Gas turbine engine with airfoil having disengagement feature

Abstract

A gas turbine engine includes a fan section, a compressor section, a combustion section. The airfoil is disposed in one of the fan section, the compressor section, or the turbine section, and includes an outer wall defining an interior. A first portion is positioned within the interior and at least one disengagement feature is positioned within the first portion to disengage or separate within the first portion in response to a force exceeding a predetermined threshold.

Description

Technical Field

[0001] This disclosure generally relates to airfoils for gas turbine engines, and to components of gas turbine engines including airfoils. Background Technology

[0002] A turbofan engine typically comprises an engine core with a compressor section, a combustor section, and a turbine section arranged in a series flow configuration. A fan section may be located upstream of the compressor section. The compressor section compresses air directed to the combustor section, where the air is mixed with fuel, and the mixture is then ignited to generate hot combustion gases. The combustion gases are directed to the turbine section, where energy is extracted from the combustion gases to power the compressor section and to generate useful work to propel the aircraft in flight or power loads such as generators.

[0003] Composite materials typically consist of a fiber-reinforced matrix and exhibit a high strength-to-weight ratio. Due to their high strength-to-weight ratio and formability into relatively complex shapes, composite materials are used in a variety of applications, such as turbine engines or aircraft. For example, composite materials can be installed on or define a portion of fuselages and / or wings, rudders, manifolds, airfoils, or other components of aircraft or turbine engines. Attached Figure Description

[0004] The complete and feasible disclosure of this disclosure, including its best mode, is set forth in the specification with reference to the accompanying drawings, for those skilled in the art, wherein:

[0005] Figure 1 This is a schematic cross-sectional view of a turbine engine based on the aspects described herein.

[0006] Figure 2 It is suitable in accordance with the aspects described in this article. Figure 1 A schematic perspective view of the airfoil assembly used in a turbine engine.

[0007] Figure 3 Based on the aspects described in this article Figure 2 The airfoil section diagram shows the interior, including the detachment feature.

[0008] Figure 4 It is cut along section IV-IV according to the aspects described in this article. Figure 3 The chordal section view of the airfoil shows the arrangement and position of the separation features in the chordal plane.

[0009] Figure 5 It is a cross-sectional view of an airfoil according to the aspects described herein, the airfoil having a first portion and a second portion including a disengagement feature and connected to a shank.

[0010] Figure 6 It is cut along section VI-VI according to the aspects described in this article. Figure 5 The chordal section view of the airfoil shows the detachment feature arranged in the second part.

[0011] Figure 7 It was cut along section VII-VII according to the aspects described in this article. Figure 5 The chordal cross-sectional view of the airfoil shows the detachment features that extend fully and partially between the pressure and suction sides of the skin layer.

[0012] Figure 8 The airfoil section diagram, based on the aspects described herein, shows the detachment features of the airfoil as a component of angular stripes, multiple sets of fillers and openings, and the airfoil stripes.

[0013] Figure 9 It is cut along section IX-IX according to the aspects described in this article. Figure 8 A cross-sectional view of the airfoil, which is aligned with one of the angled strips in the angular stripe.

[0014] Figure 10 The airfoil section view based on the aspects described herein shows the separation features of the chordal strips and chordal paired holes arranged in the radially outward first part.

[0015] Figure 11 It is cut along section XI-XI according to the aspects described in this article. Figure 10 The chordal cross-sectional view of the airfoil shows the separation features as chordal paired holes and additional holes that partially extend between the pressure side and the suction side. Detailed Implementation

[0016] The embodiments described in this disclosure relate to composite components, and particularly as composite airfoils for turbine engines. For illustrative purposes, this disclosure will be described with respect to airfoils for aircraft turbine engines. However, it will be understood that this disclosure is not limited thereto and can be generally applicable in applications such as non-aircraft or non-turbine engine applications, other airfoil-based applications or component applications (such as other mobile and non-mobile industrial, commercial, and residential applications), or in applications where composite components or detached features can be utilized.

[0017] As used herein, the term "front" or "upstream" refers to movement in the direction toward the engine inlet, or one component being relatively closer to the engine inlet compared to another component. The term "rear" or "downstream," used in conjunction with "front" or "upstream," refers to movement in the direction toward the rear of the engine or the outlet, or one component being relatively closer to the engine outlet compared to another component.

[0018] As used herein, "a set" can include any number of separately described elements, including only one element. Additionally, as used herein, the terms "radial" or "radially" refer to the dimension extending between the central longitudinal axis of the engine and the outer periphery of the engine.

[0019] All directional references (e.g., radial, axial, proximal, distal, up, down, upward, downward, left, right, lateral, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, backward, etc.) are for illustrative purposes only to aid the reader in understanding this disclosure and do not impose limitations, particularly regarding the location, orientation, or use of this disclosure. Connecting references (e.g., attachment, connection, joint, and engagement) are to be interpreted broadly and may include intermediate members between sets of elements and relative movement between elements, unless otherwise indicated. Therefore, a connecting reference does not necessarily mean that two elements are directly connected and fixed relative to each other. Exemplary figures are for illustrative purposes only, and the dimensions, positions, order, and relative sizes reflected in the accompanying figures may vary.

[0020] As used herein, “wingspan” or “wingspan direction” can refer to the direction extending along the wingspan between the tip and root of the airfoil structure. As used herein, “chord direction” or “chord direction” can refer to a cross-sectional view taken extending in the direction between the leading and trailing edges of the airfoil structure.

[0021] As used herein, a “detachment feature” can include features that form, set or otherwise define within a body, which are designed to detach or separate a portion of the body from the remainder of the body in a predetermined manner, wherein such predetermined manner may be one or more of the following: under a threshold force, in a predetermined direction, or at a predetermined location, region or volume.

[0022] As used herein, the term "composite" refers to a component having two or more materials. A composite can be a combination of at least two or more metals, nonmetals, or metal and nonmetal 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, polymeric resins, thermoplastic resins, bismaleimide (BMI) materials, polyimide materials, epoxy resins, glass fibers, and silicon matrix materials.

[0023] As used herein, a "composite" component refers to a structure or component comprising any suitable composite material. A composite component (e.g., a composite airfoil) may comprise several layers or several plies of composite material. The stiffness, material, and dimensions of the layers or plies may vary to achieve a composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0024] One or more layers of adhesive can be used to form or join composite components. The adhesive may include resins and phenolic resins, and the adhesive may be cured at elevated temperatures or other curing techniques.

[0025] As used herein, PMC refers to a class of materials. As an example, PMC materials are partially defined by prepregs, which are reinforcing materials pre-impregnated with a polymer matrix material (e.g., a thermoplastic resin). Non-limiting examples of processes used to produce thermoplastic prepregs include: hot melt prepreg, in which the fiber reinforcement is drawn through a molten bath of resin; and powder prepreg, in which the resin is deposited onto the fiber reinforcement, as a non-limiting example, electrostatically deposited onto the fiber reinforcement, and then adhered to the fibers, as a non-limiting example, in an oven or with the aid of heated rollers. The prepregs may be in the form of unidirectional tapes or woven fabrics, which are then stacked on top of each other to produce a layup number for forming parts.

[0026] Multilayer prepregs are stacked to the appropriate thickness and orientation of the composite part, and then the resin is cured and solidified to provide fiber-reinforced composite parts. Resins used for PMC matrix materials are generally classified as thermosetting or thermoplastic resins. Thermoplastic resins are generally classified as polymers that can repeatedly soften and flow upon heating and harden upon sufficient cooling due to physical rather than chemical changes. Well-known examples of thermoplastic resins include nylon, thermoplastic polyesters, polyaryletherketones (PAEKs), and polycarbonate resins. Specific examples of high-performance thermoplastic resins envisioned for aerospace applications include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK), and polyphenylene sulfide (PPS). In contrast, thermosetting resins do not undergo significant softening upon heating once fully cured into a rigid solid, but rather thermally decompose upon sufficient heating. Well-known examples of thermosetting resins include epoxy resins, bismaleimide (BMI), and polyimide resins.

[0027] Instead of using prepreg, in another non-limiting example, woven fabrics can be utilized by using thermoplastic polymers. Woven fabrics may include, but are not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg woven structures can be fabricated in a similar manner. With this method, the fiber volume of the part can be customized by specifying the relative concentrations of the woven or braided thermoplastic fibers and reinforcing fibers. Furthermore, different types of reinforcing fibers can be woven or braided together at different concentrations to customize the properties of the part. For example, glass fibers, carbon fibers, and thermoplastic fibers can be woven together at different concentrations to customize the properties of the part. Carbon fibers provide the strength of the system, can be incorporated into glass fibers to enhance impact characteristics—a design feature of parts located near the engine inlet—and thermoplastic fibers provide bonding for the reinforcing fibers.

[0028] In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of a composite part. Typically, RTM involves applying a dry fiber or matrix material to a mold or cavity. The dry fiber or matrix material may include prepreg, braided material, woven material, or any combination thereof.

[0029] Resin can be pumped into or otherwise supplied to a mold or cavity to impregnate dry fibers or matrix material. The impregnated fibers or matrix material, combined with the resin, is then cured and removed from the mold. The composite component can be post-cured upon removal from the mold.

[0030] It is conceivable that RTM could be a vacuum-assisted process. That is, air in the cavity or mold can be removed and replaced with resin before heating or curing. It is further conceivable that the placement of dry fibers or matrix materials can be manual or automated.

[0031] Dry fibers or matrix materials can be molded to form composite components or guide resins. Optionally, additional layers or reinforcing layers of materials different from the dry fibers or matrix materials may be included or added prior to heating or curing.

[0032] As used herein, CMC refers to a class of materials having reinforcing fibers within a ceramic matrix. Typically, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of reinforcing fibers may 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, alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates (such as mullite), or mixtures thereof), or mixtures thereof.

[0033] Examples of ceramic matrix materials may 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, alumina (Al₂O₃), 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) may also be included within the ceramic matrix.

[0034] Typically, a particular CMC can be referred to as a combination of its fiber type / matrix type. For example, C / SiC is carbon fiber reinforced silicon carbide, SiC / SiC is silicon carbide fiber reinforced silicon carbide, SiC / SiN is silicon carbide fiber reinforced silicon nitride, and SiC / SiC-SiN is a silicon carbide fiber-reinforced silicon carbide / silicon nitride matrix mixture, etc. In other examples, a CMC may consist of a matrix comprising an oxide-based material (such as alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates, and mixtures thereof) and reinforcing fibers. Aluminosilicates may include crystalline materials (e.g., mullite (3Al₂O₃·2SiO₂)) as well as glassy aluminosilicates.

[0035] In some non-limiting examples, the reinforcing fibers may be bundled and / or coated before being incorporated into the matrix. For example, the fiber bundles may be formed as reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes may be stacked together to form a preform component. The fiber bundles may be impregnated with a slurry composition before or after the formation of the preform. The preform may then undergo heat treatment and subsequent chemical treatment to obtain a component formed from a CMC material having a predetermined chemical composition. For example, the preform may undergo curing or burnout to produce a high coke residue in the preform and subsequently melt infiltration with silicon, or undergo curing or pyrolysis to produce a silicon carbide matrix in the preform and subsequently chemical vapor infiltration with silicon carbide. Additional steps may be taken to enhance the densification of the preform, either before or after chemical vapor infiltration, by injecting the preform with a liquid resin or polymer and then performing a heat treatment step to fill the voids with silicon carbide. The CMC materials used herein can be formed using any known or later developed methods (including, but not limited to, melt infiltration, chemical vapor infiltration, polymer impregnation pyrolysis (PIP), or any combination thereof).

[0036] These materials, along with certain monolithic ceramics (i.e., ceramic materials without reinforcement), are particularly well-suited for higher-temperature applications. Furthermore, these ceramic materials are lighter than superalloys while still providing strength and durability for components made from them. Therefore, the use of such materials in many gas turbine components used in the higher-temperature range of gas turbine engines (such as airfoils (e.g., turbine and blades), combustors, shields, etc.) is currently being considered, as they will benefit from the lighter weight and higher-temperature capabilities these materials can offer.

[0037] As used herein, the term "metal" refers to materials that include metals (such as, but not limited to, titanium, iron, aluminum, stainless steel, and nickel alloys). Metallic materials or alloys can be combinations of at least two or more elements or materials, at least one of which is a metal.

[0038] Figure 1 This is a schematic cross-sectional view of a gas turbine engine 10 for use in an aircraft. The gas turbine engine 10 has a generally longitudinally extending axis or centerline 12 extending from the front 14 to the rear 16. The gas turbine engine 10 includes the following downstream series flow relationships: a fan section 18, which includes a fan 20; a compressor section 22, which includes a turbocharger or low-pressure (LP) compressor 24 and a high-pressure (HP) compressor 26; a combustion section 28, which includes a combustor 30; a turbine section 32, which includes an HP turbine 34 and an LP turbine 36; and an exhaust section 38.

[0039] Fan section 18 includes a fan housing 40 surrounding fan 20. Fan 20 includes a plurality of fan blades 42 arranged radially about centerline 12. HP compressor 26, combustor 30 and HP turbine 34 form the core 44 of gas turbine engine 10, which generates combustion gases. Core 44 is surrounded by core housing 46, which can be coupled to fan housing 40.

[0040] An HP shaft or spool 48, coaxially arranged around the centerline 12 of the gas turbine engine 10, drives the HP turbine 34 to the HP compressor 26. An LP shaft or spool 50, coaxially arranged around the centerline 12 of the gas turbine engine 10 within a larger diameter annular HP spool 48, drives the LP turbine 36 to the LP compressor 24 and the fan 20. The spools 48 and 50 are rotatable about the centerline 12 and are coupled to multiple rotatable elements that collectively define the rotor 51.

[0041] LP compressor 24 and HP compressor 26 each include multiple compressor stages 52 and 54, respectively, in which a set of compressor blades 56 and 58 rotate relative to a corresponding set of static compressor blades 60 and 62 to compress or pressurize the fluid flow passing through the stage. In a single compressor stage 52 or 54, the multiple compressor blades 56 and 58 may be arranged in a ring and may extend radially outward from the blade platform relative to the centerline 12 to the blade tips, while the corresponding static compressor blades 60 and 62 are positioned upstream of and adjacent to the rotating compressor blades 56 and 58. It is worth noting that... Figure 1 The number of blades, impellers, and compressor stages shown is selected for illustrative purposes only, and other numbers are also possible.

[0042] The compressor blades 56 and 58 for the first stage of LP and HP compressors 24 and 26 can be mounted to (or integrated into) a disc 61, which is mounted to a corresponding one of the HP and LP spools 48 and 50. The static compressor impellers 60 and 62 for the first stage of LP and HP compressors 24 and 26 can be mounted to the core housing 46 in a circumferential arrangement.

[0043] HP turbine 34 and LP turbine 36 each comprise multiple turbine stages 64 and 66, in which a set of turbine blades 68 and 70 rotate relative to a corresponding set of static turbine blades 72 and 74 (also referred to as nozzles) to extract energy from the fluid flow passing through the stage. In a single turbine stage 64 and 66, the multiple turbine blades 68 and 70 may be arranged in a ring and may extend radially outward relative to a centerline 12, while the corresponding static turbine blades 72 and 74 are positioned upstream of and adjacent to the rotating turbine blades 68 and 70. It is worth noting that... Figure 1 The number of blades, impellers, and turbine stages shown is selected for illustrative purposes only; other numbers are also possible.

[0044] Turbine blades 68 and 70 for the first stage of HP and LP turbines 34 and 36 can be mounted to disc 71, which is mounted to a corresponding one of HP and LP spools 48 and 50. Static turbine blades 72 and 74 for the first stage of LP and HP compressors 24 and 26 can be mounted to the core housing 46 in a circumferential arrangement.

[0045] Complementing the rotor section, the stationary parts of the gas turbine engine 10 (e.g., the static compressor and turbine blades 60, 62, 72, 74 in the compressor section 22 and turbine section 32) are also referred to individually or collectively as the stator 63. Therefore, the stator 63 can refer to the combination of non-rotating elements throughout the gas turbine engine 10.

[0046] In operation, the airflow leaving fan section 18 is split, with a portion directed to LP compressor 24 as pressurized airflow 76 to HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from HP compressor 26 mixes with and ignites fuel in combustor 30, generating combustion gases. HP turbine 34 extracts some work from these gases, driving HP compressor 26. The combustion gases are discharged to LP turbine 36, which extracts additional work to drive LP compressor 24, and the exhaust gas is ultimately discharged from gas turbine engine 10 via exhaust section 38. The drive of LP turbine 36 drives LP spool 50 to rotate fan 20 and LP compressor 24.

[0047] A portion of the pressurized gas flow 76 can be drawn from the compressor section 22 as bleed air 77. Bleed air 77 can be drawn 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 increased. Therefore, the cooling provided by bleed air 77 can be used to operate these engine components in an elevated temperature environment.

[0048] The remaining airflow exiting fan section 18 (referred to as bypass airflow 78) bypasses the LP compressor 24 and core 44, and exits the gas turbine engine 10 via a stationary blade row at the fan exhaust side 84, and more specifically, via an outlet guide vane assembly 80 (comprising multiple airfoil guide vanes 82) at the fan exhaust side 84. More specifically, the airfoil guide vanes 82 are arranged in a circumferential row of radially extending airfoil guide vanes 82 used adjacent to fan section 18 to exert some directional control on the bypass airflow 78.

[0049] Figure 2 Is it suitable for Figure 1 A schematic perspective view of the airfoil assembly 100 and disk 102 used in the gas turbine engine 10. Disk 102 is suitable for use as disk 61, 71 ( Figure 1 ) or any other disk, such as, but not limited to, gas turbine engine 10 ( Figure 1 Fan section 18 () Figure 1 ), compressor section 22 ( Figure 1 ) or turbine section 32 ( Figure 1 The airfoil assembly 100 can be rotatable or non-rotating, such that the airfoil assembly 100 can include static compressor blades 60, 62. Figure 1 ), compressor blades 56, 58 ( Figure 1 ), static turbine blades 72, 74 ( Figure 1 ), turbine blades 68, 70 ( Figure 1 ) or multiple fan blades 42 ( Figure 1At least one of the following. As a non-limiting example, the airfoil assembly 100 may be a composite airfoil (such as a composite fan blade) or at least partially made of composite material.

[0050] The airfoil assembly 100 includes an airfoil 104, which is coupled to or integrally formed with a mounting portion or a shank portion 106. The airfoil 104 extends between a leading edge 110 and a trailing edge 112 to define a chordal direction, extends between a root 114 and a tip 116 to define a span direction, and includes a pressure side 118 and a suction side 120.

[0051] Disk 102 can rotate or remain stationary about axis of rotation 122. The axis of rotation 122 can be aligned with center line 12 (…). Figure 1 ) Coincident, parallel, or offset. The disk 102 includes a plurality of slots 108 extending axially through the radial outer surface 124 of the disk 102. The plurality of slots 108 are circumferentially spaced about the disk 102 relative to the axis of rotation 122 and allow the airfoil assembly 100 to be slidably secured to the disk 102 at the shank 106.

[0052] The airfoil assembly 100 is coupled to the disk 102 by inserting at least a portion (such as the shank 106) of the airfoil assembly 100 into a corresponding slot 108 among a plurality of slots 108. The airfoil assembly 100 can be coupled to the slots 108 via any suitable coupling method (such as, but not limited to, welding, bonding, fastening, etc.). Although only a single airfoil assembly 100 is shown, it will be understood that any number of one or more airfoil assemblies 100 can be coupled to the disk 102. As a non-limiting example, a plurality of airfoil assemblies 100 corresponding to the total number of slots 108 may exist.

[0053] For ease of reference, a set of relative reference directions and a coordinate system can be applied to the airfoil assembly 100 and the disk 102. An axial direction (Ad) can extend from front to back and is shown to extend at least partially into the page. The axial direction (Ad) can be arranged parallel to the axis of rotation 122, which can also be arranged parallel to the centerline 12 (…). Figure 1 The radial direction (Rd) extends perpendicular to the axial direction (Ad), and the radial direction (Rd) can be perpendicular to the centerline 12. Figure 1 The circumferential direction (Cd) can be defined as perpendicular to the radial direction (Rd), the circumferential direction (Cd) can be defined as the curvature along the circumference of a circle about the axial direction (Ad), can be defined as a ray locally extending from the radial direction (Rd), and / or can be defined relative to the centerline 12 ( Figure 1 ) or rotation axis 122 ( Figure 1 Along the gas turbine engine 10 ( Figure 1 The circumference of ).

[0054] Figure 3 The diagram shows a cross-sectional view of the airfoil 126, which can be... Figure 2 The airfoil 104 includes an interior 130 defined within an outer wall 138. A first airfoil portion 132 and a second airfoil portion 134 are positioned within the interior 130. For example, the first airfoil portion 132 may be a spar portion, which may be a structural portion or spar coupled to and extending from the shank 128. Further contemplated, the shank 128 may extend into the interior 130 to engage with the first airfoil portion 132. In a non-limiting example, for example, the shank 128 may at least partially define a mounting portion (such as... Figure 2 The handle 106) is used to connect the airfoil 126 to the disk, such as Figure 2 The disc 102. The second airfoil portion 134 is positioned within the interior 130, between the first airfoil portion 132 and the skin layer 136. In a non-limiting example, the skin layer 136 may form the outer wall 138 of the airfoil 126, while additional external materials, coatings, or layers may be considered, including but not limited to external sealing or finishing layers, such as corrosion-resistant or erosion-resistant layers, paint layers, UV or heat-resistant layers, hydrophobic or icing-resistant layers, or combinations thereof.

[0055] The first airfoil portion 132 or the skin layer 136, or both, may be laminated, such as formed from a set of laminated layups stacked together. In a non-limiting example, the first airfoil portion 132 or the skin layer 136, or both, may be a composite portion, which may be made of one or more composite materials and may be formed as a preform. Such a composite material may include a foam or polymer, and an adhesive or resin for bonding to adjacent materials. In another non-limiting example, the composite material may be formed as a woven structure comprising a plurality of interlaced or interwoven fibers in a two-dimensional or three-dimensional manner, or may be formed as a woven pattern with a braid. In yet another non-limiting example, the first airfoil portion 132 may be a composite composed of chopped fibers (such as thermoplastics, resins, or other suitable chopped fiber materials). In yet another non-limiting example, the first airfoil portion 132 may be a composite sparsity portion comprising a composite material suitable for attaching the airfoil 126 to the shank 128.

[0056] The second airfoil portion 134 may have at least one detachment feature, which has a detachment characteristic selected from at least one of a smaller density, a smaller mass, or both than that of the first airfoil portion 132. The second airfoil portion 134 may be made of a foam material or a polymer material. In non-limiting examples, the foam material or polymer material includes, but is not limited to, open-cell foam, closed-cell foam, fiber-reinforced foam, metal foam, composite foam, metal-matrix foam, resin foam, vinyl foam, random or regular foam, ceramic foam, microporous foam, polymer foam, or polymers, or combinations thereof.

[0057] A separation feature 140 is disposed within the first airfoil portion 132. The separation feature 140 includes a first separation feature 142, a second separation feature 144, an angular separation feature 146, and a chordal separation feature 148. The first separation feature 142 is located inside the first airfoil portion 132 and is shown in dashed lines. The position of the first separation feature 142 can be... Figure 4 Further understanding is needed. (Still referencing...) Figure 3 The first and second disengagement features 142, 144 include curved cross-sectional shapes extending in the spanwise direction (SPd). In a non-limiting example, the first and second disengagement features 142, 144 may be formed as strips extending in the spanwise direction (SPd) and having curvature. Figure 3 As shown, when the curvature extends in the spanwise direction (SPd), the curvature bends in the chordwise direction (CHd), and any curvature, geometry, arrangement, or extent of the strip can be envisioned. In a non-limiting example, the first and second detachment features 142, 144 may be filled with the same material as the second airfoil portion 134. The first and second detachment features 142, 144, or any detachment feature 140 may include a material having detachment properties selected from at least one of the following: lower density, lower mass, lower tensile strength, greater brittleness, or combinations thereof than the first airfoil portion 132, the second airfoil portion 134, or both. In a non-limiting example, detachment feature 140 may include foam or polymer, including but not limited to open-cell foam, closed-cell foam, fiber-reinforced foam, metal foam, composite foam, metal matrix foam, resin foam, vinyl foam, random or regular foam, ceramic foam, microporous foam, polymer foam, or combinations thereof. In another non-limiting example, the detachment feature 140 may be of a polymer, such as a polymer foam. In additional non-limiting examples, the polymer foam may include ethylene-vinyl acetate foam, polyethylene foam, or polypropylene foam. In yet another non-limiting example, the detachment feature 140 may be located at 20% of the airfoil span or radially outward at 20% of the airfoil span, wherein the span is defined as extending radially outward from the root 114 to the tip 116 in the spanwise direction (SPd). Figure 2In other words, when the airfoil span is limited to 100% in the span direction (SPd), extending from the root 114 at 0% to the tip 116 at 100%, the departure feature 140 can be positioned to be greater than or equal to 20% span and less than or equal to 100% span.

[0058] Angular departure feature 146 and chordal departure feature 148 can also be formed as strips, similar to the strips of the first and second departure features 142, 144, without curvature or planarity. In a non-limiting example, the planar strips can be aligned with one of the spanwise (SPd) or chordwise (CHd) directions. Angular departure feature 146 and chordal departure feature 148 can be filled with the same or similar material as the first and second departure features 142, 144, which can include foam material or polymer foam, similar to the material of the first airfoil portion 132, while it is conceivable that no filling material is used (e.g., the angular and chordal departure features 146, 148 can be configured as voids). In a non-limiting example, angular departure feature 146 can have an angular orientation, such as being arranged at an angle 158 relative to the spanwise (SPd), chordwise (CHd), radial (Rd), axial (Ad) direction, or a combination thereof. For example, chordal departure feature 148 can be arranged parallel to the chordwise (CHd), parallel to the axial (Ad) direction, or both. It is conceivable that, in a non-limiting example, the detachment feature 140 may have various orientations or geometries within the first airfoil portion 132, including linear, curved, planar, or complex orientations or geometries.

[0059] Figure 4 It shows along Figure 3 The chordal section view taken from section IV-IV further illustrates the internal arrangement of the separation feature 140 within the interior 130 of the airfoil 126. Figure 4 Section III-III, shown by the dashed line in the middle, represents... Figure 3 The cross section relative to Figure 4 The location of the section shown.

[0060] As can be understood, the first and second disengagement features 142, 144 may be integrally formed with the second airfoil portion 134 and may be made of the same material. Contact between the first and second disengagement features 142, 144 and the second airfoil portion 134 is conceivable, and some or all of the first disengagement feature 142, the second disengagement feature 144, or the second airfoil portion 134 may comprise one or more different materials.

[0061] exist Figure 3The second airfoil portion 134, which appears to be separated from the first airfoil portion 132, can be connected via the intermediate airfoil portion 160. The first airfoil portion 132 can be divided into a pressure-side portion 162 and a suction-side portion 164 separated by the intermediate airfoil portion 160. A first disengagement feature 142 is arranged within the suction-side portion 164, while a second disengagement feature 144 and a chordal disengagement feature 148 are arranged within the pressure-side portion 162. It should be understood that one or more disengagement features 140 can be arranged at any location or arrangement within the first airfoil portion 132. Furthermore, the first airfoil portion 132 or the second airfoil portion 134, or both, can be divided into multiple discrete portions, or can extend within the airfoil member 126 with any arrangement or geometry.

[0062] During operation, when a threshold force is experienced or exceeded, the disengagement feature 140 can cause at least some of the airfoil 126 to disengage or separate from the airfoil 126 at the disengagement feature 140. Such a threshold force may be experienced during engine operation, including forces outside of normal operation, such as those entering the gas turbine engine 10 ( Figure 1 The impact force of the fragments. When subjected to such a force, the detachment feature 140 facilitates detachment or separation under a predetermined threshold force. In a non-limiting example, this threshold force can be defined as a force suitable for allowing the airfoil 126 to separate at the detachment feature 140. In another non-limiting example, the threshold force can be specific to each detachment feature 140. More specifically, in order to allow a segment of the airfoil 126 to separate from the rest of the airfoil 126 at a particular detachment feature 140, a threshold force can be defined that is sufficient to detach or separate the segment of the airfoil 126 from the rest of the airfoil 126 at the particular detachment feature 140, while the remaining detachment features 140 have a larger threshold force and will not detach or separate before those with smaller threshold forces.

[0063] More specifically, the shape, size, geometry, location, arrangement, or material of the detachment feature 140 may be defined to detach under a threshold force prior to detachment or separation from other segments of the airfoil 126. For example, the density of the detachment feature 140 may be less than the density of the first airfoil portion 132, the second airfoil portion 134, or both, wherein such a lower density may detach under a smaller force than segments having a relatively higher density. In additional, non-limiting examples, the detachment feature 140 may include a smaller density, a smaller mass, a smaller tensile strength, greater brittleness, one or more other properties different from the first airfoil portion 132, or a combination thereof, to facilitate detachment at the detachment feature 140 prior to detachment or separation from other segments of the airfoil 126, such as segments of the first and second airfoil portions 132, 134, or the skin layer 136 without the detachment feature 140.

[0064] Events during engine operation may cause the forces applied to the airfoil 126 to exceed the inherent threshold capacity of the airfoil 126 or the materials constituting the airfoil 126, such as from the gas turbine engine 10 ( Figure 1 () debris or foreign objects. During such an event, the gas turbine engine 10 ( Figure 1 Accidental damage to a section of a component within the airfoil 126 can lead to a cascading series of events, the intensity of which increases along the series, resulting in an ever-increasing impact on the surrounding engine environment. To reduce the overall impact on the engine environment, control over the disengagement or separation of a section of the airfoil 126 can be achieved, at least partially, where such controlled disengagement or separation results in a reduction, lessening, or even cessation or prevention of the cascading series of events on the surrounding engine environment. This controlled disengagement or separation is achieved through a disengagement feature 140. The first threshold force at which the disengagement feature 140 disengages from the remainder of the airfoil 126 can be a force greater than those experienced by the airfoil 126 during standard or even maximum engine operation. Relatively low density, low mass, low tensile strength, high brittleness, or one or more other distinct characteristics of the disengagement feature 140 inherently allow the airfoil 126 to disengage or separate at the disengagement feature 140 before disengaging or separating at other areas of the airfoil 126, while determining the manner in which the airfoil disengages or separates when experiencing this threshold force. This disengagement or separation method can be defined by the geometry of the disengagement feature 140. For example, the airfoil 126 may be designed to disengage or separate along the disengagement feature 140, rather than separating at a location spaced apart from the disengagement feature 140. For example, the planar geometry of the chordal disengagement feature 148 may define a linear or planar range or directionality for the expected separation or deformation under conditions exceeding a threshold force, thereby allowing the airfoil 126 to disengage or separate along such a line, plane, or directionality.

[0065] In this way, when a force exceeding a certain threshold is applied to the airfoil 126, the airfoil 126 can detach or separate at the detachment feature 140 in a predetermined manner, which reduces or diminishes the overall engine shock during events that result in a force exceeding the force threshold.

[0066] Additionally, it is conceivable that different disengagement features 140 are tailored to different threshold forces. In a non-limiting example, the airfoil 126 may separate or detach along the first and second disengagement features 142, 144 under a first threshold force, but not separate or detach at the angular or chordal disengagement features 146, 148. More specifically, the force acting on the airfoil 126 may cause the first or second disengagement features 142, 144 to separate or detach, while the force acting on the airfoil 126 does not reach the threshold force for separation at the angular or chordal disengagement features 146, 148. In this way, the disengagement or separation of the airfoil 126 can be tailored to a specific threshold force. Such tailoring of the disengagement features 140 may include location, size, material, or a combination thereof to determine disengagement or separation under a specific threshold, or, in an additional non-limiting example, may include differences in the material properties of the specific disengagement features 140, such as having greater or lesser density, weight, tensile strength, or brittleness, or different materials limiting different material properties. A specific arrangement, geometry, or material (or its absence) used with a particular detachment feature 140 can be customized for different threshold forces or different sections of the airfoil 104. In this way, different detachment or separation scenarios can be covered within a single airfoil or component via multiple detachment features 140. Different detachment features 140 at different regions of the airfoil 126 can be customized for different amounts of threshold, type, or directionality of force, thereby allowing control of deformation under different load scenarios.

[0067] The use of the detachment feature 140 described herein reduces the force exerted on the gas turbine engine 10 from the airfoil 126, engine components, or sections thereof during events resulting in forces exceeding a predetermined force threshold. Figure 1 Impacts on the outer casing (e.g., fan casing 40 or core casing 46) or other sections of the gas turbine engine 10. More specifically, events such as foreign debris or fan blade detachment can cause damage to the gas turbine engine 10. Figure 1 Damage to the surrounding environment or components therein. Such damage may further lead to the separation of components, thereby affecting the surrounding environment (such as fan housing 40 or core housing 46) and any components downstream of the initial event (such as compressor blades and impellers 56, 58, 60, 62). Figure 1 The airfoil 126 can cause a cascading series of damage to the gas turbine engine 10 (or turbine blades and impellers 68, 70, 72, 74), as well as any other part of the surrounding environment (such as the casing, disk, combustor, combustor liner, or shroud in a non-limiting example). Therefore, a system capable of controlling the deformation or separation of the airfoil 126 can reduce the damage to the gas turbine engine 10. Figure 1Cascade damage to the surrounding environment of the gas turbine engine 10. More specifically, controlled deformation or separation can control the mass, density, orientation, size, or force of the detached or separated portion of the airfoil 126. This controlled deformation or separation can be controlled by the detachment feature 140, which results in the detached section of the airfoil 126 being applied to the gas turbine engine 10 (compared to a gas turbine engine or airfoil without the detachment feature 140). Figure 1 The force is relatively small in magnitude or quantity. Example forces may include foreign debris, fan blade detachment events, or other unexpected forces applied to the airfoil 126, and the resulting impact forces or cascading events. Additionally, including the detachment feature 140 with lower density, lower mass, lower tensile strength, or greater brittleness can reduce overall engine weight, which can improve engine efficiency while reducing cost and fuel consumption.

[0068] The use of the disengagement feature 140 may include the total number of disengagement features, the orientation of the disengagement features, or both, which are balanced with the rest of the airfoil 126 to ensure limited impact on intake or no intake failure. More specifically, while the disengagement feature 140 provides disengagement of a section of the airfoil 126 under threshold force, such disengagement features 140 and the airfoil 126 containing them can still meet the minimum operational requirements for normal operation of the airfoil 126 during standard turbine engine operation. For example, the airfoil 126 may meet standard intake or fan blade detachment requirements when the disengagement feature 140 is included or even after disengagement at the disengagement feature 140.

[0069] Now for reference Figure 5 The airfoil 200 includes an outer wall 202 surrounding an interior 204. The airfoil 200 includes a leading edge 206, a trailing edge 208, a root 210, and a tip 212. A shank 214 is attached to the airfoil 200 and extends at least partially into the interior 204. For example, a first airfoil portion 216 of the airfoil 200 may be a spar or spar portion extending from and attached to the shank 214, and its dimensions may be designed to complement the shank 214. The first airfoil portion 216 extends between the shank 214 and the tip 212, while any wingspan range is conceivable. A second airfoil portion 218 is disposed within the interior 204 and positioned between the first airfoil portion 216 and the skin layer 220.

[0070] The disengagement features 230 are arranged within the first airfoil portion 216 as a set of four planar disengagement features 232, a set of recessed disengagement features 234, a filling hole disengagement feature 236, and an opening hole disengagement feature 238. The planar disengagement features 232 are arranged at different span positions between the root 210 and the tip 212 and extend in the chordal direction (CHd). The set of recessed disengagement features 234 can be formed as holes or recesses within the first airfoil portion 216, extending at least partially between the pressure side 222 and the suction side 224 (see...). Figure 7 The set of recessed release features 234 are holes formed into the first airfoil portion 216 and can have different geometries (including but not limited to spherical, elliptical, cylindrical, conical, or fan-shaped or combinations thereof), or have any cross-sectional shape (including but not limited to circular, oval, racetrack-shaped, elliptical, hyperbolic, conical, or fan-shaped or combinations thereof). The filled hole release feature 236 can generally be similar to the set of recessed release features 234, while including the material used to fill the filled hole release feature 236 (such as the same material used in the second airfoil portion 218) or other suitable materials (such as materials with lower density, lower mass, lower tensile strength, or greater brittleness than the first airfoil portion 216 or the second airfoil portion 218). The size, shape, or location of the open hole release feature 238 can be designed to be similar to the filled hole release feature 236, while the open hole release feature 238 is configured as a single hole compared to the three holes in the set of recessed release features 234. The difference between the lack of material filling the recessed release feature 234 and the material filling the release feature 236 can limit different force thresholds in order to determine the release of the airfoil 200 at different locations under different force thresholds. In this way, the release feature 236 can be the same as or similar to the opening release feature 238, except that the opening release feature 236 is filled with material.

[0071] Figure 6 The section cut along section VI-VI is shown. Figure 5 A cross-sectional view, which is aligned with a planar detachment feature 232 cut along the chord direction (CHd), wherein the wingspan direction (SPd) extends in and out. Figure 6The page (indicated by "X"). The first airfoil portion 216 extends between the skin layer 220 at the pressure side 222 and the suction side 224, while the planar separation feature 232 is formed having a generally rectangular shape with rounded corners formed within the first airfoil portion 216. It should be understood that the planar separation feature 232 extends along a plane extending in the chord direction (CHd) and has a thickness perpendicular to its definition. The planar separation feature 232 extends at least partially in the direction defined as extending between the pressure side 222 and the suction side 224. When subjected to force, the planar separation feature 232 can define a planar region of separation or detachment. Although the planar separation feature 232 is shown as extending in the chord direction (CHd) and defining a plane parallel to the chord direction (CHd), it is conceivable that the plane defined by the planar separation feature 232 may vary from the chord direction (CHd) (such as extending in the spanwise direction (SPd), or may be arranged in any direction of the chord direction (CHd), the spanwise direction (SPd), a circumferential direction perpendicular to the spanwise direction (SPd), the direction between the pressure side 222 and the suction side 224, or any combination thereof. In this way, planar separation or decoupling can be controlled about the airfoil 200 in any suitable direction or orientation, exist within the three-dimensional shape of the airfoil 200, and is not required to be limited to the spanwise direction (SPd) or the chord direction (CHd).

[0072] Figure 7 The section taken along section VII-VII is shown. Figure 5 The cross-sectional view shows three recessed detachment features 234. A first recessed detachment feature 234a extends fully between the epidermal layer 220 at the pressure side 222 and the suction side 224, while a second recessed detachment feature 234b extends only partially from the pressure side 222 towards the suction side 224, and a third recessed detachment feature 234c extends only partially from the suction side 224 towards the pressure side 222. In this way, it should be understood that the detachment features 230 may extend fully or partially between the pressure side 222 and the suction side 224, and in other directions (such as the chordal direction (CHd) or the spanwise direction (SPd)), or various combinations thereof.

[0073] When the airfoil 200, or one or more of the separation features 230, namely planar separation feature 232, recessed separation feature 234, or filled hole separation feature 236, experiences a force exceeding a predetermined threshold, the airfoil 200 may detach or separate along one or more separation features 230. Different configurations of the separation features 230 (e.g., geometry, length, location, material, etc.) can be used to define different force thresholds leading to detachment or separation. Additionally, different geometries or lengths can collectively define a force threshold gradient across the airfoil 200 between the separation features 230, wherein a different amount of force at each individual separation feature 230 can define a minimum local threshold for initial detachment or separation among all separation features 230.

[0074] refer to Figure 8 The airfoil 300 includes an outer wall 302 defining an interior 304. A skin layer 306 may at least partially form the outer wall 302 and may be coupled to a handle 308 for mounting the airfoil 300. A first airfoil portion 310 is disposed within the interior 304 and within the space defined by the skin layer 306. The first airfoil portion 310 may be made of a composite material that may include a specified first strength, first density, first tensile strength, or first brittleness, or a combination thereof.

[0075] The detachment feature 312 is disposed within the first airfoil portion 310 as a component of an angle strip 314, a set of filling holes 316, a set of opening holes 318, and a wingspan strip 320. By utilizing multiple detachment features, different force thresholds can be limited for detachment or separation of the airfoil 300 at different wingspan positions along the airfoil 300.

[0076] The first axis 322 may be defined along each of the angled strips 314, wherein the angled strips 314 are arranged parallel to each other and define the parallel arrangement of the first axis 322. The constituent angled strips 314 may be arranged at an angle 336 relative to the radial direction (Rd), the spanwise direction (SPd), or both, and may be filled with a material having less strength, less density, less tensile strength, or greater brittleness than the first airfoil portion 310. The angle 336 may be limited to equal to -45 degrees, 45 degrees, or between -45 degrees and 45 degrees (-45° to 45°), while any angle from -180 degrees to 180 degrees (-180° to 180°) is conceivable.

[0077] The set of filling holes 316 can also be aligned with an angled orientation similar to that of the angled strip 314. More specifically, a second axis 324 defined by the center of at least some of the filling holes 316 can be arranged at an angle 336. Angle 336 can be the same in both the constituent angled strip 314 and the set of filling holes 316, such that the orientation of the set of filling holes 316 is the same as or matches that of the constituent angled strip 314.

[0078] Similarly, a third axis 326 may be defined to extend through the center of at least some of the holes in the set of openings 318. Similar to the axis of the set of filling holes 316, the third axis 326 may be arranged at an angle 336. The angle 336 of the set of openings 318 may be the same as the angle of the set of angled strips 314 and the set of filling holes 316, such that the orientation of the set of openings 318 is the same as the orientation of the set of filling holes 316 or the angled strips 314.

[0079] The wingspan strip 320 can be aligned or parallel to the spanwise direction (SPd). Therefore, it should be understood that the alignment of the wingspan strip 320, or any strip, can be in the spanwise direction (SPd) with one or more of the holes in the set of filling holes 316 or the set of opening holes 318. In this way, different deformation geometries can be limited within the span of the airfoil 300, allowing the disengagement feature 312 of the airfoil 300 to provide multiple disengagement scenarios under different threshold forces or loads.

[0080] It should be understood that the detachment feature 312 is arranged in a partially patterned manner, wherein angled stripes 314 are configured such that at least one angled stripe 314 is positioned between the set of filling holes 316 and the set of opening holes 318, and at least one angled stripe 314 is positioned between the set of opening holes 318 and the wingspan stripe 320. In one example, the spacing between the angled stripe 314 and each of the set of filling holes 316, the set of opening holes 318, and the wingspan stripe 320 can be consistent, while various spacing relationships can limit different geometries for the intended detachment or separation at different locations.

[0081] Figure 9 The section cut along section IX-IX is shown. Figure 8 A cross-sectional view of the airfoil 300, the cross-section being along the constituent angle strip 314 ( Figure 8An angled strip 314 extends from the skin layer 306 in one of the angled strips 314. As will be understood, the angled strip 314 may be spaced apart from the skin layer 306 on all sides by the first airfoil portion 310. The angled strip 314 may have a shape complementary to the shape of the airfoil 300, such as including a concave surface 328 facing the pressure side 330 and a convex surface 332 facing the suction side 334. In a non-limiting example, the complementary shape between the angled strip 314 and the airfoil 300 may be defined by a constant thickness of the first airfoil portion 310 between the angled strip 314 and the skin layer 306. In another non-limiting example, the thickness of the first airfoil portion 310 between the angled strip 314 and the skin layer 306 may vary to less than or equal to 10%, or less than or equal to 5%, while other percentages are conceivable. It should be understood that the complementary shape may be identified along the angled strip 314, or by... Figure 8 The first axis 322 defines the section IX-IX, which is cut at the first axis 322 and defined along the angled strip 314, such that the complementary shape of the angled strip 314 is angled within the airfoil 300.

[0082] Detachment feature 312 (such as Figure 8 and Figure 9 The component angle strip 314, the set of filling holes 316, or the set of opening holes 318) provide for the airfoil 300 to detach or separate along the detachment feature 312 under a threshold force. When the airfoil 300 or its segment experiences a force that meets or exceeds the threshold force, the airfoil 300 can detach or separate along the detachment feature 312, which can reduce or minimize the impact on the gas turbine engine 10. Figure 1 The overall impact would otherwise occur without the airfoil 300's predetermined detachment at the detachment feature 312. More specifically, detachment at the detachment feature 312 can result in a smaller mass separating from the airfoil 300 compared to an airfoil without detachment feature 312, where the smaller mass results in a smaller overall force impact on the surrounding environment, or fewer cascading events caused by detachment at the detachment feature 312.

[0083] refer to Figure 10The airfoil 400 includes an outer wall 402 defining an interior 404. The airfoil 400 includes a leading edge 406 and a trailing edge 408 defining a chord direction (CHd), and a root 410 and a tip 412 defining a spanwise direction (SPd). A skin layer 414 may at least partially form the outer wall 402 and may be coupled to a shank 416 for mounting the airfoil 400. A first airfoil portion 418 is disposed in the interior 404 and adjacent to the tip 412, while a second airfoil portion 420 is disposed in the interior 404 and adjacent to the root 410. The first airfoil portion 418 may include a first material, and the second airfoil portion 420 may include a second material different from the first material. In a non-limiting example, the first airfoil portion 418 may be a material with a lower density, mass, or both than the second airfoil portion 420. In another non-limiting example, the second airfoil portion 420 may be a sparsity portion made of a material with a higher density, mass, or both than the first airfoil portion 418. In an additional, non-limiting example, the first airfoil portion 418 and the second airfoil portion 420 may be made of similar materials having similar material properties, or even of the same material. The first airfoil portion 418 meets the second airfoil portion 420 at a joint 422, which extends between skin layers 414 at the leading edge 406 and the trailing edge 408. The joint 422 may be a curved joint, which bends in the spanwise direction (SPd) or the chordwise direction (CHd) or both as it extends through the interior 404.

[0084] Detachment features 430 are provided in the first airfoil portion 418 as radially outer stripe detachment features 432 and radially inner stripe detachment features 434, opening hole detachment feature 438, and filling hole detachment feature 440. Although opening hole detachment feature 438 and filling hole detachment feature 440 are shown as a first hole and a second hole, respectively, it should be understood that additional holes not visible in the truncated section may be included, such as a third hole detachment feature 444 and a fourth hole detachment feature 446, generally in… Figure 10 It is shown in dashed lines and in Figure 11 Visible in the cross-section. The opening hole separation feature 438 and the filling hole separation feature 440 can define a first axis 442 between the centers of the holes, and the first axis 442 can be arranged parallel to the radially outer stripe separation feature 432 and the radially inner stripe separation feature 434.

[0085] Figure 11 It shows along Figure 10 The cross-sectional view taken from section XI-XI is aligned with the first axis 442. The third hole disengagement feature 444 and the fourth hole disengagement feature 446 are... Figure 11 It is visible in the cross-section shown, but... Figure 10 It is not visible in the chordal section. For example... Figure 10The cross-section shown is represented by dashed line 424, thus it can be visually seen that the opening hole separation feature 438 and the filling hole separation feature 440 are related to... Figure 10 The cross sections intersect, while the third hole separation feature 444 and the fourth hole separation feature 446 do not intersect. Figure 10 The cross sections intersect. In this way, it should be understood that, in a non-limiting example, the detachment feature 430 or a group of detachment features 430 may be arranged three-dimensionally within the airfoil 400 or the first airfoil portion 418, such as in the spanwise direction, the chordwise direction or at any position extending in the spanwise direction, the chordwise direction, at any position between the pressure side and the suction side, or a combination thereof.

[0086] Figure 10-11 The detachment features 430 (including radially outer stripe detachment feature 432, radially inner stripe detachment feature 434, opening hole detachment feature 438, filling hole detachment feature 440, third hole detachment feature 444, and fourth hole detachment feature 446) provide for the detachment or separation of the airfoil 400 along the detachment features 430 under a threshold force. When the airfoil 400 or a section thereof experiences a force that meets or exceeds the threshold force, the airfoil 400 can detach or separate along the detachment features 430, which can reduce or minimize the impact on the gas turbine engine 10 ( Figure 1 The overall impact would otherwise occur without the airfoil 400's predetermined disengagement at the disengagement feature 312.

[0087] This disclosure provides various benefits. The use of separation features 140, 230, 312, and 430 as described herein provides for the separation of a segment of an airfoil or component in a predetermined manner under a predetermined threshold force. This separation under the predetermined threshold force reduces the impact forces applied to the surrounding environment, such as the outer casing (e.g., fan casing 40 or core casing 46) surrounding the airfoil in a turbine engine environment. Additionally, this separation reduces or mitigates the impact on engine systems downstream of the airfoil or component, and reduces or mitigates the cascading effects caused by uncontrolled separation of the airfoil or component. Furthermore, separation features 140, 230, 312, and 430 may comprise materials having a lower density, lower mass, lower tensile strength, or greater brittleness, or combinations thereof, than other materials forming the airfoil or component, which can reduce the overall weight of the component. In turbine engine airfoils, the reduced weight improves overall engine efficiency.

[0088] Within the scope not yet described, different features and structures of the various embodiments may be used in combination or substituted for each other. The fact that a feature is not shown in all embodiments does not mean that it cannot be shown in this way. For example, Figure 3-4 , Figure 5-7 , Figure 8-9 or Figure 10-11 The features shown in the embodiments can be related to Figure 3-4 , Figure 5-7 , Figure 8-9 or Figure 10-11 One or more other embodiments may be interchanged or mixed with each other. Therefore, various features of different embodiments can be combined and matched to form new embodiments, regardless of whether the new embodiments are explicitly described. All combinations or arrangements of the features described herein are covered by this disclosure. Furthermore, all features can be incorporated into a single airfoil (such as...). Figure 2 The airfoil 104) is used within the airfoil and is not mutually exclusive.

[0089] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system and performing any combination of methods. The patentable scope of the invention is defined by the claims, but may include other examples that would occur to a person skilled in the art. These other examples are intended to fall within the scope of the claims if they have structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

[0090] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0091] A gas turbine engine includes: a fan section, a compressor section, a combustion section, and a turbine section, the fan section, the compressor section, the combustion section, and the turbine section being arranged in a series flow configuration and defining an engine centerline extending between a forward and a backward direction; and an airfoil disposed in one of the fan section, the compressor section, or the turbine section, the airfoil including an outer wall defining an interior, the airfoil extending from a leading edge to a trailing edge defining a chordal direction therebetween, and extending from a root to a tip defining a spanwise direction therebetween, and including a pressure side and a suction side; a first airfoil portion positioned within the interior; and at least one detachment feature positioned within the first airfoil portion, the at least one detachment feature having a detachment characteristic selected from at least one of a smaller density, a smaller mass, a smaller tensile strength, or a greater brittleness than the first airfoil portion; wherein the detachment characteristic of the at least one detachment feature is adapted to detach a section of the airfoil from the first airfoil portion in response to a force exceeding a predetermined threshold.

[0092] The gas turbine engine according to any of the foregoing clauses further includes a second airfoil portion disposed within the interior and positioned adjacent to the first airfoil portion.

[0093] According to any of the foregoing clauses, in a gas turbine engine, at least one of the densities or masses of the second airfoil portion is the same as the density or mass of the at least one separation feature.

[0094] According to any of the foregoing clauses, in a gas turbine engine, the second airfoil portion is disposed outside the first airfoil portion.

[0095] According to any of the foregoing clauses, in a gas turbine engine, the at least one detachment feature is arranged within the first airfoil portion and contacts the second airfoil portion.

[0096] The gas turbine engine according to any of the foregoing clauses further includes a skin layer that at least partially defines the outer wall and surrounds the first airfoil portion.

[0097] According to any of the foregoing clauses, the gas turbine engine, wherein the airfoil further includes a shank coupled to the first airfoil portion.

[0098] According to any of the foregoing clauses, the gas turbine engine wherein the at least one detachment feature is formed as at least one hole in the first airfoil portion.

[0099] According to any of the preceding clauses, in a gas turbine engine, the at least one hole further includes at least one filler hole filled with a material having a lower density, lower mass, lower tensile strength, or greater brittleness than the first airfoil portion.

[0100] In any of the preceding clauses of the gas turbine engine, the at least one hole is formed as a set of at least two holes, wherein the set of holes is aligned along a first axis.

[0101] According to any of the foregoing clauses, in a gas turbine engine, the at least one detachment feature is located at or outside 20% of the span in the wingspan direction.

[0102] According to any of the foregoing clauses, the gas turbine engine wherein the at least one detachment feature is formed as a strip extending through the first airfoil portion.

[0103] According to any of the preceding clauses, the gas turbine engine wherein the strip is planar and aligned with one of the wingspan direction or the chord direction.

[0104] According to any of the preceding clauses, the gas turbine engine wherein the strip is bent in at least one of the spanwise direction and the chordwise direction.

[0105] The gas turbine engine according to any of the foregoing clauses further includes a skin layer outside the first airfoil portion, and wherein the at least one detachment feature extends completely between the skin layer on the pressure side and the skin layer on the suction side.

[0106] According to any of the foregoing clauses, the gas turbine engine comprises a plurality of release features arranged in a wingspan, and wherein the force for each predetermined threshold of each of the plurality of release features increases toward the root in the wingspan direction.

[0107] According to any of the foregoing clauses, the gas turbine engine wherein the first airfoil portion comprises a foam or polymer material.

[0108] According to any of the foregoing clauses, in a gas turbine engine, the first airfoil portion includes an adhesive or resin for bonding to the at least one detachment feature.

[0109] According to any of the foregoing clauses, in a gas turbine engine, the at least one detachment feature is co-cured or co-bonded with the first airfoil portion.

[0110] According to any of the foregoing clauses, in a gas turbine engine, the first airfoil portion is co-cured or co-bonded with at least one of the separation feature or the second airfoil portion.

[0111] The gas turbine engine according to any of the foregoing clauses, wherein the at least one disengagement feature includes open-cell foam, closed-cell foam, fiber-reinforced foam, metal foam, composite foam, metal matrix foam, resin foam, vinyl foam, random or regular foam, ceramic foam, microporous foam, polymer foam, or combinations thereof.

[0112] According to any of the preceding clauses, the gas turbine engine wherein the second airfoil portion comprises open-cell foam, closed-cell foam, fiber-reinforced foam, metal foam, composite foam, metal matrix foam, resin foam, vinyl foam, random or regular foam, ceramic foam, microporous foam, polymer foam, or combinations thereof.

[0113] According to any of the foregoing clauses, the gas turbine engine wherein the material of the second airfoil portion is the same as the material including the at least one separation feature.

[0114] According to any of the foregoing clauses, the gas turbine engine wherein the material used for the second airfoil portion has a greater density, greater mass, greater tensile strength, or less brittleness than the at least one separation feature.

[0115] According to any of the foregoing clauses, the gas turbine engine wherein the first airfoil portion is made of composite material.

[0116] According to any of the preceding clauses, the gas turbine engine wherein the strip is arranged at a non-zero angle relative to at least one of the wingspan direction or the chord direction.

[0117] According to any of the foregoing clauses, the gas turbine engine is wherein the non-zero angle is arranged relative to both the wingspan direction and the chord direction.

[0118] According to any of the preceding clauses, the gas turbine engine wherein the at least one disengagement feature comprises a set of strips and a set of holes, wherein the set of strips and the set of holes are arranged in an alternating pattern extending in the wingspan direction.

[0119] In any of the preceding clauses, the gas turbine engine wherein the set of holes arranged between the strips in the set of strips includes at least two holes.

[0120] A gas turbine engine according to any of the foregoing clauses, wherein the at least two holes define a second axis, and wherein the second axis is arranged parallel to at least one of the set of strips.

[0121] An airfoil for a turbine engine, characterized in that the airfoil comprises: an outer wall defining an interior, the airfoil extending from a leading edge to a trailing edge defining a chordal direction therebetween, and extending from a root to a tip defining a spanwise direction therebetween; a first airfoil portion positioned within the interior; and at least one detachment feature positioned within the first airfoil portion, the at least one detachment feature having a detachment characteristic selected from at least one of a smaller density, a smaller mass, a smaller tensile strength, or a greater brittleness than the first airfoil portion; wherein the detachment characteristic of the at least one detachment feature is adapted to detach a segment of the airfoil at the first airfoil portion in response to a force exceeding a predetermined threshold.

[0122] The airfoil according to any of the foregoing clauses further includes a second airfoil portion positioned within the interior, dividing the first airfoil portion into a pressure-side portion and a suction-side portion.

[0123] According to any of the foregoing clauses, at least one detachment feature is provided in each of the pressure side portion and the suction side portion.

[0124] According to any of the foregoing clauses, the at least one disengagement feature contacts the second airfoil portion.

[0125] According to any of the foregoing clauses, wherein the at least one detachment feature is integral with the second airfoil portion and extends from the second airfoil portion into the first airfoil portion.

[0126] The airfoil element according to any of the foregoing clauses further includes a second airfoil portion disposed within the interior and positioned adjacent to the first airfoil portion.

[0127] According to any of the foregoing clauses, at least one of the densities or masses of the second airfoil portion is the same as the density or mass of the at least one separation feature.

[0128] According to any of the foregoing clauses, the second airfoil portion is disposed outside the first airfoil portion.

[0129] According to any of the foregoing clauses, the at least one detachment feature is arranged within the first airfoil portion and contacts the second airfoil portion.

[0130] The airfoil according to any of the foregoing clauses further includes a skin layer that at least partially defines the outer wall and surrounds the first airfoil portion.

[0131] The airfoil according to any of the foregoing clauses, wherein the airfoil further includes a shank coupled to the first airfoil portion.

[0132] According to any of the foregoing clauses, the at least one detachment feature is formed as at least one hole in the first airfoil portion.

[0133] According to any of the foregoing clauses, the at least one hole further includes at least one filling hole filled with a material having a lower density, lower mass, lower tensile strength, or greater brittleness than the first airfoil portion.

[0134] According to any of the preceding clauses, the airfoil is formed as a set of at least two holes, wherein the set of holes is aligned along a first axis.

[0135] According to any of the foregoing clauses, the at least one detachment feature is located at or outside 20% of the span in the wingspan direction.

[0136] According to any of the foregoing clauses, the at least one detachment feature is formed as a strip extending through the first airfoil portion.

[0137] According to any of the foregoing clauses, the airfoil strip is planar and aligned with one of the wingspan direction or the chord direction.

[0138] According to any of the foregoing clauses, the airfoil is curved in at least one of the spanwise direction and the chordwise direction.

[0139] According to any of the foregoing clauses, the airfoil further includes a skin layer outside the first airfoil portion, and wherein the at least one detachment feature extends completely between the skin layer on the pressure side and the skin layer on the suction side.

[0140] According to any of the foregoing clauses, the at least one detachment feature comprises a plurality of detachment features arranged in a wingspan, and wherein the force for each predetermined threshold of each of the plurality of detachment features increases toward the root in the wingspan direction.

[0141] According to any of the foregoing clauses, the first airfoil portion comprises a foam or polymer material.

[0142] According to any of the foregoing clauses, the first airfoil portion includes an adhesive or resin for bonding to the at least one release feature.

[0143] According to any of the foregoing clauses, the at least one detachment feature is co-cured or co-bonded with the first airfoil portion.

[0144] According to any of the foregoing clauses, the first airfoil portion is co-cured or co-bonded with at least one of the detachment feature or the second airfoil portion.

[0145] According to any of the foregoing clauses, the at least one detachment feature includes open-cell foam, closed-cell foam, fiber-reinforced foam, metal foam, composite foam, metal matrix foam, resin foam, vinyl foam, random or regular foam, ceramic foam, microporous foam, polymer foam, or combinations thereof.

[0146] According to any of the foregoing clauses, the second airfoil portion includes open-cell foam, closed-cell foam, fiber-reinforced foam, metal foam, composite foam, metal matrix foam, resin foam, vinyl foam, random or regular foam, ceramic foam, microporous foam, polymer foam, or combinations thereof.

[0147] According to any of the foregoing clauses, the material of the second airfoil portion is the same as the material including the at least one separation feature.

[0148] According to any of the foregoing clauses, the material used for the second airfoil portion has a greater density, greater mass, greater tensile strength, or less brittleness than the at least one separation feature.

[0149] According to any of the foregoing clauses, the first airfoil portion is made of a composite material.

[0150] According to any of the foregoing clauses, the airfoil is arranged at a non-zero angle relative to at least one of the wingspan direction or the chord direction.

[0151] According to any of the foregoing clauses, the non-zero angle is arranged relative to both the wingspan direction and the chord direction.

[0152] According to any of the foregoing clauses, the at least one detachment feature comprises a set of strips and a set of holes, wherein the set of strips and the set of holes are arranged in an alternating pattern extending in the wingspan direction.

[0153] According to any of the foregoing clauses, the set of holes arranged between the strips in the set of strips includes at least two holes.

[0154] According to any of the foregoing clauses, the at least two holes define a second axis, and the second axis is arranged parallel to at least one of the set of strips.

Claims

1. A gas turbine engine, characterized in that, include: The fan section, compressor section, combustion section, and turbine section are arranged in a series flow configuration and define an engine centerline extending from front to rear. as well as An airfoil, disposed in one of the fan section, the compressor section, or the turbine section, the airfoil including an outer wall defining an interior, the airfoil extending from a leading edge to a trailing edge defining a chordal direction therebetween, and extending from a root to a tip defining a span direction therebetween, and including a pressure side and a suction side; The first airfoil portion is positioned inside the interior; as well as At least one detachment feature, the at least one detachment feature being located within the first airfoil portion, the at least one detachment feature having a detachment characteristic selected from at least one of a smaller density, a smaller mass, a smaller tensile strength, or a greater brittleness than the first airfoil portion; The detachment characteristic of the at least one detachment feature is configured to detach the segment of the airfoil at the at least one detachment feature in response to a force exceeding a predetermined threshold.

2. The gas turbine engine according to claim 1, characterized in that, It further includes a second airfoil portion, which is disposed within the interior and positioned adjacent to the first airfoil portion.

3. The gas turbine engine according to claim 2, characterized in that, in, At least one of the densities or masses of the second airfoil portion is the same as the density or mass of the at least one detachment feature.

4. The gas turbine engine according to claim 2, characterized in that, in, The second airfoil portion is arranged outside the first airfoil portion.

5. The gas turbine engine according to claim 2, characterized in that, in, The at least one detachment feature contacts the second airfoil portion.

6. The gas turbine engine according to claim 1, characterized in that, It further includes a skin layer that at least partially defines the outer wall and surrounds the first airfoil portion.

7. The gas turbine engine according to claim 1, characterized in that, It further includes a shank coupled to the first airfoil portion, and wherein the first airfoil portion further includes a spar portion extending from the shank.

8. The gas turbine engine according to claim 1, characterized in that, in, The at least one detachment feature includes at least one hole.

9. The gas turbine engine according to claim 8, characterized in that, in, The at least one hole further includes at least one filled hole filled with a material having the detachment properties.

10. An airfoil for a turbine engine, characterized in that, The airfoil includes: The outer wall defines the interior, the airfoil extends from the leading edge to the trailing edge, defining a chordal direction therebetween, and extends from the root to the tip, defining a wingspan direction therebetween; The first airfoil portion, the first airfoil portion being positioned within the interior; and At least one detachment feature, the at least one detachment feature being located within the first airfoil portion, the at least one detachment feature having a detachment characteristic selected from at least one of a smaller density, a smaller mass, a smaller tensile strength, or a greater brittleness than the first airfoil portion; The detachment characteristic of the at least one detachment feature is adapted to detach the segment of the airfoil at the first airfoil portion in response to a force exceeding a predetermined threshold.

Images