Gas Turbine Airfoil Forming With Stagger Angle Control
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Solution Overview
Problem
Existing methods for forming gas turbine engine components, such as hollow fan blades, face challenges in achieving precise deformation and temperature control to maintain structural integrity and aerodynamic performance, particularly in establishing the correct stagger angle and minimizing residual stresses.
Innovation Solution
A method involving attaching a cover skin to an airfoil body, heating it between dies, and deforming it while maintaining precise temperature control, followed by controlled cooling to establish a predefined temperature gradient, ensuring minimal change in the stagger angle and reducing residual stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the airfoil is deformed using conventional methods, then the component can be formed, but the stagger angle changes excessively and residual stresses increase
Solution Approach 1:
The patent applies parameter changes by heating the airfoil to a predefined temperature threshold (e.g., 1200°F or higher) before deformation. This temperature change modifies the material properties, allowing deformation while maintaining stagger angle precision and reducing residual stresses through controlled thermal-mechanical processing
Solution Approach 2:
The patent employs preliminary action by heating the airfoil to the target temperature and holding it between dies before deformation occurs. This preparatory thermal treatment ensures the material is ready for deformation while minimizing stagger angle changes and residual stress accumulation during the actual forming process
2Manufacturing precision
If the airfoil is heated and deformed between dies, then precise stagger angle control is achieved, but the process complexity increases
Solution Approach 1:
The patent segments the deformation process into distinct stages: heating to a predefined temperature threshold, holding between dies, deforming to the target shape, and controlled cooling. This segmentation allows precise control of each parameter while managing overall process complexity through systematic step-by-step execution
Solution Approach 2:
The patent incorporates feedback by monitoring temperature to ensure it reaches the predefined threshold before deformation, and by controlling the cooling process to establish a predefined temperature gradient. This feedback mechanism ensures precise deformation control while managing process complexity through automated temperature management
3Productivity
If rapid cooling is applied after deformation, then productivity increases, but residual stresses and distortion increase
Solution Approach 1:
The patent applies periodic action through controlled cooling that establishes a predefined temperature gradient through the airfoil thickness. This controlled thermal history allows rapid cooling while managing residual stresses and distortion by directing heat flow in a predictable pattern during the cooling phase
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the precise formation of gas turbine engine components with improved structural integrity and aerodynamic performance by maintaining the desired stagger angle and minimizing residual stresses, enhancing the components' fatigue capability and overall engine efficiency.
Implementation Method 1
heating the airfoil body to a first predefined temperature threshold between the first and second dies
Implementation Method 2
cooling the airfoil in the cooling chamber to a second predefined temperature threshold less than the first predefined temperature threshold
Implementation Method 3
conveying cooling flow to a plurality of cooling regions along the longitudinal axis of the cooling chamber such that a predefined temperature gradient is established between the first and second end portions during the cooling step
Implementation Method 4
deforming the airfoil between the first and second dies
Implementation Method 5
deforming the airfoil between the first and second dies subsequent to the heating step
Implementation Method 6
welding a cover skin to an airfoil body to define an airfoil
Data Source
AI summary
A method of forming a gas turbine engine component according to an example of the present disclosure includes, among other things, attaching a cover skin to an airfoil body, the airfoil body and the cover skin cooperating to establish pressure and suction sides of an airfoil, positioning the airfoil between first and second dies of a deforming station, heating the airfoil body to a first predefined temperature threshold between the first and second dies, and moving the first die relative to the second die to hold the airfoil between the first and second dies subsequent to the heating step, and then deforming the airfoil between the first and second dies.