Multiple piece engine component

Patent metadata

Field	Value
Publication number	US-2016265362-A1
Application number	US-201415030243-A
Country	US
Kind code	A1
Filing date	Oct 17, 2014
Priority date	Oct 18, 2013
Publication date	Sep 15, 2016
Grant date	—

Abstract

One exemplary embodiment of this disclosure relates to a gas turbine engine, including a component having a first portion formed using one of a casting and a forging process, and a second portion formed using an additive manufacturing process.

First claim

What is claimed is:

1 . A gas turbine engine, comprising:
a component including a first portion formed using one of a casting and a forging process, and a second portion formed using an additive manufacturing process.

2 . The gas turbine engine as recited in claim 1 , wherein the component includes a third portion formed using an additive manufacturing process.

3 . The gas turbine engine as recited in claim 2 , wherein the second portion and the third portion provide pressure and suction side walls of the component.

4 . The gas turbine engine as recited in claim 2 , wherein the first portion includes a root, platform, and at least one radial support projecting from the platform.

5 . The gas turbine engine as recited in claim 4 , wherein the root, platform, and at least one radial support are integrally formed of one of a single crystal, directionally solidified, and an equiax alloy.

6 . The gas turbine engine as recited in claim 4 , wherein the at least one radial support includes at least one rib projecting into a corresponding slot formed in one of the second portion and the third portion.

7 . The gas turbine engine as recited in claim 6 , wherein the at least one radial support includes a plurality of radial supports, each of the radial supports including a first rib and a second rib projecting into slots formed in the second portion and the third portion.

8 . The gas turbine engine as recited in claim 4 , wherein the at least one radial support provides a mate face corresponding to a mate face of one of the second portion and the third portion.

9 . The gas turbine engine as recited in claim 4 , wherein the second portion and the third portion are joined to the at least one radial support by one of welding, brazing, diffusion bonding, and gluing.

10 . The gas turbine engine as recited in claim 2 , wherein the second portion and the third portion include microchannels formed therein.

11 . The gas turbine engine as recited in claim 2 , wherein the component is one of a rotor blade and a stator vane.

12 . A component for a gas turbine engine, comprising:
a platform, and an airfoil section including a pressure side wall and a suction side wall, wherein the platform is formed using one of a casting process and a forging process, and wherein the pressure and suction side walls are formed using an additive manufacturing process.

13 . The component as recited in claim 12 , including at least one radial support projecting from the platform, the at least one radial support formed integrally with the platform during the casting process.

14 . The component as recited in claim 13 , wherein the at least one radial support provides a joining interface with one of the pressure side wall and the suction side wall.

15 . The component as recited in claim 13 , wherein the at least one radial support includes a rib projecting into a corresponding slot in one of the pressure side wall and the suction side wall.

16 . A method of forming a component, comprising:
forming a first portion of the component using one of a casting and a forging process; additively manufacturing a second portion of the component; and joining the second portion to the first portion.

17 . The method as recited in claim 16 , including:
additively manufacturing a third portion of the component; and joining the third portion to the first portion.

18 . The method as recited in claim 16 , wherein the joining step includes one of welding, brazing, and gluing.

19 . The method as recited in claim 16 , wherein the additive manufacturing step includes one of a direct metal laser sintering (DMLS) process, an electron beam melting (EBM) process, electron beam wire deposition (EBWD) process, a laser powder deposition (LPD) process, and a laser powder plasma spray (LPPS) process.

20 . The method as recited in claim 16 , wherein the additive manufacturing step includes selectively melting a powdered metal, the powdered metal being one of (1) a titanium alloy, (2) tungsten alloy, (3) nickel alloy, (4) cobalt alloy, (5) steel alloy, and (6) a molybdenum alloy.

Assignees

• United Technologies Corp
• Unitedtechnologies Corp

Inventors

• Slavens Thomas N
• Zelesky Mark F

Classifications

• B22F10/40

  Structures for supporting workpieces or articles during manufacture and removed afterwards · 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

• B23K2103/04

  Steel {or steel} alloys · CPC title

• B23K26/0006

  taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence) · CPC title