Electroformed Metal Edge Shell for Gas Turbine Airfoils

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Solution Overview

Problem

Current gas turbine engine airfoils face challenges in reducing fan noise and meeting structural requirements, such as bird strikes, while maintaining a low weight and efficient airflow, particularly in the design of outlet guide vanes and other airfoils.

Innovation Solution

The method involves electroforming a metal edge shell with a sculpted non-linear pattern over a composite airfoil body, incorporating a filler material and an intermediate conductive layer to secure the shell, which reduces noise and enhances structural integrity by forming a robust leading edge capable of withstanding foreign object collisions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal leading edge is added to the airfoil to withstand bird strikes and foreign object collisions, then structural strength and reliability are improved, but the overall weight of the airfoil increases

Engineering Contradiction:

Improvestructural integrityVSAvoidairfoil weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The airfoil is divided into two distinct parts: a composite airfoil body and a separate metal leading edge shell. This segmentation allows each component to be optimized independently - the composite body for lightweight strength and the metal shell for impact resistance - thereby improving reliability without proportionally increasing overall weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines two different materials - composite material for the airfoil body and metal material for the leading edge shell - into a single hybrid structure. This composite approach leverages the advantages of both materials: the lightweight and corrosion-resistant properties of composites and the high strength and impact resistance of metals, resolving the contradiction between weight and reliability.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If a complex sculpted leading edge with non-linear pattern is formed to reduce fan noise, then noise reduction performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefan noiseVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The invention replaces traditional mechanical manufacturing methods (such as machining or molding) with an electroforming process to create the sculpted leading edge. Electroforming allows complex non-linear patterns to be formed through electrochemical deposition, simplifying the manufacturing process while achieving the precise geometric complexity needed for noise reduction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electroforming process enables precise control of the leading edge geometry by adjusting electrochemical parameters such as current density, deposition time, and electrolyte composition. This allows the complex sculpted pattern to be manufactured with high precision without proportionally increasing manufacturing complexity, as parameter adjustments replace complex mechanical tooling.

Inventive Principle:

Principle #35Parameter changes

3Strength

If a metal edge shell is electroformed over the composite airfoil body, then the bond strength between the metal and composite is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvebond strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention merges two manufacturing processes - composite airfoil fabrication and metal shell formation - into a single integrated electroforming operation. The metal leading edge shell is electroformed directly over the completed composite airfoil body, creating a permanent metallurgical bond that eliminates the need for separate attachment processes, thereby improving bond strength while managing overall process complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electroforming process acts as an intermediary that creates a strong bond between the composite airfoil body and the metal leading edge shell. Through electrochemical deposition, the metal forms a metallurgical bond with the composite surface, serving as an effective mediator that achieves superior bond strength without requiring additional mechanical fasteners or adhesives.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution effectively reduces fan noise, enhances structural integrity to withstand bird strikes and other foreign object collisions, and maintains a lightweight design by providing a strong bond between the metal edge shell and the composite airfoil body.

Implementation Method 1

electroforming a metal edge shell over: a filler, located at a leading edge of the airfoil body, and at least a portion of the airfoil body

Methodology Applied

Scientific EffectElectrodeposition: Electrodeposition

Data Source

PatentUS12123324B2Engine airfoil metal edge

Publication Date: 2024.10.22 GENERAL ELECTRIC CO POLSKA SP ZOO

AI summary

A method of electroforming an airfoil comprising an airfoil body. The method comprising electroforming a metal edge shell over a filler, located at a leading edge of the airfoil body, and over the airfoil body. The filler can be encapsulated within the metal edge shell and the metal edge shell has a sculpted leading edge defining a non-linear pattern.