Cooled blisk with dual wall blades for gas turbine engine

Patent metadata

Field	Value
Publication number	US-10247015-B2
Application number	US-201715405476-A
Country	US
Kind code	B2
Filing date	Jan 13, 2017
Priority date	Jan 13, 2017
Publication date	Apr 2, 2019
Grant date	Apr 2, 2019

Abstract

A gas turbine engine and a blisk are disclosed, including methods of making the same. The blisk may include a disk, spars of airfoils, platforms, and shanks of airfoils integrally formed as a unit. Such blisk features may be integrally formed by a casting process or additive manufacturing. The blisk includes cooled airfoils, such that the spar is hollow, and a cover panel is bonded to an outer surface of standoffs to define passages between the cover panel and the spar. Cooling air is fed to the hollow spar through a cooling feed channel defined in the disk or shank portion.

First claim

What is claimed is:

1. A blisk for a gas turbine engine having a longitudinal axis, the blisk comprising a disk, a spar, a platform, and a shank portion integrally formed as a unit, the disk disposed about a longitudinal axis and having an upstream side and a downstream side, the spar extending radially outward from the platform relative to the longitudinal axis, the shank portion extending between the platform and the disk, wherein the spar includes a cooling air plenum defined therein disposed along an airfoil axis radially extended from the longitudinal axis, a plurality of standoffs extending away from an outer surface of the spar, wherein the blisk further comprises a cover panel bonded to an outer surface of the standoffs, wherein the standoffs are spaced from one another such that cooling passages are defined between the cover panel and the spar, the spar comprising one or more inlet ports defined therein in communication with the cooling air plenum and the cooling passages, the cover panel having one or more discharge ports defined therein in communication with the cooling passages, wherein a cooling feed channel is defined in the disk or shank portion that is in communication with the cooling air plenum, wherein the cooling feed channel is configured to receive cooling air upstream of the disk for delivery to the cooling air plenum.

2. The blisk of claim 1 , wherein the disk, the spar, the platform, and the shank portion are a casted unit.

3. The blisk of claim 1 , wherein the spar, the platform, and the shank portion are a successively layered formed unit.

4. The blisk of claim 1 , wherein the cooling feed channel includes an inlet formed in the upstream side of the disk or the shank portion.

5. The blisk of claim 1 , wherein the disk includes a cooling cavity defined therein between the shank portions that are adjacent to one another, the cooling cavity extending from the upstream side in a downstream direction, wherein the cooling feed channel includes an inlet formed in a lateral wall that defines a portion of the cooling cavity.

6. The blisk of claim 1 , wherein the cover panel comprises a single sheet.

7. The blisk of claim 1 , wherein the cover panel comprises a suction-side panel and a pressure-side panel.

8. The blisk of claim 1 , wherein the plurality of standoffs includes a first standoff and a second standoff, each having an elongated shape and adjacent to one another to define cooling passage channels.

9. The blisk of claim 1 , wherein the plurality of standoffs includes pedestals or pins.

10. A method of making a blisk for a gas turbine engine, the method comprising the steps of:
forming a disk, a spar, a platform, and a shank portion integrally as a unit, wherein the spar extends radially outward from the platform, the shank portion extends between the platform and the disk, wherein the spar includes a cooling air plenum defined therein, a plurality of standoffs extending away from an outer surface of the spar, the standoffs spaced away from one another such that cooling passages are defined therebetween, and one or more inlet ports defined in the spar and in communication with the cooling air plenum and the cooling passages, wherein a cooling feed channel and a cooling cavity are defined in the disk or shank portion that are in communication with the cooling air plenum;
coupling a cover panel to an outer surface of the standoffs; and
coupling a coverplate over the cooling cavity.

11. The method of claim 10 , wherein the disk, the spar, the platform, and the shank portion are integrally formed as a casted unit.

12. The method of claim 10 , wherein the forming the disk, the spar, the platform, and the shank portion integrally as a unit step includes forming the disk; providing a computer-readable three-dimensional model of the spar, the platform, and the shank portion, the three-dimensional model configured to be converted into a plurality of slices that each define a cross-sectional layer of the spar, the platform, and the shank portion; and successively forming each layer of the spar, the platform, and the shank portion directly on the disk by additive manufacturing.

13. The method of claim 10 , wherein the forming step and the coupling step include forming the disk; providing a computer-readable three-dimensional model of the spar, the platform, the shank portion, and the cover panel, the three-dimensional model being configured to be converted into a plurality of slices that each define a cross-sectional layer of the spar, the platform, the shank portion, and the cover panel; and successively forming each layer of the spar, the platform, the shank portion, and the cover panel directly on the disk by additive manufacturing.

14. The method of claim 10 , wherein the cooling feed channel is formed including an inlet defined in the upstream side of the disk or the shank portion.

15. The method of claim 10 , further comprising forming a cooling cavity in the disk between the shank portions that are adjacent to one another, the cooling cavity extending from the upstream side in a downstream direction, wherein the cooling feed channel includes an inlet formed in a lateral wall that defines a portion of the cooling cavity.

16. The method of claim 10 , wherein the coupling step includes bonding the cover panel comprising a single sheet to the outer surface of the standoffs.

17. The method of claim 10 , wherein the cover panel comprises a suction side panel and a pressure side panel, wherein the coupling step includes bonding the suction side panel and the pressure side panel to the outer surface of the standoffs.

18. A gas turbine engine having a longitudinal axis, the engine comprising a turbine section, the turbine section including a blisk, the blisk comprising a disk, a spar, a platform, and a shank portion integrally formed as a unit, the disk disposed about a longitudinal axis and having an upstream side and a downstream side, the spar extending radially outward from the platform relative to the longitudinal axis, the shank portion extending between the platform and the disk, wherein the spar includes a cooling air plenum defined therein disposed along an airfoil axis radially extended from the longitudinal axis, a plurality of standoffs extending away from an outer surface of the spar, wherein the blisk further comprises a cover panel bonded to an outer surface of the standoffs, wherein the standoffs are spaced from one another such that cooling passages are defined between the cover panel and the spar, the spar comprising one or more inlet ports defined therein in communication with the cooling air plenum and the cooling passages, the cover panel having one or more discharge ports defined therein in communication with the cooling passages, wherein a cooling feed channel is defined in the disk or shank portion that is in communication with the cooling air plenum, wherein the cooling feed channel is configured to receive cooling air upstream of the disk for delivery to the cooling air plenum.

19. The gas turbine engine of claim 18 , wherein the disk, the spar, the platform, and the shank portion are a casted unit.

20. The gas turbine engine of claim 18 , wherein the spar, the platform, and the shank portion are a successively layered formed unit.

Assignees

• Rolls Royce Corp
• Rolls Royce Nam Tech Inc

Inventors

• Kush Matthew T
• Dierksmeier Douglas D

Classifications

• F05D2220/32

  in gas turbines · CPC title

• F05D2230/31

  Layer deposition · CPC title

• F01D5/34 Primary

  Rotor-blade aggregates of unitary construction {, e.g. formed of sheet laminae; (discs formed of sheet laminae F01D5/028; ceramic materials F01D5/284, composite materials F01D5/282)} · CPC title

• F05D2260/202

  by film cooling · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title