Trw Limited

Istvan J Toth

Istvan M Matay

Thomas Derkacs

Charles W Fetheroff

Donald J Moracz

Charles R Cook

An improved method of making an airfoil includes stacking plies in two groups. A separator ply is positioned between the two groups of plies. The groups of plies and the separator ply are interconnected to form an airfoil blank. The airfoil blank is shaped, by forging or other methods, to have a desired configuration. The material of the separator ply is then dissolved or otherwise removed from between the two sections of the airfoil blank to provide access to the interior of the airfoil blank. Material is removed from inner sides of the two separated sections to form core receiving cavities. After cores have been placed in the cavities, the two sections of the airfoil blank are interconnected and the shaping of the airfoil is completed. The cores are subsequently removed from the completed airfoil.

Method of making an airfoil

Although the method and apparatus of the present invention can be utilized to apply either a uniform or a nonuniform covering of material over many different workpieces, the apparatus (20) is advantageously utilized to apply a thermal barrier covering (64) to an airfoil (22) which is used in a turbine engine. The airfoil is held by a gripper assembly (86) while a spray gun (24) is effective to apply the covering over the airfoil. When a portion of the covering has been applied, a sensor (28) is utilized to detect the thickness of the covering. A control apparatus (32) compares the thickness of the covering of material which has been applied with the desired thickness and is subsequently effective to regulate the operation of the spray gun to adaptively apply a covering of a desired thickness with an accuracy of at least plus or minus 0.0015 of an inch (1.5 mils) despite unanticipated process variations.

Airfoil

Although the method and apparatus of the present invention can be utilized to apply either a uniform or a nonuniform covering of material over many different workpieces, the apparatus (20) is advantageously utilized to apply a thermal barrier covering (64) to an airfoil (22) which is used in a turbine engine. The airfoil is held by a gripper assembly (86) while a spray gun (24) is effective to apply the covering over the airfoil. When a portion of the covering has been applied, a sensor (28) is utilized to detect the thickness of the covering. A control apparatus (32) compares the thickness of the covering of material which has been applied with the desired thickness and is subsequently effective to regulate the operation of the spray gun to adaptively apply a covering of a desired thickness with an accuracy of at least plus or minus 0.0015 inches (1.5 mils) despite unanticipated process variations.

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Richmond Heights, OH, United States of America

Istvan J Toth