Composite airfoil bonded to a metallic root

Patent metadata

Field	Value
Publication number	US-2016010658-A1
Application number	US-201514866194-A
Country	US
Kind code	A1
Filing date	Sep 25, 2015
Priority date	Jun 17, 2013
Publication date	Jan 14, 2016
Grant date	—

Abstract

The present disclosure relates to composite airfoils bonded to a metallic root. A composite body ( 510 ) may be formed with a metallic co-molded detail ( 520 ). The co-molded detail ( 520 ) may be transient liquid phase (TLP) bonded to an attachment feature ( 530 ). The attachment feature ( 530 ) may allow the composite body ( 510 ) to be attached to a rotor ( 200 ). The airfoil ( 500 ) may also have a metallic edge ( 550 ) which is TLP bonded to the composite body ( 510 ) via a co-molded edge ( 540 ).

First claim

1 . A fan blade comprising:
a composite body; a co-molded detail coupled to the composite body; and an attachment feature bonded to the co-molded detail.

2 . The fan blade of claim 1 , wherein the composite body comprises a laminated structure.

3 . The fan blade of claim 1 , wherein the composite body comprises a plurality of plies of reinforced fabric.

4 . The fan blade of claim 1 , wherein the co-molded detail comprises metal.

5 . The fan blade of claim 1 , wherein the co-molded detail is integrally formed within the composite body.

6 . The fan blade of claim 1 , wherein the attachment feature comprises metal.

7 . The fan blade of claim 1 , further comprising a transient liquid phase bond region between the co-molded detail and the attachment feature.

8 . The fan blade of claim 1 , wherein the attachment feature is coupled to the co-molded detail via at least one of transient liquid phase bonding and partial transient liquid phase bonding.

9 . The fan blade of claim 1 , further comprising a metallic edge coupled to the composite body via a co-molded edge.

10 . The fan blade of claim 9 , wherein the metallic edge is coupled to the co-molded edge via transient liquid phase bonding.

11 . A rotor comprising:
a disk; and an airfoil coupled to the disk, the airfoil comprising:
a composite body;
a metallic co-molded detail integrally formed within the composite body; and
a metallic root transient liquid phase bonded to the co-molded detail;
wherein the metallic root couples the airfoil to the disk.

12 . The rotor of claim 11 , wherein the airfoil further comprises a transient liquid phase bond region located between the co-molded detail and the root.

13 . The rotor of claim 11 , wherein the airfoil further comprises a co-molded edge integrally formed within the composite body, and a metallic edge transient liquid phase bonded to the co-molded edge.

14 . The rotor of claim 11 , wherein the co-molded detail is further coupled to the composite body via at least one of interleaves, stitching, weaving, and interlock.

15 . A method of manufacturing a fan blade comprising:
co-molding a composite body and a co-molded detail; providing a metallic interlayer between the co-molded detail and an attachment feature; and heating a bonding region comprising the interlayer to a bonding temperature, wherein the interlayer diffuses into at least one of the co-molded detail and the attachment feature, wherein the heating results in a bond between the co-molded detail and the attachment feature.

16 . The method of claim 15 , further comprising maintaining the bonding region at the bonding temperature until the interlayer has isothermally solidified.

17 . The method of claim 15 , wherein the interlayer comprises at least one of a thin foil, an amorphous foil, a fine powder, a powder compact, a brazing paste, a vapor deposition, a spray coating, and an electroplating.

18 . The method of claim 15 , further comprising homogenizing the bond.

19 . The method of claim 15 , wherein a remelting temperature of the bond is higher than a melting temperature of the interlayer.

20 . The method of claim 15 , further comprising transient liquid phase bonding a metallic edge to a co-molded edge coupled to the composite body.

Assignees

• United Technologies Corp

Inventors

• Roach James T
• Cook Iii Grant O

Classifications

• B23K20/16

  with interposition of special material to facilitate connection of the parts, e.g. material for absorbing or producing gas · CPC title

• B23K1/0018

  Brazing of turbine parts · CPC title

• B23K2101/001

  Turbines · CPC title

• B23K20/026

  with diffusion of soldering material · CPC title

• Y10T29/49337

  Composite blade · CPC title