A hybrid compressor blade having an airfoil portion and a root portion that includes an outer shell comprised of one or multiple types of material that are each located at a predesignated section on the compressor blade, having at least one transition region between two different sections. The trans
A hybrid compressor blade having an airfoil portion and a root portion that includes an outer shell comprised of one or multiple types of material that are each located at a predesignated section on the compressor blade, having at least one transition region between two different sections. The transition region is comprised of one or multiple layers with a compositional gradient based upon materials in the neighboring sections to provide a gradual transition from one section to another.
대표청구항▼
1. A gas turbine hybrid compressor blade comprising: an airfoil having a leading edge and a trailing edge that are connected by a pressure side surface and a suction side surface, and a root portion radially inward of the airfoil portion;an inner core within the airfoil, wherein the inner core is fo
1. A gas turbine hybrid compressor blade comprising: an airfoil having a leading edge and a trailing edge that are connected by a pressure side surface and a suction side surface, and a root portion radially inward of the airfoil portion;an inner core within the airfoil, wherein the inner core is formed of a first material;a transition zone covering the inner core;an outer shell covering the transition zone and surrounding the inner core, the outer shell includes the leading edge surface on a first section formed of a second material different from the first material, the trailing edge surface, the pressure side surface formed of a third material different from the second material, and the suction side surface of the airfoil; anda transition region in the outer shell between the first section and the second section of the outer shell, wherein the transition region is an amalgam of the second and third materials, andwherein the transition zone between the inner core and the outer shell has a first transition section aligned with the transition region of the outer shell, and the transition zone is an amalgam of the first, second and third materials. 2. The hybrid compressor blade of claim 1, wherein the transition region includes a first edge neighboring the first section and a second edge, opposite to the first edge, neighboring the second section. 3. The hybrid compressor blade of claim 2, wherein the transition zone has a second transition section aligned with the first section of the outer shell, and the second transition section is an amalgam of the first and second materials, but not the third material. 4. The hybrid compressor blade of claim 3, wherein the composition of the amalgam of the first and second materials in the second transition section varies with respect to the concentrations of the first material to the second material along a direction from the inner core to the outer shell. 5. The hybrid compressor blade of claim 2, wherein a center of the transition region has a ratio of 50% by weight or volume of the second material and 50% by weight or volume of the third material. 6. The hybrid compressor blade of claim 1, wherein the transition zone includes a first surface neighboring the inner core, and a second surface, opposite to the first surface, neighboring the outer shell. 7. The hybrid compressor blade of claim 6, wherein the composition of the transition zone gradually changes from a maximum of the first composition at the first surface to a minimum of the first composition at the second surface. 8. The hybrid compressor blade of claim 2, wherein the amount of the second material in the transition region varies from one edge of the transition region to an opposite edge of the transition region. 9. The hybrid compressor blade of claim 6, wherein the transition zone is comprised of multiple layers. 10. The hybrid compressor blade of claim 1, wherein the second material and the third material each includes at least one of a superalloy, iron based alloy, nickel based alloy, cobalt based alloy, an austenitic stainless steel, a martensitic stainless steel, a ferritic stainless steel, a carbon steel, an alloy steel, a titanium based alloy, an inter-metallic titanium alloy, and a combination thereof. 11. The hybrid compressor blade of claim 1, wherein first material is at least one of a superalloy, iron based alloy, nickel based alloy, cobalt based alloy, an austenitic stainless steel, a martensitic stainless steel, a ferritic stainless steel, a carbon steel, an alloy steel, a titanium based alloy, an inter-metallic titanium alloy, and a combination thereof. 12. A hybrid compressor blade, comprising: an airfoil having a leading edge and a trailing edge that are connected by a pressure side surface and a suction side surface, and a root portion radially inward of the airfoil portion;an inner core within the airfoil;a transition zone covering the inner core;an outer shell covering the transition zone and surrounding the inner core, the outer shell includes the leading edge surface, the trailing edge surface, pressure side surface and the suction side surface of the airfoil, and the outer shell includes sections each formed of different material; andat least one transition region included in the outer shell wherein the transition region is between the sections of the outer shell,wherein the sections and the transition regions extend along the radial length of the airfoil portion and the root portion of the compressor blade. 13. A method of manufacturing a compressor blade that includes an inner core and an outer shell having sections wherein each section is formed of a different type of material, the method comprising: defining locations for a first section of the outer shell, a second section of the outer shell and a transition region between the first and second sections of the outer shells;selecting a first outer shell material composition for the first outer shell section and a second outer shell material composition for the second outer shell section, wherein the second outer shell material composition differs from the first outer shell material compositionselecting an inner core material which differs from the first and second outer shell materials;forming the inner core from the inner core material using one of an Additive Manufacturing method, forging, and casting;forming a transition zone on a surface of the inner core by, using at least one of an Additive Manufacturing process, forging and casting, wherein the formation of the transition zone includes depositing an amalgam of the inner core material, the first outer shell material and the second outer shell material to form a region of the transition zone aligned with the transition region of the outer shell,forming the outer shell the at least one of an Additive Manufacturing process, forging and casting, wherein the formation of the outer shell includes depositing the first outer shell material composition to form the first section of the outer shell, depositing the second outer shell material composition to form the second section of the outer shell, and depositing an amalgam of the first and second outer shell materials to form the transition region of the outer shell. 14. The method of manufacturing of claim 13, wherein the Additive Manufacturing method includes Electron Beam Melting, Direct Metal Laser Melting, Direct Metal Laser Sintering, Laser Deposition, or a combination thereof. 15. The method of manufacturing of claim 13, wherein the materials for the outer shell sections are chosen from the group consisting of a superalloy, iron based alloy, nickel based alloy, cobalt based alloy, an austenitic stainless steel, a martensitic stainless steel, a ferritic stainless steel, a carbon steel, an alloy steel, a titanium based alloy, an inter-metallic titanium alloy, and a combination thereof. 16. The method of manufacturing of claim 13, wherein the inner core material is chosen from the group consisting of a superalloy, iron based alloy, nickel based alloy, cobalt based alloy, an austenitic stainless steel, a martensitic stainless steel, a ferritic stainless steel, a carbon steel, an alloy steel, a titanium based alloy, an inter-metallic titanium alloy, and a combination thereof. 17. The method of manufacturing of claim 13, wherein the compositional gradient in the transition region includes a non-linear combination of materials to create a gradient composition to transition from one section to another. 18. The method of manufacturing of claim 13, wherein the compositional gradient in the transition region creates a linear tapering of material from one section to another.
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