Blade made of composite material with variable-density attached leading edge

Patent metadata

Field	Value
Publication number	US-2023003133-A1
Application number	US-202017784932-A
Country	US
Kind code	A1
Filing date	Dec 14, 2020
Priority date	Dec 18, 2019
Publication date	Jan 5, 2023
Grant date	—

Abstract

A method for manufacturing a blade in composite material having an added metal leading edge for gas turbine aeroengine, includes producing a blade body in composite material including in longitudinal direction, a blade root part, a shank part and an airfoil body part; manufacturing, via additive manufacturing, a leading edge extending in longitudinal direction between a lower end present at the shank part in composite material and an upper end present at the tip; bonding the manufactured leading edge onto the foremost edge portion of the airfoil body of the blade body in composite material.

First claim

1 . A method for manufacturing a blade in composite material having an added metal leading edge for gas turbine aeroengine, the method comprising:
producing a blade body in composite material comprising in longitudinal direction a blade root part, a shank part and an airfoil body part, the airfoil body part extending in longitudinal direction between the shank part and an airfoil body tip and in transverse direction between a foremost edge portion and a rear edge portion, manufacturing, via additive manufacturing, a leading edge extending in the longitudinal direction between a lower end intended to be present at the shank part of the blade body in composite material and an upper end intended to be present at the tip of the airfoil body part, bonding the manufactured leading edge onto the foremost edge portion of the airfoil body of the blade body in composite material, wherein the leading edge comprises a first portion in a first metal material and extending from the lower end of the leading edge as far as an intermediate position located between the lower end and upper end of the leading edge, and a second portion in a second metal material extending from the intermediate position as far as the upper end of said leading edge, the second metal material having greater density than the density of the first metal material.

2 . The method according to claim 1 , wherein the first portion extends in longitudinal direction over a height corresponding to 30% of total airflow height while the second portion extends in longitudinal direction over a height corresponding to 70% of total airflow height.

3 . The method according to claim 1 , wherein the first metal material is steel or titanium, while the second metal material is a nickel or cobalt alloy.

4 . The method according to claim 1 , wherein the first metal material is titanium while the second metal material is steel.

5 . A method for manufacturing a blade in composite material having an added metal leading edge for gas turbine aeroengine, the method comprising:
producing a blade body in composite material comprising in longitudinal direction a blade root part, a shank part and an airfoil body part, the airfoil body part extending in longitudinal direction between the shank part and an airfoil body tip and in transverse direction between a foremost edge portion and rear edge portion, manufacturing, via additive manufacturing, a leading edge extending in longitudinal direction between a lower end intended to be present at the shank part of the blade body in composite material and an upper end intended to be present at the tip of the airfoil body part, bonding the manufactured leading edge onto the foremost edge portion of the airfoil body of the blade body in composite material, wherein the leading edge comprises a first portion in a first metal material and extending from the lower end of the leading edge as far as a first intermediate position located between the lower end and upper end of the leading edge, a second portion in a second metal material and extending from the first intermediate position as far as a second intermediate position, and a third portion in a third metal material and extending from the second intermediate position as far as the upper end of said leading edge, the second metal material having greater density than the density of the first and third metal materials.

6 . The method according to claim 5 , wherein the first portion extends in longitudinal direction over a height corresponding to 30% of total airflow height while the second portion extends in longitudinal direction over a height corresponding to 60% of total airflow height and the third portion extends in longitudinal direction over a eight corresponding to 10% of total airflow height.

7 . The method according to claim 5 , wherein the first and third metal materials are steel or titanium, while the second metal material is a nickel or cobalt alloy.

8 . The method according to claim 5 , wherein the first and third metal materials are titanium while the second metal material is steel.

9 . A blade in composite material having an added metal leading edge for gas turbine aeroengine, the blade comprising a blade structure in composite material comprising in longitudinal direction a blade root, a shank and an airfoil body, the airfoil body extending in longitudinal direction between the shank and a blade tip and in transverse direction between a foremost edge portion and rear edge, and a leading edge bonded onto the foremost edge portion of the airfoil body of the blade structure in composite material, the leading edge extending in longitudinal direction between a lower end present at the shank of the blade structure in composite material and an upper end present at the blade tip of said blade structure, wherein the leading edge comprises a first portion in a first metal material and extending from the lower end of the leading edge as far as an intermediate position located between the lower end and upper end of the leading edge, and a second portion in a second metal material and extending from the intermediate position as far as the upper end of said leading edge, the second metal material having greater density than the density of the first metal material.

10 . The blade according to claim 9 , wherein the first portion extends in longitudinal direction over a height corresponding to 30% of total airflow height while the second portion extends in longitudinal direction over a height corresponding to 70% of total airflow height.

11 . A blade in composite material having an added metal leading edge for gas turbine aeroengine, the blade comprising a blade structure in composite material comprising in longitudinal direction, a blade root, a shank and an airfoil body, the airfoil body extending in longitudinal direction between the shank and a blade tip and in transverse direction between a foremost edge portion and rear edge, and a leading edge bonded onto the foremost edge portion of the airfoil body of the blade structure in composite material, the leading edge extending in longitudinal direction between a lower end present at the shank of the blade structure in composite material and an upper end present at the blade tip of said blade structure, wherein the leading edge comprises a first portion in a first metal material and extending from the lower end of the leading edge as far as a first intermediate position located between the lower end and upper end of the leading edge, a second portion in a second metal material and extending from the first intermediate position as far as a second intermediate position, and a third portion in a third metal material and extending from the second intermediate position as far as the upper end of said leading edge, the second metal material having greater density than the density of the first and third metal materials.

12 . The blade according to claim 11 , wherein the first portion extends in longitudinal direction over a height corresponding to 30% of total airflow height, while the second portion extends in longitudinal direction over a height corresponding to 60% of total airflow height, and the third portion extends in longitudinal direction over a height corresponding to 10% of total airflow height.

Assignees

• Safran Aircraft Engines

Inventors

• Gondre Guillaume Pascal Jean-Charles
• Bazot Olivier
• Dubosc Matthieu Pierre Michel

Classifications

• F01D5/147

  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

• F01D5/288 Primary

  Protective coatings for blades · CPC title

• F04D29/324

  Blades · CPC title

• F04D29/023

  especially adapted for elastic fluid pumps · CPC title

• F05D2240/30

  Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor · CPC title