Abstract: A wind turbine blade assembly is provided. The assembly includes at least one wind turbine blade. The blade includes a blade root portion. The assembly also includes at least one blade root hub fitting coupled to the blade root portion. The blade root hub fitting is configured to couple to a rotatable hub.

Abstract: A wind turbine blade includes an upper shell member and a lower shell member defining an internal cavity therebetween. The shell members are joined with a bond paste along bond lines at the leading edge and trailing edge of the blade. A seal member is disposed between the upper and lower shell members at a designed width of the bond line along at least one of the trailing or leading edges. The seal member has a configuration such that excess flowable bond paste is prevented from migrating past the seal member and into the internal cavity upon mating the upper and lower shell members in assembly of the blade.

Abstract: The present invention relates to a reinforced blade for a wind turbine, particularly to a blade having a new arrangement of two or more girders in the blade, wherein each of the girders is connected to the upper part and the lower part of the shell and forms an angle with another girder thereby strengthening the shell against transverse shear distortion.

Abstract: Systems and methods for providing localized heat treatment of metal components are provided. In this regard, a representative method includes: identifying a portion of a metal component to which localized heat treatment is to be performed; shielding an area in a vicinity of the portion of the metal component; and directing electromagnetic energy in the infrared (IR) spectrum toward the portion of the metal component such that the portion is heated to a desired temperature and such that the area in the vicinity of the portion that is subjected to shielding does not heat to the temperature desired for the heat treatment.

Abstract: A blade for a gas turbine engine includes an aerofoil portion and a root portion defined by concave and convex walls having opposing inner surfaces. A reinforcing member is located between the concave and convex walls and is bonded to the inner surfaces of the concave and convex walls, and the root portion includes an unbonded region in which the reinforcing member contacts an inner surface of one of the concave and convex walls but is not bonded to the concave and convex walls.

Abstract: A method of assembling an air distribution system for use in a rotor blade of a wind turbine. The rotor blade includes a sidewall at least partially defining a cavity extending from a blade root towards a blade tip. The method includes positioning at least a portion of a manifold within the cavity and coupling the manifold to the sidewall. The manifold extends from the blade root towards the blade tip and has a root end and an opposing tip end. A passage is defined from the root end to the tip end. A flow control device is coupled to the manifold root end and configured to channel air through the manifold. A bypass flow assembly is coupled to the manifold and configured to channel air through the air distribution system with the flow control device in a non-operating configuration.

Abstract: A method for producing gas turbine components, in particular blades, blade sections or rotors with integral blades for a jet engine is provided. The method comprises at least the following steps: preparation of at least one metallic powder and at least one expanding agent; mixing of the metallic powder or each metallic powder with the expanding agent or each expanding agent; compression of the resultant mixture to form at least one semi-finished product; expansion of the semi-finished product or each semi-finished product by heating to achieve a defined degree of expansion; termination of the expansion process by cooling, once the defined degree of expansion has been reached.

Abstract: A method of manufacturing a hollow article (10) comprising the steps of cold pressing two members (30,34) to form at least one depression (32,36) in the members (30,34). Arranging the two members (30,34) in abutting relationship such that the at least one depression (32,36) defines at least one chamber between the two members (30,34). Sealing (41) the edges (40,42) of the two members (30,34) together to form a core structure (44). Positioning the core structure (44) in a mold (46) to define a cavity (48) between the external surface (50) of the core structure (44) and the internal surface (52) of the mold (46), the internal surface (52) of the mold (46) substantially defining the external shape of the hollow article (10). Filling the cavity (48) between the core structure (44) and the mold (46) with a powder material (54), sealing the open edge of the core structure (44) to the mold (46).

Abstract: A sparcap for a wind turbine rotor blade. The sparcap includes a first carbon material layer coupled to an inner surface of the wind turbine rotor blade. The first carbon material layer extends along at least a portion of a length of the wind turbine rotor blade. A core material is coupled to the first carbon material layer. The core material is positioned with respect to a buckling prone region of the wind turbine rotor blade. A second carbon material layer covers the core material and is coupled to the first carbon material layer and/or the core material. The second carbon material layer extends along at least a portion of the length of the wind turbine rotor blade.

Abstract: A blade for a turbine engine made by the diffusion-bonding/superplastic-forming (DB/SPF) process has a hollow skin made of front and back panels 1, 3 and internal reinforcement in the form of webs 5 extending between the two faces or panels at an angle to the plane of the blade. The cavities are filled with viscoelastic damping filler 7. In order to allow the blade to deform more easily so that the filler can take up the strain, the webs are pre-buckled so as to compress at least some of the webs. When the blade is deformed, the webs straighten or buckle further, applying a deformation to the filler as they do so and thus dissipating energy. The blade is thus well reinforced against impact but still capable of damping vibrations.

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: The present invention includes a method for fabricating elongated wind turbine blades and wind turbine blades formed by the method. The method includes providing a first shell reinforcing fiber structure. At least one shear web reinforcing fiber structure is positioned adjacent to the first shell reinforcing fiber structure. The method includes infusing the first shell reinforcing fiber structure and shear web reinforcing fiber structure with a matrix material and curing the matrix material to form a unitary composite first shell component. Thereafter a composite second shell component is attached to the composite first shell component to form an elongated composite airfoil suitable for use as a wind turbine blade. The wind turbine blades formed include unitary components providing reduced number of adhesive joints.

Abstract: The invention relates to a method for manufacturing a wind turbine blade or a section of a wind turbine blade. The method includes, establishing a first part having a first wind turbine blade part in a first fixating unit, establishing a second part having a second wind turbine blade part in a second fixating unit, and positioning the first part in contact with, or in close proximity of, the second part. After this, a pressure below atmospheric pressure is established, forcing the first wind turbine blade part and the second wind turbine blade part against each other. The invention further relates to a wind turbine blade manufacturing facility, wind turbine blades as well as uses hereof.

Abstract: A method for manufacturing a hollow blade for a turbomachine including drilling channels into a blank of the blade, placing inserts into the channels, forging the blank, and removing the inserts by chemical dissolution, and the blade is an aluminum alloy and the inserts are a copper alloy.

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 rotor blade for a wind turbine comprising at least one pair of girders lying opposite each other which extend in the longitudinal direction of the rotor blade and carry forces acting on the rotor blade, and at least one shear web which has two front surfaces, each of which is facing one of the two girders, and two lateral surfaces, wherein that shear web extends between the two girders in the longitudinal direction of the rotor blade and is permanently joined to the two girders, wherein at least one connecting profile having a single- or multi-piece cross-section is running in the longitudinal direction of the rotor blade and comprises a collet, into which the at least one shear web is inserted, wherein a first surface of the connecting profile is glued to one of the girders and a second surface of the connecting profile is glued to a lateral surface of the at least one shear web.

Abstract: A quantity of particles (28) may be cold-sprayed toward the distal surface (22) of a turbine blade (6) at a temperature below a melting point of the particles at a velocity sufficiently high to cause at least a portion of the particles to adhere to the surface to form squealer ridge (24) with a desired cutting profile. The cutting profile may be defined by a face (52) and a land (54) disposed at a relief angle (38) relative to a direction of motion (58) of a cutting edge (48). The ridge may be built by multiple passes of a cold spray gun depositing sequential layers (30, 32, 34) of varying widths. An in-service blade having worn distal surface may be repaired using this technique.

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: An aerofoil made from a sheet metal blank which is bent in the shape of an aerofoil such that it has a leading edge, a trailing edge, a pressure side and a suction side, and the blank is joined at the trailing edge. The regions of the sheet metal blank that form the leading edge, trailing edge and pressure side of the aerofoil comprise a plurality of perforations. The suction side region of the sheet metal blank is imperforate.

Abstract: A metal leading edge of a turbine fan blade is manufactured by cutting and shaping an elongated metal part. The metal part has front and rear edges extending lengthwise of the part, and has a generally wedge-shaped transverse cross-section with opposite sides diverging from the front edge toward the rear edge. A cavity is cut inward from the rear edge toward the front edge. This provides the part with a generally V-shaped transverse cross-section having opposite side walls diverging rearwardly from the front edge. A mandrel is inserted into the cavity, and the side walls of the V-shaped part are deflected toward each other to constrict the cavity into the configuration of the mandrel. The part is then mounted as a metal leading edge by inserting a turbine fan blade component into the constricted cavity and fastening the part to the component.

Abstract: A hollow airfoil and a method for manufacturing a hollow airfoil is provided.

Abstract: A turbomachine blade comprising a root portion and an aerofoil portion, the aerofoil portion having a leading edge, a trailing edge, a concave metal wall portion extending from the leading edge to the trailing edge and a convex metal wall portion extending from the leading edge to the trailing edge, the concave metal wall portion and the convex metal wall portion forming a continuous integral metal wall, the aerofoil portion having a hollow interior defined by at least one internal surface, the hollow interior of the aerofoil portion being at least partially filled with a vibration damping material that is separated from the metal wall portions by a thermally insulating material.

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: An inflatable rotor blade for a wind turbine includes a flexible skin. The flexible skin assumes, when inflated by means of an inflation medium, the shape of an airfoil which has an inner cavity. When the inner cavity is formed, at least one stiffener unit is arranged in the inner cavity of the rotor blade and maintains the airfoil shape of the flexible skin.

Abstract: A method includes joining an integral bulkhead and a blade shell to form a blade and separating the blade into two blade segments at a location including the integral bulkhead such that each blade segment comprises a portion of the integral bulkhead and a portion of the blade shell.

Abstract: Disclosed is a system for forming a blade-section including a transporting frame, at least one transporting support removeably associated with the transporting frame, and a blade-section forming structure receptive of the transporting frame and the at least one transporting support.

Abstract: A turbine airfoil with a thermal barrier coating applied to the surface for protection from a hot gas flow, where the TBC includes a plurality of micro-tubes extending from a cooling hole in the airfoil substrate and passing through the TBC to provide both reinforcement to and cooling of the TBC. The micro-tubes extend out from a separate hole and open onto the surface of the TBC, or a plurality of micro-tubes extends from a common hole and spread out from the hole. The micro-tubes are formed from nickel or another high temperature resistant material and have a diameter of about 0.009 inches.

Abstract: An aerofoil 50 and in particular an aerofoil utilised as a turbine blade within gas turbine engines generally incorporate passages 52, 53 along which fluid flows to provide cooling within the aerofoil 50. Previously straight webs were utilised in order to define passages but such configurations limit design choices with regard to achieving torsional and flap vibrational characteristics. By provision of webs 51 which have chordal variation in a serpentine or S shape wider design choices are provided with respect to achieving torsional and flat vibration control. Webs 51 with such chordal variation are achieved through manufacturing processes which remove forming cores by leaching or a lost wax technique or other erosion process. It will also be understood that chordal variations in the webs can create flow rate variations to facilitate particulate separation in a fluid flow through the passages 52, 53 within an aerofoil.

Abstract: In primary press forming process, a piece of blank sheet metal is draw worked so as to form a preformed work piece (Wb) provided with a bent portion (a) substantially conforming to a three dimensional contour of a leading edge of a blade to be protected and extending along a longitudinal direction, and a pair of planar portions (b and c) extending from either side of the bent portion. In a secondary press forming process, the planar portions (b and c) of the preformed work piece are stretch formed into a final shape that conforms to the corresponding profile of the blade while the bent portion (a) of the preformed work piece is clamped and protected from deformation.

Abstract: The present invention relates to a reinforced blade for a wind turbine, and in particular to a wind turbine blade comprising a shell having a section with an aerodynamic profile, and at least one internal reinforcing floor connected inside the shell and extending substantially along the profile chord in order to increase the strength of the blade and to prevent or reduce deformations of the surface of the blade caused by edgewise and flapwise loading of the blade structure.

Abstract: A process for manufacturing reinforcing parts (14) for leading edges (10) and/or trailing edges (12) of fan blades (1) is described. In particular, this invention relates to the use of the SPF/DB (<<Super Plastic Forming/Diffusion Bonding >>) process for this type of non-hollow part.

Abstract: An air-cooled turbine blade is provided having an airfoil shape defined by a convex suction side wall, a concave pressure side wall, a leading edge, a trailing edge, a root and a tip, the walls and the tip each including an interior surface that defines an interior with the root, the trailing edge including a plurality of slots formed thereon. The blade includes a suction side flow circuit formed therein comprising a forward and an aft flow circuit. The blade also includes a tip flow circuit extending along the tip interior surface to at least one of the trailing edge slots and including a first and a second opening, the first opening in flow communication with the suction side forward flow circuit outlet, and the second opening in flow communication with a cross-over hole of the suction side aft flow circuit. Methods of manufacturing the blade are also provided.

Abstract: An aerofoil (35) for example a fan blade (26) comprises a leading edge (36), a trailing edge (38), a concave pressure surface extending (40) from the leading edge (36) to the trailing edge (38) and a convex suction surface (42) extending from the leading edge (36) to the trailing edge (38). The aerofoil (35) comprises a metal foam (50) arranged within a cavity defined by metal workpieces (52, 54). The metal foam (50) of the aerofoil (26) ideally has a density of less than 1g/cm3, is cheaper to manufacture and has improved fatigue behaviour and impact capability.

Abstract: A turbine blade with a tip squealer and method of rebuilding a turbine blade for a gas turbine engine. The blade is of the type including an airfoil having first and second spaced-apart sidewalls defining an interior void and joined at a leading edge and a trailing edge. The first and second sidewalls extending from a root disposed adjacent the dovetail to a tip cap for channeling combustion gases, and a squealer tip including at least one tip rib extending outwardly from the tip cap. The method includes the steps of removing the squealer tip, including the at least one rib tip, from the tip cap and adding new material to the tip cap to serve as a new squealer tip. A plurality of spaced-apart notches is formed in the new material between the leading edge and the trailing edge of the airfoil. At least one hole is formed in each notch communicating with the interior void of the airfoil for channeling cooling air from the interior void of the airfoil to thereby form a squealer tip.

Abstract: Reduction in weight is an important factor with respect to turbine engines used in aircraft. Blades (20) used in such turbine engines may fragment such that it is necessary that the containment casing (42) can resist such fragmentation. Root portions of blades are generally less deformable and therefore require conventionally more robust containment casings. Use of super plastically formed blades allows provision of slots (4, 14, 24, 46) in the root portion which facilitate fragmentation and deformation by the root portion under impact reducing the necessity for greater reinforcement of the containment casing. The slots (4, 14, 24, 24, 46) are created in a membrane utilised for web reinforcement of the blade rather than through intrusive drilling and cutting processes which may introduce machining stresses into their creation and potential tool loss within the high value blade.

Abstract: A method of constructing a turbine blade for a gas turbine engine is provided. The method includes casting the blade, forming a plurality of spaced-apart notches in the airfoil proximate the tip on the pressure sidewall and forming at least one hole in each tip shelf communicating with the interior void of the airfoil for channeling cooling air from the interior void of the airfoil to thereby form a squealer tip.

Abstract: In a method for manufacturing a hollow blade for a turbomachine, the blade is made from a preform derived from external primary parts. Each primary part comprising a root part is formed by flattening a blank cut out from a ring with a large diameter provided with a protuberance, in order to reduce costs.

Abstract: Methods are provided for modifying an airfoil internal cooling circuit that include a flow path configured to direct air through the airfoil in a direction and the airfoil having a leading edge, a trailing edge, and a first and a second wall therebetween, each wall having an inner and an outer surface, the inner surfaces defining a cavity and having features forming at least a portion of the internal cooling circuit. The methods may include the steps of forming a pilot hole through the airfoil first and second walls at a predetermined location, forming an insert hole based on the predetermined location, the insert hole enveloping the pilot hole and configured to receive at least a portion of an insert configured to modify the internal cooling circuit flow path, placing the insert into the insert hole, and bonding the insert to the airfoil first and second walls.

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.

Abstract: Method of manufacturing a hollow blade (1) for a turbomachine in which the blade (1) is made from a preform (14) obtained from external primary parts (28, 30). In order to reduce costs, the root part (2) of the blade is formed from spare material (34) entirely located on only one of the two external primary parts of the preform (14).

Abstract: A method for surface treating a titanium gas turbine engine component. The method includes providing a gas turbine engine component having a titanium-containing surface. The component is heated to a temperature sufficient to diffuse carbon into the titanium and below 1000° F. The surface is contacted with a carbon-containing gas to diffuse carbon into the surface to form carbides. Thereafter, the carbide-containing surface is coated with a lubricant comprising a binder and a friction modifier. The binder preferably including titanium oxide and the friction modifier preferably including tungsten disulfide. The coefficient of friction between the surface and another titanium-containing surface is less than about 0.6 in high altitude atmospheres.

Abstract: A butt connection of divided hollow profile members, which is suitable in particular for rotor blades of wind power installations, comprises a multiplicity of straps which are arranged along the joint and which bridge over same and which are respectively fixed with their ends to one of the profile members to be connected. In this respect the arrangement is preferably such that one of the two bolts fixing the strap at the ends thereof has a wedge-shaped flattening, by means of which a tensile prestressing can be imparted to the strap.

Abstract: A method of thermal forming of refractory alloy suture needles is disclosed. Needle blanks made from refractory alloys are used to form surgical needles, which are heated to a temperature above the ductile to brittle transition temperature but below the recrystallization temperature of the refractory alloy. The heated needle blanks are then mechanically formed into a surgical needle.

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 cooled turbine engine component is made by providing first and second pieces respectively having first and second surfaces. At least one circuit is formed in at least one of the first and second surfaces. A first plurality of apertures is provided in the first piece to form inlets to the at least one circuit. A second plurality of apertures is provided in the second piece to form outlets to the at least one circuit. A combination of the first and second pieces is assembled and integrated.

Abstract: A blade for a turbine engine is described, having a base body, made from a titanium alloy, with a first and a second component piece, which are connected in the connection region by means of a bonding process. A groove with a groove wall runs through the connection region, to prevent local concentration of tension, such that the above borders directly on the second component piece and forms therewith a connection angle greater than 70 degrees.

Abstract: A method of fabricating a hollow mechanical part includes a step of depositing an anti-diffusion substance in a predefined pattern on at least one face of primary parts to be assembled together. The depositing step is performed by applying a layer of anti-diffusion substance including a powder over a surface of the face of the primary parts; and by localized sintering of the anti-diffusion substance in the predefined pattern by the heating that results from localized application of a laser beam along a track.

Abstract: A method for producing hollow blade blades, in particular for gas turbines such as aircraft jet engines is provided. At least three elements (20, 21, 22) are located one on top of the other in a sandwich structure, are joined together at least in sections by diffusion welding and are then superplastically formed by expansion in such a way that a first element (20) forms a first external wall of the hollow blade to be produced, a second element (22) forms a second external wall of the hollow blade to be produced and a third element (21) forms a central element running between the two external walls of the hollow blade to be produced. At least one nick-minimizing structure is introduced into the first element (20) and the second element (22), which form the two external walls of the hollow blade to be produced, before said elements are arranged together with the third element (21) in the sandwich structure.

Abstract: A rotor blade for use in a wind energy system is provided with the rotor blade having a rotor blade body comprising a rotor blade body tip; a rotor blade body cavity; and a lightning protection unit. The lightning protection unit includes a conductive part that is connected to a down conductor and positioned within the rotor blade body cavity close or at the rotor blade body tip, the conductive part having an extension protruding out of the rotor blade body for receiving a receptor. According to another aspect of the invention, a wind energy system is provided with at least one of such a rotor blade.

Abstract: A rotor component assembly including at least one void space formed therein that provides for reduction in weight of the component and/or cooling of the component during operation. The rotor component is formed by positioning a coated mild steel insert within a mold having an internal cross-section substantially the same in dimensions as the final rotor component. The mold is filled with a superalloy metal powder and undergoes hot-isostatic pressing to consolidate the powder about the coated core insert and form a superalloy structure. The mold is removed from about the superalloy structure and the core insert is removed from within the superalloy structure, thereby defining the at least one internal void within the rotor component.