Abstract: A steam turbine, a rotor and a method for making an extruded rotor are disclosed as having a rotor bore formed of an extruded high temperature alloy. The method includes providing a high temperature alloy, melting the high temperature alloy, extruding the high temperature alloy to form a bore, and forming the bore into a rotor.

Abstract: A method for manufacturing a hollow blade for a turbomachine is disclosed in which the blade is manufactured using a preform derived from external primary parts. A primary part including a root portion is formed by upset forging a bar in which material has been forced into a large volume area. Finish forging is done in at least two complementary stamping operations using an intermediate blank in order to limit costs and to use mechanical presses even for large and thin primary parts. Dies for forging the primary part are defined so as to double up at least the forging capacity of a press.

Abstract: The present invention relates to a turbine blade of a gas turbine with an airfoil arranged on a blade root and having at least one cooling air duct running in the longitudinal direction of the turbine blade, arranged inside the turbine blade and extending through the blade root, characterized in that at least one swirl-generating element is arranged in the transitional area between blade root and airfoil in the cooling air duct, with the swirl-generating element including an outer ring and several swirl-generating stator vanes arranged thereon, which are connected to a centric area, as well as to a method for its manufacture.

Abstract: A wind turbine blade including a number of segments attached together end-to-end in a predetermined arrangement so that the respective covering subassemblies of the segments cooperate to form a substantially smooth surface of the wind turbine blade. Each segment includes a number of fiber tubes extending along preselected lengths of the segment respectively, the fiber tubes being laterally spaced apart from each other respectively to define gaps therebetween. The segment also includes a covering subassembly at least partially supported by the fiber tubes and at least partially defining an internal cavity.

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 fairing for a turbine engine strut includes: inner and outer bands; a vane extending between the bands; the fairing is split along a generally transverse plane passing through the bands and the vane, defining nose and tail pieces; wherein the vane is defined by spaced-apart sidewalls extending between a leading edge and a trailing edge, each sidewall split into forward and aft portions by the transverse plane; wherein each sidewall portion carries a radially-inwardly extending post, the posts positioned such that pairs of the posts lie adjacent to each other when the nose piece and tail piece are assembled, wherein each pair of adjacent posts includes at least two non-parallel faces; and a pair of slotted buckles, wherein each slotted buckle surrounds and clamps together a pair of the posts, wherein each pair of adjacent posts contacts a slot of the corresponding buckle in a tripod contact configuration.

Abstract: A method for producing a coated turbine blade, with which the frequency property thereof can be particularly easily adjusted to the required boundary conditions is provided. Recesses are introduced into a blade tip of the blade leaf of the turbine blade after coating of turbine blade. In one aspect a plurality of bores are made which are distributed along the blade leaf center line.

Abstract: Methods of fabricating coated components using multiple types of fillers are provided. One method comprises forming one or more grooves in an outer surface of a substrate. Each groove has a base and extends at least partially along the outer surface of the substrate. The method further includes disposing a sacrificial filler within the groove(s), disposing a permanent filler over the sacrificial filler, disposing a coating over at least a portion of the substrate and over the permanent filler, and removing the first sacrificial filler from the groove(s), to define one or more channels for cooling the component. A component with a permanent filler is also provided.

Abstract: A film cooling hole for a turbine airfoil having a diffusion section with a convergent wall and two divergent side walls, and with a thin exit slot that opens onto the airfoil surface. The divergent side walls have an expansion of 15 to 25 degrees and the convergent wall converges up to 15 degrees. The film hole is formed by an electrode than is pushed into the metal surface to form the divergent side walls and then pivoted to form the convergent wall.

Abstract: A method of forming an internal structure in a hollow component that includes the steps of forming an assembly having first, second, and third plates the first and second plates each with a substantially planar surface and a surface that includes at least one protrusion and is on the exterior facing surfaces of the assembly. The third plate is sandwiched between the first and second plates. The method also includes the steps of selectively bonding portions of the third plate to sections of the first and second plates substantially opposite the at least one protrusions of the first and second plates; and forming the assembly against a die such that the at least one protrusions of the first and second plates are transferred from the exterior facing surfaces to the interior facing surfaces of the first and second plates.

Abstract: An airfoil includes an airfoil body that defines a longitudinal axis. The airfoil body includes a leading edge and a trailing edge and a first sidewall and a second sidewall that is faced apart from the first sidewall. The first sidewall and the second sidewall join the leading edge and the trailing edge and at least partially define a cavity in the airfoil body. A damper member is enclosed in the cavity. The damper member includes a first end and a second end. The first end is connected in a first joint to the first sidewall at a first longitudinal location and the second end is connected in a second joint to the second sidewall at a second, different longitudinal location.

Abstract: A turbine rotor blade formed from three pieces with a pressure wall side piece and a suction wall side piece bonded to an intermediate piece so that a pressure side cooling circuit can be formed as a separate cooling circuit from a suction side cooling circuit. The intermediate piece has film cooling holes and blade tip cooling holes and trailing edge exit slots formed in it that are enclosed when the outer two pieces are boded to it.

Abstract: A method of manufacturing a blade comprising: applying a stop-off material in a first predetermined pattern between a first layer and a membrane so as to prevent a diffusion bond from forming between the first layer and the membrane across said first predetermined pattern; and applying the stop-off material in a second predetermined pattern between a second layer and the membrane; wherein the first and second predetermined patterns are arranged to allow a diffusion bond to be formed along the blade tip edge, the diffusion bond along the blade tip edge extending across the blade in a chord-wise direction; applying the first and second predetermined patterns so that over at least a first portion of the blade chord at the blade tip, a greater portion of the first layer at the tip edge, extending in a span-wise direction, is diffusion bonded to the membrane than the opposing second layer.

Abstract: A method of manufacturing a component is provided. The method includes forming one or more grooves in an outer surface of a substrate. Each groove extends at least partially along the surface of the substrate and has a base, a top and at least one discharge point. The method further includes forming a run-out region adjacent to the discharge point for each groove and disposing a coating over at least a portion of the surface of the substrate. The groove(s) and the coating define one or more channels for cooling the component. Components with cooling channels are also provided.

Abstract: Methods of fabricating coated components using multiple types of fillers are provided. One method comprises forming one or more grooves in an outer surface of a substrate. Each groove has a base and extends at least partially along the outer surface. A sacrificial filler is deposited within the groove, a second filler is deposited over the sacrificial filler, and a coating is disposed over at least a portion of the outer surface and over the second filler. The method further includes removing the sacrificial filler and at least partially removing the second filler from the groove(s), to define one or more channels for cooling the component.

Abstract: A composite turbine blade and a method of manufacture thereof is disclosed. The composite turbine blade comprises a turbine blade portion comprising a first material and a first tip plate comprising a second material. The turbine blade portion has an exterior wall and an interior wall surrounding a hollow interior cavity, and a top surface extending from the exterior wall to the interior wall bounding an orifice that is fluidly connected to the hollow interior cavity. The first tip plate may be attached to the turbine blade along the top surface and extending from proximate the exterior wall of the turbine blade across the orifice to cover the orifice.

Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components that are assembled and held in place using a roller assembly. The roller assembly is removed after pre-cure lay up and compaction of the composite material. Once the roller assembly is removed, the remaining mandrel components can be separated from each other and easily removed from the spar. The mandrel components, including the roller assembly, can then be re-assembled and re-used to form additional composite spars.

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: An airfoil (30) and fabrication process for turbine blades with cooling channels (26). Tapered tubes (32A-32D) are bonded together in a parallel sequence, forming a leading edge (21), a trailing edge (22), and pressure and suction side walls (23, 24) connected by internal ribs (25). The tapered tubes may be extruded without camber to simplify the extrusion process, then bonded along matching surfaces (34), forming a non-cambered airfoil (28), which may be cambered in a hot forming process and cut (48) to length. The tubes may have tapered walls that are thinner at the blade tip (T1) than at the base (T2), reducing mass. A cap (50) may be attached to the blade tip. A mounting lug (58) may be forged (60) on the airfoil base and then machined, completing the blade for mounting in a turbine rotor disk.

Abstract: A turbine engine component has an airfoil portion with a tip portion and the tip portion has at least one chamfered edge on one side. If desired, the tip portion may have a first chamfered edge on a first side and a second chamfered edge on a second side opposed to the first side. A flattened tip portion may extend between the first and second chamfered edges. A tip treatment may be applied to the flattened tip portion.

Abstract: A turbine airfoil (20) fabricated as an assembly of U-channels (22A-E), each U-channel having a closed side formed by a cross wall (25), an open side (26) opposite the cross wall, and two side walls (27) extending from the cross wall to the open side. The U-channels are attached to each other in a parallel, closed-side to open-side sequence, forming a series of cooling channels (23) oriented span-wise (S) in the airfoil. A first of the U-channels (22A) has a curved cross wall forming the leading edge (24) of the airfoil. A last of the U-channels (22E) may have side walls (27) that converge to form a trailing edge (28) of the airfoil. Alternately, a solid trailing edge (22E?) may be attached to a last of the U-channels. Each U-channel may be bonded to an adjacent U-channel using half-lap joints (30).

Abstract: A fan blade comprises a main body extending between a leading edge and a trailing edge. Channels are formed into the main body, with a plurality of ribs extending intermediate the channels. The fan blade has a dovetail, and an airfoil extending radially outwardly from the dovetail. Material is deposited within the channels, with one type of material being selected to provide additional stiffness to the fan blade, and a second type of material being selected for having good damping characteristics. A method and gas turbine engine are is also disclosed.

Abstract: A wind turbine blade comprises a profiled contour having a pressure side and a suction side, a leading edge and a trailing edge with a chord extending between the leading edge and the trailing edge. The profiled contour generating a lift when being impacted by an incident airflow is formed by a hollow shell body. The hollow shell body is formed by at least a first shell body part and a second shell body part, which are mutually connected at least at the trailing edge and/or the leading edge. An edge stiffener is arranged within the hollow shell body at a first part of the edges, a first surface part of the edge stiffener being connected to an inner side of the first shell body part, and a second surface part of the edge stiffener being connected to an inner side of the second shell body part.

Abstract: Method for configuring the constituent elements of hollow helical wheels or their cages, which is based on using geometrical figures whose centers serve as reference for constructing them and defining their areas. Values of angles, offsets of the centers, and pitches, make it possible to control all the constituent elements.

Abstract: A method of fabricating a component is provided. The method includes forming one or more grooves in a surface of a substrate, where the substrate has at least one hollow interior space. Each of the one or more grooves extends at least partially along the substrate surface and has a base and a top. The base is wider than the top, such that each of the one or more grooves comprises a re-entrant shaped groove. The method further includes forming one or more access holes through the base of a respective groove, to connect the groove in fluid communication with respective ones of the hollow interior space(s), and disposing a coating over at least a portion of the substrate surface. The one or more grooves and coating define one or more re-entrant shaped channels for cooling the component. A component with one or more re-entrant shaped channels and a method of coating a component are also provided.

Abstract: Blade insert connected in the lamination of a blade determining a double shear joint between insert and lamination. The insert is made up of two defined parts, head (2), designed to screw the insert to another structure (2?), and the body (3) that determines a cylindrical or conical shape with an internal conical cavity. In an embodiment, the insert is designed to be joined to the lamination (1) of the blade with adhesive means (4). In another embodiment, the insert is embedded in the blade lamination with an inner part (5) stuck to the body (3) of the insert.

Abstract: A stiffener rib for a non-cooled, hollow core airfoil of a turbine blade is described. The stiffener rib is constituted by an elongated solid metal piece dimensioned for securement in a hollow region of a core portion of the airfoil. The stiffener rib is shaped and oriented upwards from a leading edge of the airfoil at a predetermined calculated angle to minimize mode 2 deformation of the blade at a trailing edge thereof while improving the rigidity of the turbine blade.

Abstract: A method of manufacturing an aerofoil for a gas turbine engine (10). The method comprises the steps of providing first and second panels (16, 18), providing a web (30) between the first and second panels, deforming the panels and the web by applying internal pressure between the panels so as to form a series of internal cavities partitioned by the web. The method further includes the step of either cutting the web (30) across its entire width or causing the web to fail across its entire width so as to define an aerofoil having first and second panels with at least one protrusion extending from the first panel partially across the space between the first and second panels.

Abstract: A gas turbine engine rotor blade has an airfoil portion containing one or more internal conduits. Each conduit extends to an end of the airfoil portion. The blade has a shroud at the end of the airfoil portion for sealing the blade to a facing stationary engine portion. There is a fillet portion which joins the end to the shroud. The fillet portion eases the transition from the outer surface of the airfoil portion to the outer surface of the shroud and has a cavity which extends from each conduit and expands laterally relative thereto. The area of the cavity on a cross-section through the fillet portion perpendicular to the radial direction of the engine and at an expanding part of the cavity is greater than the area of the conduit, or the combined areas of the conduits, on a parallel cross-section at the end of the airfoil portion.

Abstract: A rotor blade section and a method for assembling a rotor blade for a wind turbine are disclosed. The rotor blade section includes a plurality of ribs each extending in a generally chord-wise direction. Each of the plurality of ribs includes an outer surface. The outer surface has a generally aerodynamic contour. The rotor blade section further includes at least one cross-member extending between adjacent ribs of the plurality of ribs, and an outer body mounted to the plurality of ribs. The outer body has an aerodynamic contour generally corresponding to the aerodynamic contour of the plurality of ribs.

Abstract: A method of manufacturing an aerofoil for a gas turbine engine (10). The method comprises the steps of providing first and second panels (16, 18), providing a web (30) between the first and second panels, deforming the panels and the web by applying internal pressure between the panels so as to form a series of internal cavities partitioned by the web. The method further includes the step of either cutting the web (30) across its entire width or causing the web to fail across its entire width so as to define an aerofoil having first and second panels with at least one protrusion extending from the first panel partially across the space between the first and second panels.

Abstract: A segmented wind rotor blade for a wind turbine generator system and the assembling method thereof are disclosed. The segmented wind rotor blade includes a blade root section adjacent to a hub and at least one radial blade. Main girders are embedded inside both the blade root section and the radial blades. The blade root section and each radial blade are connected end to end through the main girders connecting one by one. The effects of great connection intensity and less aerodynamic loss can be realized by the segmented wind rotor blade.

Abstract: A ceramic matrix composite (CMC) airfoil assembled from a pressure side wall (42) and a suction side wall (52) joined by interlocking joints (18, 19) at the leading and trailing edges (22, 24) of the airfoil to produce a tapered thin trailing edge. The trailing edge (24) is thinner than a combined thicknesses of the airfoil walls (42, 52). One or both of the interlocking joints (18, 19) may be formed to allow only a single direction of assembly, as exemplified by a dovetail joint. Each joint (18, 19) includes keys (44F, 54F, 56F, 46F) on one side and respective keyways (44K, 54K, 56K, 46K) on the other side. Each keyway may have a ramp (45) that eliminates indents in the airfoil outer surface that would otherwise result from the joint.

Abstract: A method of manufacturing a component, the method including the steps of: providing a component having a first portion, which first portion defines a cavity, characterized by; identifying a first frequency response of the first portion and/or the entire component, and introducing material into the cavity to achieve an adjusted frequency response of the first portion and hence a desired frequency response of the component.

Abstract: A method and system for assembling large wind turbine blades that includes providing a plurality of wind turbine blade segments. An adhesive distribution arrangement is disposed on a surface of at least one of the plurality of the wind turbine blade segments. The adhesive distribution arrangement includes a bonding grid having a plurality of adhesive distribution openings. The wind turbine blade segments are directed together and sufficient adhesive is provided to the bonding grid to substantially fill an area between the wind turbine segments. The adhesive is then cured to form a bonded joint, the bonding grid being incorporated into the bonded joint. A bonding grid for use with the method and system and a segmented wind turbine blade are also disclosed.

Abstract: One embodiment of the present invention is a unique method for producing a turbomachine airfoil. Other embodiments include unique methods for manufacturing an airfoil for a gas turbine engine. Still other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for airfoils for gas turbine engines and other turbomachinery. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.

Abstract: A wind turbine rotor blade and a wind turbine incorporating the rotor blade include a first and second composite skin. A first and a second spar pultrusion having a base and a plurality of integral ribs generally normal to the base are attached to the inside surface of the first and second composite skins and extend the span of the rotor blade. At least one shear web connects a rib of the first spar pultrusion to a corresponding rib of the second spar pultrusion. The width of the spar pultrusions decreases in a step-wise fashion along the span of the rotor blade from the root to the tip. The leading or trailing edge of the rotor blade may be selectably opened for inspection and repair.

Abstract: An active flow control system for use with a wind turbine is provided. The wind turbine includes at least one blade. The active flow control system includes an air distribution system at least partially defined within said at least one blade. The air distribution system includes at least one aperture defined through the at least one blade. An aperture control system is in operational control communication with the air distribution system. The aperture control system includes an actuator at least partially positioned within the at least one blade and configured to control a flow of air discharged through the at least one aperture.

Abstract: In one aspect, a method for assembling an outlet guide vane is provided. The method includes providing an outlet guide vane frame having a first side and a second side. The outlet guide vane includes a radially inward flange coupled to a radially outward flange by a leading edge. A trailing edge is coupled to the radially inward flange and the radially outward flange aft of the leading edge. A cavity is defined between the radially inward flange, the radially outward flange, the leading edge, and the trailing edge. A first and a second mating surface circumscribe the cavity on the first and second sides respectively. The method further includes coupling a filler portion within the cavity wherein the filler portion includes a third side and a fourth side, coupling a first skin to the third side and the first mating surface, and coupling a second skin to the fourth side and the second mating surface, wherein at least one of the first skin and the second skin are fabricated from a composite material.

Abstract: Wind turbine systems and methods are disclosed herein. A representative system includes a wind turbine blade having an inner region that has an internal load-bearing truss structure, and an outer region that has an internal, non-truss, load-bearing structure. In particular embodiments, the truss structure can include a triangular arrangement of spars, and/or can include truss attachment members that connect components of the truss without the use of holes in the spars. Spars can be produced from a plurality of pultruded composite members laminated together in longitudinally extending portions. The longitudinally extending portions can be connected at joints that interleave projections and recesses of each of the spar portions. The blades can include fan-shaped transitions at a hub attachment portion, formed by laminated layers and/or a combination of laminated layers and transition plates.

Abstract: A hollow aerofoil (30) comprises an aerofoil portion (40) having a leading edge (42), a trailing edge (44), a concave pressure surface wall (46) extending from the leading edge (42) to the trailing edge (44) and a convex suction surface (48) extending from the leading edge (42) to the trailing edge (44). The concave pressure surface wall (46) and the convex suction surface wall (48) are integral and define a cavity (50). A plurality of webs (52) extend across the cavity (50) between the concave pressure surface wall (46) and the convex suction surface wall (48). At least one of the webs (52A) extends substantially perpendicularly to the concave pressure surface wall (46) and the convex suction surface wall (48) and at least one of the webs (52B) extends substantially diagonally to the concave pressure surface wall (46) and the convex suction surface wall (48).

Abstract: A bucket assembly and a method for forming the bucket assembly are disclosed. The bucket assembly includes a platform, an airfoil, and a lower body portion. The platform defines a platform cooling circuit configured to flow cooling medium therethrough. The airfoil extends radially outward from the platform. The lower body portion extends radially inward from the platform. The lower body portion defines a root and a cooling passage extending from the root. The cooling passage is configured to flow cooling medium therethrough. The platform and lower body portion further include a ligament between the cooling passage and the platform cooling circuit. The ligament defines a bore hole extending through the ligament between the cooling passage and the platform cooling circuit.

Abstract: The invention relates to a wind turbine rotor blade comprising a blade tip and a lightning protection system. The rotor blade includes at least one lightning receptor at the surface of the blade in an external distance (Lex) from the distal end of the blade tip, and a lightning receptor base inside the rotor blade arranged at an first internal distance (Li1) from the distal end of the blade tip. The rotor blade further includes means for changing at least one electric property of the rotor blade at the lightning receptor base, as compared to the electric properties of the ambient air by increasing the electric field supported between the lightning receptor base and the inner surface of the rotor blade. The invention further relates to a method for manufacturing a wind turbine rotor blade.

Abstract: A method of making a combustion turbine component includes forming a metallic body by direct metal fabrication (DMF) to have at least one surface portion defining a first plurality of surface cooling features each having a first dimension and at least one second surface cooling feature on at least one of the first plurality of surface cooling features and having a second dimension less than said first dimension and less than 200 ?m. Forming the metallic body by DMF may include forming a plurality of metallic combustion turbine subcomponent greenbodies by DMF and assembling the plurality of metallic combustion turbine subcomponent greenbodies together to form a metallic greenbody assembly. The metallic greenbody assembly may be sintered to thereby form the metallic body.

Abstract: A spar for a wind turbine blade includes at least one shear web extending between pressure and suction sides of the blade; and a joint, arranged substantially midway between ends of the shear web, for sizing the shear web. The joint may include a resilient and/or expandable spacer.

Abstract: A blade is presented. The blade includes a proximal end and a distal end, and a pronounced camber running between the proximal end to the distal end, wherein the pronounced camber is located in proximity to a trailing edge and on a suction side of the blade, and an amplitude of the pronounced camber at a location varies between about 0.7% to about 1.4% of a chord's length of a cross-section of the blade at said location.

Abstract: A method for the production of secondary fluid ducts for a turbomachine, especially for fluid supply or fluid removal to/from a flow-wetted surface of the turbomachine, with the secondary fluid ducts being produced by an electrochemical machining process.

Abstract: A turbine rotor blade with a spar and shell construction, where the shell has an airfoil shape and is formed of two shell segments with an upper shell half and a lower shell half. The upper shell half is radially supported by a tip of the spar while the lower shell half is radially loaded by an attachment so that its load is not carried by the upper shell half and the tip of the spar in order to reduce overall stress levels.

Abstract: An impeller of a centrifugal fan includes an end plate, a plurality of blades and an end ring. The blades include blade bodies that are annularly disposed around a shaft and fixed to the end plate. The blades further include blade covers that are attached to the blade bodies. The blade covers and the blade bodies form a hollow space. The end ring is disposed such that it sandwiches the plural blades between itself and the end plate in a shaft direction. The blade covers form at least part of negative-pressure surfaces.

Abstract: A wind turbine blade root having fully bonded insert bushings with internal threads for mounting bolts for releasable attachment to a hub of a wind turbine is manufactured by arrangement of a plurality of the insert bushings on a first layer of fibre mat arranged on a holder having a plurality of spaced recesses for accommodation of the insert bushings such that the bushings extend largely in a longitudinal direction of the blade accommodated in the spaced recesses. Subsequently, a number of additional layers of fibre mat are arranged on top of the bushings, and the fibre mat layers are consolidated.