Abstract: A method of manufacturing a hollow aerofoil component 100 for a gas turbine engine 10 comprises joining a first panel 200 to a second panel 300 using bonding, and hot forming the panels into shape. The bonding step and the hot forming step are performed in the same rig, thereby optimizing process time and component quality.

Abstract: A method of diffusion bonding two components together comprises providing a first component having a first bonding surface, and a second component having a second bonding surface. Each of the first bonding surface and the second bonding surface is etched. A cold working process is applied to each of the first bonding surface and the second bonding surface. Each of the first bonding surface and the second bonding surface is then etched. The first component is positioned adjacent to the second component with the first bonding surface abutting against the second bonding surface, to define a joint surface between the first component and the second component. A peripheral edge of the joint surface is sealed. The first bonding surface is diffusion bonded to the second bonding surface.

Abstract: A method of manufacturing a hollow aerofoil component 100 for a gas turbine engine 10 comprises joining a first panel 200 to a second panel 300 using bonding, and hot forming the panels into shape. The bonding step and the hot forming step are performed in the same rig, thereby optimizing process time and component quality.

Abstract: A method of manufacturing a part comprises providing a component for cutting and directing a water jet at the component so as to cut the component. The water jet comprises water and abrasive particles having a nucleus made from a first substance and a second substance surrounding the nucleus, the first substance being denser than the second substance.

Abstract: A method of manufacturing a hollow aerofoil component for a gas turbine engine includes using a capping panel to cover a pocket in a pocketed aerofoil body. An activation material is placed between the capping panel and the pocketed aerofoil body, and the temperature of the assembly is raised to a bonding temperature. The capping panel and pocketed aerofoil assembly are thereby joined together using activated diffusion bonding to form the hollow aerofoil component.

Abstract: A composite fan blade for a gas turbine engine, the blade comprises a root portion for connecting the blade to a hub and an aerofoil portion. The aerofoil portion comprises an external cover formed from a non-metallic material and an internal structure enclosed within the cover. The internal structure comprises a plurality of support members extending generally from a pressure side of the internal structure to a suction side of the internal structure, and wherein the plurality of support members define a plurality of cells or channels.

Abstract: A diffusion bonded and superplastically formed turbomachine blade, the turbomachine blade comprising: a first layer (4); a second layer (6); and a membrane (2) disposed between the first and second layers (4, 6); wherein the membrane (2) is diffusion bonded to the first layer (4) along a plurality of first strips (10) and the membrane (2) is diffusion bonded to the second layer (6) along a plurality of second strips (12), wherein the first and second strips (10, 12) are offset from one another so that the membrane (2) is bonded to the first and second layers (4, 6) in an alternating pattern; wherein the membrane (2) has a recess (28) which extends into an area between an adjacent pair of first or second strips (10, 12).

Abstract: A ducted fan gas turbine engine aerofoil is made by electron beam welding together at least two metal sheets (10) and (12) and electron beam welding that sub assembly via an end to a root that has been manufactured in a separate operation, and then heating the whole to a temperature that will convert the electron beam welds to diffusion bonds.

Abstract: A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing two metallic panels; assembling and joining the two metallic panels to one another to form the aerofoil structure; wherein the two metallic panels each comprise a surface capable of forming an aerofoil and further comprise a root or section thereof which is either integral with or fixed to the aerofoil surface; and incorporating a section of a different material into a part, the said section being made from a material which is different from the material of another part of the aerofoil structure.

Abstract: A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing a metallic plate for forming the aerofoil structure; joining mounting elements to opposing end surfaces of said metallic plate; dividing said plate along a plane extending substantially in a span-wise direction so as to produce two metallic panels each with one of said mounting elements joined thereto; assembling the two metallic panels so that the surfaces of the panels opposite to the surfaces which have been divided are facing each other; and joining the two metallic panels to one another to form the aerofoil structure; wherein the mounting elements are joined to one another to form the root of the aerofoil.

Abstract: A diffusion bonded and superplastically formed turbomachine blade, the turbomachine blade comprising: a first layer (4); a second layer (6); and a membrane (2) disposed between the first and second layers (4, 6); wherein the membrane (2) is diffusion bonded to the first layer (4) along a plurality of first strips (10) and the membrane (2) is diffusion bonded to the second layer (6) along a plurality of second strips (12), wherein the first and second strips (10, 12) are offset from one another so that the membrane (2) is bonded to the first and second layers (4, 6) in an alternating pattern; wherein the membrane (2) has a recess (28) which extends into an area between an adjacent pair of first or second strips (10, 12).

Abstract: A ducted fan gas turbine engine aerofoil is made by electron beam welding together at least two metal sheets (10) and (12) and electron beam welding that sub assembly via an end to a root that has been manufactured in a separate operation, and then heating the whole to a temperature that will convert the electron beam welds to diffusion bonds.

Abstract: A method of manufacturing an aerofoil structure to have a portion with an increased erosion resistance, the method comprising: providing one or more titanium elements (2, 4, 6) and a beta-stabilizing material (8); wherein the one or more elements (2, 4, 6) have an alpha-beta microstructure; assembling the one or more elements (2, 4, 6) and the beta-stabilizing material (8) such that the beta-stabilizing material (8) is adjacent to the one or more elements (2, 4, 6); and heating the assembly such that the beta-stabilizing material (8) diffuses into an adjacent portion of the one or more elements (2, 4, 6), causing the adjacent portion of the one or more elements (2, 4, 6) to have a beta microstructure which provides an increased erosion resistance.

Abstract: A method of manufacturing an aerofoil structure to have a portion with an increased erosion resistance, the method comprising: providing one or more titanium elements (2, 4, 6) and a beta-stabilizing material (8); wherein the one or more elements (2, 4, 6) have an alpha-beta microstructure; assembling the one or more elements (2, 4, 6) and the beta-stabilizing material (8) such that the beta-stabilizing material (8) is adjacent to the one or more elements (2, 4, 6); and heating the assembly such that the beta-stabilizing material (8) diffuses into an adjacent portion of the one or more elements (2, 4, 6), causing the adjacent portion of the one or more elements (2, 4, 6) to have a beta microstructure which provides an increased erosion resistance.

Abstract: A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing a metallic plate for forming the aerofoil structure; joining mounting elements to opposing end surfaces of said metallic plate; dividing said plate along a plane extending substantially in a span-wise direction so as to produce two metallic panels each with one of said mounting elements joined thereto; assembling the two metallic panels so that the surfaces of the panels opposite to the surfaces which have been divided are facing each other; and joining the two metallic panels to one another to form the aerofoil structure; wherein the mounting elements are joined to one another to form the root of the aerofoil.

Abstract: A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing two metallic panels (8, 10, 16); assembling and joining the two metallic panels (8, 10, 16) to one another to form the aerofoil structure; wherein the two metallic panels each comprise a surface (8, 10, 16) capable of forming an aerofoil and further comprise a root or section thereof (4, 14) which is either integral with or fixed to the aerofoil surface; and incorporating a section of a different material into a part, the said section being made from a material which is different from the material of another part of the aerofoil structure.

Abstract: A method of manufacturing a gas turbine engine fan blade (10) comprises forming three metal workpieces (30,32,34). The metal workpieces (30,32,34) are assembled into a stack (36) so that the flat surfaces (38,42,46,48) are in mating abutment. Heat and pressure is applied across the thickness of the metal workpieces (30,32,34) to diffusion bond the metal workpieces (30,32,34) together to form an integral structure (80). The integral structure (80) is upset forged at one end (58) to produce an increase in thickness (82) for forming the blade root (26). The upset forged integral structure (80) is then hot creep formed and superplastically formed to produce the required aerofoil shape and the thickened end (82) is machined to form the blade root (26). The method enables thinner metallic workpieces with better microstructure to be used and increases the yield of metallic workpieces.

Abstract: A method of manufacturing a gas turbine engine fan blade (10) comprises forming three metal workpieces (30, 32, 34). The metal workpieces (30, 32, 34) are assembled into a stack (36) so that the flat surfaces (38, 42, 46, 48) are in mating abutment. Heat and pressure is applied across the thickness of the metal workpieces (30, 32, 34) to diffusion bond the metal workpieces (30, 32, 34) together to form an integral structure (80). The integral structure (80) is upset forged at one end (58) to produce an increase in thickness (82) for forming the blade root (26). The upset forged integral structure (80) is then hot creep formed and superplastically formed to produce the required aerofoil shape and the thickened end (82) is machined to form the blade root (26). The method enables thinner metallic workpieces with better microstructure to be used and increases the yield of metallic workpieces.