Rolls-royce Corporation

Michael James Wallis

Ian J Andrews

Paul J Mason

Simon M Barlow

David Rugg

Ian Fearn

Andrew R Fearn

Ian John Andrews

Simon Mark Barlow

A method of manufacturing a hollow aerofoil componentfor a gas turbine enginecomprises joining a first panelto a second panelusing bonding, and hot forming the panels into shape. The bonding step and the hot forming step are performed in the same rig, thereby optimizing process time and component quality.

Manufacture of a hollow aerofoil

A method of manufacturing a hollow component, such as a fan blade for a gas turbine engine, includes the steps of: (a) providing first and second panels and a membrane; (b) providing a stop-off material on at least one of the first and second panels and the membrane to define regions where no diffusion bonding is to take place; (c) assembling the panels and the membrane together so the membrane is between the panels; (d) diffusion bonding the panels and the membrane together. The method is such that when assembled in step (c) the membrane does not extend to at least one edge of the first and second panels, so that in that region the first and second panels are diffusion bonded directly to each other.

Hollow component manufacture

A diffusion bonded and superplastically formed turbomachine blade, the turbomachine blade comprising: a first layer (); a second layer (); and a membrane () disposed between the first and second layers (); wherein the membrane () is diffusion bonded to the first layer () along a plurality of first strips () and the membrane () is diffusion bonded to the second layer () along a plurality of second strips (), wherein the first and second strips () are offset from one another so that the membrane () is bonded to the first and second layers () in an alternating pattern; wherein the membrane () has a recess () which extends into an area between an adjacent pair of first or second strips ().

Diffusion bonded and superplastically formed turbomachine blade

A ducted fan gas turbine engine aerofoil is made by electron beam welding together at least two metal sheets () and () and electron beam welding that sub assembly via an end to a root that has been manufactured in a separate operation, and then heating the whole to a temperature that will convert the electron beam welds to diffusion bonds.

Method of making and joining an aerofoil and root

A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing two metallic panels; assembling and joining the two metallic panels to one another to form the aerofoil structure; wherein the two metallic panels each comprise a surface capable of forming an aerofoil and further comprise a root or section thereof which is either integral with or fixed to the aerofoil surface; and incorporating a section of a different material into a part, the said section being made from a material which is different from the material of another part of the aerofoil structure.

Method of manufacturing an aerofoil

A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing a metallic plate for forming the aerofoil structure; joining mounting elements to opposing end surfaces of said metallic plate; dividing said plate along a plane extending substantially in a span-wise direction so as to produce two metallic panels each with one of said mounting elements joined thereto; assembling the two metallic panels so that the surfaces of the panels opposite to the surfaces which have been divided are facing each other; and joining the two metallic panels to one another to form the aerofoil structure; wherein the mounting elements are joined to one another to form the root of the aerofoil.

A method of manufacturing an aerofoil structure to have a portion with an increased erosion resistance, the method comprising: providing one or more titanium elements () and a beta-stabilizing material (); wherein the one or more elements () have an alpha-beta microstructure; assembling the one or more elements () and the beta-stabilizing material () such that the beta-stabilizing material () is adjacent to the one or more elements (); and heating the assembly such that the beta-stabilizing material () diffuses into an adjacent portion of the one or more elements (), causing the adjacent portion of the one or more elements () to have a beta microstructure which provides an increased erosion resistance.

A method of manufacturing a gas turbine engine fan blade ( ) comprises forming three metal workpieces ( ). The metal workpieces ( ) are assembled into a stack ( ) so that the flat surfaces ( ) are in mating abutment. Heat and pressure is applied across the thickness of the metal workpieces ( ) to diffusion bond the metal workpieces ( ) together to form an integral structure ( ). The integral structure ( ) is upset forged at one end ( ) to produce an increase in thickness ( ) for forming the blade root ( ). The upset forged integral structure ( ) is then hot creep formed and superplastically formed to produce the required aerofoil shape and the thickened end ( ) is machined to form the blade root ( ). The method enables thinner metallic workpieces with better microstructure to be used and increases the yield of metallic workpieces.

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Clitheroe, United Kingdom

Michael James Wallis