AIRFOIL MATEFACE SEALING

Abstract

An airfoil includes an airfoil working portion and an adjoining endwall. The endwall has a leading edge, a trailing edge, a first mateface, and a second mateface that collectively define a perimeter of the endwall, with the first and second matefaces arranged opposite one another. A forward zone is defined by the endwall that extends to the leading edge. The first and second matefaces are each oriented at an angle αII relative to radial in the forward zone. An aft zone is defined by the endwall that extends to the trailing edge. The first and second matefaces are each oriented at an angle αII relative to radial in the aft zone. The angles αII and αII are not equal. A middle zone is defined in between the forward and aft zones, and the first and second matefaces transition between the angles αII and αI in the middle zone.

Description

BACKGROUND

The present invention relates to airfoil mateface sealing, and more particularly to an apparatus and associated method for sealing adjoining matefaces of airfoil platforms.

In gas turbine engines, cascades of airfoils are provided in a primary gas flowpath. These airfoil cascades can include rotatable blades and/or non-rotating stator vanes. Typical blades and stators include an airfoil adjoining a platform at its root or hub end, and possibly also at a shroud at an opposite tip end. Collectively platforms and shrouds can be referred to as endwalls, which define boundaries of the primary gas flowpath. In modern engines these endwalls are often segmented, such that an endwall segment is integrally formed or attached to each airfoil. Adjacent endwall segments in the cascade adjoin each other at matefaces. Matefaces are generally separated by small gaps. In hot (e.g., turbine) sections of a gas turbine engine, airfoil cascades may be cooled with a cooling fluid, a portion of which may flow through the gaps between endwall matefaces and into the primary flowpath.

In a basic prior art design, as shown in FIGS. 2A and 3A, endwall matefaces are machined radially with a break edge. Various endwall or platform designs are known to reduce vortices produced in fluid passing through the primary flowpath and other aerodynamic losses, such as that shown in FIG. 3B.

However, it is desired to provide improved endwall matefaces that further reduce vortices and secondary losses (i.e., pressure losses) in the primary flowpath.

SUMMARY

An airfoil for use in an airfoil cascade according to the present invention includes an airfoil working portion and an adjoining endwall. The endwall has a leading edge, a trailing edge, a first mateface, and a second mateface that collectively define a perimeter of the endwall, with the first and second matefaces arranged opposite one another. A forward zone is defined by the endwall that extends to the leading edge. The first and second matefaces are each oriented at an angle α_II relative to radial in the forward zone. An aft zone is defined by the endwall that extends to the trailing edge. The first and second matefaces are each oriented at an angle α_I relative to radial in the aft zone. The angles α_I and α_II are not equal. A middle zone is defined in between the forward and aft zones, and the first and second matefaces transition between the angles α_II and α_I in the middle zone.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a pair of adjacent airfoils having adjoining endwall matefaces.

FIG. 2A is a cross-sectional view of a prior art endwall mateface configuration.

FIGS. 2B and 2C are cross-sectional views of embodiments of endwall mateface configurations according to the present invention.

FIGS. 3A and 3B are cross-sectional views of prior art endwall mateface configurations and associated airflow patterns.

FIGS. 3C and 3D are cross-sectional views of the endwall mateface configuration of FIGS. 2B and 2C, respectively, and associated airflow patterns.

FIGS. 4A-4D are cross-sectional views of various embodiments of endwall mateface configurations according to the present invention.

FIGS. 5A-5D are cross-sectional views of the various embodiments of endwall mateface configurations of FIGS. 4A-4D, taken at different axial locations than the views shown in FIGS. 4A-4D.

While the above-identified drawing figures set forth embodiments of the invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention. The figures may not be drawn to scale, and applications and embodiments of the present invention may include features and components not specifically shown in the drawings.

DETAILED DESCRIPTION

FIG. 1 is a top view of a pair of adjacent airfoils 20A and 20B (generically referred to as simply airfoils 20) each having an airfoil working portion 22 and an endwall 24. The airfoils 20A and 20B can be used in a gas turbine engine (not shown), and can form part of a cascade of similarly-configured airfoils. The working portions 22 each have a pressure side 22P and an opposite suction side 22S defined between a leading edge 22LE and a trailing edge 22TE. In the illustrated embodiment, the airfoil working portion 22 is cambered. The endwalls 24 each have matefaces 26 and 28 along opposing lateral edges, as well as a leading edge 30 and trailing edge 32. The matefaces 26 and 28 and the edges 30 and 32 collectively define a perimeter of each endwall 24. The endwall mateface 26 of the airfoil 20A adjoins the mateface 28 of the airfoil 20B, with a small gap 34 between the adjoining matefaces 26 and 28 of the respective airfoils 20A and 20B. A size of gap 34 can vary for particular applications and can potentially vary during use, such as during different operational conditions. A flowpath surface 36 is defined by the endwalls 24 adjacent to each of the matefaces 26 and 28 and the edges 30 and 32 that extends to the perimeter collectively defined by the matefaces 26 and 28 and the edges 30 and 32, such that the perimeter of the endwalls 24 is also the perimeter of the flowpath surface 36. The flowpath surface 36 can have nearly any desired configuration, such as an axisymmetric or non-axisymmetric contour. Sealing between the adjacent airfoils 20A and 20B is defined at least in part by the matefaces 26 and 28 and the gap 34.

The airfoils 20A and 20B can be positioned in a primary flowpath of a gas turbine engine, with the endwalls 24 defining segments or portions of a boundary of the primary flowpath. In the illustrated embodiment the airfoils 20A and 20B are represented as rotatable turbine blades, but in further embodiments the airfoils 20A and 20B can be turbine stator vanes, or could alternatively be blades or vanes of a compressor section of the engine. The endwalls 24 can be configured as platforms located at or adjoining a root or hub end of the working portions 22 or as shrouds located at or adjoining a tip end of the working portions 22, and the endwalls 24 can be integrally and monolithically formed with the working portions 22, in various embodiments. The basic configuration of gas turbine engines is well known in the art, and therefore further explanation here is unnecessary. The configuration of the working portions 22 and other features of the airfoils 20A and 20B are shown merely by way of example, and not limitation. Those of ordinary skill in the art will recognize that a variety of airfoil configurations are possible for use in conjunction with the present invention.

FIG. 2A is a cross-sectional view of a prior art endwall mateface configuration taken along line I-I of FIG. 1, with the matefaces 26 and 28 both radially oriented along an entire distance from the leading edge 30 to the trailing edge 32 of the endwall 24. The matefaces 26 and 28 each form right angles at respective intersections with the flowpath surfaces 36.

FIGS. 2B and 2C are cross-sectional views of embodiments of configurations of the endwall matefaces 26 and 28, taken along line II-II of FIG. 1 (for simplicity, structures beyond the section plane are not shown in FIGS. 2B and 2C).

In the embodiment illustrated in FIG. 2B, an arcuate flow modifying edge 38 is formed at a boundary between the mateface 26 and the flowpath surface 36, and an arcuate flow modifying edge 40 is formed at a boundary between the mateface 28 and the flowpath surface 36. The flow modifying edges 38 and 40 can each extend along the entire lengths of the matefaces 26 and 28 between the leading edge 30 and the trailing edge 32 of the endwalls 24 (see also FIG. 3C). Each flow modifying edge 38 and 40 can be generally arcuate with a radius R. In one embodiment, the radius R is approximately 0.127 to 6.35 mm (0.005 to 0.250 inch), or another range significantly or substantially larger than a break edge radius. In another embodiment, the radius R can be established as a function of a size of the gap 34, measured as circumferential distance G, such as with the relationship 0.5×G≦R≦2×G. In the illustrated embodiment, the flow modifying edges 38 and 40 have a substantially identical configuration (i.e., identical radius R), though in alternative embodiments the configurations of the flow modifying edges 38 and 40 can be different from one another (e.g., having different radiuses R). In still further embodiments, the flow modifying edges 38 and 40 can be defined by other types of curved surfaces (e.g., elliptical, parabolic, complex polynomial, etc.), rather than a simple radius.

In the embodiment illustrated in FIG. 2C, a chamfered flow modifying edge 42 is formed at a boundary between the mateface 26 and the flowpath surface 36, and a chamfered flow modifying edge 44 is formed at a boundary between the mateface 28 and the flowpath surface 36. The flow modifying edges 42 and 44 can each extend along the entire lengths of the matefaces 26 and 28 between the leading edge 30 and the trailing edge 32 of the endwalls 24. Each chamfered edge 42 and 44 can be oriented at an angle θ with respect to the respective adjoining matefaces 26 and 28. In one embodiment, the angle θ is approximately 45° to 75°. In another embodiment, the angle θ can be established as a function of a size of the gap 34, measured as the circumferential distance G, such as θ=a×tan (o/a), where a is a radial dimension of the chamfered edges 42 and 44 and o is a circumferential dimension of the chamfered edges 42 and 44. In one embodiment, the relationships 0.5×G≦o≦2×G and 0.5×G≦a≦2×G can be established. Further, o can be generally greater than a.

By having the flow modifying edges 38, 40, 42 and 44 extend along entire lengths of the corresponding matefaces 26 and 28, from the leading edge 30 to the trailing edge 32, manufacturing can be simplified as compared to flow modifying structures that extend only partially along the mateface 26 or 28. Flow modifying benefits are also obtained by having the flow modifying edges 38, 40, 42 and 44 extend along entire lengths of the corresponding matefaces 26 and 28, from the leading edge 30 to the trailing edge 32.

In further embodiments, different flow modifying edge configurations can be utilized for different edges of a single endwall 24. For instance, a chamfered flow modifying edge 42 can be used adjacent to the mateface 26 and an arcuate flow modifying edge 40 can be used adjacent to the mateface 28 for a given endwall 24, or vice-versa.

Although not shown in FIGS. 2B and 2C, it should be understood that additional features can be included with the illustrated endwalls 24 in further embodiments. For example, feather seals, ladder seals or other sealing structures can be used to help seal the gap 34, and damping structures can be positioned at or near the endwalls 24. Additionally, cooling holes can be provided in the platforms 24, such as in any of the matefaces 26 and/or 28, and/or in any of the flow modifying edges 38, 40, 42 and/or 44.

FIGS. 3A and 3B are cross-sectional views of prior art endwall mateface configurations and associated airflow patterns, taken along line II-II of FIG. 1. FIG. 3A illustrates airflow for the configuration shown in FIG. 2A. As shown in FIG. 3A, relatively large vortices 50 and 50′ are formed as the fluid flow 52 of the primary flowpath passes the gap 34. The vortices 50 and 50′ produce secondary losses, specifically pressure loses, that undesirably reduce efficiency. FIG. 3B illustrates another prior art endwall configuration, which has a rounded edge 54 at the mateface 26 that is downstream relative to the fluid flow 52 but a right angle edge along the upstream mateface 28. The rounded edge 54 extends along only a portion of the mateface 26, and does not extend an entire length between a leading edge 30 and trailing edge 32 of the endwall 24. As the fluid flow 52 passes the gap 34, relatively large vortices 50 are still formed in the gap 34, though a reduction or elimination of the vortices 50′ has been achieved.

FIGS. 3C and 3D are a cross-sectional views of endwall mateface embodiments of FIGS. 2B and 2C, respectively, and associated airflow patterns. The cross-sections of FIGS. 3C and 3D are taken along line II-II of FIG. 1. As shown in FIG. 3C, a size and magnitude of vortices 50 at the gap can be achieved in comparison to the prior art configurations shown in FIGS. 3A and 3B, reducing in reduced secondary pressure and mixing losses and produce less turbulent flow that exhibits relatively little flow separation. The airflow 32 closely follows or hugs the endwall 24 as a result of both the upstream flow modifying edge 40 or 44 and the downstream flow modifying edge 38 or 42. In addition, as shown in FIGS. 3C and 3D, the vortices 50′ can be reduced or eliminated as compared to FIG. 3A. It should be noted that reference to “upstream” and downstream” refer to the illustrated embodiment, as best shown in FIG. 1, in which the fluid flow 52 of the primary flowpath approaches the gap 34 at a generally transverse angle at or near the section line II-II. Particular flow characteristics will vary for particular applications, based on the configurations of the airfoils 20A and 20B and fluid flow characteristics upstream from the airfoils 20A and 20B.

In further embodiments, an interface of the matefaces 26 and 28 of adjacent endwalls 24 at the gap 34 can have different angular orientations relative to the radial direction, as shown in the embodiments illustrated in FIGS. 4A-5D. More specifically, the matefaces 26 and 28 can each be oriented at an angle α relative to the radial direction (see FIGS. 4B and 5B). The angle α can be the same for both adjoining matefaces 26 and 28 in one embodiment, such that the adjoining matefaces 26 and 28 can be parallel. The angle α can be constant along the matefaces 26 and 28 from the leading edge 30 to the trailing edge 32 of the endwalls 24. Alternatively, the angle α can vary along a length of the matefaces 26 and 28 between the leading edge 30 and the trailing edge 32. Variation in the angle α can be implemented in zones. For example, a forward zone 100 that extends to the leading edge 30, an aft zone 102 that extends to the trailing edge 32, and a middle zone 104 located between the forward and aft zones 100 and 102 can be defined. In the forward zone 100 the angle α can be constant at a value α_II, in the aft zone 102 the angle α can be constant at a value a₁, and in the middle zone 104 a transition in the angle α can be made between the angles α_I and α_II, that is, the angle α can vary between the angles α_I and α_II such that a relatively smooth transition in provided at boundaries between the middle zone 104 and each of the forward and aft zones 100 and 102.

In some embodiments, at least portions of the matefaces 26 and 28 can be substantially planar. For example, the forward zones 100 and aft zones 102 of the matefaces 26 and 28 can be substantially planar, while the middle zone 104 would generally be non-planar to accomplish the variation in the angle α. In alternatively embodiment, curved or non-linear endwalls 24 can be used, such that the matefaces 26 and 28 have significant non-planar regions.

FIGS. 4A-4D are cross-sectional views of various additional embodiments of endwall mateface configurations taken along line I-I of FIG. 1. As shown in the embodiment illustrated in FIG. 4A, the angle α of the matefaces 26 and 28 is 0° and no flow modifying edge is present between the matefaces 26 and 28 and the flowpath surface 36 of the endwalls 24. A secondary flow 152 is shown passing through the gap 34 toward a fluid flow 52′ of the primary flowpath. Here is should be noted that as illustrated in FIG. 1, the fluid flow 52 that enters a throat area between the adjacent airfoils 20A and 20B changes direction (i.e., turns) relative to an axial direction to form the exiting fluid flow 52′. The secondary flow 152 can be a cooling air flow that mixes with the fluid flow 52 and 52′ of the primary flowpath. As shown in the embodiment illustrated in FIG. 4B, the matefaces 26 and 28 are arranged at a non-zero angle α relative to the radial direction (where the angle α is positive in a clockwise direction when looking forward, that is, to the right in FIGS. 4A-4D), such that the secondary flow 152 is at least partially angled from the radial direction in generally the same direction as the fluid flow 52′. No flow modifying edge is present between the matefaces 26 and 28 and the flowpath surface 36 of the endwalls 24 as shown in FIG. 4B. As shown in FIG. 4C, arcuate flow modifying edges 38 and 40 are present between the matefaces 26 and 28 and the flowpath surface 36 of the endwalls 24, and the matefaces 26 and 28 are arranged at a non-zero angle α relative to the radial direction, such that the secondary flow 152 is at least partially angled from the radial direction in generally the same direction as the fluid flow 52′. As shown in FIG. 4D, chamfered flow modifying edges 42 and 44 are present between the matefaces 26 and 28 and the flowpath surface 36 of the endwalls 24, and the matefaces 26 and 28 are arranged at a non-zero angle α relative to the radial direction, such that the secondary flow 152 is at least partially angled from the radial direction in generally the same direction as the fluid flow 52′.

FIGS. 5A-5D are cross-sectional views of the various embodiments of endwall mateface configurations, taken along line II-II of FIG. 1. As shown in the embodiment illustrated in FIG. 5A, the angle α of the matefaces 26 and 28 is 0° and no flow modifying edge is present between the matefaces 26 and 28 and the flowpath surface 36 of the endwalls 24. A secondary flow 152 is shown passing through the gap 34 toward a fluid flow 52′ of the primary flowpath. As shown in the embodiment illustrated in FIG. 5B, the matefaces 26 and 28 are arranged at a non-zero angle α relative to the radial direction, such that the secondary flow 152 is at least partially angled from the radial direction in generally the same direction as the fluid flow 52. No flow modifying edge is present between the matefaces 26 and 28 and the flowpath surface 36 of the endwalls 24 as shown in FIG. 5B. As shown in FIG. 5C, arcuate flow modifying edges 38 and 40 are present between the matefaces 26 and 28 and the flowpath surface 36 of the endwalls 24, and the matefaces 26 and 28 are arranged at a non-zero angle α relative to the radial direction, such that the secondary flow 152 is at least partially angled from the radial direction in generally the same direction as the fluid flow 52. As shown in FIG. 5D, chamfered flow modifying edges 42 and 44 are present between the matefaces 26 and 28 and the flowpath surface 36 of the endwalls 24, and the matefaces 26 and 28 are arranged at a non-zero angle α relative to the radial direction, such that the secondary flow 152 is at least partially angled from the radial direction in generally the same direction as the fluid flow 52.

In one embodiment, an absolute value of the angle α can be in the range of approximately 0°≦|α|≦45°. In a further embodiment, the angle α₁ in the forward zone 100 can be in the range of approximately 0°<α_II≦45°, and the angle α₂ in the aft zone 102 can be in the range of approximately −45°≦α_I≦0° (where α_I≠α_II). In still a further embodiment, the angle α_II in the forward zone 100 can be in the range of approximately −45°≦α_II≦0°, and the angle α_I in the aft zone 102 can be in the range of approximately 0°<α_I<45° (where α_I≠α_II). In one embodiment, the angle α_II in the forward zone 100 can be approximately 0° and the angle α_I in the aft zone 102 can be in the range of approximately 0°<α_I≦45°. In an alternative embodiment, the angle α_II in the forward zone 100 can be in the range of approximately −45°≦α_II<0° and the angle α_I in the aft zone 102 can be approximately 0°. It is possible to incorporate the flow modifying edges 38, 40, 42 and/or 44 into embodiments of the endwalls 24 having any angle or angles α.

It may be desirable for simplification of assembly of the airfoils 20A and 20B into a corresponding mounting structure, such as a rotor disk or case (not shown) having one or more airfoil retention slots of a conventional configuration, to have the angle α of the matefaces 26 and 28 in the forward or aft zone 100 or 102 to be 0° or close to 0°. For example, in one embodiment, the matefaces 26 and 28 can have the angle α be zero or near-zero in the forward zone 100. In an alternative embodiment, the matefaces 26 and 28 can have the angle α be zero or near-zero in the aft zone 102.

Although not shown in FIGS. 4A-5D, it should be understood that additional features can be included with the illustrated endwalls 24 in further embodiments. For example, feather seals, ladder seals or other sealing structures can be used to help seal the gap 34, and damping structures can be positioned at or near the endwalls 24. Additionally, cooling holes can be provided in the platforms 24, such as in any of the matefaces 26 and/or 28, and/or in any of the flow modifying edges 38, 40, 42 and/or 44.

Any relative terms or terms of degree used herein, such as “substantially”, “essentially”, “generally” and the like, should be interpreted in accordance with and subject to any applicable definitions or limits expressly stated herein. In all instances, any relative terms or terms of degree used herein should be interpreted to broadly encompass any relevant disclosed embodiments as well as such ranges or variations as would be understood by a person of ordinary skill in the art in view of the entirety of the present disclosure, such as to encompass ordinary manufacturing tolerance variations, incidental alignment variations, alignment or shape variations induced by thermal or rotational operational conditions, and the like.

While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

DISCUSSION OF POSSIBLE EMBODIMENTS

The following are non-exclusive descriptions of possible embodiments of the present invention.

An airfoil for use in an airfoil cascade includes an airfoil working portion; an endwall adjoining an end of the airfoil working portion, the endwall having a leading edge, a trailing edge, a first mateface, and a second mateface, wherein the first and second matefaces are arranged opposite one another, and wherein the leading edge, trailing edge, and first and second matefaces collectively define a perimeter of the endwall; a forward zone defined by the endwall that extends to the leading edge, wherein the first and second matefaces are each oriented at an angle α_II relative to a radial direction in the forward zone; an aft zone defined by the endwall that extends to the trailing edge, wherein the first and second matefaces are each oriented at an angle α_I relative to a radial direction in the aft zone, and wherein the angles α_I and α_II are not equal; and a middle zone defined by the endwall in between the forward and aft zones, wherein the first and second matefaces transition between the angle α_II and the angle α_I in the middle zone.

The airfoil of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

the endwall can comprise a platform adjoining a root end of the airfoil working portion;

the endwall can be integrally and monolithically formed with the airfoil working portion;

the angle α_II can be in the range of approximately 0°≦α_II≦45°, and the angle α_I can be in the range of approximately −45°≦α_I≦0°;

the angle α_II can be in the range of approximately −45°≦α_II≦0°, and the angle α_I can be in the range of approximately 0°−α_I≦45°;

the angle α_II can be approximately 0°, and the angle α_I can be in the range of approximately 0°<α_I<45°;

the angle α_II can be in the range of approximately −45°<α_II<0°, and the angle α_I can be approximately 0°; and/or

a flowpath surface adjacent to each of the first and second matefaces and the leading and trailing edges, and that extends to the perimeter of the endwall; a first flow modifying edge between the first mateface and the flowpath surface, wherein the first flow modifying edge extends along an entire length of the first mateface between the leading edge and the trailing edge; and a second flow modifying edge between the second mateface and the flowpath surface, wherein the second flow modifying edge extends along an entire length of the second mateface between the leading edge and the trailing edge.

An airfoil for using in an airfoil cascade includes an airfoil working portion; an endwall adjoining an end of the airfoil working portion, the endwall having a leading edge, a trailing edge, a first mateface, a second mateface, and a flowpath surface, wherein the first and second matefaces are arranged opposite one another, and wherein the leading edge, trailing edge, and first and second matefaces collectively define a perimeter of the flowpath surface of the endwall; a first flow modifying edge between the first mateface and the flowpath surface, wherein the first flow modifying edge extends along an entire length of the first mateface between the leading edge and the trailing edge; and a second flow modifying edge between the second mateface and the flowpath surface, wherein the second flow modifying edge extends along an entire length of the second mateface between the leading edge and the trailing edge.

The airfoil of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

the first flow modifying edge can comprise an arcuate flow modifying edge;

the arcuate flow modifying edge can have a radius R in a range of approximately 0.127 to 6.35 mm (0.005 to 0.250 inch)

the second flow modifying edge can comprise an arcuate flow modifying edge configured substantially identically to the first flow modifying edge;

the first flow modifying edge can comprise a chamfered flow modifying edge;

the chamfered flow modifying edge can be defined at an angle θ with respect to the adjoining first mateface, and the angle θ can be in the range of approximately 45° to 75°;

a forward zone defined by the endwall that extends to the leading edge, wherein the first and second matefaces each are oriented at an angle α_II relative to a radial direction in the forward zone, and wherein an absolute value of the angle α_II is in the range of approximately 0°≦|α|≦45°; an aft zone defined by the endwall that extends to the trailing edge, wherein the first and second matefaces each are oriented at an angle α_I relative to a radial direction in the aft zone, wherein an absolute value of the angle α_I is in the range of approximately 0°≦|α|≦45°, and wherein the angles α_I and α_II are not equal; and a middle zone defined by the endwall in between the forward and aft zones, wherein the first and second matefaces transition between the angle α_II and the angle α_I in the middle zone; and/or

the first and second matefaces can both be substantially planar within the forward and aft zones.

A method includes providing an endwall adjoining an end of an airfoil working portion, the endwall having a leading edge, a trailing edge, a first mateface, and a second mateface, wherein the first and second matefaces are arranged opposite one another, and wherein the leading edge, trailing edge, and first and second matefaces collectively define a perimeter of the endwall; defining the first and second matefaces at an angle α_II relative to a radial direction in a forward zone of the endwall that extends to the leading edge; defining the first and second matefaces at an angle α_I relative to the radial direction in an aft zone of the endwall that extends to the trailing edge, and wherein the angles α_I and α_II are not equal; and defining a middle zone of the endwall in between the forward and aft zones, wherein the first and second matefaces transition between the angle α_I and the angle α_II in the middle zone.

The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features and/or additional steps:

defining a first flow modifying edge between the first mateface and the flowpath surface along an entire length of the first mateface between the leading edge and the trailing edge, wherein the flowpath surface is adjacent to each of the first and second matefaces and the leading and trailing edges; and defining a second flow modifying edge between the second mateface and the flowpath surface along an entire length of the second mateface between the leading edge and the trailing edge.

A method includes providing an endwall adjoining an end of an airfoil working portion, the endwall having a leading edge, a trailing edge, a first mateface, a second mateface, and a flowpath surface, wherein the first and second matefaces are arranged opposite one another, wherein the leading edge, trailing edge, and first and second matefaces collectively define a perimeter of the endwall, and wherein the flowpath surface is adjacent to each of the first and second matefaces and the leading and trailing edges; defining a first flow modifying edge between the first mateface and the flowpath surface along an entire length of the first mateface between the leading edge and the trailing edge; and defining a second flow modifying edge between the second mateface and the flowpath surface along an entire length of the second mateface between the leading edge and the trailing edge.

The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features and/or additional steps:

defining the first and second matefaces at an angle α_II relative to a radial direction in a forward zone of the endwall that extends to the leading edge; defining the first and second matefaces at an angle α_I relative to the radial direction in an aft zone of the endwall that extends to the trailing edge, and wherein the angles α_I and α_II are not equal; and defining a middle zone of the endwall in between the forward and aft zones, wherein the first and second matefaces transition between the angle α_I and the angle α_II in the middle zone;

the step of defining a first flow modifying edge can comprise defining one of forming a chamfer and forming an arcuate edge at a radius R, wherein R is in a range of approximately 0.127 to 6.35 mm (0.005 to 0.250 inch); and/or

the step of defining a second flow modifying edge can comprise defining one of forming a chamfer and forming an arcuate edge at a radius R, wherein R is in a range of approximately 0.127 to 6.35 mm (0.005 to 0.250 inch).

Claims

1. An airfoil for use in an airfoil cascade, the airfoil comprising:

an airfoil working portion;

an endwall adjoining an end of the airfoil working portion, the endwall having a leading edge, a trailing edge, a first mateface, and a second mateface, wherein the first and second matefaces are arranged opposite one another, and wherein the leading edge, trailing edge, and first and second matefaces collectively define a perimeter of the endwall;

a forward zone defined by the endwall that extends to the leading edge, wherein the first and second matefaces are each oriented at an angle αII relative to a radial direction in the forward zone;

an aft zone defined by the endwall that extends to the trailing edge, wherein the first and second matefaces are each oriented at an angle αI relative to a radial direction in the aft zone, and wherein the angles αI and αII are not equal; and

a middle zone defined by the endwall in between the forward and aft zones, wherein the first and second matefaces transition between the angle αII and the angle αI in the middle zone.

2. The airfoil of claim 1, wherein the endwall comprises a platform adjoining a root end of the airfoil working portion.

3. The airfoil of claim 1, wherein the endwall is integrally and monolithically formed with the airfoil working portion.

4. The airfoil of claim 1, wherein the angle αII is in the range of approximately 0°≦αII≦45°, and wherein the angle αI is in the range of approximately −45°≦αI≦0°.

5. The airfoil of claim 1, wherein the angle αII is in the range of approximately −45°≦αII≦0°, and wherein the angle αI is in the range of approximately 0°≦αI≦45°.

6. The airfoil of claim 1, wherein the angle αII is approximately 0°, and wherein the angle αI is in the range of approximately 0°<αI≦45°.

7. The airfoil of claim 1, wherein the angle αII is in the range of approximately −45°≦αII<0°, and wherein the angle αI is approximately 0°.

8. The airfoil of claim 1 and further comprising:

a flowpath surface adjacent to each of the first and second matefaces and the leading and trailing edges, and that extends to the perimeter of the endwall;

a first flow modifying edge between the first mateface and the flowpath surface, wherein the first flow modifying edge extends along an entire length of the first mateface between the leading edge and the trailing edge; and

a second flow modifying edge between the second mateface and the flowpath surface, wherein the second flow modifying edge extends along an entire length of the second mateface between the leading edge and the trailing edge.

9. An airfoil for using in an airfoil cascade, the airfoil comprising:

an airfoil working portion;

an endwall adjoining an end of the airfoil working portion, the endwall having a leading edge, a trailing edge, a first mateface, a second mateface, and a flowpath surface, wherein the first and second matefaces are arranged opposite one another, and wherein the leading edge, trailing edge, and first and second matefaces collectively define a perimeter of the flowpath surface of the endwall;

a first flow modifying edge between the first mateface and the flowpath surface, wherein the first flow modifying edge extends along an entire length of the first mateface between the leading edge and the trailing edge; and

a second flow modifying edge between the second mateface and the flowpath surface, wherein the second flow modifying edge extends along an entire length of the second mateface between the leading edge and the trailing edge.

10. The airfoil of claim 9, wherein the first flow modifying edge comprises an arcuate flow modifying edge.

11. The airfoil of claim 10, wherein the arcuate flow modifying edge has a radius R in a range of approximately 0.127 to 6.35 mm (0.005 to 0.250 inch).

12. The airfoil of claim 10, wherein the second flow modifying edge comprises an arcuate flow modifying edge configured substantially identically to the first flow modifying edge.

13. The airfoil of claim 9, wherein the first flow modifying edge comprises a chamfered flow modifying edge.

14. The airfoil of claim 13, wherein the chamfered flow modifying edge is defined at an angle θ with respect to the adjoining first mateface, and wherein the angle θ is in the range of approximately 45° to 75°.

15. The airfoil of claim 9 and further comprising:

a forward zone defined by the endwall that extends to the leading edge, wherein the first and second matefaces each are oriented at an angle αII relative to a radial direction in the forward zone, and wherein an absolute value of the angle αII is in the range of approximately 0°≦|αII|≦45°;

an aft zone defined by the endwall that extends to the trailing edge, wherein the first and second matefaces each are oriented at an angle αI relative to a radial direction in the aft zone, wherein an absolute value of the angle αI is in the range of approximately 0°≦|αI|≦45°, and wherein the angles αI and αII are not equal; and

a middle zone defined by the endwall in between the forward and aft zones, wherein the first and second matefaces transition between the angle αII and the angle αI in the middle zone.

16. The airfoil of claim 15, wherein the first and second matefaces are both substantially planar within the forward and aft zones.

17. A method comprising:

providing an endwall adjoining an end of an airfoil working portion, the endwall having a leading edge, a trailing edge, a first mateface, a second mateface, and a flowpath surface, wherein the first and second matefaces are arranged opposite one another, wherein the leading edge, trailing edge, and first and second matefaces collectively define a perimeter of the endwall, and wherein the flowpath surface is adjacent to each of the first and second matefaces and the leading and trailing edges;

defining a first flow modifying edge between the first mateface and the flowpath surface along an entire length of the first mateface between the leading edge and the trailing edge; and

defining a second flow modifying edge between the second mateface and the flowpath surface along an entire length of the second mateface between the leading edge and the trailing edge.

18. The method of claim 17 and further comprising:

defining the first and second matefaces at an angle αII relative to a radial direction in a forward zone of the endwall that extends to the leading edge;

defining the first and second matefaces at an angle αI relative to the radial direction in an aft zone of the endwall that extends to the trailing edge, and wherein the angles αI and αII are not equal; and

defining a middle zone of the endwall in between the forward and aft zones, wherein the first and second matefaces transition between the angle αI and the angle αII in the middle zone.

19. The method of claim 17, wherein the step of defining a first flow modifying edge comprises defining one of forming a chamfer and forming an arcuate edge at a radius R, wherein R is in a range of approximately 0.127 to 6.35 mm (0.005 to 0.250 inch).

20. The method of claim 17, wherein the step of defining a second flow modifying edge comprises defining one of forming a chamfer and forming an arcuate edge at a radius R, wherein R is in a range of approximately 0.127 to 6.35 mm (0.005 to 0.250 inch)