Abstract: A composite axial flow rotary machine blade (10) and method of blade construction is disclosed. A substantially full length composite spar (30) is spanwisely disposed within an airfoil planform (18) which supports an airfoil surface (11a). A pad of reinforcing fibers (40) is sandwiched between the spar's periphery and the airfoil surfaces' proximate inner surfaces (24a, b) corresponding to the pressure (22) and suction (24) sides of the airfoil planform in a spanwise distribution. A quantity of structural foam filler (50) is disposed through the balance of the blade's cavity (16).

Abstract: A root attachment for a turbine blade is integrally molded with a composite turbine blade for a ram air turbine. The root attachment includes an insert at the one end of the root attachment for integrally molding within the blade and a hub connector at an opposite end for connecting the blade to a rotor hub. The insert has a geometry and surface area such that a dual load carrying capability is achieved during molding by the formation of an adhesive bond between the material of the blade and the insert and also a mechanical locking which resists failure in bearing. Each of the adhesive bond and the mechanical locking is designed to fail above an ultimate design load.

Abstract: A molded, composite, airfoil-defining, synthetic resin blade for large diameter cooling tower fans is disclosed wherein a moderately dense synthetic resin foam core is first formed that is generally of the same size and shape as the final desired blade. A shank embedded in the foam core extends outwardly from the end of the blade that is adapted to be fastened to the fan hub. A skin of fiberglass reinforced synthetic resin material is placed over the foam core with the thickness of the skin being greatest at the hub end of the blade and especially around the shank. The foam core with the skin thereon is molded into the final desired configuration thereof under pressure and temperature conditions such that the core is compressed and the thickness reduced to an extent correlated with the thickness of the synthetic resin skin on opposite faces thereof.

Abstract: A method of injection molding a thermoplastic material around a two-piece insert having a rotational axis through which a bore passes is disclosed. The insert is formed from two pieces which are axially spaced to define an annular gate through which the injected thermoplastic material passes radially outward. This technique is particularly useful for forming mixing impellers, because it orients fibers contained within the thermoplastic material in a radially outward direction within the impeller's blades to provide increased strength. The insert also allows improved performance for injection molding parts by reducing their cross-sectional thickness to optimal values. The insert also allows machining the bore without harming the injected plastic material.

Abstract: A composite rotor blade comprising an outboard portion defining an airfoil surface, an inboard portion defining an end tang having a mounting section and an extension lug section. The mounting section of the end tang having at least one mounting aperture with an axis parallel to the chordline of the airfoil for mounting of the blade, and the extension lug section having at least one extension lug extending inboard of the mounting aperture to provide a lever surface for interaction with suitable mounting mechanisms.

Abstract: A propeller blade spar/foam subassembly is manufactured by disposing a lamination of prepreg within a mold, closing the mold about a spar and injecting foam into mold cavities formed at the lead edge and the trailing edge of the spar.

Abstract: A component is fabricated by depositing a succession of overlying beads of a material, the pattern and position of the beads being assigned the proper characteristics of the corresponding section of the desired component. Shape definition is accomplished by characterizing the component as a series of sections or slices having the thickness of the bead, and programming a computer-controlled deposition head to deposit a succession of beads with the respective patterns and positions. Deposition is preferably by precision laser welding. Complex shapes having properties comparable to properties of forged or cast material are readily prepared. The material used in successive beads may be varied, producing a component of graded composition to achieve particular properties in various regions.

Abstract: A fan and hub assembly (60) having a plastic fan structure (62) molded to a hub (66) to achieve a predetermined resonance frequency. The hub (66) has a plurality of integrally formed arms (84) having one of more openings (88) of a predetermined size and predetermined location for permitting the flow-through of the plastic and to achieve a predetermined resonance frequency of the fan blades (64). A plurality of openings (86) are formed in the hub body (82) to permit the flow-through of liquid plastic to achieve a strong attachment of the blade root (76) to the hub (66).

Abstract: Helicopter rotor blade constructed of composite materials has a structural core (1) and a covering of profiled cladding (8). The structural core (1) includes all the structural elements of the blade, while the covering of the cladding (8) is a non-stress-bearing covering comprising an external rigid and thin shell (9a-9b), with the desired aerodynamic porfile, and a layer (10a-10b) of a ligth and flexible comformable non-stress-bearing material, such as a foam, ensuring the filling between the structural core (1) and the external shell (9a-9b). The foam layer (10a-10b) absorbs and compensates for the differences in shape between the contour of the structural core (1) and the precise aerodynamic profile of the non-stress-bearing external shell (9a-9b). The blade covering is expendable and evolutive spanwise as well as chordwise, with an external shell exhibiting an excellent surface condition, good erosion behavior and impact resistance, and easy to repair.

Abstract: A rotor blade for a horizontal axis wind turbine wherein a multiplicity of sucker rods are utilized internally of the blade root for securing the blade to the rotating hub of the turbine including the method of attaching the blade root to the hub and the method of making the blade root.

Abstract: A self-locking retention system is provided for a composite rotor blade supported on a rotor hub. A radially extending, stud-like retention member is provided on the rotor hub. A composite thickness projects radially inwardly from the rotor blade and substantially surrounds the retention member. The composite thickness is woven in a pattern which grips the retention member in response to outward forces applied to the rotor blade and the woven composite thickness.

Abstract: An integral connection for a plastic water pump impeller includes a molded non circular plug and inwardly facing, radially flexible cylindrical wall in the center of the impeller, and a matching female socket and matching outwardly facing cylindrical wall on the end of the shaft. A rib on the impeller wall and groove in the shaft wall pop fit together and flex the impeller wall out as the impeller and shaft are push pitted together. The socket and plug prevent relative turning, and the rib and groove prevent the impeller from pulling off of the shaft.

Abstract: A composite material blade is provided having a twin longeron and twin box structure with laminated honeycomb sandwich coverings, including a front leading edge longeron of a C shaped section, a central longeron with two sole pieces at the ends of a transverse web with honeycomb filling sandwiched between lateral sheets, and laminated coverings made from honeycomb panels sandwiched between external and internal sheets formed by stacking layers of fiber fabric, so as to define two boxes filled with very light foam cores, the sole pieces being integrated in the coverings which are joined at the level of the trailing edge by a rider in the form of a foam wedge.

Abstract: A vane-type impeller having a plurality of abuttably-adjacent, interconnected components at least some of which are made of an abrasion-resistant ceramic material is improved by a layer of a resiliently-flexible material between at least each component made of an abrasion-resistant ceramic material and each component it is abuttably adjacent for increasing the capability of each component made of the abrasion-resistant material of withstanding impact forces.

Abstract: There are disclosed a blade for use as part of an axial flow fan and a method of forming such a blade wherein a large concentration of silica particles are molded into the leading edge of a hollow, one-piece molded body which includes a core of reinforced, thermosetting resin having relatively low abrasion resistance.

Abstract: The fiber reinforced metal composite material according to this invention provides a composite material comprising, in combination, alumina-fibers or alumina-silica fibers excellent in abrasion resistance, heat resistance and seizure resistance and hypereutectic aluminum-silicon-type alloys enriched with proeutectic silicon which is hard grains.

Abstract: A hollow aerofoil cross-section aircraft propeller blade is provided with a tow of KEVLAR fibres internally thereof. The fibres which are anchored to the blade root and tip portions are arranged to be passive under all normal operating conditions of the blade. However in the event of a structural failure of the blade between its root and tip portions the fibres serve to contain the blade tip together with any portion of the blade attached thereto. The invention is additionally applicable to prop-fan and fan blades for gas turbine engines.

Abstract: A blade for a ceiling fan, the blade is formed of laminated sheets of timber which are moulded in a press so as to give the blade an aerodynamic shape for efficient use of the rotary power provided by the motor of the ceiling fan.

Abstract: An improved method is disclosed for forming articles, especially airfoils, comprised of a fiber reinforced plastic bonded to a metal object. In the manufacture of a propeller blade a subassembly is made by coating a metal spar with a certain class of adhesive to a depth of 5-40 mils to compensate for dimensional variations in the spar surface, transferably coating the interior of a subassembly mold with the adhesive, then inserting the coated spar into the mold and injecting a lightweight filler material. The adhesive and filler are then precured and the subassembly removed from the mold. A fibrous reinforcing material, such as glass fiber cloth, is then used to cover or wrap the subassembly, the subassembly thus covered is placed in a second mold and a synthetic polymeric material such as epoxy resin, previously or subsequently applied, is then cured.

Abstract: Each blade is fixed to the hub by the root part of the spar, arranged in the form of a loop surrounding a connection element bolted on the hub, with the interposition of rigid rings by a pin simultaneously fixing the hub on a drive sleeve transmitting thereto the driving torque of the central shaft. The hub comprises two coaxial cylindrical walls in each of which is pierced, for each blade, a circular opening in which the member for controlling the angle of attack which is fast with the blade root is mounted to rotate via self-lubricating rings. The invention is particularly applicable to helicopters.

Abstract: A wooden wind turbine blade is formed by laminating wood veneer in a compression mold having the exact curvature needed for one side of the blade, following which the other side of the blade is ground flat along its length but twisted with respect to the blade axis.

Abstract: A dual alloy cooled turbine is manufactured by casting a hollow cylinder of first nickel-base alloy material with high creep resistance to produce directionally oriented grain boundaries. A preform of a second nickel-base alloy material with high tensile strength and high low-cycle-fatigue strength is diffusion bonded into the bore of the hollow cylinder by subjecting the cylinder and preform to hot isostatic pressing. The resulting cylindrical block is cut into thin precisely flat wafers. A plurality of alignable holes for forming fluid cooling passages are photochemically etched into the individual wafers. The wafers then are laminated by vacuum diffusion bonding techniques, with the holes aligned to form fluid cooling passages. The resulting laminated block is machined to produce the turbine wheel with turbine blades through which the cooling passages extend.

Abstract: An improved method of making an airfoil includes stacking plies in two groups. A separator ply is positioned between the two groups of plies. The groups of plies and the separator ply are interconnected to form an airfoil blank. The airfoil blank is shaped, by forging or other methods, to have a desired configuration. The material of the separator ply is then dissolved or otherwise removed from between the two sections of the airfoil blank to provide access to the interior of the airfoil blank. Material is removed from inner sides of the two separated sections to form core receiving cavities. After cores have been placed in the cavities, the two sections of the airfoil blank are interconnected and the shaping of the airfoil is completed. The cores are subsequently removed from the completed airfoil.

Abstract: The invention is concerned with the problem of joining ceramic components to metal components.A composite ceramic-metal component is proposed, e.g. a rotor disc for a gas turbine engine (see FIG. 2), in which the main body of the component is made from a ceramic, e.g. Silicon Nitride, but the areas at which attachment is to be made to a metal component is formed from metal compacted onto the ceramic by a hot isostatic pressing process.The method of manufacture described is to form a ceramic core with holes appropriately positioned in it where a connection is to be made to another component, surround the core with a powdered metal, e.g. a Nickel-based superalloy, ensuring that the holes also fill with powder, compacting the powder by hot isostatic pressing, and then machining away unwanted metal.

Abstract: A method of manufacturing boat parts submerged when in use comprises producing a metallic skeleton structure shaped for easiest production by conventional metal-forming methods, and covering this structure in a mold with an adhering layer or coating of a thermoplastic resin or a rubber-based vulcanizable substance. The inner walls of the mold have high finish and the desired streamlined outer shape of the finished product, such as a lower unit of a propulsion system, or a propeller and the like. The coating functionally neutralizes the technologically conditioned and generally not streamlined shapes of the skeleton structure and provides a protection of the skeleton structure against electroerosive corrosion.

Abstract: Hollow wind turbine blades and the like comprising abutting blade sections, with nose forming strips and converging walls forming a tail section connecting with the ends of the nose forming strips, and a method of fabricating them comprising machining the facial end walls of the abutting blade sections to provide a precise alignment thereof providing a flush joint when the sections are butted together, adhesively bonding the blade sections in abutting relation and permitting the bond to cure, cutting communicating splice receiving slots in the abutting nose forming strips, and inserting adhesively bonding splice inserts which fit the slots in place in the slots.

Abstract: An improved method of making an airfoil includes stacking plies in two groups. A separator ply is positioned between the two groups of plies. The groups of plies and the separator ply are interconnected to form an airfoil blank. The airfoil blank is shaped, by forging or other methods, to have a desired configuration. The material of the separator ply is then dissolved or otherwise removed from between the two sections of the airfoil blank to provide access to the interior of the airfoil blank. Material is removed from inner sides of the two separated sections to form core receiving cavities. After cores have been placed in the cavities, the two sections of the airfoil blank are interconnected and the shaping of the airfoil is completed. The cores are subsequently removed from the completed airfoil.

Abstract: A wooden wind turbine blade is formed by laminating wood veneer in a compression mold having the exact curvature needed for one side of the blade, following which the other side of the blade is ground flat along its length but twisted with respect to the blade axis.

Abstract: The present rotor blade is constructed as a so-called monocoque or shell type blade for use in large fans and windmill rotors. For this purpose the blade is made of fiber reinforced synthetic material with a differnt orientation of the fibers in different sections of the blade. The transition between the blade proper and the connecting end of the blade is formed by a blade root section which has a connecting end of circular or elliptical cross-section and a wing facing end corresponding in cross-section to the blade cross-section. The blade root section has three zones. In the main leading edge zone including the leading edge and adjacent sides of the blade root section the reinforcing fibers extend in parallel to one another. The fibers also extend unidirectionally in a rear zone forming the trailing edge of the blade root section and in this trailing edge zone the fibers also extend in parallel to one another but at an angle relative to the fibers in the leading edge zone.

Abstract: A method for making helicopter blade spars in which a tape of reinforced resin is laid up with a continuous circulatory movement along an annular path defined by a lateral surface of a former of a forming mould in such a way as to define an annular body constituted by two ribs of the spar, rigidly connected together and opposite one another; each rib being subsequently separated from the other by cutting the said annular body.

Abstract: In a rotor for a rotary wing aircraft, an integral central headpiece supps the rotor blades. The headpiece consists of two plates interconnected by a centrally arranged distance member. Each plate has a similar star-shape with at least four angularly spaced point-like arms. Each plate is formed of a number of superposed layers with each layer containing continuous loops extending in the direction of the point-like arms. At least one loop extends from one point-like arm into another diametrically opposite point-like arm. Others of the loops, located in the other point-like arms, extend radially outwardly from the loop extending through the two point-like arms. The headpiece consisting of the plates and distance member, is a unitary or integral structure.

Abstract: A blade for a wind motor comprises a load-bearing structure and an external covering of plastic material. The load-bearing structure is of flat tubular form and is composed of a pair of facing half shells constituted by sheet metal pressings of substantially channel section. Flat-bottomed impressions are provided along the edges of the shells. The shells are joined together by spot welds welding the bottoms of the impressions of one shell to the bottoms of corresponding impressions of the other shell.

Abstract: To prevent the generation of noise from axial oscillations of the fan wheel on electric machinery, especially motors and generators in motor vehicles, the fan wheel is composed of a support assembly consisting of a plurality of adjacent metal discs or rings, surrounded by a preferably molded plastic fan circle in which the fan blades are embedded. The component discs of the support assembly may be of different thickness to provide different natural resonant frequencies, thereby further suppressing axial oscillations.

Abstract: A wind motor blade of composite construction has a blade shell of plastics material reinforced internally by transverse ribs and intersecting longitudinal struts in which metal fork arms are embedded, the fork arms being connected to a metal root attachment spigot through a metal cross-piece encapsulated in the plastics material.

Abstract: Ths invention relates to a method of making a foam-containing structure which includes placing and suitably retaining a respective shaped sheet in each of first and second complementary parts of an open mould. Each sheet includes at least one layer of fibrous material and on that face thereof remote from the respective mould part at least one filter layer. When the two mould parts are closed together a foamable material is introduced into a cavity formed between the sheets and is then caused to expand. Some of the expanding material passes through the filter layers into the fibrous material, the characteristics of those layers being so chosen as to produce a desired extent of penetration of the expanding material into the fibrous material.

Abstract: A blade is disclosed having an upper airfoil configuration and a lower platform with a root constructed with conventional fir-tree design. The forward part of the blade is formed of radial wafers wherein desired configurations of cooling passageways can be formed on mating surfaces of the wafers so that bonding of these wafers together forms intricate internal passageways. Film cooling is shown on the pressure side of the blade, while convection cooling and some film cooling is shown on the suction side. The radial wafers of the forward part are open at the center thereof to provide a cavity in a finished blade for a cooling fluid to flow from an opening in the root thereof to the internal passageways. The cavity extends to the top of the blade and is covered by a tip cap. The cap extends over the side wafers of the rearward part. The rearward part of the blade is formed of side wafers with one forming the suction side of the blade, while the other forms the pressure side of the blade.

Abstract: A load absorbing elastic member or members is incorporated in the design of a rotor blade to assist in reducing flapwise and chordwise bending moments, torsional loading, and to reduce or eliminate the control system loads induced by rotor blade moment stall. In all its embodiments, the load absorbing elastic member has operatively associated therewith a constraining member which serves as a strain amplifier permitting the load absorbing elastic member to achieve its purpose effectively.

Abstract: A fluid coupling device and fan mounting arrangement is disclosed. The fan is of the type having a hub portion and a plurality of fan blades integrally molded therewith from a plastic material and an annular spider having its outer periphery attached to the hub portion and a plurality of inwardly extending tabs bolted to bolt bosses projecting forwardly from the front surface of the output coupling member. The bolt bosses define a bolt circle having a radius R.sub.1 and the output coupling member includes a plurality of pilot portions defining a pilot diameter of radius R.sub.2, wherein R.sub.2 is greater than R.sub.1. The annular spider includes a plurality of inwardly extending pilot tabs, each of which engages the outer periphery of one of the pilot portions of the output member.

Abstract: A system of spars, each having a rectangular cross-section, is provided by placing the spars in lateral juxtaposition to one another like a plank to form a rotor blade. A skin of plastic foam is provided on the blade. The cross-sections of the spars, and the corresponding cross-sections of the blade, are varied in accordance with aerodynamic requirements. The spars are kept in position by means of clamps and/or connections and/or rings, forming an integral unit similar to a plank; and the integrated spars are directly attached to a hub or an electric generator.

Abstract: A method of manufacturing hollow pieces comprising the steps of forming a blank of single sheets each having a layer of gluing substance applied thereto; placing the blank onto an appropriate mandrel and subjecting it to a preliminary compression so as to impart to the blank a stiffness and to shape it into an unclosed profile as required for subsequent steps. Then the blank ends are brought together so as to define a cavity accommodating an elastic bag. The resulting blank is placed into a mould, and pressure is fed into the elastic bag to perform a final pressing.The above-described method is preferably used to manufacture helicopter rotor blades of glass plastic, which have variable cross-sectional shape over their length and exhibit higher strength and longer service life as compared with metal blades.