초록 ▼

A system for manufacturing an integrally bladed rotor is provided. This system includes a ring component, wherein the ring component further includes at least one metal matrix composite and a plurality of radially outwardly facing blade conical surfaces; an airfoil component, wherein the airfoil com

A system for manufacturing an integrally bladed rotor is provided. This system includes a ring component, wherein the ring component further includes at least one metal matrix composite and a plurality of radially outwardly facing blade conical surfaces; an airfoil component, wherein the airfoil component further includes: a plurality of individual airfoil blades, wherein each of the plurality of airfoil blades further includes a radially inwardly facing blade conical surface; and inertia welding means for frictionally engaging under an axially applied weld load the ring component and the airfoil component to effect an inertia weld therebetween along the conical surfaces.

대표청구항 ▼

What is claimed is: 1. A system for manufacturing an integrally bladed rotor, comprising: (a) a ring component, wherein the ring component further includes: (i) at least one metal matrix composite, wherein the metal matrix composite includes at least one reinforcing fiber, and wherein the reinforci

What is claimed is: 1. A system for manufacturing an integrally bladed rotor, comprising: (a) a ring component, wherein the ring component further includes: (i) at least one metal matrix composite, wherein the metal matrix composite includes at least one reinforcing fiber, and wherein the reinforcing fiber extends circumferentially in the direction of rotor rotation, and the circumferentially oriented fiber includes a stack of multiple fiber layers oriented in a radial manner within the ring; (ii) a plurality of radially outwardly facing blade conical surfaces or a continuous outwardly facing conical surface; and iii) a build-up region, wherein the build-up region is located along the plurality of radially outwardly facing blade conical surfaces or the continuous outwardly facing conical surface of the outer diameter of the ring component; (b) an airfoil component, wherein the airfoil component further includes: (i) a plurality of individual airfoil blades; (ii) wherein each of the plurality of airfoil blades further includes a radially inwardly facing blade conical surface; and (c) inertia welding means for frictionally engaging under an axially applied weld load the ring component and the airfoil component to effect an inertia weld therebetween along the build-up region of the ring component and the inwardly facing blade conical surface of the airfoil component. 2. The system of claim 1, wherein the circumferentially oriented fiber is a single, continuous, fiber tow. 3. The system of claim 2, wherein the fiber layers include nano-size whisker fibers arranged randomly, circumferentially, or in layers. 4. The system of claim 1, wherein prior to application of the inertia welding means, each of the individual airfoil blades is machined to a predetermined shape for forming a complete circle around the ring component following the welding of the airfoil component to the ring component. 5. The system of claim 1, wherein following the welding of the airfoil component to the ring component, a quantity of material around the base of each airfoil blade is removed to a diameter smaller than the weld diameter between each conical surface. 6. The system of claim 1, wherein the angle of each conical surface is about 10° -75° relative to the rotor's centerline of rotation. 7. The system of claim 1 wherein the reinforcing fiber is selected from SCS6 or other ceramic or non-metallic material having a carbon coating around the fiber outer surface. 8. The system of claim 7 wherein the coated fiber is mixed with a wet metal alloy slurry, wherein the wet metal alloy slurry comprises a Ti-alloy, a Ni-alloy, a Al-alloy, and other powder metals with adhesive binder. 9. The system of claim 1 wherein the build-up region is at least 1.27 centimeters (0.5 inches) in height. 10. An integrally bladed rotor, comprising: (a) a ring component, wherein the ring component further includes: (i) at least one metal matrix composite, wherein the metal matrix composite includes at least one reinforcing fiber, and wherein the reinforcing fiber extends circumferentially in the direction of rotor rotation, and the circumferentially oriented fiber includes a stack of multiple fiber layers oriented in a radial manner within the ring; (ii) a plurality of radially outwardly facing blade conical surfaces or a continuous outwardly facing conical surface; and (iii) a build-up region, wherein the build-up region is located along the plurality of radially outwardly facing blade conical surfaces or the continuous outwardly facing conical surface of the outer diameter of the ring component; (b) an airfoil component, wherein the airfoil component further includes: (i) a plurality of individual airfoil blades; (ii) wherein each of the plurality of airfoil blades further includes a radially inwardly facing blade conical surface; and (c) inertia welding means for frictionally engaging under an axially applied weld load the ring component and the airfoil component to effect an inertia weld therebetween along the build-up region of the ring component and the inwardly facing blade conical surface of the airfoil component. 11. The rotor of claim 10, wherein the circumferentially oriented fiber is a single, continuous, fiber tow. 12. The rotor of claim 11, wherein the fiber layers include nano-size whisker fibers arranged randomly, circumferentially, or in layers. 13. The rotor of claim 10, wherein prior to application of the inertia welding means, each of the individual airfoil blades is machined to a predetermined shape for forming a complete circle around the ring component following the welding of the airfoil component to the ring component. 14. The rotor of claim 10, wherein following the welding of the airfoil component to the ring component, a quantity of material around the base of each airfoil blade is removed to a diameter smaller than the weld diameter between each conical surface. 15. The rotor of claim 10, wherein the angle of each conical surface is about 10° -75° relative to the rotor's centerline of rotation. 16. A method for manufacturing an integrally bladed rotor, comprising: (a) providing a ring component, wherein the ring component further includes: (i) at least one metal matrix composite, wherein the metal matrix composite includes at least one reinforcing fiber, and wherein the reinforcing fiber extends circumferentially in the direction of rotor rotation, and the circumferentially oriented fiber includes a stack of multiple fiber layers oriented in a radial manner within the ring; (ii) a plurality of radially outwardly facing blade conical surfaces or a continuous outwardly facing conical surface; and (iii) a build-up region, wherein the build-up region is located along the plurality of radially outwardly facing blade conical surfaces or the continuous outwardly facing conical surface of the outer diameter of the ring component; (b) providing an airfoil component, wherein the airfoil component further includes: a plurality of individual airfoil blades, wherein each of the plurality of airfoil blades further includes a radially inwardly facing blade conical surface; and (c) using inertia welding means for frictionally engaging under an axially applied weld load the ring component and the airfoil component to effect an inertia weld therebetween along the build-up region of the ring component and the inwardly facing blade conical surface of the airfoil component. 17. The method of claim 16, further comprising forming each of the individual airfoil blades into a predetermined shape prior to the application of the inertia welding means so that the airfoil blades will form a complete circle around the ring component following the welding of the airfoil component to the ring component. 18. The method of claim 16, further comprising removing a quantity of material around the base of each airfoil blade following the welding of the airfoil component to the ring component to a diameter smaller than the weld diameter between each conical surface. 19. The method of claim 16, further comprising subjecting the assembled integrally bladed rotor to heat treatment sufficient for relieving internal stresses generated by inertia welding. 20. The method of claim 16, wherein the circumferentially oriented fiber further comprises at least one of a single, continuous, fiber tow and a group of randomly arranged nano-size whisker fibers. 21. The method of claim 16, wherein the fiber layers include nano-size whisker fibers arranged randomly, circumferentially, or in layers. 22. The method of claim 16, wherein the angle of each conical surface is about 10° -75° relative to the rotor's centerline of rotation. 23. The method of claim 16, wherein the build-up region is created by plasma spray of a powdered metal along the outer diameter of the fiber-reinforced ring or by stacking a plurality of metal foils on the outer diameter of the fiber-reinforced ring.