Airfoil structure manufacturing method

Patent metadata

Field	Value
Publication number	US-2018328186-A1
Application number	US-201816043931-A
Country	US
Kind code	A1
Filing date	Jul 24, 2018
Priority date	Feb 16, 2016
Publication date	Nov 15, 2018
Grant date	—

Abstract

Disclosed is a method of manufacturing an airfoil structure. The airfoil structure includes a plurality of airfoils, a support for supporting the airfoils, and a case for covering the airfoils. Each airfoil includes an airfoil body, and an airflow generator for producing induced airflow by generating plasma. The method includes a process of forming the airflow generator that includes a first electrode forming step of forming a first electrode on the airfoil body, a dielectric layer forming step of forming a dielectric layer on the airfoil body by forming ceramic powder into a film to cover the first electrode through room temperature impact consolidation, and a second electrode forming step of forming a second electrode on a surface of the dielectric layer, such that the second electrode is electrically connected to the first electrode, and an alternating-current voltage is applied to the second electrode.

First claim

What is claimed is:

1 . A method of manufacturing an airfoil structure to be used in a jet engine,
the airfoil structure including
a plurality of airfoils,
a support for supporting the airfoils at their lower ends, and
a case for covering upper ends of the airfoils, and each airfoil including
an airfoil body formed extending in a longitudinal direction of the airfoil, and
an airflow generator, provided to the airfoil body, for producing induced airflow by generating plasma,
the method comprising a process of forming the airflow generator that includes:
a first electrode forming step of forming a first electrode on the airfoil body;
a dielectric layer forming step of forming a dielectric layer on the airfoil body by forming ceramic powder into a film to cover the first electrode through room temperature impact consolidation; and
a second electrode forming step of forming a second electrode on a surface of the dielectric layer in a way that exposes the second electrode to an outside, such that the second electrode is electrically connected to the first electrode, and an alternating-current voltage is applied to the second electrode, wherein
in the first electrode forming step, the first electrode is formed on an airfoil lateral surface of the airfoil body, spanning from a trailing edge-side part of a negative pressure surface to a trailing edge-side part of a positive pressure surface via a leading edge, in the dielectric layer forming step, the dielectric layer is formed on all the airfoil lateral surface of the airfoil body, and in the second electrode forming step, the second electrode is formed on the surface of the dielectric layer, which is opposite from the airfoil body, in the way that exposes the second electrode to the outside.

2 . A method of manufacturing an airfoil structure to be used in a jet engine,
the airfoil structure including
a plurality of airfoils,
a support for supporting the airfoils at their lower ends, and
a case for covering upper ends of the airfoils, and each airfoil including
an airfoil body formed extending in a longitudinal direction of the airfoil, and
an airflow generator, provided to the airfoil body, for producing induced airflow by generating plasma,
the method comprising a process of forming the airflow generator that includes:
a first electrode forming step of forming a first electrode on the airfoil body;
a dielectric layer forming step of forming a dielectric layer on the airfoil body by forming ceramic powder into a film to cover the first electrode through room temperature impact consolidation; and
a second electrode forming step of forming a second electrode on a surface of the dielectric layer in a way that exposes the second electrode to an outside, such that the second electrode is electrically connected to the first electrode, and an alternating-current voltage is applied to the second electrode, wherein
in the first electrode forming step, the first electrode is formed on a leading edge-side part of an airfoil lateral surface of the airfoil body, in the dielectric layer forming step, the dielectric layer is formed on a leading edge-side part of the airfoil lateral surface of the airfoil body, and in the second electrode forming step, the second electrode is formed on the surface of the dielectric layer, which is opposite from the airfoil body, in the way that exposes the second electrode to the outside.

3 . A method of manufacturing an airfoil structure to be used in a jet engine,
the airfoil structure including
a plurality of airfoils,
a support for supporting the airfoils at their lower ends, and
a case for covering upper ends of the airfoils, and each airfoil including
an airfoil body formed extending in a longitudinal direction of the airfoil, and
an airflow generator, provided to the airfoil body, for producing induced airflow by generating plasma,
the method comprising a process of forming the airflow generator that includes:
a first electrode forming step of forming a first electrode on the airfoil body;
a dielectric layer forming step of forming a dielectric layer on the airfoil body by forming ceramic powder into a film to cover the first electrode through room temperature impact consolidation; and
a second electrode forming step of forming a second electrode on a surface of the dielectric layer in a way that exposes the second electrode to an outside, such that the second electrode is electrically connected to the first electrode, and an alternating-current voltage is applied to the second electrode, wherein
in the first electrode forming step, the first electrode is formed on an upper end surface of the airfoil body, in the dielectric layer forming step, the dielectric layer is formed on the upper end surface of the airfoil body, and in the second electrode forming step, the second electrode is formed on a side surface of the dielectric layer in the way that exposes the second electrode to the outside.

4 . A method of manufacturing an airfoil structure to be used in a jet engine,
the airfoil structure including
a plurality of airfoils,
a support for supporting the airfoils at their lower ends, and
a case for covering upper ends of the airfoils, and each airfoil including
an airfoil body formed extending in a longitudinal direction of the airfoil, and
an airflow generator, provided to the airfoil body, for producing induced airflow by generating plasma,
the method comprising a process of forming the airflow generator that includes:
a first electrode forming step of forming a first electrode on the airfoil body;
a dielectric layer forming step of forming a dielectric layer on the airfoil body by forming ceramic powder into a film to cover the first electrode through room temperature impact consolidation; and
a second electrode forming step of forming a second electrode on a surface of the dielectric layer in a way that exposes the second electrode to an outside, such that the second electrode is electrically connected to the first electrode, and an alternating-current voltage is applied to the second electrode, wherein
in the first electrode forming step, the first electrode is formed on an upper end surface of the airfoil body, in the dielectric layer forming step, the dielectric layer is formed on the upper end surface of the airfoil body, and in the second electrode forming step, the second electrode is formed on the surface of the dielectric layer, which is opposite from the airfoil body, in the way that exposes the second electrode to the outside.

5 . The method of manufacturing an airfoil structure according to claim 1 , wherein
the process of forming the airflow generator further comprises a third electrode forming step of forming a third electrode on the surface of the dielectric layer in a way that exposes the third electrode to the outside, such that the third electrode is away from the second electrode, the third electrode is electrically connected to the first electrode, and a direct-current voltage is applied to the third electrode.

6 . The method of manufacturing an airfoil structure according to claim 2 , wherein
the process of forming the airflow generator further comprises a third electrode forming step of forming a third electrode on the surface of the dielectric layer in a way that exposes the third electrode to the outside, such that the third electrode is away from the second electrode, the third electrode is electrically connected to the first electrode, and a direct-current voltage is applied to the third electrode.

7 . The method of manufacturing an airfoil structure according to claim 3 , wherein
the process of forming the airflow generator further comprises a third electrode forming step of forming

Assignees

• Ihi Corp

Inventors

• ASAUMI Norio
• Tanaka Nozomi
• KOUWA Junya
• Inoue Kaoru

Classifications

• F01D5/20

  Specially-shaped blade tips to seal space between tips and stator {(F01D5/225 takes precedence)} · 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

• F15D1/0075

  comprising electromagnetic or electrostatic means for influencing the state of the fluid, e.g. for ionising the fluid or for generating a plasma · CPC title

• F05D2220/32

  in gas turbines · CPC title

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title