Rolls-royce Corporation

Oliver Michael Strother

Keith Christopher Goldfinch

Julian MacKechnie-Jarvis

Richard M Jones

Dean G Jones

Julian Mackechnie-Jarvis

A method of manufacturing a component having first and second layers, the first and/or second layers including one or more depressions provided on a surface of the respective layer. The method including: arranging the first and second layers so that they face one another and with the depressions on inner facing surfaces of the layers; diffusion bonding the first and second layers together about their edges; applying a first differential pressure across each of the first and second layers to evacuate an inner space defined by the layers, thereby forming one or more depressions on an outer facing surface of the first or second layer; and applying a second differential pressure across each of the first and second layers to expand the inner space defined by the layers.

Method of manufacturing a component

An aerofoil has first and second panels spaced apart from each other to provide a cavity, the cavity containing a damping material, the first panel has at least one protrusion extending therefrom within the cavity towards the second panel, the protrusion having a proximal end and a distal end, wherein the proximal end is secured to the first panel and the distal end is slidably mounted to the second panel.

Article with an internal structure

A method of manufacturing an aerofoil for a gas turbine engine (). The method comprises the steps of providing first and second panels (), providing a web () between the first and second panels, deforming the panels by applying internal pressure between the panels so as to form an internal cavity. The method further includes the step of providing a pattern of ribs () on the web so as to define a aerofoil having first and second panels with at least one rib () forming a protrusion extending from the first panel partially across the space between the first and second panels.

Method of forming an aerofoil with a damping filler

A method is provided of rotationally balancing a rotating part. A rotor hub or ring and a plurality of rotor blades for assembly onto the hub or ring are provided, each blade having an unfilled internal cavity. The respective masses and moment weights of the blades with filled internal cavities are then predicted. Next, the rotor blades are assembled onto the hub or ring to form the rotating part. The relative positions of the assembled blades are determined on the basis of their predicted masses and moment weights with filled internal cavities. The internal cavities of the assembled rotor blades are then filled.

Rotationally balancing a rotating part

A method of forming a hollow component with an internal structure from first and second panels includes the step of forming at least one protrusion on a surface of at least one of the first and second panels by a material deposition process. The first and second panels are assembled into a preform the panels being oriented such that each panel defines an interior and an exterior facing surface, with the at least one protrusion extending from an exterior facing surface of a panel. The preform is expanded against a die, such that the at least one protrusion is transferred from the exterior surface of a panel to the interior surface of a panel so as to define an internal structure. Forming the at least one protrusion may include encapsulating an elongate member on the surface of a panel by a material deposition process.

Method of forming a hollow component with an internal structure

A method of forming an internal structure in a hollow component that includes the steps of forming an assembly having first, second, and third plates the first and second plates each with a substantially planar surface and a surface that includes at least one protrusion and is on the exterior facing surfaces of the assembly. The third plate is sandwiched between the first and second plates. The method also includes the steps of selectively bonding portions of the third plate to sections of the first and second plates substantially opposite the at least one protrusions of the first and second plates; and forming the assembly against a die such that the at least one protrusions of the first and second plates are transferred from the exterior facing surfaces to the interior facing surfaces of the first and second plates.

Method of forming an internal structure in a hollow component

A method of making an aerofoil comprises the steps of providing first and second skin panels and first and second web-forming membranes. The web-forming membranes each have a series of elongate slots formed longitudinally therein so as to define a series of alternating wide and narrow strips. The wide strips of one membrane are arranged against the narrow strips of the other membrane and the skin panels are arranged either side of the two web-forming membranes. Parts of the web-forming membranes and parts of the skin panels are treated with a release layer and the sub-assembly is compressed and heated so as to effect diffusion bonding between those parts of the membranes and skin panels which are not treated with the release layer. The sub-assembly is then heated and inflated so as to draw the first and second skin panels apart and that, in turn, causes the web-forming membranes to form webs internally.

Aerofoil sub-assembly, an aerofoil and a method of making an aerofoil

A method of manufacturing an aerofoil for a gas turbine engine (). The method comprises the steps of providing first and second panels (), providing a web () between the first and second panels, deforming the panels and the web by applying internal pressure between the panels so as to form a series of internal cavities partitioned by the web. The method further includes the step of either cutting the web () across its entire width or causing the web to fail across its entire width so as to define an aerofoil having first and second panels with at least one protrusion extending from the first panel partially across the space between the first and second panels.

Component with a damping filler and method

A method of joining plates of material to form a predetermined structure, the method comprising: assembling a first plate () of a material comprising at least one recess () against a second plate () of material such that the at least one recess () of the first plate () is in an exterior surface of the first plate () on a side of the first plate opposite to the side which faces the second plate (); bonding a portion () of the first and second plates () to one another; superplastically forming the bonded plates, wherein the superplastic forming causes the material of the second plate () which is opposite to the at least one recess () of the first plate () to be driven towards the recess (), and wherein the unbonded portion of the second plate () is deflected away from the plate to form the predetermined structure.

Method of joining plates of material to form a structure

Within hollow structures, such as blade structures in a gas turbine engine, traditionally rigid girdered reinforcement has been utilised to define structure and shape. Such rigid definition can inhibit utilisation of damping fillers within the hollow structure. By providing a web former comprising spaced bond areas suspended upon angled interconnecting membranes a hollow structure is achieved which is flexible and can be used in conjunction with a damping filler to achieve desired performance. The web former supports skins defining the shape and takes some load such that the damping filler does not separate within the hollow structure.

Component structure

A component () and method for manufacturing a component. The component comprises first and second panels () spaced apart from each other, the first panel () having at least one protrusion () extending therefrom towards the second panel (). The protrusion () extends partially across the space () between the first and second panels so as to define a free end of the protrusion. The free end is surrounded by damping material ().

Growing community of inventors

Nottingham, United Kingdom

Oliver Michael Strother