US20140112796A1 - Composite blade with uni-tape airfoil spars - Google Patents
Composite blade with uni-tape airfoil spars Download PDFInfo
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- US20140112796A1 US20140112796A1 US13/658,209 US201213658209A US2014112796A1 US 20140112796 A1 US20140112796 A1 US 20140112796A1 US 201213658209 A US201213658209 A US 201213658209A US 2014112796 A1 US2014112796 A1 US 2014112796A1
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- Prior art keywords
- blade
- airfoil
- spars
- core section
- chordwise
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Classifications
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- 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
- F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
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- 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
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- 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
- F04D29/26—Rotors specially for elastic fluids
- F04D29/32—Rotors specially for elastic fluids for axial flow pumps
- F04D29/321—Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
- F04D29/324—Blades
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- 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
- F01D5/16—Form or construction for counteracting blade vibration
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- 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
- F05D2220/00—Application
- F05D2220/30—Application in turbines
- F05D2220/36—Application in turbines specially adapted for the fan of turbofan engines
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- 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
- F05D2240/305—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the pressure side of a rotor blade
-
- 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
- F05D2240/306—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the suction side of a rotor blade
-
- 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
- F05D2260/00—Function
- F05D2260/94—Functionality given by mechanical stress related aspects such as low cycle fatigue [LCF] of high cycle fatigue [HCF]
- F05D2260/941—Functionality given by mechanical stress related aspects such as low cycle fatigue [LCF] of high cycle fatigue [HCF] particularly aimed at mechanical or thermal stress reduction
-
- 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
- F05D2300/603—Composites; e.g. fibre-reinforced
-
- 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
- F05D2300/603—Composites; e.g. fibre-reinforced
- F05D2300/6034—Orientation of fibres, weaving, ply angle
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Definitions
- the invention relates to gas turbine engine blades and, particularly, to composite blades.
- Composite blades made from elongated filaments composited in a light-weight matrix have been developed for aircraft gas turbine engines.
- the blades are light-weight having high strength.
- the term composite has come to be defined as a material containing a reinforcement such as fibers or particles supported in a binder or matrix material.
- Many composites are used in the aerospace industry including both metallic and non-metallic composites.
- the composites used for the blades disclosed herein are made of a unidirectional tape material and an epoxy resin matrix. A discussion of this and other suitable materials may be found in the “Engineering Materials Handbook” by ASM INTERNATIONAL, 1987-1989 or later editions.
- the composite blades disclosed herein are made from the non-metallic type made of a material containing a fiber such as a carbonaceous, silica, metal, metal oxide, or ceramic fiber embedded in a resin material such as Epoxy, PMR15, BMI, PEEU, etc.
- the fibers are unidirectionally aligned in a tape that is impregnated with a resin, formed into a part shape, and cured via an autoclaving process or press molding to form a light weight, stiff, relatively homogeneous article having laminates or plies within.
- Composite fan blades have been developed for aircraft gas turbine engines to reduce weight and cost, particularly, for fan blades in larger engines.
- a large engine composite wide chord fan blades offer a significant weight savings over a large engine having standard chorded fan blades.
- all gas turbine engine blades face resonance or flexural modes.
- Large composite fan blades for high bypass ratio aircraft gas turbine engines with relatively wide diameter fans are faced with this problem. This is particularly true for the frequencies that cause the blade to experience first and second flexural airfoil modes.
- a gas turbine engine composite fan blade includes an airfoil having pressure and suction sides extending outwardly in a spanwise direction from a blade root of the blade along a span to a blade tip.
- a core section of the blade includes composite quasi-isotropic plies extending spanwise outwardly through the blade including the root and the airfoil towards the tip.
- One or more spars including a stack of uni-tape plies having a preferential 0 degree fiber orientation with respect to the span spanwise outwardly through the root and through a portion of the airfoil towards the tip.
- the chordwise extending portion of the core section may be centered about a maximum thickness location of the airfoil.
- the spars may have a spanwise height, chordwise width, and spar thickness that avoids flexural airfoil modes such as first and second flexural airfoil modes.
- the one or more spars may include pressure and suction side spars sandwiching a chordwise extending portion of the core section in the airfoil which may be located near or along the pressure and suction sides respectively.
- the one or more spars include chordwise spaced apart upstream and downstream pressure side spars and chordwise spaced apart upstream and downstream suction side spars sandwiching a chordwise extending portion of the core section in the airfoil.
- FIG. 1 is a perspective view illustration of an aircraft gas turbine engine composite fan blade having a composite uni-tape spar.
- FIG. 2 is a cross-sectional illustration of the composite fan blade through 2 - 2 in FIG. 1 .
- FIG. 3 is a perspective diagrammatical view illustration of an alternative aircraft gas turbine engine composite fan blade having a composite uni-tape spar.
- FIG. 4 is a perspective diagrammatical view illustration of the composite uni-tape spar illustrated in FIG. 3 .
- FIG. 5 is perspective diagrammatical view illustration of ⁇ P degree, 0 degree, and +P degree plies of the composite fan blade illustrated in FIG. 2 .
- FIG. 6 is a perspective view illustration of an alternative aircraft gas turbine engine composite fan blade having a composite uni-tape spar.
- FIG. 7 is a cross-sectional illustration of the composite fan blade through 7 - 7 in FIG. 6 .
- FIGS. 1 and 2 Illustrated in FIGS. 1 and 2 is a composite fan blade 10 for a high bypass ratio fanjet gas turbine engine (not shown) having a composite airfoil 12 .
- Composite fan blade 10 is made up of filament reinforced laminations 30 formed from a composite material lay-up 36 of filament reinforced composite plies 40 (illustrated in FIG. 5 ).
- the terms “lamination” and “ply” are synonymous.
- the airfoil 12 includes pressure and suction sides 41 , 43 extending outwardly in a spanwise direction from a fan blade root 20 along a span S to a blade tip 47 .
- the root 20 includes an integral dovetail 28 that enables the fan blade 10 to be mounted to a rotor disk.
- the exemplary pressure and suction sides 41 , 43 illustrated herein are concave and convex respectively.
- the airfoil 12 extends along a chord C between chordwise spaced apart leading and trailing edges LE, TE. Thickness T of the airfoil 12 varies in both chordwise and spanwise directions C, S and extends between pressure and suction sides 41 , 43 of the blade 10 also referred to as convex and concave sides of the blade or airfoil.
- the airfoil 12 may be mounted on and be integral with a hub to form an integrally bladed rotor (IBR) or integrally with a disk in a BLISK configuration.
- IBR integrally bladed rotor
- the plies 40 are generally all made from a unidirectional fiber filament ply material, preferably a tape, as it is often referred to, arranged generally in order of span and used to form a composite airfoil 12 as shown in FIG. 1 .
- the plies 40 are essentially those plies that form the airfoil 12 and root 20 of the blade 10 as illustrated in FIGS. 1 and 3 .
- the composite fan blade 10 is made up of filament reinforced laminations 30 formed from a composite material lay-up 36 of different filament reinforced airfoil plies 40 .
- the blade 10 uses filament reinforced laminations or plies with a filament orientation of 0 degrees, +P degrees, and ⁇ P degrees as illustrated in FIG. 5 .
- the angle P is a predetermined angle as measured from 0 degrees which corresponds to a generally radially extending axis of the airfoil which may be its centerline or stacking line and is typically about 45 degrees.
- An exemplary arrangement is more particularly pointed out and explained in U.S. Pat. No. 4,022,547 by Stanley.
- the composite fan blade 10 includes a core section 50 of composite quasi-isotropic plies 52 .
- Pressure and suction side spars 54 , 56 sandwich a chordwise extending portion 58 of the core section 50 made of composite quasi-isotropic plies 52 generally near or along the pressure and suction sides 41 , 43 respectively in the airfoil 12 .
- the chordwise extending portion 58 of the core section 50 extends chordwise partially through the airfoil 12 .
- the chordwise extending portion 58 of the core section 50 is generally centered chordwise in the airfoil 12 .
- the exemplary embodiment of the chordwise extending portion 58 illustrated herein extends chordwise about 1 ⁇ 3 through the airfoil 12 and is generally centered chordwise about in the middle of the airfoil 12 .
- the composite quasi-isotropic ply chordwise extending portion 58 of the core section 50 is preferably limited to a thicker cross sectional area of the airfoil 12 around or centered about a maximum thickness Tmax location 61 of the airfoil 12 , as illustrated in FIG. 2 , so as to be most effective.
- the Tmax location 61 is about a middle third of the airfoil between the leading and trailing edges LE, TE in the chordwise direction C for the exemplary airfoil illustrated herein.
- the pressure and suction side spars 54 , 56 are made from stacks 62 of preferential 0 degree uni-tape plies 63 (see FIG. 5 ) with a 0 degree fiber orientation with respect to the span S.
- the pressure and suction side spars 54 , 56 (and the uni-tape plies they are made from extend) spanwise S through the fan blade root 20 and through a portion 53 of the airfoil 12 to a spar tip 57 .
- the pressure and suction side spars 54 , 56 have a spanwise height H as measured from the fan blade root 20 to the spar tip 57 which is less than the span S of the airfoil.
- the pressure and suction side spars 54 , 56 extend all the way through the root 20 including the dovetail 28 .
- the quasi-isotropic ply core section 50 generally include alternating plies of tape with different +P, 0, and ⁇ P fiber orientations.
- the pressure and suction side spars 54 , 56 include uni-tape plies with a predominately 0 degree fiber orientation.
- An exemplary blade ply lay-up is disclosed in U.S. Pat. No. 5,375,978, entitled “Foreign Object Damage Resistant Composite Blade and Manufacture” to Evans, which issued Dec. 27, 1994, is assigned to the same assignee of this patent, and is incorporated herein by reference.
- the ply lay-up disclosed in U.S. Pat. No. 5,375,978 is referred to as a standard quasi-isotropic lay-up sequence of 0. degree, +45 degree, 0 degree, ⁇ 45 degree fiber orientations with the plies having the numerous ply shapes.
- the stacks 62 of the spars include uni-tape plies with a predominately 0 degree fiber orientation. A few of the plies may have another fiber orientation. An example is a stack having a total of 8 plies with 4 plies of 0 degree fiber orientation on both sides of two plies having +30 and a ⁇ 30 degree plies. This ply layup may be represented or denoted by 0,0,0,0,+30, ⁇ 30,0,0,0,0.
- the spars have a spanwise height H, chordwise width W, and spar thickness TS designed to increase radial or spanwise stiffness of the airfoil 12 without increasing the weight of the blade.
- the spars are also designed or tailored or tuned to avoid flexural airfoil modes such as first and second flexural airfoil modes 1 F and 2 F.
- the spanwise height H and the spar thickness TS are designed or tailored to tuned or avoid flexural airfoil modes such as first and second flexural airfoil modes 1 F and 2 F.
- the uni-tape ply spar with predominately a 0 degree fiber orientation allows for a stiffer blade without adding thickness and without adding weight and performance penalties.
- the exemplary embodiment of the composite blade illustrated herein is a fan blade but the composite blade with a quasi-isotropic ply core section and spars made from stacks 62 of 0 degree uni-tape plies 63 may also be used for other gas turbine engine blades such as compressor blades.
- the exemplary embodiment of the composite blade 10 illustrated herein includes one or more outer cover plies 66 around the core section 50 , made of composite quasi-isotropic plies, and the pressure and suction side spars 54 , 56 .
- a leading edge metallic shield 68 is bonded around the leading edge LE.
- the shield is often referred to as metallic cladding.
- an alternative spar design for the composite fan blade 10 includes a core section 50 of composite quasi-isotropic plies and two sets of pressure and suction side spars.
- the two sets include chordwise spaced apart upstream and downstream pressure side spars 74 , 76 and chordwise spaced apart upstream and downstream suction side spars 78 , 80 sandwiching the chordwise extending portion 58 of the core section 50 made of composite quasi-isotropic plies generally near or along the pressure and suction sides 41 , 43 respectively.
Abstract
A gas turbine engine composite blade includes an airfoil having pressure and suction sides extending outwardly in a spanwise direction from a blade root along a span to a blade tip. A core section of the blade including composite quasi-isotropic plies extends spanwise outwardly through the blade. One or more spars including a stack of uni-tape plies having predominately a 0 degree fiber orientation with respect to the span and extending spanwise outwardly through the root and a portion of the airfoil towards the tip. Spars may include pressure and suction side spars sandwiching a chordwise extending portion of the core section in the airfoil and which be located near or along the pressure and suction sides respectively. Chordwise extending portion may be centered about a maximum thickness location of the airfoil. Spars may have height, width, and thickness that avoids flexural airfoil modes.
Description
- 1. Field of the Invention
- The invention relates to gas turbine engine blades and, particularly, to composite blades.
- 2. Description of Related Art
- Composite blades made from elongated filaments composited in a light-weight matrix have been developed for aircraft gas turbine engines. The blades are light-weight having high strength. The term composite has come to be defined as a material containing a reinforcement such as fibers or particles supported in a binder or matrix material. Many composites are used in the aerospace industry including both metallic and non-metallic composites. The composites used for the blades disclosed herein are made of a unidirectional tape material and an epoxy resin matrix. A discussion of this and other suitable materials may be found in the “Engineering Materials Handbook” by ASM INTERNATIONAL, 1987-1989 or later editions.
- The composite blades disclosed herein are made from the non-metallic type made of a material containing a fiber such as a carbonaceous, silica, metal, metal oxide, or ceramic fiber embedded in a resin material such as Epoxy, PMR15, BMI, PEEU, etc. The fibers are unidirectionally aligned in a tape that is impregnated with a resin, formed into a part shape, and cured via an autoclaving process or press molding to form a light weight, stiff, relatively homogeneous article having laminates or plies within.
- Composite fan blades have been developed for aircraft gas turbine engines to reduce weight and cost, particularly, for fan blades in larger engines. A large engine composite wide chord fan blades offer a significant weight savings over a large engine having standard chorded fan blades. Among the problems, all gas turbine engine blades face resonance or flexural modes. Large composite fan blades for high bypass ratio aircraft gas turbine engines with relatively wide diameter fans are faced with this problem. This is particularly true for the frequencies that cause the blade to experience first and second flexural airfoil modes.
- It is highly desirable to provide light-weight and strong aircraft gas turbine engine fan blades that avoid passing through or experiencing assonance and flexural modes and, in particular, first and second flexural airfoil modes.
- A gas turbine engine composite fan blade includes an airfoil having pressure and suction sides extending outwardly in a spanwise direction from a blade root of the blade along a span to a blade tip. A core section of the blade includes composite quasi-isotropic plies extending spanwise outwardly through the blade including the root and the airfoil towards the tip. One or more spars including a stack of uni-tape plies having a preferential 0 degree fiber orientation with respect to the span spanwise outwardly through the root and through a portion of the airfoil towards the tip.
- The chordwise extending portion of the core section may be centered about a maximum thickness location of the airfoil. The spars may have a spanwise height, chordwise width, and spar thickness that avoids flexural airfoil modes such as first and second flexural airfoil modes. The one or more spars may include pressure and suction side spars sandwiching a chordwise extending portion of the core section in the airfoil which may be located near or along the pressure and suction sides respectively.
- In one embodiment of the blade, the one or more spars include chordwise spaced apart upstream and downstream pressure side spars and chordwise spaced apart upstream and downstream suction side spars sandwiching a chordwise extending portion of the core section in the airfoil.
- The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings where:
-
FIG. 1 is a perspective view illustration of an aircraft gas turbine engine composite fan blade having a composite uni-tape spar. -
FIG. 2 is a cross-sectional illustration of the composite fan blade through 2-2 inFIG. 1 . -
FIG. 3 is a perspective diagrammatical view illustration of an alternative aircraft gas turbine engine composite fan blade having a composite uni-tape spar. -
FIG. 4 is a perspective diagrammatical view illustration of the composite uni-tape spar illustrated inFIG. 3 . -
FIG. 5 is perspective diagrammatical view illustration of −P degree, 0 degree, and +P degree plies of the composite fan blade illustrated inFIG. 2 . -
FIG. 6 is a perspective view illustration of an alternative aircraft gas turbine engine composite fan blade having a composite uni-tape spar. -
FIG. 7 is a cross-sectional illustration of the composite fan blade through 7-7 inFIG. 6 . - Illustrated in
FIGS. 1 and 2 is acomposite fan blade 10 for a high bypass ratio fanjet gas turbine engine (not shown) having acomposite airfoil 12.Composite fan blade 10 is made up of filament reinforcedlaminations 30 formed from a composite material lay-up 36 of filament reinforced composite plies 40 (illustrated inFIG. 5 ). As used herein, the terms “lamination” and “ply” are synonymous. Theairfoil 12 includes pressure andsuction sides fan blade root 20 along a span S to ablade tip 47. In the exemplary embodiment, theroot 20 includes anintegral dovetail 28 that enables thefan blade 10 to be mounted to a rotor disk. - The exemplary pressure and
suction sides airfoil 12 extends along a chord C between chordwise spaced apart leading and trailing edges LE, TE. Thickness T of theairfoil 12 varies in both chordwise and spanwise directions C, S and extends between pressure andsuction sides blade 10 also referred to as convex and concave sides of the blade or airfoil. Theairfoil 12 may be mounted on and be integral with a hub to form an integrally bladed rotor (IBR) or integrally with a disk in a BLISK configuration. - The
plies 40 are generally all made from a unidirectional fiber filament ply material, preferably a tape, as it is often referred to, arranged generally in order of span and used to form acomposite airfoil 12 as shown inFIG. 1 . Theplies 40 are essentially those plies that form theairfoil 12 androot 20 of theblade 10 as illustrated inFIGS. 1 and 3 . - The
composite fan blade 10 is made up of filament reinforcedlaminations 30 formed from a composite material lay-up 36 of different filament reinforcedairfoil plies 40. Theblade 10 uses filament reinforced laminations or plies with a filament orientation of 0 degrees, +P degrees, and −P degrees as illustrated inFIG. 5 . The angle P is a predetermined angle as measured from 0 degrees which corresponds to a generally radially extending axis of the airfoil which may be its centerline or stacking line and is typically about 45 degrees. An exemplary arrangement is more particularly pointed out and explained in U.S. Pat. No. 4,022,547 by Stanley. - Referring to
FIGS. 1-4 , thecomposite fan blade 10 includes acore section 50 of composite quasi-isotropicplies 52. Pressure and suction side spars 54, 56 sandwich a chordwise extendingportion 58 of thecore section 50 made of composite quasi-isotropicplies 52 generally near or along the pressure andsuction sides airfoil 12. Thechordwise extending portion 58 of thecore section 50 extends chordwise partially through theairfoil 12. Thechordwise extending portion 58 of thecore section 50 is generally centered chordwise in theairfoil 12. The exemplary embodiment of thechordwise extending portion 58 illustrated herein extends chordwise about ⅓ through theairfoil 12 and is generally centered chordwise about in the middle of theairfoil 12. The composite quasi-isotropic ply chordwise extendingportion 58 of thecore section 50 is preferably limited to a thicker cross sectional area of theairfoil 12 around or centered about a maximumthickness Tmax location 61 of theairfoil 12, as illustrated inFIG. 2 , so as to be most effective. The Tmaxlocation 61 is about a middle third of the airfoil between the leading and trailing edges LE, TE in the chordwise direction C for the exemplary airfoil illustrated herein. The pressure and suction side spars 54, 56 are made fromstacks 62 of preferential 0 degree uni-tape plies 63 (seeFIG. 5 ) with a 0 degree fiber orientation with respect to the span S. - Referring to
FIGS. 3 and 4 , the pressure and suction side spars 54, 56 (and the uni-tape plies they are made from extend) spanwise S through thefan blade root 20 and through aportion 53 of theairfoil 12 to aspar tip 57. The pressure and suction side spars 54, 56 have a spanwise height H as measured from thefan blade root 20 to thespar tip 57 which is less than the span S of the airfoil. In the embodiment of thecomposite fan blade 10 illustrated herein, the pressure and suction side spars 54, 56 (and the uni-tape plies are made from) extend all the way through theroot 20 including thedovetail 28. - The quasi-isotropic
ply core section 50 generally include alternating plies of tape with different +P, 0, and −P fiber orientations. The pressure and suction side spars 54, 56 include uni-tape plies with a predominately 0 degree fiber orientation. An exemplary blade ply lay-up is disclosed in U.S. Pat. No. 5,375,978, entitled “Foreign Object Damage Resistant Composite Blade and Manufacture” to Evans, which issued Dec. 27, 1994, is assigned to the same assignee of this patent, and is incorporated herein by reference. The ply lay-up disclosed in U.S. Pat. No. 5,375,978 is referred to as a standard quasi-isotropic lay-up sequence of 0. degree, +45 degree, 0 degree, −45 degree fiber orientations with the plies having the numerous ply shapes. - The
stacks 62 of the spars include uni-tape plies with a predominately 0 degree fiber orientation. A few of the plies may have another fiber orientation. An example is a stack having a total of 8 plies with 4 plies of 0 degree fiber orientation on both sides of two plies having +30 and a −30 degree plies. This ply layup may be represented or denoted by 0,0,0,0,+30,−30,0,0,0,0. - Referring to
FIGS. 1 , 2, and 3, the spars have a spanwise height H, chordwise width W, and spar thickness TS designed to increase radial or spanwise stiffness of theairfoil 12 without increasing the weight of the blade. The spars are also designed or tailored or tuned to avoid flexural airfoil modes such as first and second flexural airfoil modes 1F and 2F. The spanwise height H and the spar thickness TS are designed or tailored to tuned or avoid flexural airfoil modes such as first and second flexural airfoil modes 1F and 2F. The uni-tape ply spar with predominately a 0 degree fiber orientation allows for a stiffer blade without adding thickness and without adding weight and performance penalties. The exemplary embodiment of the composite blade illustrated herein is a fan blade but the composite blade with a quasi-isotropic ply core section and spars made fromstacks 62 of 0 degree uni-tape plies 63 may also be used for other gas turbine engine blades such as compressor blades. - The exemplary embodiment of the
composite blade 10 illustrated herein includes one or more outer cover plies 66 around thecore section 50, made of composite quasi-isotropic plies, and the pressure and suction side spars 54, 56. A leading edgemetallic shield 68 is bonded around the leading edge LE. The shield is often referred to as metallic cladding. - Referring to
FIGS. 6 and 7 , an alternative spar design for thecomposite fan blade 10 includes acore section 50 of composite quasi-isotropic plies and two sets of pressure and suction side spars. The two sets include chordwise spaced apart upstream and downstream pressure side spars 74, 76 and chordwise spaced apart upstream and downstream suction side spars 78, 80 sandwiching thechordwise extending portion 58 of thecore section 50 made of composite quasi-isotropic plies generally near or along the pressure andsuction sides - The present invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. While there have been described herein, what are considered to be preferred and exemplary embodiments of the present invention, other modifications of the invention shall be apparent to those skilled in the art from the teachings herein and, it is, therefore, desired to be secured in the appended claims all such modifications as fall within the true spirit and scope of the invention.
- Accordingly, what is desired to be secured by Letters Patent of the United States is the invention as defined and differentiated in the following claims:
Claims (26)
1. A gas turbine engine composite blade comprising:
an airfoil having pressure and suction sides extending outwardly in a spanwise direction from a blade root of the blade along a span to a blade tip,
a core section of the blade including composite quasi-isotropic plies extending spanwise outwardly through the blade including the root and the airfoil towards the tip,
one or more spars including a stack of uni-tape plies having predominately a 0 degree fiber orientation with respect to the span, and
the one or more spars extending spanwise outwardly through the root and through a portion of the airfoil towards the tip.
2. The blade as claimed in claim 1 further comprising the one or more spars including pressure and suction side spars sandwiching a chordwise extending portion of the core section in the airfoil.
3. The blade as claimed in claim 2 further comprising the chordwise extending portion of the core section located near or along the pressure and suction sides respectively.
4. The blade as claimed in claim 1 further comprising the chordwise extending portion of the core section centered about a maximum thickness location of the airfoil.
5. The blade as claimed in claim 4 further comprising the one or more spars including pressure and suction side spars sandwiching a chordwise extending portion of the core section in the airfoil.
6. The blade as claimed in claim 5 further comprising the chordwise extending portion of the core section located near or along the pressure and suction sides respectively.
7. The blade as claimed in claim 1 further comprising the spars having a spanwise height, chordwise width, and spar thickness that avoids flexural airfoil modes.
8. The blade as claimed in claim 7 further comprising the flexural airfoil modes including first and second flexural airfoil modes.
9. The blade as claimed in claim 8 further comprising the one or more spars including pressure and suction side spars sandwiching a chordwise extending portion of the core section in the airfoil.
10. The blade as claimed in claim 9 further comprising the chordwise extending portion of the core section located near or along the pressure and suction sides respectively.
11. The blade as claimed in claim 8 further comprising the chordwise extending portion of the core section centered about a maximum thickness location of the airfoil.
12. The blade as claimed in claim 11 further comprising the one or more spars including pressure and suction side spars sandwiching a chordwise extending portion of the core section in the airfoil.
13. The blade as claimed in claim 12 further comprising the chordwise extending portion of the core section located near or along the pressure and suction sides respectively.
14. The blade as claimed in claim 1 further comprising the one or more spars including chordwise spaced apart upstream and downstream pressure side spars and chordwise spaced apart upstream and downstream suction side spars sandwiching a chordwise extending portion of the core section in the airfoil.
15. The blade as claimed in claim 14 further comprising the chordwise extending portion of the core section located near or along the pressure and suction sides respectively.
16. The blade as claimed in claim 15 further comprising the chordwise extending portion of the core section centered about a maximum thickness location of the airfoil.
17. The blade as claimed in claim 16 further comprising the upstream and downstream pressure side spars and the chordwise spaced apart upstream and downstream suction side spars having a spanwise height, chordwise width, and spar thickness that avoids flexural airfoil modes.
18. The blade as claimed in claim 17 further comprising the flexural airfoil modes including first and second flexural airfoil modes.
19. The blade as claimed in claim 17 further comprising the chordwise extending portion of the core section located near or along the pressure and suction sides respectively.
20. The blade as claimed in claim 19 further comprising the flexural airfoil modes including first and second flexural airfoil modes.
21. The blade as claimed in claim 1 further comprising:
the root includes an integral dovetail,
one or more outer cover plies around the core section, and
a leading edge metallic shield bonded around the leading edge.
22. The blade as claimed in claim 21 further comprising the spars having a spanwise height, chordwise width, and spar thickness that avoids flexural airfoil modes.
23. The blade as claimed in claim 22 further comprising the flexural airfoil modes including first and second flexural airfoil modes.
24. The blade as claimed in claim 23 further comprising the one or more spars including pressure and suction side spars sandwiching a chordwise extending portion of the core section in the airfoil.
25. The blade as claimed in claim 24 further comprising the chordwise extending portion of the core section centered about a maximum thickness location of the airfoil.
26. The blade as claimed in claim 25 further comprising the chordwise extending portion of the core section located near or along the pressure and suction sides respectively.
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/658,209 US20140112796A1 (en) | 2012-10-23 | 2012-10-23 | Composite blade with uni-tape airfoil spars |
CN201380054437.7A CN104981586A (en) | 2012-10-23 | 2013-09-24 | Composite blade with uni-tape airfoil spars |
BR112015009060A BR112015009060A2 (en) | 2012-10-23 | 2013-09-24 | composite gas turbine engine blade. |
JP2015537713A JP6179961B2 (en) | 2012-10-23 | 2013-09-24 | Composite blade with unidirectional tape airfoil girder |
CA2888777A CA2888777A1 (en) | 2012-10-23 | 2013-09-24 | Composite blade with uni-tape airfoil spars |
PCT/US2013/061294 WO2014065968A1 (en) | 2012-10-23 | 2013-09-24 | Composite blade with uni-tape airfoil spars |
EP13774557.6A EP2917496A1 (en) | 2012-10-23 | 2013-09-24 | Composite blade with uni-tape airfoil spars |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/658,209 US20140112796A1 (en) | 2012-10-23 | 2012-10-23 | Composite blade with uni-tape airfoil spars |
Publications (1)
Publication Number | Publication Date |
---|---|
US20140112796A1 true US20140112796A1 (en) | 2014-04-24 |
Family
ID=49326854
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/658,209 Abandoned US20140112796A1 (en) | 2012-10-23 | 2012-10-23 | Composite blade with uni-tape airfoil spars |
Country Status (7)
Country | Link |
---|---|
US (1) | US20140112796A1 (en) |
EP (1) | EP2917496A1 (en) |
JP (1) | JP6179961B2 (en) |
CN (1) | CN104981586A (en) |
BR (1) | BR112015009060A2 (en) |
CA (1) | CA2888777A1 (en) |
WO (1) | WO2014065968A1 (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20170292530A1 (en) * | 2016-04-11 | 2017-10-12 | United Technologies Corporation | Airfoil |
US20180156037A1 (en) * | 2016-12-05 | 2018-06-07 | MTU Aero Engines AG | Turbine blade comprising a cavity with wall surface discontinuities and process for the production thereof |
WO2019224496A1 (en) * | 2018-05-24 | 2019-11-28 | Safran Aircraft Engines | Fabric comprising aramid fibres for protecting a blade against impacts |
FR3081914A1 (en) * | 2018-06-05 | 2019-12-06 | Safran Aircraft Engines | BLOWER BLADE IN COMPOSITE MATERIAL WITH LARGE INTEGRATED GAME |
WO2021005312A1 (en) * | 2019-07-11 | 2021-01-14 | Safran Aircraft Engines | Blower vane |
US20230081843A1 (en) * | 2020-02-18 | 2023-03-16 | Safran Aircraft Engines | Composite blade for a turbine engine rotor |
US11898464B2 (en) | 2021-04-16 | 2024-02-13 | General Electric Company | Airfoil for a gas turbine engine |
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- 2012-10-23 US US13/658,209 patent/US20140112796A1/en not_active Abandoned
-
2013
- 2013-09-24 CN CN201380054437.7A patent/CN104981586A/en active Pending
- 2013-09-24 BR BR112015009060A patent/BR112015009060A2/en not_active IP Right Cessation
- 2013-09-24 JP JP2015537713A patent/JP6179961B2/en not_active Expired - Fee Related
- 2013-09-24 EP EP13774557.6A patent/EP2917496A1/en not_active Withdrawn
- 2013-09-24 WO PCT/US2013/061294 patent/WO2014065968A1/en active Application Filing
- 2013-09-24 CA CA2888777A patent/CA2888777A1/en not_active Abandoned
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US5375978A (en) * | 1992-05-01 | 1994-12-27 | General Electric Company | Foreign object damage resistant composite blade and manufacture |
US6607358B2 (en) * | 2002-01-08 | 2003-08-19 | General Electric Company | Multi-component hybrid turbine blade |
US20070065291A1 (en) * | 2005-09-16 | 2007-03-22 | General Electric Company | Hybrid blisk |
US7828526B2 (en) * | 2007-04-11 | 2010-11-09 | General Electric Company | Metallic blade having a composite inlay |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10465703B2 (en) * | 2016-04-11 | 2019-11-05 | United Technologies Corporation | Airfoil |
US20170292530A1 (en) * | 2016-04-11 | 2017-10-12 | United Technologies Corporation | Airfoil |
US10947989B2 (en) | 2016-04-11 | 2021-03-16 | Raytheon Technologies Corporation | Airfoil |
US20180156037A1 (en) * | 2016-12-05 | 2018-06-07 | MTU Aero Engines AG | Turbine blade comprising a cavity with wall surface discontinuities and process for the production thereof |
US11168566B2 (en) * | 2016-12-05 | 2021-11-09 | MTU Aero Engines AG | Turbine blade comprising a cavity with wall surface discontinuities and process for the production thereof |
US11371357B2 (en) | 2018-05-24 | 2022-06-28 | Safran Aircraft Engines | Fabric comprising aramid fibres for protecting a blade against impacts |
WO2019224496A1 (en) * | 2018-05-24 | 2019-11-28 | Safran Aircraft Engines | Fabric comprising aramid fibres for protecting a blade against impacts |
FR3081496A1 (en) * | 2018-05-24 | 2019-11-29 | Safran Aircraft Engines | FABRIC COMPRISING ARAMID FIBERS FOR PROTECTING A DAWN FROM IMPACTS |
FR3081914A1 (en) * | 2018-06-05 | 2019-12-06 | Safran Aircraft Engines | BLOWER BLADE IN COMPOSITE MATERIAL WITH LARGE INTEGRATED GAME |
EP3578760A1 (en) * | 2018-06-05 | 2019-12-11 | Safran Aircraft Engines | A composite material fan blade integrating large clearance |
US11732602B2 (en) | 2018-06-05 | 2023-08-22 | Safran Aircraft Engines | Composite material fan blade integrating large clearance |
FR3098544A1 (en) * | 2019-07-11 | 2021-01-15 | Safran Aircraft Engines | Blower blade |
WO2021005312A1 (en) * | 2019-07-11 | 2021-01-14 | Safran Aircraft Engines | Blower vane |
US11821333B2 (en) | 2019-07-11 | 2023-11-21 | Safran Aircraft Engines | Blower vane |
US20230081843A1 (en) * | 2020-02-18 | 2023-03-16 | Safran Aircraft Engines | Composite blade for a turbine engine rotor |
US11898464B2 (en) | 2021-04-16 | 2024-02-13 | General Electric Company | Airfoil for a gas turbine engine |
Also Published As
Publication number | Publication date |
---|---|
CA2888777A1 (en) | 2014-05-01 |
EP2917496A1 (en) | 2015-09-16 |
JP6179961B2 (en) | 2017-08-16 |
WO2014065968A1 (en) | 2014-05-01 |
JP2015537143A (en) | 2015-12-24 |
CN104981586A (en) | 2015-10-14 |
BR112015009060A2 (en) | 2017-07-04 |
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