Hybrid manufacturing for rotors

Patent metadata

Field	Value
Publication number	US-2016010469-A1
Application number	US-201414329298-A
Country	US
Kind code	A1
Filing date	Jul 11, 2014
Priority date	Jul 11, 2014
Publication date	Jan 14, 2016
Grant date	—

Abstract

A method for manufacturing a rotor includes manufacturing a hub using a conventional manufacturing process and manufacturing an airfoil on the hub using a layer-by-layer additive manufacturing process. A rotor includes a hub that has been manufactured with a conventional manufacturing process and an airfoil that has been manufactured on the hub with a layer-by-layer additive manufacturing process.

First claim

1 . A method for manufacturing a rotor, the method comprising:
manufacturing a hub using a conventional manufacturing process; and manufacturing an airfoil on the hub using a layer-by-layer additive manufacturing process.

2 . The method of claim 1 , wherein the conventional manufacturing process is a process selected from the group consisting of machining, forging, milling, or combinations thereof.

3 . The method of claim 1 , wherein the layer-by-layer additive manufacturing process is a process selected from the group consisting of cold spray, thermal spray, plasma spray, selective laser sintering, direct metal laser sintering, electron beam melting, selective laser melting, and combinations thereof.

4 . The method of claim 1 , wherein manufacturing the hub includes manufacturing the hub out of a first material, and wherein manufacturing the airfoil includes manufacturing the airfoil out of a second material.

5 . The method of claim 1 , wherein manufacturing the airfoil includes manufacturing a first portion of the airfoil out of a first airfoil material and manufacturing a second portion of the airfoil out of a second airfoil material.

6 . The method of claim 1 , and further comprising:
manufacturing a plurality of airfoils on the hub using a layer-by-layer additive manufacturing process.

7 . The method of claim 6 , wherein the plurality of airfoils are manufactured simultaneously.

8 . The method of claim 6 , wherein the plurality of airfoils are manufactured one at a time.

9 . The method of claim 1 , and further comprising:
processing the hub and the airfoil to create a final part.

10 . The method of claim 9 , wherein the processing the hub and the airfoil includes using a process selected from the group consisting of milling, grinding, machining, finishing, and combinations thereof.

11 . A rotor comprising:
a hub that has been manufactured with a conventional manufacturing process; and an airfoil that has been manufactured on the hub with a layer-by-layer additive manufacturing process.

12 . The rotor of claim 11 , wherein the hub is made of a first material and the airfoil is made out of a second material.

13 . The rotor of claim 11 , wherein the airfoil has a first portion made of a first airfoil material and a second portion made of a second airfoil material.

14 . The rotor of claim 13 , wherein the first airfoil material is a material that is capable of withstanding high stress, and wherein the second airfoil material is a material that is a capable of withstanding high temperature.

15 . The rotor of claim 11 , wherein the rotor further comprises:
a plurality of airfoils that have been manufactured on the hub with a layer-by-layer additive manufacturing process.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Guo Changsheng

Classifications

• B22F10/66

  by mechanical means · CPC title

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• F01D5/282 Primary

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