Dual-walled components for a gas turbine engine

Patent metadata

Field	Value
Publication number	US-10519780-B2
Application number	US-201615264338-A
Country	US
Kind code	B2
Filing date	Sep 13, 2016
Priority date	Sep 13, 2016
Publication date	Dec 31, 2019
Grant date	Dec 31, 2019

Abstract

Techniques for forming a dual-walled component for a gas turbine engine that include chemically etching at least one of a hot section part or a cold section part to form an etched part having plurality of support structures and bonding the etched part to a corresponding cold section part or a corresponding hot section part to form a dual-walled component, with the plurality of support structures defining at least one cooling channel between the at least one of the hot section part or the cold section part and the corresponding cold section part or the corresponding hot section part.

First claim

What is claimed is:

1. A method for forming a dual-walled component for a gas turbine engine, the method comprising:
applying a mask to a curved surface of the at least one hot section part or cold section part to define a cooling channel pattern on a surface of the at least one hot section part or cold section part;
chemically etching the curved surface of the at least one hot section part or cold section part to form an etched part having a plurality of support structures;
removing the mask after chemically etching the curved surface; and
bonding the etched part to a corresponding cold section part or a corresponding hot section part to form a dual-walled component, wherein the plurality of support structures define at least one cooling channel between the at least one of the hot section part or the cold section part and the corresponding cold section part or the corresponding hot section part.

2. The method of claim 1 , wherein the dual-walled component comprises an airfoil.

3. The method of claim 1 , wherein the etched part comprises the hot section part.

4. The method of claim 1 , wherein bonding the etched part to the corresponding cold section part or the corresponding hot section part comprises at least one of diffusion bonding or brazing.

5. The method of claim 1 , further comprising installing the dual-walled component in a gas turbine engine.

6. A method comprising:
forming a dual-walled component for a gas turbine engine, wherein the dual-walled component comprises a spar comprising a superalloy material and a coversheet bonded to the spar, wherein forming the dual-walled component comprises:
applying a mask to a curved surface of at least one of the coversheet or the spar to define a cooling channel pattern on the curved surface of the at least one coversheet or spar;
chemically etching the curved surface of the at least one spar or coversheet to form a plurality of support structures;
removing the mask after chemically etching the curved surface; and
bonding the coversheet to the spar, wherein the plurality of support structures define at least one cooling channel between the spar and the coversheet.

7. The method of claim 6 , further comprising:
forming a plurality of cooling apertures in the coversheet; and
forming a plurality of impingement apertures in the spar; wherein after bonding, at least one cooling aperture of the plurality of cooling apertures, at least one impingement aperture of the plurality of impingement apertures, and the at least one cooling channel are fluidly connected through the dual-walled component.

8. The method of claim 6 , further comprising, prior to chemically etching the at least one of the spar or the coversheet, machining the spar and the coversheet to have corresponding complementary bond surfaces by mechanically removing material from at least one of the spar or the coversheet.

9. The method of claim 6 , wherein the dual-walled component comprises an airfoil.

10. The method of claim 6 , further comprising installing the dual-walled component in a gas turbine engine.

11. The method of claim 10 , wherein installing the component includes connecting the component to an air-cooling system of the gas turbine engine.

Assignees

• Rolls Royce Corp

Inventors

• Varney Bruce

Classifications

• F05D2230/11

  by electrochemical methods · CPC title

• F05D2260/204

  by the use of microcircuits · CPC title

• F01D5/189

  the insert having a tubular cross-section, e.g. airfoil shape · CPC title

• F01D9/065

  Fluid supply or removal conduits traversing the working fluid flow, e.g. for lubrication-, cooling-, or sealing fluids (see also F01D25/16, F01D25/24 and F01D25/26) · CPC title

• F01D5/186 Primary

  Film cooling (F01D5/187 takes precedence) · CPC title