Engine component

Abstract

An engine component of a turbine engine. The engine component has a composite structure and a cover structure. The composite structure has a composite structure outer wall and a composite structure edge. The cover structure surrounds at least a portion of the composite structure outer wall. The cover structure has a main body. The body extends along at least a portion of the composite structure outer wall.

Description

TECHNICAL FIELD

[0001] The present invention relates generally to an engine component, and more particularly to an engine component of a turbine engine having a composite structure. BACKGROUND

[0002] Turbine engines, particularly gas or combustion turbine engines, are rotary engines that extract energy from a flow of gas, which flows through a fan with multiple fan blades, then through a series of compressor stages, including pairs of rotating blades and stationary vanes, into the engine, through a combustor, then through a series of turbine stages, including pairs of rotating blades and stationary vanes. The blades are mounted to a rotating disk, while the vanes are mounted to a stator disk.

[0003] During operation, air enters the compressor section through the fan section, then is pressurized in the compressor and mixed with fuel and ignited in the combustor to produce hot combustion gases that flow downstream through the turbine stages, where the air expands and is exhausted from the exhaust section. The expansion of the air in the turbine section is used to drive the rotating sections of the fan and compressor sections. The intake of air, pressurization of the air, and expansion of the air are accomplished by the rotation of various rotating blades mounted to respective disks of the fan section, compressor section, and turbine section, respectively. The rotation of the rotating blades exerts mechanical stresses along various portions of the blades; particularly, where the blades are mounted to the disks. BRIEF DESCRIPTION OF DRAWINGS

[0004] The complete and enabling disclosure of the present disclosure, including the best mode thereof, is set forth in the specification and illustrated in the accompanying drawings, which are to be construed in accordance with the following detailed description of the disclosure, where:

[0005] Figure 1 is a schematic cross-sectional view of a turbine engine according to an exemplary embodiment of the present disclosure.

[0006] Figure 2 is an exploded view of an engine component suitable for use within a turbine engine according to Figure 1 , the engine component including an airfoil portion and a cover structure.

[0007] Figure 3 is a schematic cross-sectional view of the engine component taken along section line III-III of Figure 2 , further illustrating the extension of the main body and the cover structure.

[0008] Figure 4 is a schematic cross-sectional view of the engine component according to Figure 2 , further illustrating the cover structure and the airfoil portion, the cover structure having a set of aligners.

[0009] Figure 5 is a schematic cross-sectional view of an engine component suitable for use as an engine component of Figure 2 further illustrating an extension having a triangular shape.

[0010] Figure 6 is a schematic cross-sectional view of an engine component suitable for use as an engine component of Figure 2 further illustrating a bifurcated extension.

[0011] Figure 7 is a schematic cross-sectional view of an engine component suitable for use as an engine component of Figure 2 further illustrating an extension having a barb shape.

[0012] Figure 8 is a schematic cross-sectional view of an engine component suitable for use as an engine component of Figure 2 having a composite structure, the engine component having a cover structure disposed along the composite structure.

[0013] Figure 9 is a schematic cross-sectional view of an engine component suitable for use as an engine component of Figure 2 having a composite structure, the engine component having a cover structure mechanically coupled to the composite structure.

[0014] Figure 10 is a schematic cross-sectional view of an engine component suitable for use as an engine component of Figure 2 being an airfoil assembly having a midspan shroud with a composite structure and a cover structure disposed along the composite structure.

[0015] Figure 11 is a schematic cross-sectional view of an engine component from Figure 10 further illustrating an extension of the cover structure.

[0016] Figure 12 is a schematic cross-sectional view of an engine component from Figure 10 further illustrating an interface between opposing portions of the cover structure. DETAILED DESCRIPTION

[0017] Aspects disclosed herein relate to a turbine engine including an engine component. The engine component has a composite structure and a cover structure. The cover structure includes a body and an extension. The composite structure includes a channel. The extension is disposed within the channel. The engine component is any suitable component disposed within the turbine engine, such as, but not limited to, an airfoil assembly, a casing (e.g., a fan casing, an engine casing, etc.), etc.

[0018] The cover structure is used to reinforce the composite structure to resist external forces or forces generated during normal operation of the turbine engine. The cover structure can also be used to couple the composite structure to another structure of the turbine engine. For purposes of illustration, the present disclosure will be described with respect to an engine component of a turbine engine. However, it should be understood that the disclosed aspects described herein are not limited in this regard and are applicable in other engines or other portions of turbine engines. For example, the present disclosure can be applicable to engine components in other engines or vehicles and can be used to provide benefits in industrial, commercial, and residential applications.

[0019] As used herein, the term "composite structure" includes a body or assembly that includes a composite material or collection of composite materials, including but not limited to polymer matrix composites (PMC), ceramic matrix composites (CMC), metal matrix composites (MMC), carbon fibers, polymeric resins, thermoplastic resins, bismaleimide (BMI) materials, polyimide materials, epoxy resins, glass fibers, and silicon matrix materials. The composite segments of the body define the composite structure.

[0020] As used herein, the term "upstream" refers to a direction opposite to the direction of fluid flow, and the term "downstream" refers to a direction the same as the direction of fluid flow. The terms "forward" or "forwardly" mean in front of something, and "rearward" or "rearwardly" mean behind something. For example, when used in relation to fluid flow, forward / forwardly can mean upstream, and rearward / rearwardly can mean downstream.

[0021] Further, as used herein, the terms "axial" and "longitudinal" both refer to a direction parallel to a centerline axis of an object, while the terms "radial" or "radially" refer to a direction perpendicular to the axial direction or away from a common center. For example, in the overall context of a turbine engine, radial refers to a direction along a ray extending between a centerline longitudinal axis of the engine and an outer periphery of the engine. Further, as used herein, the term "group of elements" or "a group of elements" can be any number of elements, including only one.

[0022] Further, as used herein, the term "fluid" or related expressions thereof can refer to any suitable fluid within a gas turbine engine, at least a portion of which is exposed to the fluid, such as but not limited to combustion gases, ambient air, pressurized air flow, working gas flow, or any combination thereof. It is further contemplated that the gas turbine engine can be another suitable turbine engine, such as but not limited to a steam turbine engine or a supercritical carbon dioxide turbine engine. By way of non-limiting example, the term "fluid" can refer to steam in a steam turbine engine, or carbon dioxide in a supercritical carbon dioxide turbine engine.

[0023] All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are used only for identification purposes to aid the reader’s understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the disclosure described herein. Connection references (e.g., attached, coupled, connected, joined, fixed, fastened, and the like) are not restricted to direct and immediate connections only, and can include indirect connections, intermediate members, and relative movement between elements unless otherwise specified. Thus, a connection reference does not necessarily infer that two elements are directly connected to each other and in fixed relation to each other. The exemplary figures are for illustrative purposes only, and the dimensions, positions, sequences, and relative sizes reflected in the figures can vary.

[0024] The term “composite material” as used herein refers to a component having two or more materials. The composite material can be a combination of at least two or more metals, non-metals, or a combination of metallic and non-metallic elements or materials. Examples of composite materials can be, but are not limited to, polymer matrix composites (PMCs), ceramic matrix composites (CMCs), metal matrix composites (MMCs), carbon fibers, polymer resins, thermoplastic resins, bismaleimide (BMI) materials, polyimide materials, epoxy resins, glass fibers, and silicon matrix materials.

[0025] As used herein, a “composite” component refers to a structure or component that includes any suitable composite material. A composite component, such as a composite airfoil, can include several layers or plies of composite material. The layers or plies can vary in stiffness, material, and size to achieve a desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0026] One or more layers of adhesive can be used to form or join composite components. The adhesive can include a resin and a phenolic resin, where the adhesive can need to be cured at high temperatures or other hardening techniques.

[0027] As described herein, PMCs refer to a class of materials. For example, PMC materials are defined in part by pre-preg, which is a reinforcing material pre-impregnated with a polymer matrix material, such as a thermoplastic resin. Non-limiting examples of methods to produce thermoplastic pre-preg include hot-melt pre-preg, in which a fiber reinforcement is pulled through a resin melt pool, and powder pre-preg, in which resin is electrostatically deposited on a fiber reinforcement, which then adheres to the fiber in an oven or with the help of heated rollers, as non-limiting examples. The pre-preg can be in the form of unidirectional tape or woven fabric, which are then stacked together to form the desired number of stacked plies for a part.

[0028] Multiple layers of prepreg are stacked to the appropriate thickness and orientation of the composite part, and the resin is then cured and solidified to form the fiber-reinforced composite part. Resins for the matrix material used in PMC can generally be divided into thermoset resins or thermoplastics. Thermoplastic resins are generally classified as polymers that can repeatedly soften and flow upon heating and harden upon sufficient cooling due to physical rather than chemical changes. A notable example class of thermoplastic resins includes nylon, thermoplastic polyester, polyaryletherketone, and polycarbonate resins. Specific examples of high-performance thermoplastic resins that have been considered for aerospace applications include polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK), and polyphenylene sulfide (PPS). In contrast, thermoset resins do not significantly soften upon heating once fully cured into a hard solid, but rather thermally decompose upon sufficient heating. Notable examples of thermoset resins include epoxy, bismaleimide (BMI), and polyimide resins.

[0029] In another non-limiting example, using thermoplastic polymers instead of using prepreg, woven fabric can be used. The woven fabric can include, but is not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg braided structures can be manufactured in a similar manner. With this method, the fiber volume of the part can be tailored by specifying the relative concentrations of the thermoplastic and reinforcing fibers that have been woven or braided together. Furthermore, different types of reinforcing fibers can be braided or woven together at different concentrations to tailor the performance of the part. For example, glass fibers, carbon fibers, and thermoplastic fibers can all be woven together at different concentrations to tailor the performance of the part. Carbon fibers provide the strength of the system, glass fibers can be added to enhance impact performance, which is a design feature of parts located near the inlet of the engine, and thermoplastic fibers provide a bond for the reinforcing fibers.

[0030] In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of the composite part. Generally, RTM includes applying dry fibers or matrix material into a mold or cavity. The dry fibers or matrix material can include prepreg, braided material, woven material, or any combination thereof.

[0031] Resin can be pumped or otherwise provided to the mold or cavity to impregnate the dry fibers or matrix material. The impregnated fibers or matrix material in combination with the resin is then cured and removed from the mold. The composite part can require post-cure processing when removed from the mold.

[0032] It is contemplated that the RTM can be a vacuum assisted process. That is, the air in the cavity or mold can be removed and replaced with resin prior to heating or curing. It is also contemplated that the placement of the dry fiber or matrix material can be manual or automated. By way of non-limiting example, the placement of the dry fiber or matrix material can be accomplished by automated fiber placement (AFP) or manually.

[0033] The dry fiber or matrix material can be shaped to sculpt the composite part or to direct the resin. Optionally, additional layers or reinforcement layers of material different from the dry fiber or matrix material can also be included or added prior to heating or curing.

[0034] As used herein, CMC refers to a class of materials having a reinforcing fiber in a ceramic matrix. Typically, the reinforcing fiber provides structural integrity to the ceramic matrix. Some examples of reinforcing fibers can include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (AI2O3), silicon dioxide (SiO2), aluminosilicates such as mullite, or mixtures thereof, or mixtures thereof.

[0035] Some examples of ceramic matrix materials can include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (AI2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) can also be included in the ceramic matrix.

[0036] Typically, specific CMCs can be referred to by their fiber type / matrix type combination. For example, C / SiC for carbon fiber reinforced silicon carbide; SiC / SiC for silicon carbide fiber reinforced silicon carbide; SiC / SiN for silicon carbide fiber reinforced silicon nitride; SiC / SiC-SiN for silicon carbide fiber reinforced silicon carbide / nitride matrix hybrid; and the like. In other examples, CMCs can be composed of a matrix and reinforcing fibers including oxide-based materials such as aluminum oxide (AI2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof. The aluminosilicates can include crystalline materials such as mullite (3AI2O3-2SiO2), as well as glassy aluminosilicates.

[0037] In certain non-limiting examples, the reinforcing fibers can be bundled and / or coated prior to inclusion in the matrix. For example, bundles of fibers can form reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes can be stacked together to form a preform. The bundles of fibers can be impregnated with a slurry composition prior to forming the preform or after the preform is formed. The preform can then be subjected to a heat treatment and subsequent chemical treatment to result in a part formed from a CMC material having a desired chemical composition. For example, the preform can be subjected to a cure or burn-out to produce a high carbon residue in the preform, followed by a melt infiltration with silicon, or a cure or pyrolysis to produce a silicon carbide matrix in the preform, followed by a chemical vapor infiltration with silicon carbide. Prior to or after the chemical vapor infiltration, an additional step can be taken to increase the densification of the preform by injecting a liquid resin or polymer into it, followed by a heat treatment step to fill the voids with silicon carbide. The CMC materials used herein can be formed using any known or hereinafter developed method, including but not limited to melt infiltration, chemical vapor infiltration, polymer impregnation pyrolysis (PIP), or any combination thereof.

[0038] Such materials, as well as certain monolithic ceramics (i.e., ceramic materials without reinforcing materials), are particularly well suited for high temperature applications. In addition, these ceramic materials are lighter in weight compared to superalloys, yet can still provide strength and durability to parts made therefrom. Accordingly, it is presently contemplated that such materials be used for many gas turbine parts used in the high temperature section of a gas turbine engine, such as airfoils (e.g., turbine and vane blades), combustors, shrouds, and other similar parts, which would benefit from the lighter weight and higher temperature performance that these materials can provide.

[0039] The term "metal" as used herein means materials that include metals, such as but not limited to titanium, iron, aluminum, stainless steel, and nickel alloys. The metallic material or alloy can be a combination of at least two or more elements or materials, at least one of which is a metal.

[0040] Figure 1 is a schematic cross-sectional view of a turbine engine 10 for an aircraft. The turbine engine 10 has a generally longitudinally extending axis or centerline 12 extending from a forward portion 14 to an aft portion 16. The turbine engine 10 includes, in downstream serial flow relationship, a fan section 18 including a fan 20, a compressor section 22 including a booster or low pressure (LP) compressor 24 and a high pressure (HP) compressor 26, a combustion section 28 including a combustor 30, a turbine section 32 including an HP turbine 34 and a LP turbine 36, and an exhaust section 38.

[0041] The fan section 18 includes a fan casing 40 that surrounds a fan 20. The fan 20 includes a set of fan blades 42 that are disposed radially about the engine centerline 12. The HP compressor 26, combustor 30, and HP turbine 34 form an engine core 44 of the turbine engine 10 that generates combustion gases. The engine core 44 is surrounded by an engine casing 46, which can be coupled with the fan casing 40.

[0042] The HP shaft 48 is coaxially disposed about the engine centerline 12 of the turbine engine 10 and drivingly connects the HP turbine 34 to the HP compressor 26. The LP shaft 50 is coaxially disposed about the engine centerline 12 of the turbine engine 10 within the larger diameter annular HP shaft 48 and drivingly connects the LP turbine 36 to the LP compressor 24 and the fan 20. The shafts 48, 50 are rotatable about the engine centerline 12 and are coupled to a plurality of rotatable elements, which can collectively define a rotor 51.

[0043] The LP compressor 24 and the HP compressor 26 each include a plurality of compressor stages 52, 54 in which a set of compressor blades 56, 58 rotate relative to a corresponding set of static compressor vanes 60, 62 to compress or pressurize a fluid flow through the stage. In a single compressor stage 52, 54, the set of compressor blades 56, 58 can be disposed in an annulus and can extend radially outward from a blade platform to a tip relative to the engine centerline 12, while the corresponding set of static compressor vanes 60, 62 are positioned upstream of and adjacent to the set of compressor blades 56, 58. It should be noted that Figure 1 The number of blades, vanes, and compressor stages shown in FIGS. 1-3 are selected for illustrative purposes only, and other numbers are possible.

[0044] The set of compressor blades 56, 58 for a compressor 24, 26 stage can be mounted to (or integrated with) a disk 61 that is mounted to a corresponding one of the HP and LP shafts 48, 50. The static compressor vanes 60, 62 for a compressor 24, 26 stage can be mounted to the engine casing 46 in a circumferential arrangement.

[0045] The HP turbine 34 and the LP turbine 36 each include a plurality of turbine stages 64, 66 in which a set of turbine blades 68, 70 rotate relative to a corresponding set of turbine vanes 72, 74 (also referred to as nozzles) to extract energy from a fluid flow through the stage. In a single turbine stage 64, 66, the set of turbine blades 68, 70 can be disposed in an annulus and can extend radially outward relative to the engine centerline 12, while the corresponding set of turbine vanes 72, 74 are positioned upstream of and adjacent to the set of turbine blades 68, 70. It should be noted that Figure 1 The number of blades, vanes, and turbine stages shown in FIGS. 1-3 are selected for illustrative purposes only, and other numbers are possible.

[0046] A set of turbine blades 68, 70 for the turbine stage can be mounted to a disc 71, which is mounted to one of the corresponding HP and LP shafts 48, 50. A set of turbine blades 72, 74 for the compressor stage can be mounted to the engine housing 46 in a circumferential arrangement.

[0047] Complementing the rotor section, the stationary parts of the turbine engine 10, such as the static compressor blades 60, 62 in the compressor section 22 and the turbine section 32, or a group of turbine blades 72, 74, are also referred to individually or collectively as the stator 63. Therefore, the stator 63 can refer to the combination of non-rotating elements in the entire turbine engine 10.

[0048] It should be understood that the turbine engine 10 can be divided into at least two separate parts: a rotor part and a stator part. The rotor part can be defined as any part of the turbine engine 10 that rotates about a corresponding axis of rotation. The stator part can be defined by a combination of non-rotating elements disposed within the turbine engine 10. As a non-limiting example, the rotor part may include one or more of a set of fan blades 42, a set of compressor blades 56, 58, or a set of turbine blades 68, 70. As a non-limiting example, the stator part may include one or more of a set of airfoil guide vanes 82 (described below), static compressor vanes 60, 62, or a set of turbine vanes 72, 74.

[0049] In operation, the airflow leaving fan section 18 is split, with a portion directed to LP compressor 24. LP compressor 24 then supplies pressurized airflow 76 to HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from HP compressor 26 mixes with fuel in combustor 30 and is ignited, producing combustion gases. Some work is extracted from these gases by HP turbine 34, which drives HP compressor 26. The combustion gases are discharged into LP turbine 36, which extracts additional work to drive LP compressor 24. The exhaust gases are finally discharged from turbine engine 10 through exhaust section 38. The drive of LP turbine 36 drives LP shaft 50 to rotate fan 20 and LP compressor 24.

[0050] A portion of the pressurized gas flow 76 can be extracted from the compressor section 22 as bleed air 77. Bleed air 77 can be extracted from the pressurized gas flow 76 and supplied to engine components for cooling. The temperature of the pressurized gas flow 76 entering the combustor 30 is significantly higher than the bleed air temperature. Bleed air 77 can be used to reduce the temperature of core components downstream of the combustor 30. Bleed air 77 can also be utilized by other systems.

[0051] Some of the air supplied by fan 20 can bypass engine core 44 to cool portions of turbine engine 10, particularly hot sections, and / or to cool or power other aspects of the aircraft. In the context of a turbine engine, the hot sections are typically located downstream of combustor 30, particularly turbine section 32, with HP turbine 34 being the hottest section as it is directly downstream of combustion section 28. Other sources of cooling fluid may be, but are not limited to, fluid discharged from LP compressor 24 or HP compressor 26.

[0052] The remaining portion of the airflow exiting fan section 18, referred to as bypass airflow 78, bypasses the LP compressor 24 and engine core 44, and exits the turbine engine 10 via a stationary blade array at the fan exhaust side 84, more specifically, an outlet guide vane assembly 80 comprising a set of airfoil guide vanes 82. More specifically, adjacent to fan section 18, radially extending airfoil guide vanes 82 in a circumferential array are used to exert at least some directional control on the bypass airflow 78.

[0053] As shown in the figure, turbine engine 10 is a turbofan engine. However, it should be understood that turbine engine 10 can be any suitable engine, such as, but not limited to, a turboprop engine, a turboshaft engine, a ducted turbofan engine, a non-ducted engine, or an open rotor turbine engine. As a non-limiting example, turbine engine 10 can be a non-ducted turbine engine. A non-ducted turbine engine includes a set of external fan blades and external fan wheel blades that extend radially outward from the nacelle or outer casing housing the engine core. The external fan blades and external fan wheel blades are functionally similar to a set of fan blades 42 and a set of airfoil guide vanes 82 of turbine engine 10, respectively. It should be understood that at least a portion of the external fan blades or external fan wheel blades may define radial limits in a non-ducted turbine engine (e.g., the portion radially furthest from the engine centerline 12). In other words, in a non-ducted turbine engine, no part of the turbine engine is located radially outside the external fan blades or external fan wheel blades.

[0054] Figure 2 It is applicable Figure 1 An exploded view of engine component 100 within a turbine engine 10. The engine component includes a composite structure 102 and a cover structure 104. For illustrative purposes, the cover structure 104 is exploded from the composite structure 102. The composite structure 102 may include an airfoil portion 106 such that the engine component 100 is an airfoil assembly suitable for use as a blade, impeller, airfoil, or other component in any turbine engine, such as, but not limited to, a gas turbine engine, a turboprop engine, a turboshaft engine, a tubular turbofan engine, and the turbine engine 10. Figure 1) or a non-ducted turbine engine. The airfoil portion 106 is any suitable airfoil of the turbine engine 10 such as, but not limited to, a set of fan blades 42 Figure 1 ), a set of airfoil guide vanes 82 Figure 1 ), a set of compressor blades 56, 58 Figure 1 ), a set of compressor vanes 60, 62 Figure 1 ), a set of turbine blades 68, 70 Figure 1 ) or a set of turbine vanes 72, 74 Figure 1 ).

[0055] The airfoil portion 106 includes a composite outer wall 108. The composite outer wall 108 extends between a composite leading edge 114 and a composite trailing edge 116 to define a chordwise direction (Cd). The composite outer wall 108 extends between a composite root 110 and a composite tip 112 to define a spanwise direction (Sd). The composite outer wall 108 defines a pressure side 120 and a suction side 118.

[0056] The composite structure 102 includes a channel 122. As a non-limiting example, the channel 122 extends along an edge of the airfoil portion 106. As another non-limiting example, the channel 122 extends along at least one of the composite leading edge 114, the composite tip 112, the composite trailing edge 116, the composite root 110, or a combination thereof. In the illustrated example, the channel 122 extends in the spanwise direction (Sd) along the composite leading edge 114. It should be appreciated that the channel 122 can be segmented or continuous. The channel 122 can extend along an entire respective edge of the airfoil portion 106 or less than an entire respective edge. As a non-limiting example, the channel 122 extends along an entire span (e.g., an extension in the spanwise direction (Sd)) of the composite leading edge 114 between the composite root 110 and the composite tip 112.

[0057] At least a portion of the composite structure 102 includes a composite material. As a non-limiting example, the composite outer wall 108 can include a composite material. As a non-limiting example, the composite outer wall 108 can include at least a PMC portion, a polymer portion, or both. The PMC portion can include, but is not limited to, a thermoset (epoxy, phenolic) or thermoplastic (polycarbonate, polyvinyl chloride, nylon, acrylic) matrix and embedded glass, carbon, steel, or a combination thereof.

[0058] The cover structure 104 includes a body 124 and an extension 126 extending from the body 124. The body 124 defines an exterior portion of the cover structure 104. The body 124 and the extension 126 are integrally formed with or coupled to one another.

[0059] The cover structure 104 includes a cover structure edge 162, a set of body distal ends 164, and an extension distal end 166. As shown, the cover structure edge 162 is the forward-most portion of the cover structure 104 in the chordwise direction (Cd).

[0060] The total distance that the extension 126 extends in the spanwise direction (Sd) can be equal to the total distance that the body 124 extends in the spanwise direction (Sd). The total distance that the extension 126 extends in the spanwise direction (Sd) can be different than the total distance that the body 124 extends in the spanwise direction (Sd). As a non-limiting example, the extension 126 can extend between 75% of the composite structure leading edge 114 in the spanwise direction (Sd), while the body 124 can extend greater than 75% of the composite structure leading edge 114 in the spanwise direction (Sd).

[0061] The cover structure 104 includes at least one of a metallic material, a plastic material, or a combination thereof. The material of the cover structure 104 can be, but is not limited to, titanium, aluminum, polyurethane, etc. As a non-limiting example, the cover structure 104 can include a metallic material such that the cover structure 104 is defined as a metallic cover structure.

[0062] The cover structure 104 is coupled to the composite structure 102 by any suitable coupling method, such as, but not limited to, welding, adhering, bonding, fastening, friction fit, etc. The extension 126 is sized to fit within the channel 122. The extension 126 is received within the channel 122 when the cover structure 104 is coupled to the composite structure 102. The cover structure 104 covers the respective portion of the composite structure 102 when coupled to the composite structure 102. In other words, the cover structure 104 covers the respective portion of the composite structure 102.

[0063] The composite structure 102 and the cover structure 104 can be coupled to one another after the composite structure 102 is assembled or formed. As a non-limiting example, the composite structure 102 and the cover structure 104 can be coupled to one another after the composite structure 102 is cured. The composite structure 102 and the cover structure 104 can be integrally formed with one another. As a non-limiting example, the cover structure 104 can be positioned along an uncured version of the composite structure 102. The cover structure 104 and the composite structure 102 can then be co-cured such that the cover structure 104 is integrally formed with and forms a unitary body with the composite structure 102. As a non-limiting example, the cover structure 104 and the composite structure 102 can be integrally formed by any suitable method, such as, but not limited to, electroforming, 3D printing, etc.

[0064] The cover structure edge 162 defines an engine component leading edge for the engine component 100. However, it should be appreciated that the cover structure edge 162 varies based on where the cover structure 104 is disposed. As a non-limiting example, the cover structure 104 can be disposed along the composite structure trailing edge 116 to define at least a portion of an engine component trailing edge. As a non-limiting example, the cover structure can be disposed along the composite structure tip 112 to define at least a portion of an engine component tip. As a non-limiting example, the cover structure can be disposed along the composite structure root 110 to define at least a portion of an engine component root. As a non-limiting example, the cover structure can be disposed along the composite structure outer wall 108 to define at least a portion of an engine component outer wall. It should be appreciated that the engine component 100 includes any number of cover structures 104 disposed along any suitable portion of the composite structure 102.

[0065] It should be appreciated that the engine component 100 is any suitable engine component 100. As a non-limiting example, the engine component 100 can be an airfoil assembly including an airfoil portion having a dovetail extending radially inward from a root (e.g., the composite structure root 110). In this case, the cover structure 104 can extend over or terminate before the dovetail portion. Other non-limiting examples of the engine component 100 include, but are not limited to, a case (e.g., a fan case, a combustor liner, an engine case, etc.), an airfoil portion including a shroud (e.g., a midspan shroud, a tip shroud, an outer platform, an inner platform, etc.), an airfoil portion extending from an inner band coupled to a root, an airfoil assembly including a spar extending from a root of the airfoil portion and coupled to a trunnion (e.g., a variable pitch airfoil assembly), an airfoil portion coupled to a disk (e.g., the disk 61, 71 of Figure 1 ), etc.

[0066] During operation, the engine component 100 is subjected to a force (F). The force (F) is any force that can be experienced during operation of a turbine engine (e.g., the turbine engine 10 of Figure 1 ). As a non-limiting example, the force (F) can be, but is not limited to, a force of an airflow (e.g., the pressurized airflow 76 of Figure 1 ) flowing through the engine component 100, a rotational force exerted on the engine component 100 due to rotation of the engine component 100, an external force (e.g., a bird strike) exerted on the engine component 100, or a combination thereof. The force (F) is shown in a chordwise direction (Cd). The force (F) can be in any suitable direction.

[0067] The cover structure 104 is used to reinforce certain portions of the composite structure 102 (e.g., the leading edge 114 of the composite structure) to ensure that the engine component 100 can withstand the force (F). It is conceivable that without the cover structure 104, the force (F) might damage certain portions of the composite structure 102.

[0068] Figure 3 It is along Figure 2 A schematic cross-sectional view of engine component 100 taken by section line III-III. Section line III-III is perpendicular to the wingspan direction (Sd). Although section line III-III is shown as approximately halfway between the composite structure root 110 and the composite structure tip 112, it can be located at any suitable portion of the composite structure leading edge 114, including the endpoints (e.g., the composite structure tip 112 and the composite structure root 110).

[0069] The corresponding portions of the main body 124 and the airfoil portion 106 meet at the joint 128. The joint 128 is configured such that when the cover structure 104 is attached to the composite structure 102, the outer portion of the main body 124 extends continuously from the outer wall 108 of the composite structure. In other words, the joint 128 may be configured such that the outer surface of the cover structure 104 abuts flush with the outer wall 108 of the composite structure. Alternatively, the joint 128 may be configured such that the outer surface of the cover structure 104 is recessed relative to the position of the outer wall 108 of the composite structure at the distal end 164 of the main body (e.g., radially closer to the centerline (C1)). The joint 128 is any suitable joint, such as, but not limited to, interlocking joints, butt joints, lap joints, etc.

[0070] The extension 126 and the main body 124 meet at the transition 130 shown by the dashed line. When viewed along section line III-III, the extension 126 includes any suitable cross-sectional area.

[0071] Engine component 100 includes a cover structure edge 162 and a composite structure trailing edge 116. Figure 2 The centerline (Cl) extends between the opposite edges of the engine component 100, which is an airfoil assembly. For the engine component 100 as an airfoil assembly, the centerline (Cl) is a mid-curve. However, it should be understood that the centerline (Cl) is any suitable centerline extending between the opposite edges of the engine component 100 and equidistant between the opposite surfaces of the composite structure outer wall 108.

[0072] The extension 126 has a cross-sectional area when viewed along a plane (e.g., section line III-III) that extends along the centerline (Cl). As shown, the cross-sectional area is rectangular. However, it should be appreciated that the cross-sectional area is any suitable shape, such as, but not limited to, circular, oval, triangular, rectangular, hexagonal, etc. As a non-limiting example, the cross-sectional area can be defined by a wavy (wavelike) cross-section. The extension 126 can be symmetric about the centerline (Cl). The extension 126 can be asymmetric about the centerline (Cl).

[0073] The cross-sectional area of the extension 126 can be constant or can vary along the extent of the channel 122. As a non-limiting example, the cross-sectional area of the extension 126 can vary in the spanwise direction (Sd). As a non-limiting example, the cross-sectional area of the extension 126 at the composite root 110 Figure 2 ) can be triangular, the cross-sectional area of the extension 126 between the composite root 110 and the composite tip 112 Figure 2 ) can be rectangular, and the cross-sectional area of the extension 126 at the composite tip 112 can be oval.

[0074] The variation in the cross-sectional area of the extension 126 is based on the cross-sectional area of the composite structure 102 where the cover structure 104 covers the composite structure 102 (e.g., along the composite leading edge 114). As a non-limiting example, the composite structure 102 can sweep along the composite leading edge 114 or include a non-constant cross-sectional area in the spanwise direction (Sd). These variations in the cross-sectional area of the composite structure 102 affect the formation of the extension 126. As a non-limiting example, a smaller cross-sectional area of the composite structure 102 in turn means that the extension 126 must be sized smaller than where the composite structure has a larger cross-sectional area. Moreover, it is contemplated that certain shapes of the extension 126 have better resistance to certain forces (e.g., force (F)) than others. As a non-limiting example, if the force (F) is an external force (e.g., bird strike), then the force (F) has a greater impact in the spanwise direction (Sd) closer to the composite tip 112 than the composite root 110. Thus, the cover structure 104, and particularly the extension 126, has a more robust design (e.g., with a larger cross-sectional area of the extension 126) closer to the composite tip 112 than the composite root 110. Figure 3

[0075] The most downstream or axially displaced body distal end of the set of body distal ends 164 is disposed a first centerline length (Cl1) from the body 124 at the transition 130. The body 124 can be symmetric about the centerline (Cl). The body 124 can be asymmetric about the centerline (Cl). ​

[0076] The extension 126 extends a second centerline length (Cl2) in the chordal direction (Cd) between the transition 130 and the distal end 166 of the extension. The first centerline length (Cl1) is greater than or equal to the second centerline length (Cl2). As a non-limiting example, the second centerline length (Cl2) is greater than or equal to 10% of the first centerline length (Cl1) and less than or equal to 100% of the first centerline length (Cl1). The distal end 166 of the extension is axially coincident with or axially offset from at least one of the distal ends 164 of the main body relative to the centerline (Cl).

[0077] It is conceivable that the selection of the second centerline length (Cl2) is for manufacturing and assembly purposes. Specifically, the shorter the second centerline length (Cl2), the easier it is to insert the extension 126 into the channel 122. Conversely, a longer second centerline length (Cl2) makes it more difficult to insert the extension 126 into the channel 122. However, the shorter the second centerline length (Cl2), the smaller the mating area between the cover structure 104 and the composite structure 102. Conversely, the longer the second centerline length (Cl2), the larger the mating area between the cover structure 104 and the composite structure 102, because the extension 126 is longer. As used herein, "mating area" is defined as the available surface area between the first structure (e.g., cover structure 104) and the second structure (e.g., composite structure 102) that can be used to join the two structures together. For example, when the composite structure 102 and the cover structure 104 are joined using an adhesive, the total available mating area is the total surface area of ​​the cover structure 104 in direct contact with the composite structure 102. A larger mating area means a stronger bond between the cover structure 104 and the composite structure 102. The above range (0.10Cl1≤Cl2≤Cl1) is chosen to ensure a sufficient balance between ease of manufacture and mating area.

[0078] Figure 4 It is applicable Figure 2 A schematic cross-sectional view of engine component 200 of engine component 100. Engine component 200 is similar to engine component 100; therefore, similar components will be identified by similar numbers increasing to the 200 series, and it should be understood that, unless otherwise stated, the description of engine component 100 applies to engine component 200.

[0079] Engine component 200 includes a composite structure 202 and a cover structure 204. Engine component 200 includes a centerline (C1). Composite structure 202 includes a composite structure outer wall 208 and a composite structure edge 268. Composite structure edge 268 can be any suitable edge of composite structure 202. As a non-limiting example, composite structure edge 268 can be, but is not limited to, a composite structure tip (e.g., ...). Figure 2composite structure tip 112), a composite structure root (e.g. Figure 2 composite structure root 110), a composite structure leading edge (e.g. Figure 2 composite structure leading edge 114), a composite structure trailing edge (e.g. Figure 2 composite structure trailing edge 116), etc. The channel 222 is formed along a composite structure edge 268. The composite structure 202 is any suitable composite structure such as, but not limited to, an airfoil portion (e.g. Figure 2 airfoil portion 106), a fan case (e.g. Figure 1 fan case 40), a shroud, etc. The cover structure 204 includes a main body 224 and an extension 226. The extension 226 meets the main body 224 at a transition 230, which is shown in dashed line. The cover structure 204 includes a cover structure edge 262, a set of main body distal ends 264, and extension distal ends 266. The cover structure 204 and the composite structure 202 meet at a joint 228.

[0080] The engine component 200 is similar to the engine component 100 in that the cover structure 204 is coupled to the composite structure 202. The cover structure 204 is disposed along the composite structure edge 268 and covers at least a portion of the composite structure outer wall 208. However, the engine component 200 further includes a set of alignment channels 232 and a set of aligners 234. As shown, each aligner of the set of aligners 234 is sized to fit within a respective aligner channel of the set of alignment channels 232. The set of aligners 234 and the set of alignment channels 232 are used to align or otherwise couple the cover structure 204 to the composite structure 202 in a desired manner or position. The set of aligners 234 and the set of alignment channels 232 also function as a lock. In other words, once the set of aligners 234 is disposed within the set of alignment channels 232, the cover structure 204 is locked or otherwise coupled to the composite structure 202. The extension 226, the set of aligners 234, and the set of alignment channels 232 collectively couple the cover structure 204 to the composite structure 202.

[0081] The set of aligners 234 is disposed on one of the cover structure 204 or the composite structure 202, and the set of alignment channels 232 is disposed on the other of the cover structure 204 or the composite structure 202. As a non-limiting example, the set of aligners 234 is disposed along the main body 224, and the set of alignment channels 232 is disposed along the composite structure outer wall 208. However, it should be appreciated that the cover structure 204 and the composite structure 202 each can include one or more respective aligners of the set of aligners 234 and one or more respective alignment channels of the set of alignment channels 232.

[0082] Each aligner of the set of aligners 234 includes a respective cross-sectional area. The respective cross-sectional area of each aligner of the set of aligners 234 is any suitable shape, such as but not limited to rectangular, circular, oval, triangular, barbed, and the like.

[0083] Figure 5 is suitable for use as an engine component 300 of an engine component 100 of Figure 2 . The engine component 300 is similar to the engine component 100, 200 Figure 4 ; therefore, like components will be identified with like numerals increased by 300, and it should be understood that the description of the engine component 100, 200 applies to the engine component 300, unless otherwise noted.

[0084] The engine component 300 includes a composite structure 302 and a cover structure 304. The engine component 300 includes a centerline (Cl). The composite structure 302 includes a composite structure outer wall 308 and a composite structure edge 368. The composite structure edge 368 can be any suitable edge of the composite structure 302. By way of non-limiting example, the composite structure edge 368 can be, but is not limited to, a composite structure tip (e.g., the composite structure tip 112 of Figure 2 ), a composite structure root (e.g., the composite structure root 110 of Figure 2 ), a composite structure leading edge (e.g., the composite structure leading edge 114 of Figure 2 ), a composite structure trailing edge (e.g., the composite structure trailing edge 116 of Figure 2 ), and the like. The channel 322 is formed along the composite structure edge 368. The composite structure 302 is any suitable composite structure, such as but not limited to an airfoil portion (e.g., the airfoil portion 106 of Figure 2 ), a fan casing (e.g., the fan casing 40 of Figure 1 ), a shroud, and the like. The cover structure 304 includes a main body 324 and an extension 326. The extension 326 meets the main body 324 at a transition 330, shown in dashed line. The cover structure 304 includes a cover structure edge 362, a set of main body distal ends 364, and an extension distal end 366. The cover structure 304 and the composite structure 302 meet at a joint 328.

[0085] The engine component 300 is similar to the engine component 100, 200 in that the cover structure 304 is coupled to the composite structure 302. The cover structure 304 is disposed along the composite structure edge 368 and covers at least a portion of the composite structure outer wall 308. However, the extension 326 includes a triangular cross-sectional area. The joint 328 is a butt joint, rather than a scarf joint like the joint 128 Figure 3 . The joint 328 can be sized such that the main body 324 and the composite structure outer wall 308 form a continuous surface, as shown.

[0086] Figure 6 is an engine component 400 suitable for use as an engine component 100 of Figure 2 . The engine component 400 is similar to the engine component 100, 200 Figure 4 ), 300 Figure 5 ; thus, like components will be identified with like numerals increased by 400, and it should be understood that the description of the engine component 100, 200, 300 applies to the engine component 400 unless otherwise noted.

[0087] The engine component 400 includes a composite structure 402 and a cover structure 404. The engine component 400 includes a centerline (Cl). The composite structure 402 includes a composite structure outer wall 408 and a composite structure edge 468. The composite structure edge 468 can be any suitable edge of the composite structure 402. By way of non-limiting example, the composite structure edge 468 can be, but is not limited to, a composite structure tip (e.g., the composite structure tip 112 of Figure 2 ), a composite structure root (e.g., the composite structure root 110 of Figure 2 ), a composite structure leading edge (e.g., the composite structure leading edge 114 of Figure 2 ), a composite structure trailing edge (e.g., the composite structure trailing edge 116 of Figure 2 ), and the like. A channel 422 is formed along the composite structure edge 468. The composite structure 402 is any suitable composite structure, such as, but not limited to, an airfoil portion (e.g., the airfoil portion 106 of Figure 2 ), a fan casing (e.g., the fan casing 40 of Figure 1 ), a shroud, and the like. The cover structure 404 includes a main body 424 and an extension 426. The extension 426 meets the main body 424 at a transition 430, shown in dashed line. The cover structure 404 includes a cover structure edge 462, a set of main body distal ends 464, and extension distal ends 466. The cover structure 404 and the composite structure 402 meet at a joint 428.

[0088] Engine component 400 is similar to engine components 100, 200, 300 in that a cover structure 404 is coupled to a composite structure 402. Cover structure 404 is disposed along a composite structure edge 468 and covers at least a portion of a composite structure outer wall 408. However, extension 426 includes a bifurcation such that extension 426 includes two or more branches 436 that terminate at respective extension distal ends 466. Each of the two or more branches 436 has a respective cross-sectional area that is any suitable shape such as, but not limited to, triangular, rectangular, ovular, trapezoidal, barbed, etc. The cross-sectional area of at least two of the two or more branches 436 can be the same. The cross-section of at least two of the two or more branches 436 can be different. The two or more branches 436 can be symmetric about a centerline (CI). The two or more branches 436 can be asymmetric about a centerline (CI). The two or more branches 436 can include any number of branches. As shown, the dimensions of joint 428 are such that body 424 is discontinuous with composite structure outer wall 408. In other words, a step is formed between composite structure outer wall 408 and body 424. Accordingly, joint 428 is defined as a stepped joint. As a non-limiting example, an outer surface or outer wall of the cover structure is disposed radially outward from outer wall 408 at body distal end 464 relative to centerline (CI).

[0089] Figure 3 is an engine component suitable for use in an engine component of Figure 2-7 Figure 2 Figure 8 Figure 2 is a schematic cross-sectional view of an engine component 500 suitable for use in an engine component of

[0090] Engine component 500 includes a composite structure 502 and a cover structure 504. Engine component 500 includes a centerline (CI). Composite structure 502 includes a composite structure outer wall 508 and a composite structure edge 568. Composite structure edge 568 can be any suitable edge of composite structure 502. As a non-limiting example, composite structure edge 568 can be, but is not limited to, a composite structure tip (e.g., composite structure tip 112 of Figure 4 Figure 5 Figure 6 Figure 7 ​​​​​​The composite structure trailing edge 116, etc. Channel 522 is formed along the edge 568 of the composite structure. The composite structure 502 is any suitable composite structure, such as, but not limited to, airfoil portions (e.g., Figure 1 The airfoil portion 106), the fan housing (e.g. Figure 1 The fan housing 40), shroud, etc. The cover structure 504 includes a main body 524 and an extension 526. The extension 526 intersects with the main body 524 at a transition 530 (shown by dashed lines). The cover structure 504 includes a cover structure edge 562, a set of main body distal ends 564, and extension distal ends 566. The cover structure 504 and the composite structure 502 intersect at a joint 528.

[0091] The engine component 500 is similar to engine components 100, 200, 300, and 400 in that a cover structure 504 is coupled to the composite structure 502. The cover structure 504 is disposed along the edge 568 of the composite structure and covers at least a portion of the outer wall 508 of the composite structure. However, the extension 526 includes a set of barbs 538 disposed along the extension 526. The set of barbs 538 extends into the composite structure 502. It is conceivable that the set of barbs 538 is used to reinforce the connection between the cover structure 504 and the composite structure 502. The set of barbs 538 is used to anchor or otherwise secure the cover structure 504 within the channel 522. The set of barbs 538 includes any number of one or more barbs. The set of barbs 538 further increases the mating area between the cover structure 504 and the composite structure 502 without increasing the length of the extension 526 (e.g., Figure 1 The second centerline length (Cl2). The extension 526 and a set of barbs 538 may be symmetrical about the centerline (Cl). The extension 526 and a set of barbs 538 may be asymmetrical about the centerline (Cl).

[0092] See Figure 1 It should be understood that cover structures 104, 204, 304, 404, and 504 may include any aspect or combination of aspects of cover structures 104, 204, 304, 404, and 504. As a non-limiting example, the cover structure may include elements along the cover structure (e.g., in...). Figure 1 The extensions having different cross-sectional areas in the wingspan direction (Sd) are such that the cover structure includes a rectangular cross-sectional area of ​​the extension 126, a set of alignment channels 232 of the engine component 200, a set of aligners 234 of the engine component 200, a triangular cross-sectional area of ​​the extension 326, two or more branches 436 of the extension 426, at least two of a set of barbs 538 of the extension 526, or any combination thereof.

[0093] Figure 1 It is applicable Figure 9FIG. 6 is a schematic cross-sectional view of an engine component 600 of the engine component 100. The engine component 600 is similar to the engine components 100, 200 Figure 2 ), 300 Figure 4 ), 400 Figure 5 ), 500 Figure 6 ); thus, like components will be identified with like numerals increased by 600 series, and it should be understood that the description of the engine components 100, 200, 300, 400, 500 applies to the engine component 600 unless otherwise noted.

[0094] The engine component 600 includes a composite structure 602 and a cover structure 604. The composite structure 602 includes a composite structure outer wall 608 extending between a composite structure leading edge 614 and a composite structure trailing edge 616. The composite structure 602 includes a channel 622. The channel 622 can be formed along the composite structure trailing edge 616. The cover structure 604 includes a main body 624 and an extension 626. The cover structure 604 includes a cover structure edge 662, a set of main body distal ends 664, and an extension distal end 666. The extension 626 is disposed within the channel 622.

[0095] The engine component 600 is similar to the engine components 100, 200, 300, 400, 500 in that the cover structure 604 is coupled to the composite structure 602. The cover structure 604 is disposed along a composite structure edge (e.g., the composite structure trailing edge 616) and covers at least a portion of the composite structure outer wall 608. However, as shown, the cover structure 604 is disposed along the composite structure trailing edge 616 and not the composite structure leading edge 614.

[0096] However, the engine component 600 is a casing of a turbine engine 682. The turbine engine 682 has an engine centerline 656, a set of fan blades 640 (e.g., Figure 7 the set of fan blades 42), and a set of fan vanes 642 (e.g. Figure 8 the set of airfoil guide vanes 82) housed within a fan casing (e.g., Figure 10 the fan casing 40). As described herein, the engine component 600 is a fan casing. The set of fan blades 640 and the set of fan vanes 642 are functionally similar to the set of fan blades 42 Figure 2 ) and the set of airfoil guide vanes 82 Figure 4 ). As a non-limiting example, the turbine engine 682 is a turbofan engine. The turbine engine 682 includes an engine casing 644. The engine casing 644 is any suitable casing separate from the fan casing (e.g., the engine component 600). As a non-limiting example, the engine casing 644 can be the engine casing 46 Figure 5 , a nacelle, etc.

[0097] The cover structure 604 can extend circumferentially around the entire engine centerline 656. The cover structure 604 can extend circumferentially around less than the entire engine centerline 656. The cover structure 604 can be a single unitary body. As a non-limiting example, the cover structure 604 can be formed as a continuous ring that forms a circumferential ring around the engine centerline 656. The cover structure 604 can be a plurality of segmented bodies circumferentially spaced apart around the engine centerline 656.

[0098] The cover structure 604 can operably couple the composite structure 602 to the engine case 644. As a non-limiting example, the cover structure 604 can be integrally formed with the engine case 644 or coupled to the engine case 644 by any suitable method, such as, but not limited to, gluing, adhering, fastening, etc. Thus, the cover structure 604 can define a coupling between the fan case (e.g., the engine component 600) and the engine case 644.

[0099] It is contemplated that mounting the composite structure 602 directly to the engine case 644 can cause damage to the composite structure 602. As a non-limiting example, during operation of the turbine engine 682, the engine component 600 can move axially, radially, or circumferentially relative to the engine centerline 656. If the composite structure 602 is allowed to freely move against or otherwise abrade another structure (e.g., the engine case 644), such movement can damage the composite structure 602. However, the cover structure 604 is more resistant to damage due to movement. Thus, providing the cover structure 604 along an edge of the composite structure 602 that would otherwise contact other portions of the turbine engine 682 protects the composite structure 602 from damage. Further, mounting the composite structure 602 to the engine case 644 by the cover structure 604 effectively stabilizes the composite structure 602, thereby reducing movement of the engine component 600.

[0100] It should be appreciated that the cover structure 604 is provided along any suitable edge of the composite structure 602, such as, but not limited to, the composite structure leading edge 614, the composite structure trailing edge 616, or any other suitable portion of the composite structure outer wall 608. As a non-limiting example, the engine component 600 can include two cover structures 604; one provided along the composite structure leading edge 614 and the other provided along the composite structure trailing edge 616. The cover structure 604 provided along the composite structure leading edge 614 is particularly advantageous along the leading edge of the fan case to prevent incoming debris (e.g., birds).

[0101] Figure 6 is an engine component suitable for use in an engine component of Figure 7 An illustrative cross-sectional view of an engine component 700 suitable for use in an engine component of Figure 8 , 300Figure 9 ), 400 ( Figure 2 ), 500 ( Figure 11 ), 600 ( Figure 10 ); thus, like components will be identified with like numerals increased by 700 series, and it should be understood that the description of the engine components 100, 200, 300, 400, 500, 600 applies to the engine components 700, unless otherwise noted.

[0102] The engine component 700 includes a composite structure 702 and a cover structure 704. The composite structure 702 includes a composite structure outer wall 708 extending between a composite structure leading edge 714 and a composite structure trailing edge 716. The composite structure 702 includes a channel 722. The channel 722 can be formed along the composite structure trailing edge 716. The cover structure 704 includes a main body 724 and an extension 726. The cover structure 704 includes a cover structure edge 762, a set of main body distal ends 764, and an extension distal end 766. The extension 726 is disposed within the channel 722.

[0103] The engine component 700 is similar to the engine components 100, 200, 300, 400, 500, 600 in that the cover structure 704 is coupled to the composite structure 702. The cover structure 704 is disposed along a composite structure edge (e.g., the composite structure trailing edge 716) and covers at least a portion of the composite structure outer wall 708.

[0104] The engine component 700, like the engine component 600, is disposed within a turbine engine 782 having an engine centerline 756, such as a set of fan blades 740, a set of fan vanes 742, and an engine casing 744. The engine component 700 is a fan casing that houses the set of fan blades 740 and the set of fan vanes 742. The cover structure 704 couples the composite structure 702 to the engine casing 744. However, the cover structure 704 is mechanically coupled to the composite structure 702 through the use of fasteners 746 in combination with the use of the extension 726. The combination use of the fasteners 746 and the extension 726 provides additional support between the coupling of the composite structure 702 and the cover structure 704.

[0105] The fasteners 746 can be formed as bolts that extend through respective portions of the composite structure 702 and the cover structure 704. The fasteners 746 can be formed as bolts that extend through respective portions of the extension 726.

[0106] Figure 12 is an engine component 800 suitable for use as an engine component of Figure 10 . The engine component 800 is similar to the engine components 100, 200 ( Figure 9 ), 300 ( ​ ), 400 ( ​), 500 ​ ), 600 ​ ), 700 ​ ; thus, like components will be identified with like numerals increased by 800 series, and it should be understood that the description of the engine components 100, 200, 300, 400, 500, 600, 700 applies to the engine components 800, unless otherwise noted.

[0107] The engine component 800 includes a composite structure 802 and a cover structure 804. The composite structure 802 includes a composite structure outer wall 808 extending between a composite structure leading edge 814 and a composite structure trailing edge 816. The cover structure 804 includes a main body 824. The engine component 800 is disposed within a turbine engine 882 having an engine centerline 856.

[0108] The engine component 800, like the engine component 100, is an airfoil assembly 870. However, the airfoil assembly 870 includes two adjacent airfoil portions 806 circumferentially spaced apart about the platform 858 relative to the engine centerline 856. However, it should be understood that the airfoil assembly 870 can include any number of two or more airfoil portions 806. Each of the two adjacent airfoil portions 806 includes an outer wall 872. Each outer wall 872 extends between a root 874 and a tip 876. Each outer wall 872 extends between a leading edge 878 and a trailing edge 880. Each outer wall 872 defines a suction side 884 and a pressure side 886.

[0109] The engine component 800 is similar to the engine components 100, 200, 300, 400, 500, 600, 700 in that the cover structure 804 is coupled to the composite structure 802. The cover structure 804 is disposed along the composite structure edge and covers at least a portion of the composite structure outer wall 808. However, the composite structure 802 is a midspan shroud. The midspan shroud (e.g., the composite structure 802) is disposed between the root 874 and the tip 876 of the two adjacent airfoil portions 806. The midspan shroud (e.g., the composite structure 802) extends from the suction side 884 of one of the two adjacent airfoil portions 806 to the pressure side 886 of the adjacent airfoil portion of the two adjacent airfoil portions 806. The midspan shroud (e.g., the composite structure 802) extends discontinuously between the two adjacent airfoil portions 806 such that the midspan shroud includes opposing midspan distal ends 854. The opposing midspan distal ends 854 interconnect respective portions of the composite structure leading edge 814 and the composite structure trailing edge 816. However, it should be understood that the midspan shroud (e.g., the composite structure 802) can extend continuously over an entire circumferential extent between the two adjacent airfoil portions 806.

[0110] As shown, the cover structure 804 includes two bodies disposed between the two adjacent airfoil portions 806: a first body 888 and a second body 890. The first body 888 is disposed on the first portion of the composite structure 802. The second body 890 is disposed on the second portion of the composite structure 802. While the first body 888 and the second body 890 are shown as separate, it should be appreciated that they can be integrally formed or otherwise formed as a unitary body. As a non-limiting example, a single body can extend between the opposing spanwise distal ends 854. As a non-limiting example, the spanwise shroud (e.g., the composite structure 802) can be continuously formed between the two adjacent airfoil portions 806, and the cover structure 804 can continuously extend as a single body along the spanwise shroud (e.g., the composite structure 802).

[0111] It should be appreciated that one or more of the two adjacent airfoil portions 806, or any other airfoil portion, can define a respective portion of the composite structure 802, or be a separate composite structure. Thus, one or more of the airfoil portions can include structures similar to the airfoil portion 106 ​ ) such that the cover structure 804, or a separate cover structure 804, can be coupled to any respective edge of any airfoil portion in conjunction with the cover structure 804 provided along the composite structure 802 defining the spanwise shroud.

[0112] ​ is a schematic cross-sectional view of the engine component 800 as seen from cross-sectional line XI-XI of ​ The cover structure 804 includes an extension 826 and a centerline (Cl). The extension 826 extends from the main body 824 at a transition 830 shown in dashed line. The extension 826 includes any suitable cross-sectional area. The composite structure includes a channel 822. The channel 822 and the extension 826 are sized such that the extension 826 fits within the channel 822. The cover structure 804 and the composite structure 802 meet at a joint 828.

[0113] ​ is a schematic cross-sectional view of the engine component 800 as seen from cross-sectional line XII-XII of ​ The first body 888 and the second body 890 meet at an interface 860. While shown as the first body 888 and the second body 890, it should be appreciated that the cover structure 804 can include a single body that interconnects the opposing spanwise distal ends 854.

[0114] The separation of the spanwise shroud (e.g., the composite structure 802) and the cover structure 804 between the first body 888 and the second body 890 allows the engine component 800 to move during operation. This movement of the engine component 800 ensures that stresses that would otherwise arise from the engine component 800 being too rigid to move do not occur.

[0115] However, if two or more composite sections of the composite structure 802 are in contact with each other and are moved in opposite directions, the movement of the engine component 800 can cause damage to the engine component 800. As a non-limiting example, if the opposing span distal ends 854 are in direct contact with each other, abrasion can occur between the opposing span distal ends 854, thereby damaging the opposing span distal ends 854. It is contemplated that certain materials, such as metal or plastic materials, are more resistant to abrasion than composite materials. Thus, the use of the cover structure 804 ensures that abrasion does not damage the engine component 800.

[0116] An advantage of the present disclosure includes a cover structure that has a stronger bond with the corresponding portion of the engine component to which it is coupled, as compared to conventional engine components having conventional cover structures. For example, conventional cover structures are coupled to the corresponding portion of the conventional engine component by traditional methods of welding, adhering, cementing, friction, fastening, etc.

[0117] When relying on fasteners or other external components to couple the conventional cover structure to the rest of the conventional engine component, additional components are needed to be added to the conventional engine component; thus, increasing the complexity, size, weight, and manufacturing burden of the conventional engine component. The increase in weight of the conventional engine component ultimately decreases the efficiency of the turbine engine. As described herein, the cover structure uses extensions to effectively couple the cover structure to the composite structure, thereby eliminating the need for a complex fastening system to couple the two together; thus, improving the overall efficiency of the turbine engine. However, in certain instances, a simple fastener (e.g., fastener 746 of FIG. 7) can be used to provide additional support and stability between the composite structure and the cover structure. In certain instances, a set of aligners and a set of alignment channels are used to lock, align, and couple the cover structure to the composite structure in conjunction with the extensions of the cover structure. ​

[0118] When relying on welding, adhering, friction, or cementing, the mating area determines the strength of the coupling. As described herein, the cover structure supports a greater mating area than conventional cover structures because the cover structure includes extensions, whereas conventional cover structures do not include extensions. Thus, the cover structure has a stronger bond with the composite structure than conventional cover structures.

[0119] ​The stronger bond between the cover structure and the composite structure further ensures that the engine component has a better ability to recover from forces (e.g., operational forces, external forces, etc.) compared to traditional engine components. When a force is applied to a traditional engine component, the cover structure can shift, damage, or fail to absorb the force as intended if the traditional cover structure does not sufficiently couple to the corresponding portion of the traditional engine component. However, as previously described, sufficient coupling can be ensured through the use of fasteners, which increases the complexity, weight, and manufacturing burden of the traditional engine component. When other coupling methods (e.g., welding, adhering, friction, gluing, etc.) are used, the ability of the cover structure to withstand higher forces depends on the cover structure fitting well with the corresponding portion of the engine component. As previously described, the cover structure has a larger fit area than traditional cover structures. Thus, the cover structure as described herein has a higher ability to recover from forces when welding, adhering, friction, or gluing is used as the coupling method.

[0120] In areas not yet described, different features and structures of various embodiments can be used in combination or replaced with each other as desired. All combinations or permutations of features described herein are contemplated by the disclosure.

[0121] This written description uses examples to describe aspects of the disclosure as claimed, including the best mode, and to enable any person skilled in the art to practice aspects of the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the aspects of the disclosure is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent

[0122] Further aspects are provided by the subject matter of the following clauses:

[0123] An engine component for a turbine engine, the engine component comprising: a composite structure having a composite structure outer wall, a composite structure edge, and a channel disposed along the composite structure edge; and a cover structure surrounding at least a portion of the composite structure outer wall, the cover structure comprising a main body extending along the at least a portion of the composite structure outer wall and an extension received within the channel.

[0124] The engine component of any of the preceding clauses, wherein the cover structure comprises a non-constant cross-sectional area along the composite structure edge when viewed along a plane that is locally perpendicular to the composite structure edge and intersects the cover structure.

[0125] The engine component of any of the preceding paragraphs, wherein the cover structure extends axially along the entire composite structure edge.

[0126] The engine component of any of the preceding paragraphs, wherein the composite structure includes an airfoil portion having an outer wall defining the composite structure outer wall.

[0127] The engine component of any of the preceding paragraphs, wherein the outer wall extends between a composite structure root and a composite structure tip and between a composite structure leading edge and a composite structure trailing edge, wherein the composite structure edge is at least one of the composite structure tip, the composite structure leading edge, or the composite structure trailing edge.

[0128] The engine component of any of the preceding paragraphs, wherein the composite structure edge is the composite structure leading edge.

[0129] The engine component of any of the preceding paragraphs, wherein the engine component is an airfoil assembly having an airfoil portion extending between a root and a tip and a midspan shroud extending from the airfoil assembly, the midspan shroud being the composite structure.

[0130] The engine component of any of the preceding paragraphs, wherein the cover structure covers at least a portion of a composite structure leading edge.

[0131] The engine component of any of the preceding paragraphs, wherein the composite structure outer wall extends between a composite structure leading edge and a composite structure trailing edge, the midspan shroud includes a midspan distal end interconnecting the composite structure trailing edge and the composite structure leading edge, and the cover structure covers at least a portion of the midspan distal end.

[0132] The engine component of any of the preceding paragraphs, wherein the turbine engine has an engine centerline; the airfoil assembly includes two adjacent airfoil portions circumferentially spaced relative to the engine centerline; the midspan shroud extends discontinuously between the composite structures to define circumferentially opposite midspan distal ends; and the cover structure is disposed along the opposite midspan distal ends.

[0133] The engine component of any of the preceding paragraphs, wherein the turbine engine includes a fan section and the composite structure is a fan casing of the fan section.

[0134] The engine component of any of the preceding paragraphs, wherein the cover structure is disposed along a composite structure trailing edge.

[0135] The engine component of any of the preceding paragraphs, wherein the turbine engine includes an engine casing, and wherein the cover structure operably couples the fan casing to the engine casing.

[0136] The engine component of any of the preceding paragraphs, wherein the composite structure includes an alignment channel disposed along the composite structure outer wall, and the cover structure includes an aligner disposed along the body, the aligner being received within the alignment channel.

[0137] The engine component of any of the preceding paragraphs, wherein the composite structure includes a centerline extending from the composite structure edge; the body extends axially relative to the centerline a first centerline length; and the extension extends axially relative to the centerline a second centerline length, the second centerline length being greater than or equal to 10% of the first centerline length and less than or equal to 100% of the first centerline length.

[0138] The engine component of any of the preceding paragraphs, wherein the extension includes a set of barbs extending into the composite structure.

[0139] The engine component of any of the preceding paragraphs, wherein the extension includes a triangular shape when viewed along a plane locally perpendicular to the composite structure edge and intersecting the extension.

[0140] The engine component of any of the preceding paragraphs, wherein at least a portion of the extension is bifurcated.

[0141] The engine component of any of the preceding paragraphs, wherein the extension includes a rectangular shape when viewed along a plane locally perpendicular to the composite structure edge and intersecting the extension.

[0142] The engine component of any of the preceding paragraphs, wherein the cover structure includes at least one of a metallic material or a plastic material.

[0143] The engine component of any of the preceding paragraphs, wherein the cover structure includes at least one of titanium, aluminum, or polyurethane.

[0144] The engine component of any of the preceding paragraphs, wherein the composite structure includes a composite material, the composite material including at least one of a polymer matrix composite material, a ceramic matrix composite material, a metal matrix composite material, a carbon fiber, a polymer resin, a thermoplastic, a bismaleimide, a polyimide, an epoxy resin, a glass fiber, or a silicon matrix.

[0145] The engine component of any of the preceding paragraphs, further comprising a fastener operably coupling the cover structure to the composite structure.

[0146] The engine component of any of the preceding paragraphs, wherein the fastener extends through respective portions of the composite structure and the cover structure.

[0147] The engine component of any of the preceding paragraphs, wherein the fastener extends through respective portions of the extension.

[0148] The engine component of any of the preceding paragraphs, wherein the cover structure continuously extends from the composite structure outer wall when the cover structure is coupled to the composite structure.

[0149] The engine component of any of the preceding paragraphs, wherein an outer surface of the cover structure is flush against the outer wall at a body distal end relative to the outer wall.

[0150] The engine component of any of the preceding paragraphs, wherein an outer surface of the cover structure is recessed relative to the outer wall at a body distal end.

[0151] The engine component of any of the preceding paragraphs, wherein the outer surface of the cover structure is disposed radially outward relative to the outer wall at a body distal end to form a stepped joint.

[0152] The engine component of any of the preceding paragraphs, wherein the cover structure is pre-cured or co-molded with the composite structure.

[0153] The engine component of any of the preceding paragraphs, wherein a joint is formed between the cover structure and the composite structure, the joint being at least one of a butt joint, a lap joint, a scarf joint, or a stepped joint.

[0154] A turbine engine, comprising: an engine core having a compressor section, a combustion section, and a turbine section in a serial flow arrangement, the engine core defining a rotor and a stator; an engine case surrounding at least a portion of the engine core; a fan section coupled to the rotor, the fan section including a fan case, the fan case including a composite structure having an outer wall, a composite structure edge, and a channel disposed along the composite structure edge; and a cover structure surrounding at least a portion of the outer wall, the cover structure coupling the fan case to the engine case.

[0155] The turbine engine of any of the preceding paragraphs, wherein the cover structure comprises a non-constant cross-sectional area along the composite structure edge when viewed along a plane locally perpendicular to the composite structure edge and intersecting the cover structure.

[0156] The turbine engine of any of the preceding paragraphs, wherein the cover structure extends axially along the entire composite structure edge.

[0157] The turbine engine of any of the preceding paragraphs, wherein the composite structure comprises an airfoil portion having an outer wall defining the composite structure outer wall.

[0158] The turbine engine of any of the preceding paragraphs, wherein the outer wall extends between a composite structure root and a composite structure tip and between a composite structure leading edge and a composite structure trailing edge, wherein the composite structure edge is at least one of the composite structure tip, the composite structure leading edge, or the composite structure trailing edge.

[0159] The turbine engine of any of the preceding paragraphs, wherein the composite structure edge is the composite structure leading edge.

[0160] The turbine engine of any of the preceding paragraphs, wherein the engine component is an airfoil assembly having an airfoil portion extending between a root and a tip and a midspan shroud extending from the airfoil assembly, the midspan shroud being the composite structure.

[0161] The turbine engine of any of the preceding paragraphs, wherein the composite structure covers at least a portion of a composite structure leading edge.

[0162] The turbine engine of any of the preceding paragraphs, wherein the composite structure outer wall extends between a composite structure leading edge and a composite structure trailing edge, the midspan shroud includes a midspan distal end interconnecting the composite structure trailing edge and the composite structure leading edge, the cover structure covering at least a portion of the midspan distal end.

[0163] The turbine engine of any of the preceding paragraphs, wherein the turbine engine has an engine centerline; the airfoil assembly includes two adjacent airfoil portions circumferentially spaced relative to the engine centerline; the midspan shroud extends discontinuously between the composite structures to define circumferentially opposing midspan distal ends; and the cover structure is disposed along the opposing midspan distal ends.

[0164] The turbine engine of any of the preceding paragraphs, wherein the turbine engine includes a fan section and the composite structure is a fan casing of the fan section.

[0165] The turbine engine of any of the preceding paragraphs, wherein the cover structure is disposed along a composite structure trailing edge.

[0166] The turbine engine of any of the preceding paragraphs, wherein the turbine engine includes an engine casing, and wherein the cover structure operably couples the fan casing to the engine casing.

[0167] The turbine engine of any of the preceding paragraphs, wherein the composite structure includes an alignment channel disposed along the composite structure outer wall, and the cover structure includes an aligner disposed along the body, the aligner being received within the alignment channel.

[0168] The turbine engine of any of the preceding paragraphs, wherein the composite structure includes a centerline extending from the composite structure edge; the body extends axially relative to the centerline a first centerline length; and the extension extends axially relative to the centerline a second centerline length, the second centerline length being greater than or equal to 10% of the first centerline length and less than or equal to 100% of the first centerline length.

[0169] The turbine engine of any of the preceding paragraphs, wherein the extension includes a set of barbs extending into the composite structure.

[0170] The turbine engine of any of the preceding paragraphs, wherein the extension includes a triangular shape when viewed along a plane locally perpendicular to the composite structure edge and intersecting the extension.

[0171] The turbine engine of any of the preceding paragraphs, wherein at least a portion of the extension is bifurcated.

[0172] The turbine engine of any of the preceding paragraphs, wherein the extension includes a rectangular shape when viewed along a plane locally perpendicular to the composite structure edge and intersecting the extension.

[0173] The turbine engine of any of the preceding paragraphs, wherein the cover structure includes at least one of a metallic material or a plastic material.

[0174] The turbine engine of any of the preceding paragraphs, wherein the cover structure includes at least one of titanium, aluminum, or polyurethane.

[0175] The turbine engine of any of the preceding clauses, wherein the composite structure comprises a composite material comprising at least one of a polymer matrix composite, a ceramic matrix composite, a metal matrix composite, carbon fiber, a polymer resin, a thermoplastic, bismaleimide, polyimide, epoxy, glass fiber, or a silicon matrix.

[0176] The turbine engine of any of the preceding clauses, wherein the engine component further comprises a fastener operably coupling the cover structure to the composite structure.

[0177] The turbine engine of any of the preceding clauses, wherein the fastener extends through respective portions of the composite structure and the cover structure.

[0178] The turbine engine of any of the preceding clauses, wherein the fastener extends through respective portions of the extension.

[0179] The turbine engine of any of the preceding clauses, wherein the cover structure continuously extends from the composite structure outer wall when the cover structure is coupled to the composite structure.

[0180] The turbine engine of any of the preceding clauses, wherein an outer surface of the cover structure is flush against the outer wall at the body distal end relative to the outer wall.

[0181] The turbine engine of any of the preceding clauses, wherein an outer surface of the cover structure is recessed relative to the outer wall at the body distal end.

[0182] The turbine engine of any of the preceding clauses, wherein the outer surface of the cover structure is disposed radially outward relative to the outer wall at the body distal end to form a stepped joint.

[0183] The turbine engine of any of the preceding clauses, wherein the cover structure is pre-cured or co-molded with the composite structure.

[0184] The turbine engine of any of the preceding clauses, wherein a joint is formed between the cover structure and the composite structure, the joint being at least one of a butt joint, a lap joint, a scarf joint, or a stepped joint.

Claims

1. An engine component for a turbine engine, characterized in that, The engine components include: A composite structure having an outer wall, an edge, and a channel along the edge; and A cover structure that surrounds at least a portion of the outer wall of the composite structure, the cover structure including a body and an extension, the body extending along the at least a portion of the outer wall of the composite structure, the extension being received within the channel.

2. The engine component according to claim 1, characterized in that, When viewed along a plane that is locally perpendicular to the edge of the composite structure and intersects with the cover structure, the cover structure includes a region of non-constant cross-section along the edge of the composite structure.

3. The engine component according to claim 1, characterized in that, The cover structure extends axially along the entire edge of the composite structure.

4. The engine component according to claim 1, characterized in that, The composite structure includes an airfoil portion having an outer wall defining the outer wall of the composite structure.

5. The engine component according to claim 4, characterized in that, The outer wall of the composite structure extends between the root and tip of the composite structure and between the leading and trailing edges of the composite structure, wherein the edge of the composite structure is at least one of the tip, leading edge, or trailing edge of the composite structure.

6. The engine component according to claim 5, characterized in that, The edge of the composite structure is the leading edge of the composite structure.

7. The engine component according to claim 1, characterized in that, The engine component therein is an airfoil assembly having an airfoil portion and a mid-span shield, the airfoil portion extending between a root and a tip, and the mid-span shield extending from the airfoil assembly, the mid-span shield being the composite structure.

8. The engine component according to claim 7, characterized in that, The cover structure covers at least a portion of the leading edge of the composite structure.

9. The engine component according to claim 7, characterized in that, The outer wall of the composite structure extends between the front edge and the rear edge of the composite structure, the mid-span cover includes a mid-span distal end that interconnects the rear edge and the front edge of the composite structure, and the cover structure covers at least a portion of the mid-span distal end.

10. The engine component according to claim 7, characterized in that, in: The turbine engine has an engine centerline; The airfoil assembly includes two adjacent airfoil portions that are circumferentially spaced apart relative to the engine centerline; The mid-span shroud extends discontinuously between the two adjacent airfoil portions to define circumferentially opposite mid-span distal ends; and The cover structure is positioned along the distal end of the opposite mid-span.

Images