Fan blade and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-10260351-B2
Application number	US-201213422541-A
Country	US
Kind code	B2
Filing date	Mar 16, 2012
Priority date	Mar 16, 2012
Publication date	Apr 16, 2019
Grant date	Apr 16, 2019

Abstract

An airfoil for a gas turbine engine includes a substrate and a sheath providing an edge. A cured adhesive secures the sheath to the substrate. The cured adhesive has a fillet that extends beyond the edge that includes a mechanically worked finished surface. A method of manufacturing the airfoil includes the steps of securing a sheath to a substrate with adhesive, curing the adhesive, and mechanically removing a portion of the adhesive extending beyond the sheath.

First claim

What is claimed is:

1. An airfoil for a gas turbine engine, comprising:
a substrate;
a sheath providing an edge;
a cured adhesive securing the sheath to the substrate, the cured adhesive having a fillet extending adjacent to and beyond the edge from underneath the sheath, the fillet including a mechanically worked finished surface, the fillet leaving a portion of the edge exposed; and
a coating arranged over the substrate and the mechanically worked finished surface, the coating abutting the portion of the edge.

2. The airfoil according to claim 1 , wherein the substrate is a first metal and the sheath is a second metal different than the first metal.

3. The airfoil according to claim 2 , wherein the cured adhesive is configured to provide a barrier between the first and second metals to prevent galvanic corrosion.

4. The airfoil according to claim 3 , wherein the cured adhesive includes a scrim embedded in resin.

5. The airfoil according to claim 4 , wherein the scrim is provided beneath the sheath and inboard of the edge.

6. The airfoil according to claim 1 , wherein the mechanically worked finished surface includes a scraped contour.

7. The airfoil according to claim 1 , wherein the airfoil is a fan blade, and the sheath provides a leading edge of the airfoil.

8. The airfoil according to claim 1 , wherein the sheath includes a flank providing the edge.

9. A method of manufacturing an airfoil for a gas turbine engine, comprising the steps of:
securing a sheath to a substrate with adhesive, wherein the adhesive flows beyond an edge of the sheath;
curing the adhesive;
mechanically removing a portion of the adhesive that flowed beyond the edge to leave a fillet extending beyond and from beneath the sheath and to expose a portion of the edge; and
applying a coating over the substrate and the mechanically worked finished surface and adjoining the portion of the edge, the coating providing a fan blade contour along with the sheath.

10. The method according to claim 9 , wherein the securing step includes providing a resin-saturated scrim between the sheath and substrate.

11. The method according to claim 9 , wherein the curing step includes providing the fillet of cured adhesive adjoining the sheath and the substrate.

12. The method according to claim 11 , wherein the removing step includes scraping the fillet with a tool to provide a mechanically worked finished surface on the cured adhesive.

13. A gas turbine engine comprising:
a fan section comprising a plurality of fan blades, at least one of said fan blades comprising:
a substrate;
a sheath providing an edge; and
a cured adhesive securing the sheath to the substrate, the cured adhesive having a fillet extending adjacent to and beyond the edge from underneath the sheath, the fillet including a mechanically worked finished surface, the fillet leaving a portion of the edge exposed, and a coating arranged over the substrate and the mechanically worked finished surface, the coating abutting the portion of the edge.

14. The gas turbine engine according to claim 13 , further comprising:
a compressor section;
a combustor section in fluid communication with the compressor section; and
a turbine section in fluid communication with the combustor section.

15. The gas turbine engine according to claim 13 , wherein the compressor section includes a high pressure compressor section and a low pressure compressor section, wherein the turbine section includes a high pressure turbine section and a low pressure turbine section, wherein the high pressure turbine section is engaged with the high pressure compressor section via a first spool and the low pressure turbine section is engaged with the low pressure compressor section via a second spool.

16. The gas turbine engine according to claim 15 , further comprising:
a geared architecture that engages both the second spool and the fan section.

Assignees

• Parkin Michael
• Hansen James O
• Hertel Christopher J
• Lyders David R
• United Technologies Corp

Inventors

• Parkin Michael
• Hansen James O
• Hertel Christopher J
• Lyders David R

Classifications

• F01D5/282

  Selecting composite materials, e.g. blades with reinforcing filaments · CPC title

• F05D2220/36

  specially adapted for the fan of turbofan engines · CPC title

• F04D29/324

  Blades · CPC title

• F05D2240/303

  related to the leading edge of a rotor blade · CPC title

• F01D5/147 Primary

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title