GB2418460A - Aerofoil with low density - Google Patents

Aerofoil with low density Download PDF

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Publication number
GB2418460A
GB2418460A GB0421057A GB0421057A GB2418460A GB 2418460 A GB2418460 A GB 2418460A GB 0421057 A GB0421057 A GB 0421057A GB 0421057 A GB0421057 A GB 0421057A GB 2418460 A GB2418460 A GB 2418460A
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United Kingdom
Prior art keywords
aerofoil
hollow
spheres
metal
hollow metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0421057A
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GB0421057D0 (en
Inventor
Simon Read
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Rolls Royce PLC
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Rolls Royce PLC
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Filing date
Publication date
Application filed by Rolls Royce PLC filed Critical Rolls Royce PLC
Priority to GB0421057A priority Critical patent/GB2418460A/en
Publication of GB0421057D0 publication Critical patent/GB0421057D0/en
Publication of GB2418460A publication Critical patent/GB2418460A/en
Withdrawn legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/40—Casings; Connections of working fluid
    • F04D29/52—Casings; Connections of working fluid for axial pumps
    • F04D29/54—Fluid-guiding means, e.g. diffusers
    • F04D29/541—Specially adapted for elastic fluid pumps
    • F04D29/542—Bladed diffusers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/22—Manufacture essentially without removing material by sintering
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2250/00—Geometry
    • F05D2250/60—Structure; Surface texture
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/40—Organic materials
    • F05D2300/43—Synthetic polymers, e.g. plastics; Rubber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/50—Intrinsic material properties or characteristics
    • F05D2300/522—Density
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/61—Syntactic materials, i.e. hollow spheres embedded in a matrix

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Architecture (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

An aerofoil, for example a fan outlet guide vane 32 is made from a plurality of hollow metal spheres 55 sintered into the shape of the aerofoil 32. It 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 32 has a density of less than lg/cm<3>, is cheaper to manufacture and has improved fatigue behaviour and impact capability. The metal may be aluminium, aluminium alloy, nickel, nickel alloy, titanium alloy, magnesium alloy or steel, the leading edge of the aerofoil may be of solid metal, and a coating of, eg polyurethane, may be provided to reduce roughness, the aerofoil may be a rotor blade, especially a fan blade or a compressor vane, or a stator vane, especially a fan outlet guide vane or a compressor vane.

Description

AN AEROFOIL AND A METHOD OF MANUFACTURING AN AEROFOIL
The present invention relates to an aerofoil for a gas turbine engine and in particular to a rotor blade or stator vane for a turbofan gas turbine engine casing.
Conventionally the compressor blades and the compressor vanes for a gas turbine engine are solid metal.
Conventionally the fan blades for a turbofan gas turbine engine are solid metal. It is known for the fan blades to be made from sold metal walls between which is provided a honeycomb structure to reduce the weight of the fan blades and the fan blade is produced by joining the peripheries of the solid metal walls together by brazing, bonding or welding. It is also known for the fan blades to be made from sold metal walls between which extends a solid metal warren girder structure to reduce the weight of the fan blades, and the fan blade is produced by diffusion bonding and superplastic forming of the solid metal pieces. It is also known for the fan blades to be made from composite material to reduce the weight of the fan blades.
However, there is still a requirement to reduce the weight and/or reduce the manufacturing cost of the metal rotor blades or stator vanes.
Accordingly the present invention seeks to provide a novel aerofoil, which reduces, preferably, overcomes the above-mentioned problems.
Accordingly the present invention provides an aerofoil comprising a leading edge, a trailing edge, a concave pressure surface extending from the leading edge to the trailing edge and a convex suction surface extending from the leading edge to the trailing edge, wherein the aerofoil comprising a plurality of hollow metal spheres, the hollow metal spheres being sistered substantially into the shape of the aerofoil.
Preferably the hollow metal spheres comprise hollow aluminium spheres, hollow nickel spheres, hollow titanium alloy spheres, hollow aluminium alloy spheres, hollow magnesium alloy spheres, hollow nickel alloy spheres or hollow steel spheres.
Preferably the aerofoil is a rotor blade or a stator vane.
Preferably the rotor blade is a fan blade or a compressor blade.
Preferably the stator vane is a fan outlet guide vane or a compressor vane.
Preferably the leading edge of the aerofoil comprises a solid metal portion.
Preferably the aerofoil, except for the solid metal portion, has a density of less than lg/cm3.
Preferably a smooth coating is provided on at least a portion of the surfaces of the aerofoil to reduce the roughness of the aerofoil.
Preferably the smooth coating is provided on all the surfaces of the aerofoil.
Preferably the smooth coating comprises a polyurethane coating.
Preferably the hollow metal spheres are hollow metal microspheres or hollow metal nanospheres.
The present invention also provides a method of manufacturing an aerofoil comprising the steps of: a) placing a plurality of hollow metal spheres in an aerofoil shaped mould, b) wintering the hollow metal spheres in the aerofoil shaped mould to form an aerofoil.
Preferably the hollow metal spheres comprise hollow aluminium spheres, hollow nickel spheres, hollow titanium alloy spheres, hollow aluminium alloy spheres, hollow magnesium alloy spheres, hollow nickel alloy spheres or hollow steel spheres.
Preferably the aerofoil is a rotor blade or a stator vane.
Preferably the rotor blade is a fan blade or a compressor blade.
Preferably the stator vane is a fan outlet guide vane or a compressor vane.
Preferably step (a) comprises placing a piece of solid metal in the aerofoil shaped mould at the leading edge of the aerofoil mould to form an aerofoil with a solid metal leading edge portion and then placing the hollow metal spheres in the aerofoil shaped mould.
Preferably the method comprises providing a smooth coating on at least a portion of the surfaces of the aerofoil to reduce the roughness of the aerofoil.
Preferably the method comprises providing the smooth coating on all the surfaces of the aerofoil.
Preferably the smooth coating comprises a polyurethane coating.
Preferably step (b) comprises sistering in a vacuum or at inert atmosphere.
Preferably the hollow metal spheres are hollow metal microspheres or hollow metal nanospheres.
The present invention will be more fully described by way of example with reference to the accompanying drawings in which: Figure 1 is a partially cut away view of a turbofan gas turbine engine having an aerofoil according to the present invention.
Figure 2 is an enlarged view of an aerofoil according to the present invention.
Figure 3 is a cross-sectional view along the line X-X in figure 2.
Figure 4 is an alternative cross-sectional view along the line X-X in figure 2.
Figure 5 is a further alternative cross-sectional view along the line X-X in figure 2.
Figure 6 is another alternative cross-sectional view along the line X-X in figure 2.
A turbofan gas turbine engine 10, as shown in figure 1, comprises in axial flow series an inlet 12, a fan section 14, a compressor section 16, a combustion section 18, a turbine section 20 and an exhaust 22. The turbine section comprises one or more turbines (not shown) arranged to drive the fan section 14 via a shaft (not shown) and one or more turbines (not shown) arranged to drive one or more compressors (not shown) in the compressor section 16 via one or more shafts (not shown). The fan section 14 comprises a fan rotor 24, which carries a plurality of circumferentially spaced radially outwardly extending fan blades 26. A fan casing 28 surrounds the fan rotor 24 and the fan blades 26 and is arranged coaxially with the fan rotor 24. The fan casing 28 is secured to the core engine casing 33 by a plurality of circumferentially spaced radially extending fan outlet guide vanes 32. The fan casing 28 partially defines a fan duct 30, which has an exhaust 34 at its downstream end.
One of the fan outlet guide vanes 32 is shown more clearly in figures 2 and 3. The fan outlet guide vane 32 comprises an aerofoil portion 35 and a radially inner end 44 and a radially outer end 46. The aerofoil portion 35 comprises a leading edge 36, a trailing edge 38, a concave pressure surface 40, which extends from the leading edge 36 to the trailing edge 38 and from the radially inner end 44 to the radially outer end 46 and a convex suction surface 42 which extends from the leading edge 36 to the trailing edge 38 and from the radially inner end 44 to the radially outer end 46. The radially inner end 44 comprises axially spaced bosses 48 and 50, which enable the radially inner end 44 to be secured to the core engine casing 33 and the radially outer end 46 comprises axially spaced bosses 52 and 54, which enable the radially outer end 46 to be secured to the fan casing 28.
The fan outlet guide vane 32 comprises a plurality of hollow metal microspheres 55, which have been sintered together.
In the example shown in figure 3 the hollow metal microspheres 55 form the whole of the fan outlet guide vane 32 and thus the hollow metal microspheres 55 define the leading edge 36, the trailing edge 38, the concave pressure surface 40 and the convex suction surface 42 of the aerofoil portion 35, the radially inner end 44 and the radially outer end 46. The fan outlet guide vane 32 is produced by firstly IS forming a mould to define the shape of the aerofoil portion and the radially inner and outer ends 44 and 46 of the fan outlet guide vane 32. Then the hollow metal microspheres 55 are introduced into the mould. The hollow metal microspheres 55 are then heated in the mould at a suitable temperature to sinter and bond the hollow metal microspheres 55 together to form an integral structure.
In the example shown in figure 4 the hollow metal microspheres 55 form the whole of the fan outlet guide vane 32 and thus the hollow metal microspheres 55 define the leading edge 36, the trailing edge 38, the concave pressure surface 40 and the convex suction surface 42 of the aerofoil portion 35, the radially inner end 44 and the radially outer end. In addition a smooth coating 56 is provided around the whole of the aerofoil portion 35 to reduce the roughness of the aerofoil portion 35 and hence increase the aerodynamic performance of the aerofoil portion 35 of the fan outlet guide vane 32. The smooth coating 56 comprises polyurethane, but other suitable smooth coatings may be used. The fan outlet guide vane 32 is produced by firstly forming a mould to define the shape of the aerofoil portion and the radially inner and outer ends 44 and 46 of the fan outlet guide vane 32. Then the hollow metal microspheres 55 are introduced into the mould. The hollow metal microspheres 55 are then heated in the mould at a suitable temperature to sinter and bond the hollow metal microspheres 55 together to form an integral structure.
Finally the smooth coating 56 is applied to the aerofoil portion 35 of the fan outlet guide vane 32.
In figure 5 the hollow metal microspheres 55 form the whole of the fan outlet guide vane 32 except for the leading edge 36 of the aerofoil portion 35, where a solid metal portion 58 is provided. The solid metal portion 58 increases the erosion resistance of the aerofoil portion 35 of the fan outlet guide vane 32. The fan outlet guide vane 32 is produced by firstly forming a mould to define the shape of the aerofoil portion 35 and the radially inner and outer ends 44 and 46 of the fan outlet guide vane 32.
Secondly a solid metal portion 58 is inserted in the mould at the position corresponding to the leading edge of the aerofoil portion of the fan outlet guide vane. Then the hollow metal microspheres 55 are introduced into the mould.
The hollow metal microspheres 55 are then heated in the mould at a suitable temperature to sister and bond the hollow metal microspheres together 55 and to the solid metal portion 58 to form an integral structure. As an alternative it may be possible to sinter the hollow metal microspheres together in the mould and then bond the solid metal portion 58 to the leading edge of the aerofoil portion and the solid metal portion 58 may be inlaid or tapered at the edges to avoid a step in the aerodynamic profile of the aerofoil portion.
In figure 6 the hollow metal microspheres 55 form the whole of the fan outlet guide vane 32 except for the leading edge 36 of the aerofoil portion 35, where a solid metal portion 58 is provided. The solid metal portion 58 increases the erosion resistance of the aerofoil portion 35 of the fan outlet guide vane 32. In addition a smooth coating 56 is provided around the whole of the aerofoil portion 35 to reduce the roughness of the aerofoil portion and hence increase the aerodynamic performance of the aerofoil portion 35 of the fan outlet guide vane 32. The smooth coating 56 comprises polyurethane, but other suitable smooth coatings may be used. The fan outlet guide vane 32 is produced by firstly forming a mould to define the shape of the aerofoil portion 35 and the radially inner and outer ends 44 and 46 of the fan outlet guide vane 32. Secondly a solid metal portion 58 is inserted in the mould at the position corresponding to the leading edge of the aerofoil portion of the fan outlet guide vane. Then the hollow metal microspheres 55 are introduced into the mould. The hollow metal microspheres 55 are then heated in the mould at a suitable temperature to sinter and bond the hollow metal microspheres 55 together and to the solid metal portion 58 to form an integral structure. Finally the smooth coating 56 is applied to the aerofoil portion 35 of the fan outlet guide vane 32.
It may be necessary to machine the radially inner and radially outer ends 44 and 46 of the fan outlet guide vane 32 to provide the bosses 48, 50, 52 and 54.
The hollow metal microspheres my be any suitable metal, alloy or intermetallic for example aluminium, nickel, aluminium alloy, magnesium alloy, titanium alloy, nickel alloy, steel, titanium aluminize, nickel aluminide etc. The solid metal portion may be any suitable metal, alloy or intermetallic and may be the same metal as the hollow metal microspheres or preferably may be a different more wear resistant metal.
The sintering takes place in a vacuum or in an inert atmosphere to prevent oxidation of the hollow metal microspheres.
The hollow metal microspheres are generally compacted under pressure in the die to create the required shape. The hollow metal microspheres may be compacted by hot, or cold, isostatic pressure, forging, rolling, extrusion or injection moulding. The pressure is sufficient to pack down the hollow metal microspheres but is insufficient to crush the hollow metal microspheres. The compacted hollow metal microspheres are then heat treated, sistered, in the controlled atmosphere at a temperature just below the melting point of the metal of the hollow metal microspheres.
The temperature, time of treatment and atmosphere may be varied to produce differing mechanical properties and these may be optimised to give the desired mechanical properties.
The sistering temperature is typically 50% to 85% of the solidus temperature, melting point, of the metal, alloy or intermetallic dependent upon the properties required.
The fan outlet guide vanes shown in figures 3 and 4 have a density of less than lg/cm3, 1 gram per cubic centimetre. The fan outlet guide vanes shown in figures 5 and 6 will have greater densities due to the solid metal portions.
For example a fan outlet guide vane 32 or a fan blade 26 may comprise hollow titanium alloy microspheres 55 and a solid titanium alloy portion 58, the titanium alloy may be Ti64, which consists of 6wt% aluminium, 4wt% vanadium and the balance titanium plus other minor additions and incidental impurities.
For example titanium alloy Ti64 mentioned above has a melting point of about 1660 C and hollow titanium alloy microspheres of Ti64 may be wintered at a temperature between 770 C and 1310 C.
Other examples of titanium alloys are Ti6242, Ti6246 and Ti679. Ti6242 consists of 6wt% aluminium, 2wt% tin, 4wt% zirconium, 2wt% molybdenum and the balance titanium plus minor additions and incidental impurities. Ti6246 consists of 6wt% aluminium, 2wt% tin, 4wt% zirconium, 6wt% molybdenum and the balance titanium plus minor additions and incidental impurities. Ti679 consists of 2.2wt% aluminium, llwt% tin, 5wt% zirconium, llwt% molybdenum and the balance titanium plus minor additions and incidental impurities.
Hollow Ti6242 microspheres may be sistered at temperatures between 794 C and 1350 C. Hollow Ti6246 microspheres may be sistered at temperatures between 800 C and 1360 C. Hollow Ti679 microspheres may be sistered at temperatures between 785 C and 1335 C.
An example of a nickel alloy is Inco 718, which consists of l9wt% chromium, 18.3wt% iron, 5.1wt% niobium, 3wt% molybdenum, 0.9wt% titanium and the balance nickel plus minor additions and incidental impurities. Hollow Inco 718 microspheres may be sistered at temperatures between 630 C and 1075 C.
An example of an aluminium alloy is RR58, which consists of 2.2wt copper, l.wt% magnesium, l.lwt% iron, 1.1wt% nickel and the balance aluminium plus minor additions and incidental impurities. Hollow RR58 microspheres may be wintered at temperatures between 270 C and 460 C.
An example of a magnesium alloy is RZ5, which consists of 4.2wt% zinc, 0. 7wt% zirconium and the balance magnesium plus minor additions and incidental impurities. Hollow microspheres of RZ5 may be sistered at temperatures between 255 C and 435 C.
An example of a steel alloy is Jethete, which consists of 12wt% chromium, 2.5wt% nickel, 1.7wt% molybdenum, 0.4wt% vanadium and the balance iron plus minor additions and incidental impurities. Hollow microspheres of Jethete may be sintered at temperatures between 720 C and 1232 C.
The diameters of the hollow metal microspheres are lOpm to lOOOpm, preferably 30pm to 200pm, but larger diameters of hollow metal microspheres may be used. The thickness of the walls of the hollow metal microspheres is about 10% of the diameter of the hollow metal microsphere, about lam for a lOpm diameter hollow metal microsphere to about loops for a lOOOrm diameter hollow metal microsphere, preferably 3m for a 30pm diameter hollow metal microsphere to about 20pm for a 200pm diameter hollow metal microsphere. Alternatively, hollow metal nanospheres may be used which have a diameter of lam to lOOOnm. The diameters and thickness of the walls of the hollow metal microspheres may be varied to optimise mechanical properties.
The compressor vanes may comprise hollow nickel alloy microspheres or hollow steel microspheres. The compressor blades may comprise hollow titanium alloy microspheres or hollow nickel alloy microspheres.
The advantages of the present invention are that the aerofoil is formed to finished size and shape in one operation reducing manufacturing costs. There is a reduction in weight of the aerofoil because the sintered hollow metal microspheres may have a density of less than lg/cm3 compared to a density of 2.5g/cm3 for a hollow aerofoil. The aerofoil has improved mechanical integrity because the sistered hollow metal microspheres have improved fatigue behaviour and impact capability due to the structure created by the sistered hollow microspheres. The aerofoil may have improved damping capability due to the structure created by the sistered hollow microspheres.
Although the present invention has been described with reference to a fan outlet guide vane, the present invention is equally applicable to a fan blade, a compressor vane or a compressor blade. Thus the term aerofoil is taken to mean any rotor blade or stator vane. In the case of rotor blades it may be necessary to machine the radially inner end of the aerofoil to form a firtree root or a dovetail root.

Claims (25)

  1. Claims: 1. An aerofoil comprising a leading edge, a trailing edge, a
    concave pressure surface extending from the leading edge to the trailing edge and a convex suction surface extending from the leading edge to the trailing edge, wherein the aerofoil comprising a plurality of hollow metal spheres, the hollow metal spheres being sistered substantially into the shape of the aerofoil.
  2. 2. An aerofoil as claimed in claim 1 wherein the hollow metal spheres comprise hollow aluminium spheres, hollow nickel spheres, hollow titanium alloy spheres, hollow aluminium alloy spheres, hollow magnesium alloy spheres, hollow nickel alloy spheres or hollow steel spheres.
  3. 3. An aerofoil as claimed in claim 1 or claim 2 wherein the aerofoil is a rotor blade or a stator vane.
  4. 4. An aerofoil as claimed in claim 3 wherein the rotor blade is a fan blade or a compressor blade.
  5. 5. An aerofoil as claimed in claim 3 wherein the stator vane is a fan outlet guide vane or a compressor vane.
  6. 6. An aerofoil as claimed in any of claims 1 to 5 wherein the leading edge of the aerofoil comprises a solid metal portion.
  7. 7. An aerofoil as claimed in any of claims 1 to 6 wherein the aerofoil, except for the solid metal portion, has a density of less than lg/cm3.
  8. 8. An aerofoil as claimed in any of claims 1 to 7 wherein a smooth coating is provided on at least a portion of the surfaces of the aerofoil to reduce the roughness of the aerofoil.
  9. 9. An aerofoil as claimed in claim 8 wherein the smooth coating is provided on all the surfaces of the aerofoil.
  10. 10. An aerofoil as claimed in claim 8 or claim 9 wherein the smooth coating comprises a polyurethane coating.
  11. 11. An aerofoil as claimed in any of claims 1 to 10 wherein the hollow metal spheres are hollow metal microspheres or hollow metal nanospheres.
  12. 12. An aerofoil substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
  13. 13. A gas turbine engine comprising an aerofoil as claimed in any of claims 1 to 12.
  14. 14. A method of manufacturing an aerofoil comprising the steps of: a) placing a plurality of hollow metal spheres in an aerofoil shaped mould, b) sistering the hollow metal spheres in the aerofoil shaped mould to form an aerofoil.
  15. 15. A method as claimed in claim 14 wherein the hollow metal spheres comprise hollow aluminium spheres, hollow nickel spheres, hollow titanium alloy spheres, hollow aluminium alloy spheres, hollow magnesium alloy spheres, hollow nickel alloy spheres or hollow steel spheres.
  16. 16. A method as claimed in claim 14 or claim 15 wherein the aerofoil is a rotor blade or a stator vane.
  17. 17. A method as claimed in claim 16 wherein the rotor blade is a fan blade or a compressor blade.
  18. 18. A method as claimed in claim 16 wherein the stator vane is a fan outlet guide vane or a compressor vane.
  19. 19. A method as claimed in any of claims 14 to 18 wherein step (a) comprises placing a piece of solid metal in the aerofoil shaped mould at the leading edge of the aerofoil mould to form an aerofoil with a solid metal leading edge portion and then placing the hollow metal spheres in the aerofoil shaped mould.
  20. 20. A method as claimed in any of claims 14 to 19 comprising providing a smooth coating on at least a portion of the surfaces of the aerofoil to reduce the roughness of the aerofoil.
  21. 21. A method as claimed in claim 20 comprising providing the smooth coating on all the surfaces of the aerofoil.
  22. 22. A method as claimed in claim 20 or claim 21 wherein the smooth coating comprises a polyurethane coating.
  23. 23. A method as claimed in any of claims 14 to 22 wherein step (b) comprises sistering in a vacuum or at inert atmosphere.
  24. 24. A method as claimed in any of claims 14 to 23 wherein the hollow metal spheres are hollow metal microspheres or hollow metal nanospheres.
  25. 25. A method of manufacturing an aerofoil substantially as hereinbefore described with reference to the accompanying drawings.
GB0421057A 2004-09-22 2004-09-22 Aerofoil with low density Withdrawn GB2418460A (en)

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Application Number Priority Date Filing Date Title
GB0421057A GB2418460A (en) 2004-09-22 2004-09-22 Aerofoil with low density

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Application Number Priority Date Filing Date Title
GB0421057A GB2418460A (en) 2004-09-22 2004-09-22 Aerofoil with low density

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GB0421057D0 GB0421057D0 (en) 2004-10-20
GB2418460A true GB2418460A (en) 2006-03-29

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2438185A (en) * 2006-05-17 2007-11-21 Rolls Royce Plc An apparatus for preventing ice accretion
WO2008000014A2 (en) 2006-06-30 2008-01-03 Facc Ag Guide vane arrangement for a driving mechanism
EP2239420A3 (en) * 2009-04-02 2014-07-09 General Electric Company Outlet guide vane assembly for a turbofan engine with combined acoustically absorbing and heat exchanging device, corresponding manufacturing method and turbofan engine
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EP2239420A3 (en) * 2009-04-02 2014-07-09 General Electric Company Outlet guide vane assembly for a turbofan engine with combined acoustically absorbing and heat exchanging device, corresponding manufacturing method and turbofan engine
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CN106599359B (en) * 2016-11-08 2020-01-21 南方科技大学 Design method of hollow blade filled by spherical net structure and engine
CN106599359A (en) * 2016-11-08 2017-04-26 南方科技大学 Design method of hollow leaf filled with spherical mesh structure, and engine
CN109763928A (en) * 2017-11-09 2019-05-17 株式会社东芝 Guide vane and fluid machinery
CN112032109A (en) * 2020-09-15 2020-12-04 中国航发沈阳发动机研究所 Blade

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