Abstract: The present invention provides tough, high modulus, low density thermoset polyurethane compositions which are useful in general as, for example, cast structural materials and in a preferred embodiment can be cured directly onto an aircraft engine fan blade, thereby providing a lighter blade, without concomitant loss in structural integrity or blade performance due to, for example, resistance to foreign object impacts and fuel efficiency. In a preferred embodiment, the composition is comprised of bis-amine compounds reacted with isocyanate-functional polyether polymers in the presence of hollow polymeric microspheres. The thermoset polymer compositions are formed by casting into a mold which is formed by a cavity within the metallic or composite fan blade or guide vane in the form of a pocket and a removable caul sheet. After the elastomeric polyurethane foam is injected through at least one injector port into the mold, the foam is cured.

Abstract: The present invention provides tough, high modulus, low density thermoset polyurethane compositions which are useful in general as, for example, cast structural materials and in a preferred embodiment can be cured directly onto an aircraft engine fan blade, thereby providing a lighter blade, without concomitant loss in structural integrity or blade performance due to, for example, resistance to foreign object impacts and fuel efficiency. In a preferred embodiment, the composition is comprised of bis-amine compounds reacted with isocyanate-functional polyether polymers in the presence of hollow polymeric microspheres. The thermoset polymer compositions are formed by casting into a mold which is formed by a cavity within the metallic or composite fan blade or guide vane in the form of a pocket and a removable caul sheet. After the elastomeric polyurethane foam is injected through at least one injector port into the mold, the foam is cured.

Abstract: A gas turbine engine rotor disk has a number of annular hubs circumscribed about a centerline and each of the hubs is connected to a disk rim by a web. A plurality of circumferentially spaced apart circular arc dovetail slots are disposed through the rim. Circumferentially extending annular burst slots extend radially through the rim into the dovetail slots between each adjacent pair of the webs. The fan blades have circular arc dovetail roots disposed within the circumferentially spaced apart circular arc dovetail slots. A one piece spinner attached to a forward extension of the disk at a location between a tip and an axially aft spinner end of the spinner. Non-integral platforms circumferentially disposed between the fan blades. A booster spool is connected to the rotor disk by a mounting plate therebetween and the platforms are radially retained to the disk and mounting plates by pins through holes in mounting lugs depending radially inwardly from the platforms.

Abstract: The present invention provides tough, high modulus, low density thermoset polyurethane compositions which are useful in general as, for example, cast structural materials and in a preferred embodiment can be cured directly onto an aircraft engine fan blade, thereby providing a lighter blade, without concomitant loss in structural integrity or blade performance due to, for example, resistance to foreign object impacts and fuel efficiency. In a preferred embodiment, the composition is comprised of bis-amine compounds reacted with isocyanate-functional polyether polymers in the presence of hollow polymeric microspheres. The thermoset polymer compositions are formed by casting into a mold which is formed by a cavity within the metallic or composite fan blade or guide vane in the form of a pocket and a removable caul sheet. After the elastomeric polyurethane foam is injected through at least one injector port into the mold, the foam is cured.

Abstract: A gas turbine engine rotor disk has a number of annular hubs circumscribed about a centerline and each of the hubs is connected to a disk rim by a web. A plurality of circumferentially spaced apart dovetail slots are disposed through the rim, extending circumferentially between disk posts, extending axially from a forward end to an aft end of the rim, and extending radially inwardly from a disk outer surface of the rim. Circumferentially extending annular burst slots extend radially through the rim into the dovetail slots between each adjacent pair of the webs. In the exemplary embodiment of the disk illustrated herein, the dovetail slots are circular arc dovetail slots. An axially forwardly extending overhang is located radially outwardly on each of the disk posts and a chamfer is on a radially outer corner of the each of the disk posts on a portion of the overhangs.

Abstract: A gas turbine engine rotor disk has a number of annular hubs circumscribed about a centerline and each of the hubs is connected to a disk rim by a web. A plurality of circumferentially spaced apart circular arc dovetail slots are disposed through the rim. Circumferentially extending annular burst slots extend radially through the rim into the dovetail slots between each adjacent pair of the webs. The fan blades have circular arc dovetail roots disposed within the circumferentially spaced apart circular arc dovetail slots. A one piece spinner attached to a forward extension of the disk at a location between a tip and an axially aft spinner end of the spinner. Non-integral platforms circumferentially disposed between the fan blades. A booster spool is connected to the rotor disk by a mounting plate therebetween and the platforms are radially retained to the disk and mounting plates by pins through holes in mounting lugs depending radially inwardly from the platforms.

Abstract: An exemplary embodiment of the invention is a spinner for a front end of a fan assembly of a gas turbine engine. The spinner includes a single piece substantially conically shaped hollow body circumscribed about a centerline extending aftwardly from a tip to an axially aft spinner end. A plurality of bolt holes extend axially parallel to the centerline through the hollow body at an axial location between the tip and the aft spinner end. The hollow body may include a forward conical section extending aftwardly from the tip to a transition section, an aft conical section extending aftwardly from the transition section to the aft spinner end, and the bolt holes are axially located in the transition section. An aft spinner flange attached to the axially aft spinner end includes a plurality of flange lightening holes axially disposed through the aft spinner flange and the flange lightening holes.

Abstract: A fan blade includes a metal airfoil having a pocket disposed in a first side thereof, with the pocket including a filler bonded thereto. The pocket includes a plurality of cells separated by corresponding ribs which are submerged in the filler.