Rolls-Royce Corporation

Facc Ag

Paul J Mason

Kristofer John Bottome

Ewan Fergus Thompson

Eric P Ravey

James Andrew Lee

Michael James Wallis

Matthew A C Hoyland

Christopher M Whitehead

Konstantin Horejsi

Jeremy Nicholas Turner

Gion Barandun

Markus Henne

Martin Fleischmann

Christof Obertscheider

Thomas Keusch

Andrew R Fearn

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 nose cone assembly is provided comprising a nose cone, a support ring on which the nose cone is mounted, and an insulating layer disposed between the nose cone and the support ring, the insulating layer at least partially comprising glass fibres. A composite nose cone is also provided comprising an attachment region A, in which composite fibres are oriented substantially perpendicular to an axis of rotation of the nose cone, and an impact region I, in which composite fibres are oriented substantially parallel to the axis of rotation of the nose cone. Also provided is a support ring for a nose cone assembly, the support ring comprising an annular main body and an annular projecting attachment flange, the attachment flange terminating in a plurality of circumferentially spaced attachment tabs, wherein the attachment flange forms with the main body a cross section having at least two C curves.

Nose cone assembly

A test blade for use in a blade-release test in which the blade is mounted on a rotatable hub and at least a portion of the blade is released therefrom by the action of a controlled explosion. The blade has a root portion for mounting on said rotatable hub and the root portion comprises a radially inner surface having a channel extending at least partly along or proximal the camber line. The channel is for receiving at least one explosive charge and at least one detonator which may be contained within a charge carrier.

Test blade

An annulus filler, mounted to a rotor disc of a gas turbine engine and bridging the gap between two adjacent blades attached to the rotor disc, is disclosed. The annulus filler, formed from a polymer matrix composite material, includes an outer lid, defining an airflow surface for air drawn through the engine in an axial airflow direction, and a support structure, connectable to the rotor disc, to support the rear of the lid on the rotor disc. The support structure has two support walls extending from opposing lateral sides of the lid to an attachment strap for receiving a hook on the rotor disc, the attachment strap bridging the support walls. Under centrifugal loads, the opposing support walls resiliently deform. Each support wall has a concave rear edge. Each rear edge has a first curved section, a second curved section and a substantially straight section therebetween.

Annulus filler

An annulus filler is provided for mounting to a rotor disc of a gas turbine engine and bridging the gap between two adjacent blades attached to the rotor disc. The annulus filler is substantially entirely formed from a polymer matrix composite material. It has an outer lid which defines an airflow surface for air being drawn through the engine in an axial airflow direction, and a support structure which is connectable to the rotor disc to support the lid on the rotor disc. The support structure has two support walls extending from opposing lateral sides of the lid to an attachment strap for receiving a hook on the rotor disc, the attachment strap bridging the support walls. In use, under centrifugal loads, the opposing support walls resiliently deform to allow outward radial movement of the lid. Each support wall is thickened in a region neighboring the attachment strap.

A nose cone assembly is provided comprising a nose cone, a support ringon which the nose coneis mounted, and an insulating layerdisposed between the nose coneand the support ring, the insulating layerat least partially comprising glass fibers. A composite nose cone is also provided comprising an attachment region A, in which composite fibers are oriented substantially perpendicular to an axis of rotation of the nose cone, and an impact region I, in which composite fibers are oriented substantially parallel to the axis of rotation of the nose cone Also provided is a support ringfor a nose cone assembly, the support ringcomprising an annular main bodyand an annular projecting attachment flange, the attachment flangeterminating in a plurality of circumferentially spaced attachment tabs, wherein the attachment flangeforms with the main bodya cross section having at least two C curves

A rotor, such as a fan of a gas turbine engine, comprises bladesand annulus fillerswhich extend between adjacent blades. Gapsbetween each bladeand the adjacent annulus fillersare sealed by sealing elements. The sealing elementsfit closely around the profile of the bladeand have annulus filler sealing surfacesfor sealing contact with the annulus fillers. The sealing elementshave low-friction blade sealing surfacesso that, when the fan is rotating, centrifugal loading displaces the sealing elementsradially outwardly so that the annulus filler sealing surfacemake sealing contact with the annulus fillers

Bladed rotor

An annulus filler for mounting to a rotor disc of a gas turbine engine. The filler comprises a lid for bridging the gap between two adjacent blades attached to the rotor disc, and forward and rearward hook members projecting below the lid and configured to respectively engage with forward and rearward outwardly directed hooks provided on the rotor disc. The filler can further comprise a lip extending from the rear of the lid, the lip being configured to fit beneath a gas-washed element located rearwards of the annulus filler. One or more guide ramps then extend from the rear of the lip, the or each guide ramp being angled down relative to the lip to encourage the lip to slide beneath said fairing when the annulus filler is translated in the generally rearwards direction.

Annulus filler for a gas turbine engine

An apparatus for simulating stresses experienced by a rotor blade root in a complementary disc fixture, especially in gas turbine engines. The apparatus comprises a mounting member for receiving a blade speciman having a root. The mounting member has an aperture for receiving the root of the blade specimen, and blade contacting regions on either side of said aperture for holding said blade specimen in said aperture. The apparatus further comprises an actuator for applying a tension load to said blade specimen. The blade contacting regions are undercut such that there is a gap between said blade contacting regions and a main body of said mounting member, whereby the blade contacting regions are able to deflect outward into said gap when a tension load is applied to the blade specimen.

Growing community of inventors

Ashbourne, United Kingdom

Paul J Mason