, wherein the second thickness of the abrasive material is less than the first thickness of the substrate.

[0061] Example 3 includes any of the preceding clauses of the engine component, wherein the component is a housing, the component surrounds rotor blades, and some of the rotor blades have leading and trailing edges.

[0062] Example 4 includes an engine component of any of the preceding clauses, wherein abrasive material is present at the leading edge of the rotor blades of the component.

[0063] The section where the operation is located has a first thickness, and a portion of the rotor blade at the trailing edge of the component where the operation is located has a second thickness. The first thickness is greater than the second thickness, and the thickness of the abrasive material varies from the first thickness to the second thickness along the axial direction.

[0064] Example 5 includes any of the preceding clauses of the engine component, wherein the abrasive material is a thermally sprayed abrasive material.

[0065] Example 6 includes any of the preceding clauses of the engine component, wherein the wearable material includes at least one of nickel-graphite or cobalt-nickel-chromium-aluminum-yttrium (CoNiCrAlY).

[0066] Example 7 includes any of the preceding clauses of the engine component, wherein the substrate is within a portion of at least one of the fan section, compressor section, or turbine section of a turbine engine.

[0067] Example 8 includes an engine component of any of the preceding clauses, wherein the processing section includes grooves manufactured in abrasive material and a substrate.

[0068] Example 9 includes an engine component of any of the preceding clauses, wherein the treatment portion of the abrasive material is collinear with the treatment portion of the substrate.

[0069] Example 10 includes a gas turbine engine comprising: an array of rotor blades, some of which have leading and trailing edges; an array of stator blades; and an engine component including a matrix having at least a first surface and a matrix thickness extending in an axial direction; an abrasive material on the first surface of the matrix, the thickness of which is defined by a distance extending from the first abrasive surface toward a second abrasive surface; and a processing unit.

[0070] Example 11 includes a gas turbine engine of any of the preceding clauses, wherein the engine components have a thickness defined by the thickness of the base material and the thickness of the abrasive material.

[0071] Example 12 includes a gas turbine engine of any of the preceding clauses, wherein the engine component has a first thickness corresponding to the engine component after the application of an abrasive material and a second thickness corresponding to the engine component after the abrasive material wears down, and wherein the abrasive material has a thickness such that the first thickness and the second thickness of the engine component are substantially equal.

[0072] Example 13 includes a gas turbine engine of any of the preceding clauses, wherein the abrasive material is applied to the first surface by at least one of thermal spraying or electron beam physical vapor deposition.

[0073] Example 14 includes a gas turbine engine of any of the preceding clauses, wherein the processing section has a first depth corresponding to an engine component before wear of the abrasive material and a second depth corresponding to an engine component after wear of the abrasive material, and wherein the abrasive material has a thickness such that the first processing section depth and the second processing section depth are substantially equal.

[0074] Example 15 includes a gas turbine engine of any of the preceding clauses, wherein the engine component is a hub, and wherein a first surface is the outer surface of the hub, the first surface of the hub being surrounded by an array of stator blades.

[0075] Example 16 includes a gas turbine engine of any of the preceding clauses, wherein the engine component is a housing, and wherein a first surface is an inner surface, the first surface of the housing surrounding an array of rotor blades.

[0076] Example 17 includes a gas turbine engine of any of the preceding clauses, wherein the abrasive material has a first thickness at the section where the leading edge of the rotor blades of the engine component operates, and a second thickness at a portion where the trailing edge of the rotor blades of the engine component operates, the first thickness being greater than the second thickness, and the thickness of the abrasive material sloping from the first thickness to the second thickness.

[0077] Example 18 includes a gas turbine engine of any of the preceding clauses, wherein the processing section includes a plurality of grooves radially formed in a first surface of an abrasive material and a substrate.

[0078] Example 19 includes a gas turbine engine of any of the preceding clauses, wherein the abrasive material treatment section is collinear with the substrate treatment section.

[0079] Example 20 includes any of the preceding clauses of a gas turbine engine, wherein the abrasive material and processing section are applied to at least one of the fan section of the turbine engine, the fore-stage compressor of the turbine engine, or the post-stage compressor of the turbine engine.

[0080] Example 21 An engine component includes: a base portion; a wearable portion; and a processing portion.

[0081] Although certain example methods, apparatuses, and articles have been disclosed herein, the scope of this patent is not limited thereto. Rather, this patent covers all methods, apparatuses, and articles that fall entirely within the scope of the claims of this patent.

[0082] The appended claims are incorporated herein by reference, each claim existing independently as a separate embodiment of this disclosure.

Claims

1. An engine component, characterized in that, include: A substrate having a first thickness and defined by a distance from a first substrate surface to a second substrate surface, the first substrate surface being radially inwardly positioned relative to the second substrate surface, the substrate extending in an axial direction; A wearable material, said wearable material being applied to the surface of the first substrate and defining (a) a first wearable material surface, the first wearable material surface contacting the first substrate surface to define an interface, and (b) a second wearable material surface, the second wearable material surface being radially inwardly spaced from the first wearable material surface; as well as The processing unit has: A closed end, wherein the closed end is located within the matrix; An open end, wherein the open end is located within the surface of the second abrasive material; as well as The sidewalls extend from the open end of the surface of the second abrasive material through the interface to the closed end within the matrix, wherein the distance between the sidewalls remains equal from the open end to the closed end.

2. The engine component according to claim 1, characterized in that, The second thickness of the wearable material is less than the first thickness of the substrate.

3. The engine component according to claim 1, characterized in that, The engine component includes a housing surrounding rotor blades, some of which have leading and trailing edges.

4. The engine component according to claim 3, characterized in that, The abrasive material has a first thickness at the section where the leading edge of the rotor blade of the engine component operates, and a second thickness at a portion where the trailing edge of the rotor blade of the engine component operates, the first thickness being greater than the second thickness, and the thickness of the abrasive material varying from the first thickness to the second thickness along the axial direction.

5. The engine component according to claim 1, characterized in that, The wearable material includes at least one of nickel-graphite or cobalt-nickel-chromium-aluminum-yttrium (CoNiCrAlY), and the wearable material is a thermally sprayable wearable material.

6. The engine component according to claim 1, characterized in that, The substrate is located within a portion of at least one of the fan section, the compressor section, or the turbine section of the turbine engine.

7. The engine component according to claim 1, characterized in that, The processing section for the abrasive material is collinear with the processing section for the substrate.

8. A gas turbine engine, characterized in that, include: An array of rotor blades, some of which have leading and trailing edges; Array of stator blades; as well as Engine components, the engine components including: A substrate having at least a first substrate surface and a first thickness; Abrasive materials, said abrasive materials include: First wearable material surface; The second wearable material surface; and A second thickness is defined between the first abrasive material surface and the second abrasive material surface, wherein the first abrasive material surface contacts the first substrate surface to define an interface; and A plurality of grooves are radially formed in the wearable material, each groove having: A closed end, wherein the closed end is located within the matrix; An open end, the open end being located within the surface of the second abrasive material; and The sidewalls extend from the open end of the surface of the second abrasive material through the interface to the closed end within the matrix, wherein the distance between the sidewalls remains equal from the open end to the closed end.

9. The gas turbine engine according to claim 8, characterized in that, The engine component has a thickness defined by the thickness of the substrate and the thickness of the wearable material.

10. The gas turbine engine according to claim 9, characterized in that, The engine component has a first thickness corresponding to the engine component after the abrasive material is applied and a second thickness corresponding to the engine component after the abrasive material is worn, wherein the abrasive material has a thickness such that the first thickness and the second thickness of the engine component are substantially equal.

11. The gas turbine engine according to claim 8, characterized in that, The abrasive material is applied to the first surface by at least one of thermal spraying or electron beam physical vapor deposition.

12. The gas turbine engine according to claim 8, characterized in that, The processing unit has a first depth corresponding to the engine component before the wearable material wears out and a second depth corresponding to the engine component after the wearable material wears out, wherein the wearable material has a thickness such that the first depth and the second depth are substantially equal.

13. The gas turbine engine according to claim 8, characterized in that, The engine component includes a hub, and a first surface is the outer surface of the hub, the first surface of the hub being surrounded by an array of stator blades.

14. The gas turbine engine according to claim 8, characterized in that, The engine component includes a housing, wherein a first surface is an inner surface, and the first surface of the housing surrounds an array of rotor blades.

15. The gas turbine engine according to claim 14, characterized in that, The abrasive material has a first thickness at the section where the leading edge of the rotor blade of the engine component operates, and a second thickness at a portion where the trailing edge of the rotor blade of the engine component operates, the first thickness being greater than the second thickness, and the thickness of the abrasive material sloping from the first thickness to the second thickness.

16. The gas turbine engine according to claim 8, characterized in that, The processing section for the abrasive material is collinear with the processing section for the substrate.

17. The gas turbine engine according to claim 8, characterized in that, The abrasive material and processing section are applied to at least one of the fan section of the turbine engine, the fore-stage compressor of the turbine engine, or the post-stage compressor of the turbine engine.

18. An engine component, characterized in that, include: basal part; A wearable portion, wherein the wearable portion is positioned on the base portion; as well as A processing section, wherein the processing section is recessed into the base section having the wearable portion thereon, the processing section including a closed end located within the base section; an open end opposite to the closed end, the open end being located within the wearable portion; and a sidewall defined between the open end and the closed end, wherein the distance between the sidewalls remains equal from the open end to the closed end.

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