Abstract: A load transferring system wherein a composite turbine disk mounted on a shaft is in contact with a backup disk which is secured to the shaft. The turbine disk is made of layers of woven carbon fibers held in a rigid configuration in a ceramic matrix. The composite disk has a plurality of lugs which have trapezoidal cross sections when cut by planes which are perpendicular to each other, with both planes being normal to the disk. The backup disk is provided with recesses which are the negative of the trapezoidal lugs to lock the two disks together. A second backup disk may be secured to the shaft to secure the composite turbine disk between the backup disks.

Abstract: A gas turbine engine airfoil assembly for damping airfoil vibrations includes a metallic airfoil having an outer surface and a chordwise extending cavity beneath the outer surface of the airfoil. A damper is trapped within the cavity and a region in the airfoil surrounding the cavity has compressive residual stresses imparted by laser shock peening. The damper is preferably a chordwise extending linear wire having a distal end tacked down within the cavity. The invention includes a method for constructing the assembly for damping airfoil vibrations.

Abstract: A steam turbine blade, such as those used in an electric power generation steam turbine, has an airfoil portion. The airfoil portion includes a metallic section consisting essentially of metal and at least one (lightweight) panel section not consisting essentially of metal. The metallic section extends from generally the blade root to generally the blade tip. Each panel section is an elastomeric section. The metallic section and the at-least-one panel section only together define a generally airfoil shape.

Abstract: A shield 40 for use in processing a flow directing assembly 10, such as a stator vane or rotor blade, is disclosed. Various construction details are developed for the shield. The shield has two sides 52, 56 and at least two tabs 56, 58 which each extend from one of the sides and through the other side.

Abstract: A plain blank is sized to produce an airfoil. The blank is plastically formed to include a pocket blending smoothly in one side thereof. Leading and trailing edges of the airfoil are benched. And, filler is placed into the pocket to effect an aerodynamic profile for the airfoil.

Abstract: An airfoil core die includes a tab for forming a continuous and smooth contour and extension of a first trailing edge slot recessed wall to a bottom of the airfoil. The contour is formed on each airfoil core at injection and is maintained through to finish casting of the airfoil.

Abstract: A vibration damped turbo-machine blade includes a shot peened metallic substrate which provides a shape for the blade. Carried on the metallic substrate and bonded to an outer surface of this substrate is a singular ceramic coating of a damping material. The substrate may be made of forged titanium, and the coating may be made of a ceramic material including cobalt at a weight percentage of from about 13% to about 21%, with the balance of the ceramic material being substantially all tungsten carbide.

Abstract: A hollow airfoil (34) for a gas turbine engine having a leading edge (50), a trailing edge (52), a pressure side (54), and a suction side (56) includes a solid region of enhanced chordal thickness (78), and buttresses (82, 84, 86, 88). The present invention airfoil is preferentially strengthened so as to reduce the risk of airfoil fracture due to impact of airfoil with successive airfoils during an airfoil loss condition.

Abstract: A fan blade includes a metal airfoil having first and second opposite sides extending radially between a root and a tip, and axially between a leading edge and a trailing edge. The airfoil further includes a pocket disposed in the first side having an elastomeric filler bonded therein. A panel is bonded to the filler along the pocket for allowing differential movement therebetween for damping vibratory response of the airfoil.

Abstract: A gas turbine engine fan blade includes an airfoil and dovetail having an integral aluminum core and a fatigue resistant reinforcing sheath.

Abstract: A turbomachine rotor stage having a thin annular body comprising a metal alloy part reinforced by at least one fibrous ring which has a radial height h of at least 1.5 times its axial width l and which is embedded in the metal alloy part so that it projects radially outwardly from the inner wall thereof in order to stiffen the body and reduce the quantity of fibre material to be used.

Abstract: A lightweight steam turbine blade includes a metallic airfoil portion with at least one surface recess containing a void volume having adjacent first and second regions. Filler material is placed in and bonded to the surface recess and generally completely fills the void volume. The filler material in the first region has a higher average modulus of elasticity than that of the filler material in the second region.

Abstract: A fan blade includes a metal airfoil having first and second opposite sides extending longitudinally between a root and a tip, and laterally between a leading edge and a trailing edge. The airfoil further includes a plurality of fine striations spaced laterally apart between the leading and trailing edges in the airfoil first side, and extending longitudinally between the root and the tip. A viscoelastic filler is bonded in the striations for damping torsional vibrations of the airfoil.

Abstract: An airfoil is provided having a cross-sectional geometry which includes a first wall, a second wall disposed opposite the first wall, a leading edge, a trailing edge disposed opposite the leading edge, and a first cavity. The first cavity is disposed between the first and second walls, and the leading and trailing edges. The cross-sectional geometry extends between a first and a second end, and the airfoil is formed from discontinuously reinforced aluminum.

Abstract: A lightweight, impact-resistant gas turbine blade, such as an aircraft engine fan blade, includes a metallic airfoil portion with at least one surface recess containing a void volume having adjacent first and second regions. Filler material is placed in and bonded to the surface recess and generally completely fills the void volume. The filler material in the first region has a higher average modulus of elasticity than that of the filler material in the second region.

Abstract: A lightweight, impact-resistant gas turbine blade, such as an aircraft engine fan blade, has an airfoil portion. The airfoil portion includes a metallic section consisting essentially of metal and at least one panel section not consisting essentially of metal. The metallic section extends from generally the blade root to generally the blade tip. Each panel section is an elastomeric section. Preferably, the metallic section and the at-least-one panel section only together define a generally airfoil shape.

Abstract: A fan blade includes a spar having first and second opposite sides. The spar sides include a fatigue-life enhanced surface layer, with the spar first side having a cavity bounded in part by the surface layer. A skin closes the cavity and is bonded to the spar for maintaining the enhanced surface layer inside the cavity.

Abstract: A lightweight, impact-resistant gas turbine blade, such as an aircraft engine fan blade, has an airfoil portion which includes a metal section and at least one foam section which together define a generally airfoil shape. The metal section extends from generally the blade root to generally the blade tip. A composite skin generally completely surrounds, and is bonded to, the metal section and the at-least-one foam section. Preferably, an erosion coating generally completely surrounds, and is bonded to, the composite skin.

Abstract: A lightweight, impact-resistant gas turbine blade, such as an aircraft engine fan blade, includes attached-together first-metal and second-composite segments together defining an airfoil portion. The first segment includes entirely the suction side, leading edge, and trailing edge from the blade root to the blade tip and further includes partially the pressure side near the leading and trailing edges from the blade root to the blade tip. The second segment includes partially the pressure side from near the leading edge to near the trailing edge from the blade root to near the blade tip.

Abstract: A double-wall airfoil for applications such as the blades and vanes of gas turbine engines. The double-wall comprises an outer airfoil skin and an inner support wall that are metallurgically bonded to one another. The double-wall contains integral channels for passage of cooling air adjacent to the airfoil skin. Airfoil skin may be a metal alloy skin or a microlaminate structure, including microlaminate composite structures. Microlaminate composites typically have a lower density than that of the material used for the airfoil support wall, and a simplified internal geometry which promote weight reductions in the airfoils and increases in engine operating efficiency.

Abstract: Stator vanes located between compressor stages in a gas turbine engine are fabricated with a composite outer shell made of graphite fibers in an epoxy binder that is laid-up over a core of felt-like material selected to have an elongation velocity that is greater than the elongation velocity of the shell.

Abstract: An assembly of a plurality of composite blades including blade roots carried by blade root receiving slots in the rotor wherein the slot has a slot wall with a radially outward portion which, when assembled, diverges from a spaced apart juxtaposed blade root pressure face radially outer surface in an amount which is a function of a predetermined amount of centrifugal loading on the blade during operation of the assembly, to allow at least a portion of the radially outer surface of the root pressure face to be in contact with the slot wall radially outward surface during operation.

Abstract: To manufacture a turbine wheel having blades made of a ceramic or composite material and inserted into a metal hub, firstly blades (16) are manufactured that are right cylindrical, each blade having a base (18) through which a hole is formed; a cylindrical ring (20) is formed, the ring being provided with orifices through which the bases (18) of the respective blades (16) are inserted; the blade bases (18) are successively threaded onto an open annular rigid metal wire (30); the resulting assembly (16, 20, 30) is disposed inside a sealed housing (161); hot isostatic compaction is performed so as to compact a metal alloy in powder form (41) inside the sealed housing (161) so as to make the hub of the turbine wheel (100) while embedding the blade bases (18) and the metal wire (30) by using the powder metallurgy technique; and the outside portion of the sealed housing (161) delimiting the hub of the turbine wheel (101) is machined. Application, in particular, to the field of aeronautical or space engineering.

Abstract: Stator vanes located between compressor stages in a gas turbine engine are fabricated with a composite outer shell made of graphite fibers in an epoxy binder that is laid-up over a core of felt-like material selected to have an elongation velocity that is greater than the elongation velocity of the shell.

Abstract: A rotor blade for a turbine engine rotor assembly is provided comprising a root, an airfoil, a platform, and apparatus for damping vibrations in the airfoil. The airfoil includes a pocket formed in a chordwise surface. The apparatus for damping vibrations in the blade includes a damper and a pocket lid. The damper is received within the pocket between an inner surface of the pocket and the pocket lid. The pocket lid is attached to the airfoil by conventional attachment apparatus and contoured to match the curvature of the airfoil.

Abstract: A coating for protection of airfoil surfaces from erosion caused by the impingement of particles in the incoming air stream of a gas turbine engine or on helicopter blades. The coating consists of an epoxy film toughened with hard particles to improve the erosion resistance and softer particles which impede the progression of cracks through the coating. A method for applying the coating is also described.

Abstract: Methods for improving the erosion resistance of composite airfoils are disclosed as are the resultant structures. Wire mesh materials are coated with an erosion-resistant coating, formed to the shape of the airfoil leading edge, and molded into the leading edge during airfoil fabrication.

Abstract: The invention provides a woven composite lightweight turbine blade in which, e.g. ceramic or carbon fibers are woven around a foam core in the airfoil section of the blade and around a removable mandrel in the dovetail section of the blade, and braided at the tip and root thereof to define a woven blade pre-form. An infiltrant of e.g. phenolic, carbon or ceramic is added to the woven pre-form, which is then pyrolized to provide a thermally stable matrix in the pre-form and define a composite woven blade therewith. The resulting blade has a cavity in the air foil section between the tip and root sections of the blade and a hollow dovetail section. The dovetail section has reinforcing carbon or ceramic fibers mounted across the resulting passageway through the dovetail, which fibers are cooled by air passing through such dovetail passage such that the dovetail acts as a heat exchanger for the so-formed woven composite blade.

Abstract: A hollow core fan blade for a gas turbine engine, having a continuous leading edge, is fabricated using a four-sheet superplastic forming/diffusion bonding process which results in a cost-efficient and lightweight, yet strong, structure. The rotor blade is comprised of a face sheet which has a 180 degree bend therein so that the two face sheet ends are aligned. Bonded to opposing sides of the face sheet are first and second core sheets, between which is the hollow core. To fabricate the blade, a core sheet assembly is inserted inside the prepared face sheet, thereby forming a Ti-Pack (titanium pack) assembly having a plurality of pressure-tight cells. The Ti-Pack is inserted into a cavity within a die, after which the rotor blade, having predetermined design characteristics, is superplastically formed by heating the die and selectively pressurizing the plurality of cells.

Abstract: The present invention provides a composite airfoil particularly useful as a fan blade, having a high degree of twist, in a large high bypass ratio turbofan engine. The composite airfoil of the present invention has a progression of filament reinforced airfoil laminations of varying span, arranged in order by span, and interrupted by at least one filament reinforced airfoil lamination having a span out of height order to form what is called a confused or broken shear plane where radially outer tips of the laminations end.

Abstract: A turbine blade, preferably used in the low pressure stages of a steam turbine, is formed from a basic titanium alloy. Near the blade tip, it has a region, including the blade leading edge with a surface of a material which is more resistant to erosion than the basic titanium alloy.This turbine blade should be simple to manufacture and should have a long life even under difficult operating conditions.This is achieved in that the region including the blade leading edge has a protective layer formed by surface treatment of the basic titanium alloy by means of a high-power energy source, such as, in particular, a laser.

Abstract: A tension strained fiber structure component comprises a plurality of mutually connected structural elements which each consists of a fiber strand plate aligned in the tension direction and of a pressure plate extending at an acute angle with respect to the tension direction, which are both connected with one another. As a result, a favorable introduction of the tension forces into a separate supporting component can be achieved.

Abstract: A fan blade and/or propeller blade such as found in a gas turbine engine having a dovetail former having sections of composite unidirectional wrap material wrapped about the dovetail former from the concave to the convex side of the airfoil and filling cutout spaces between dovetail sections. Layers of non-wrapped composite material are cut and tapered and attached to the front and back sides of the dovetail sections.

Abstract: A turbomachine blade made of a fiber-reinforced composite material includes an aerodynamic portion and a fixing root portion, the latter being formed by at least two distinct arms which branch and spread without discontinuity from the aerodynamic portion and which are each formed into a loop which completely surrounds a separation core.

Abstract: A hollow core fan blade for a gas turbine engine, having a continuous leading edge, is fabricated using a four-sheet superplastic forming/diffusion bonding process which results in a cost-efficient and lightweight, yet strong, structure. The rotor blade is comprised of a face sheet which has a 180 degree bend therein so that the two face sheet ends are aligned. Bonded to opposing sides of the face sheet are first and second core sheets, between which is the hollow core. To fabricate the blade, a core sheet assembly is inserted inside the prepared face sheet, thereby forming a Ti-Pack (titanium pack) assembly having a plurality of pressure-tight cells. The Ti-Pack is inserted into a cavity within a die, after which the rotor blade, having predetermined design characteristics, is superplastically formed by heating the die and selectively pressurizing the plurality of cells.

Abstract: The wheel (10), which is made from a composite material having a ceramic matrix comprises a hub that bears a drive gear (16) formed of teeth (20) that extend radially on one of the wheel's surfaces (10a). Each tooth is asymmetrical with respect to the meridian plane (21) that passes through its apex, and has first shoulder (20b) that subtends an angle a, preferably between 15.degree. and 45.degree., relative to that plane, and a second shoulder (20c) that subtends an angle b, preferably between 55.degree. and 85.degree., relative to that plane. Advantageously, the sum of the two angels is at least equal to 100.degree.. The turbine wheel has an improved resistance against inter-laminar shear stresses that result from tightening to a drive gear wheel.

Abstract: A laminated airfoil for use in a high bypass engine. The airfoil preferably has a large tip chord and is comprised of alternating layers of thin metallic foil and elastomeric layers. The exterior surfaces of the airfoil are comprised of a thin, metallic foil. The airfoil also has a metal sheath secured to the leading edge. High strength metal members extend through the dovetail root sections.

Abstract: A lightweight propulsor blade (10) is constructed 10 of a hollow internal spar (30) and an exterior airfoil shell (20) which defines and encompasses a hollow interior cavity (26). The internal spar (30) is disposed within the cavity 26 and extends spanwisely from its tip portion to terminate in a spar root portion (40). The spar has at least forward and aft spanwisely extending, chordwisely spaced, hollow box-like cavities (52A, 52B), a leading edge shear web (53) projecting chordwisely forward from the forward cavity (52A), a trailing edge shear web (55) projecting chordwisely rearward from the aft cavity (52B), and an intermediate chordwise shear web (57) spanning the space between and interconnecting the forward and aft cavities (52A, 52B). An additional intermediate box-like cavity (52C) may be incorporated in the intermediate chordwise shear web (57) in spaced relationship between the forward and aft cavities (52A, 52B).

Abstract: The fan blades of a hot gas blower are cooled by the forced passage of cooling air or gas through the blades, the cooling air or gas being vented either into the hot gases or being isolated therefrom and being recirculated after cooling.

Abstract: This invention relates to abrasive layers for use in the gas turbine industry. The preferred embodiment of the invention comprises nickel coated, yttria doped silicon nitride particulates dispersed within a nickel base superalloy matrix which is substantially free of oxides. The layer is formed using low pressure plasma spray processes.

Abstract: A method and apparatus for forming a hardened contact surface on a shroud of a turbomachinery blade comprising casting the blade and internal shroud with a metal insert into the casting mold so that the blade is cast with the insert in place. The insert may be formed with a projection extending from a wear surface of the shroud into the plane of the blade shroud such that the material from which the blade is made is cast about the projection to firmly and mechanically hold the insert in place. Each insert is preferably formed of a relatively low coefficient of friction and high wear resistant material whereby contact between abutting inserts on adjacent shroud surfaces have a high degree of slippage.

Abstract: A radial inflow rotor for a gas turbine engine has a dual structure for improving the low cycle fatigue life of the saddle region. The interior core or hub of the rotor is a high strength polycrystalline alloy while a series of outer blade segments is individually cast as single crystals and bonded so that their low modulus (100) crystallographic axis is aligned substantially tangential to the rotor's circumference at the saddle.

Abstract: A composite gas turbine engine blade is made by braiding a plurality of fibers to form a preform having an airfoil precursor portion and an integral root precursor portion. A plurality of fiber shaping inserts are positioned in the root precursor portion, either by braiding the root precursor portion around the inserts or inserting the fiber shaping inserts into the root precursor portion after braiding, to impart an enlarged, divergent shape (e.g., dovetail precursor shape) to the braided root precursor portion. The braided preform with the enlarged, shaped root precursor portion is infiltrated with matrix material and shaped to near net shape to provide the composite blade with a dovetail shaped root.

Abstract: A composite rotor blade (2) with airfoil surfaces (4) used in rotary machines and a method for making the rotor blade (2) are disclosed. The rotor blade (2) includes a spar (8) with a root (12) which incorporates chordwise distributed recesses (13) which capture the composite laminate (16) which forms external airfoil surfaces (4). The root recesses (13) are sized so as to capture the volumetric bulk of the composite laminate (16) below the loadbearing surfaces (21) of the root (12) which fits into a complementary shaped recess (7) located within the rotatable hub (14). The method includes the steps of forming a composite rotor blade (2).

Abstract: A fiber-structured [guide] rotor blade is connected to a metallic rotor in that a supporting core, around which fiber layers are wound, and which extends over the whole blade width, has radial webs in its central section. This results in a form-locking fastening which utilizes the characteristics of the fiber materials.

Abstract: A composite member includes circumferentially extending ceramic fibers in a metallic matrix. A rotor member integrally includes such a ceramic fiber/metal matrix composite member to reinforce a homogeneous remainder portion of the rotor member with respect to centrifugally induced stresses. Method of making are included in the disclosure.

Abstract: A generally flat core of foam material extends outwardly from a wedge-shaped metal base plug, and the core is covered with overlapping plies of resin-bonded plastics materials having unidirectional fibers. The plies are covered by outer layers or skins of resin-bonded woven fabric plastics materials. The fibers of the inner plies are orientated at positive and negative acute angles relative to the longitudinal axis of the blade to provide the blade with predetermined torsional stiffness, and the fibers of the outer plies extend generally parallel to the axis and wrap around the base plug in an interleaving manner to provide high stiffness and strength to bending forces. Some of the plies extending around the base plug receive metal shell elements, and the shell elements engage propeller hub lip portions which cooperate to define an under-cut recess and clamp the plies to the base plug.

Abstract: A turbine blade produced from reinforced plastic material having a plurality of reinforcement sections (4, 6), arranged so that the direction of the reinforcement, and/or the structure, and/or the material in one section (4) differs from the corresponding reinforcement in another section, (5, 6), but that the reinforcement material in one section extends mainly in the same direction. The turbine blade also is so designed, that the deformations caused by loads and stresses optimize its pitch at increasing load.

Abstract: A gas turbine vane (1) is subject to distortion and wear during operation or repair which results in an increase in the spacing between successive vanes (6 and 7) which define nozzle gas flow areas (8 and 9). During refurbishment, the nozzle spacing must be returned to the original dimension to insure optimum turbine performance. A build up of alloy in the wear area is accomplished by controllably applying layers of a tape (12) of uniform thickness to the vane. The tape includes a mixture of a binder and an alloy powder, which is compatible with the substrate alloy, with the mixture formed into a sheet of uniform thickness and having an adhesive backing. After applying the tape in layers to a desired thickness, the vane is heated to a temperature at which the binder and adhesive decompose and the alloy in the tape diffusion bonds with the substrate alloy. Utilization of this process reduces the cost of refurbishing used turbine vanes and avoids hot forming or bending processes which could damage the vanes.

Abstract: A rotary component of a rotary device for heat engines, such as a turbine wheel of a gas turbine or a turbocharger, formed in an integral ceramic-fiber-reinforced sintered ceramic structure. The reinforcing ceramic fibers in the edges of the vanes of the rotary component are oriented radially to prevent the chipping of the edges of the vanes liable to occur in a direction perpendicular to the direction of thickness of the vanes. The rotary component is formed by molding a mixture of a ceramic powder, ceramic fibers and organic additive or additives in a mold having a cavity having the same shape as that of the rotary component except that the depth of sections of the cavity corresponding to the vanes is greater than the height of the vanes to be formed, sintering the molding, and cutting the vanes of the molding in a predetermined height.