U.S. patent application number 13/676793 was filed with the patent office on 2015-01-01 for aircraft engine component with locally tailored materials.
This patent application is currently assigned to United Technologies Corporation. The applicant listed for this patent is JinQuan Xu. Invention is credited to JinQuan Xu.
Application Number | 20150003995 13/676793 |
Document ID | / |
Family ID | 52115769 |
Filed Date | 2015-01-01 |
United States Patent
Application |
20150003995 |
Kind Code |
A1 |
Xu; JinQuan |
January 1, 2015 |
AIRCRAFT ENGINE COMPONENT WITH LOCALLY TAILORED MATERIALS
Abstract
A method for making a component according to one embodiment of
this disclosure includes modeling a response of the component to
operating conditions. The model is then mapped to materials that
would influence the response of the component to the operating
conditions. A component is then fabricated using the materials such
that the component includes a graded composition.
Inventors: |
Xu; JinQuan; (Groton,
CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Xu; JinQuan |
Groton |
CT |
US |
|
|
Assignee: |
United Technologies
Corporation
Hartford
CT
|
Family ID: |
52115769 |
Appl. No.: |
13/676793 |
Filed: |
November 14, 2012 |
Current U.S.
Class: |
416/241R ;
29/889.7 |
Current CPC
Class: |
B22F 2207/01 20130101;
Y02T 50/60 20130101; B22F 7/06 20130101; F01D 25/005 20130101; Y02P
10/25 20151101; B22F 5/04 20130101; F05D 2230/22 20130101; B22F
3/1055 20130101; Y02T 50/672 20130101; B22F 5/009 20130101; F01D
5/28 20130101; Y10T 29/49336 20150115; Y02P 10/295 20151101 |
Class at
Publication: |
416/241.R ;
29/889.7 |
International
Class: |
F01D 5/14 20060101
F01D005/14 |
Claims
1. A method for making a component, comprising: modeling a response
of a component to operating conditions; mapping the model to
materials that would influence the response of the component to the
operating conditions; and fabricating a component using the mapped
materials, the component provided with a graded composition.
2. The method as recited in claim 1, wherein the model provides a
response of the component at each of a plurality of regions of the
component.
3. The method as recited in claim 2, wherein each of the plurality
of regions of the component is mapped to a material that would
influence the response of the component to the operating
conditions.
4. The method as recited in claim 3, wherein the component is
fabricated such that each of the plurality of regions of the
component is fabricated using a respective one of the mapped
materials.
5. The method as recited in claim 1, wherein the component is an
airfoil of a gas turbine engine.
6. The method as recited in claim 1, wherein the component is
fabricated using an additive manufacturing process.
7. The method as recited in claim 1, wherein the component is
provided with a graded composition such that the component changes
in composition in at least one direction.
8. The method as recited in claim 1, wherein the model is the
result of a finite element analysis performed by a computing
device.
9. The method as recited in claim 1, wherein the model indicates a
thermal response of each of a plurality of regions of the component
relative to the operating conditions.
10. The method as recited in claim 9, wherein each of the plurality
of regions is mapped to a material that would influence the thermal
response of the component relative to the operating conditions.
11. The method as recited in claim 10, wherein a region modeled to
experience the highest temperature, relative to the remainder of
the plurality of regions, is mapped to a material having the lowest
thermal expansion coefficient, relative to the materials mapped to
the remainder of the plurality of regions.
12. The method as recited in claim 1, wherein the model indicates
stresses and strains experienced by each of a plurality of regions
of the component relative to the operating conditions.
13. The method as recited in claim 12, wherein each of the
plurality of regions is mapped to a material that would influence
the strength of the component relative to the operating
conditions.
14. The method as recited in claim 1, wherein the model indicates a
vibratory signature of each of a plurality of regions of the
component relative to the operating conditions.
15. The method as recited in claim 14, wherein each of the
plurality of regions is mapped to a material that would influence
the stiffness of the component relative to the operating
conditions.
16. A component, comprising: a composition graded according to a
modeled response of the component to operating conditions, the
composition including a plurality of materials that influence the
response of the component to the operating conditions.
17. The component as recited in claim 16, wherein the component is
an airfoil.
18. The component as recited in claim 16, wherein the plurality of
materials influences one of (1) a thermal response, (2) strength,
and (3) stiffness, of the component relative to the operating
conditions.
19. The component as recited in claim 16, wherein at least one of
the plurality of materials includes a different chemical
composition relative to at least one other of the plurality of
materials.
20. The component as recited in claim 16, wherein the composition
is graded such that the component changes in composition in at
least one direction.
Description
BACKGROUND
[0001] Aircraft components, such as the airfoils of the compressor
and turbine sections of a gas turbine engine, are exposed to high
temperatures and are subjected to large forces during operation of
the engine. These airfoils are typically made from a single
material, such as steel or nickel based alloys, that is selected to
withstand the expected engine operating conditions. In another
example, a component is formed in two halves, with each half being
made of a different material. The two halves are then welded
together to form a composite component.
SUMMARY
[0002] A method for making a component according to one embodiment
of this disclosure includes modeling a response of the component to
operating conditions. The model is then mapped to materials that
would influence the response of the component to the operating
conditions. A component is then fabricated using the materials such
that the component includes a graded composition.
[0003] In a further non-limiting embodiment of the present
disclosure, the model provides a response of the component at each
of a plurality of regions of the component.
[0004] In a further non-limiting embodiment of the present
disclosure, each of the plurality of regions of the component is
mapped to a material that would influence the response of the
component to the operating conditions.
[0005] In a further non-limiting embodiment of the present
disclosure, the component is fabricated such that each of the
plurality of regions of the component is fabricated using an
respective one of the mapped materials.
[0006] In a further non-limiting embodiment of the present
disclosure, the component is an airfoil of a gas turbine
engine.
[0007] In a further non-limiting embodiment of the present
disclosure, the component is fabricated using an additive
manufacturing process.
[0008] In a further non-limiting embodiment of the present
disclosure, the component is provided with a graded composition
such that the component changes in composition in at least one
direction.
[0009] In a further non-limiting embodiment of the present
disclosure, the model is the result of a finite element analysis
performed by a computing device.
[0010] In a further non-limiting embodiment of the present
disclosure, the model indicates a thermal response of each of a
plurality of regions of the component relative to the operating
conditions.
[0011] In a further non-limiting embodiment of the present
disclosure, each of the plurality of regions is mapped to a
material that would influence the thermal response of the component
relative to the operating conditions.
[0012] In a further non-limiting embodiment of the present
disclosure, a region modeled to experience the highest temperature,
relative to the remainder of the plurality of regions, is mapped to
a material having the lowest thermal expansion coefficient,
relative to the materials mapped to the remainder of the plurality
of regions.
[0013] In a further non-limiting embodiment of the present
disclosure, the model indicates stresses and strains experienced by
each of a plurality of regions of the component relative to the
operating conditions.
[0014] In a further non-limiting embodiment of the present
disclosure, each of the plurality of regions is mapped to a
material that would influence the strength of the component
relative to the operating conditions.
[0015] In a further non-limiting embodiment of the present
disclosure, the model indicates a vibratory signature of each of a
plurality of regions of the component relative to the operating
conditions.
[0016] In a further non-limiting embodiment of the present
disclosure, each of the plurality of regions is mapped to a
material that would influence the stiffness of the component
relative to the operating conditions.
[0017] A component according to one non-limiting embodiment of this
disclosure includes a composition graded according to a modeled
response of the component to operating conditions. The composition
includes a plurality of materials that influence the response of
the component to the operating conditions.
[0018] In a further non-limiting embodiment of the present
disclosure, the component is an airfoil.
[0019] In a further non-limiting embodiment of the present
disclosure, the plurality of materials influences one of (1) a
thermal response, (2) strength, and (3) stiffness, of the component
relative to the operating conditions.
[0020] In a further non-limiting embodiment of the present
disclosure, at least one of the plurality of materials includes a
different chemical composition relative to at least one other of
the plurality of materials.
[0021] In a further non-limiting embodiment of the present
disclosure, the composition is graded such that the component
changes in composition in at least one direction.
[0022] These and other features of the present disclosure can be
best understood from the following drawings and detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The drawings can be briefly described as follows:
[0024] FIG. 1 schematically illustrates a method according to one
embodiment of this disclosure.
[0025] FIG. 2 illustrates an example modeled response of an
aircraft component to operating conditions.
[0026] FIG. 3 illustrates an example process for forming an
aircraft component.
[0027] FIG. 4 schematically illustrates an example additive
manufacturing machine.
DETAILED DESCRIPTION
[0028] FIG. 1 illustrates an example method 10 for making an
aircraft component, such as a component for a gas turbine engine of
the aircraft. The method 10 includes modeling a response of an
aircraft component to operating conditions, at 12. The response
includes, but is not limited to, at least one of a thermal
response, a vibratory response, and a stresses-and-strains response
of the component to operating conditions. The model generated at 12
is then mapped, at 14, to materials that would influence the
response of the aircraft component to the operating conditions. At
16, an aircraft component is fabricated with a graded composition
corresponding to the mapped materials.
[0029] FIG. 2 illustrates an example of a modeled response of an
aircraft component, here illustrated as an airfoil 18, to operating
conditions. In this example, the airfoil 18 is an airfoil of the
compressor or the turbine section of a gas turbine engine. While an
airfoil 18 is illustrated, it should be understood that this
disclosure is not limited to airfoils, and extends to other types
of aircraft components, such as fan blades, stator vanes, and blade
outer air seals (BOAS), as well as other components found within a
gas turbine engine. While gas turbine engine components for an
aircraft are specifically contemplated by this disclosure, this
disclosure extends to components for other applications, including
components used with industrial gas turbines, marine power plants
and other portions of an aircraft (such as actuators and flaps for
wings, etc.). This disclosure further extends to components for
wind turbines.
[0030] With continued reference to FIG. 2, the airfoil 18 is
exposed to a flow 20 during operating conditions. In the example,
the flow 20 includes a core flow of the gas turbine engine. The
operating conditions can further include rotations per minute (RPM)
of the airfoil 18, and other such conditions that the airfoil 18
would be subjected to during operation. The operating conditions
used to generate the model, at 12, can include expected operating
conditions, actual operating conditions, and any other type of
condition (such as a redline or failure condition) desired to be
modeled. In other examples, where the aircraft component is not an
airfoil, the operating conditions include the conditions
experienced by such a component during operation of the associated
gas turbine engine.
[0031] In FIG. 2, the model of the response of the airfoil 18 to
the flow 20 is a thermal model, representing the temperatures the
airfoil 18 is subjected to during operating conditions. In this
example, the model generates a plurality of regions 22a-22f. Each
of the regions 22a-22f corresponds to a temperature range
experienced by a particular portion of the airfoil 18 during
operating conditions. In another example, the model includes a
model of the stresses and strains experienced by the airfoil 18
during the operating conditions. In yet another example, the model
includes a vibratory signature of the airfoil during the operating
conditions.
[0032] Based on the model, materials are mapped to the regions
22a-22f that would influence the response of the airfoil 18 to the
operating conditions. For example, in FIG. 2, the model indicates
that region 22a, which generally corresponds to the leading edge of
the airfoil 18, experiences the highest temperatures during
operating conditions. Accordingly, the region 22a is mapped to a
material having a low thermal expansion coefficient relative to the
remaining regions 22b-22f, for example.
[0033] Materials, such as steels, with low thermal expansion
coefficients are known to be relatively expensive, and therefore it
is not cost effective to make the entire airfoil 18 out of such a
material. Instead, according to an example method 10 of this
disclosure, the relatively cool regions 22b-22f of the airfoil 18
can be mapped to materials having relatively high thermal expansion
coefficients when compared to region 22a.
[0034] For example, the model generated at 12 indicates that region
22b experiences a lower temperature than region 22a during
operating conditions, and thus is mapped to a material having a
relatively higher thermal expansion coefficient than the material
mapped to region 22a. Similarly, region 22c experiences a lower
temperature than region 22b and is thus mapped to a material having
a relatively higher thermal expansion coefficient, and so on for
the remaining regions. Each region 22a-22f may be mapped to a
unique material relative to the remaining regions. In another
example, certain regions, such as regions 22b and 22f, may be
modeled to experience substantially the same temperature and are
thus mapped to the same material.
[0035] As used herein, reference to "different" materials mapped to
each of the regions 22a-22f should be understood to include
materials having different chemical compositions. For example, the
materials mapped to regions 22a and 22b could both be steel or
alloys, although they can have different chemical compositions.
Further, while steel is mentioned herein, this application is not
limited to steel. Instead, other materials, such as other metals,
plastics, or ceramics, can be used herein.
[0036] In examples where the model does not model temperature, but
models some other response of the aircraft component to the
operating conditions, the materials mapped to the regions in the
model can be selected to influence the aircraft component in some
other appropriate manner. For example, when the stresses and
strains of the aircraft component are modeled, the model is mapped
to materials that would influence the strength of the aircraft
component. In this case, the result of the model may indicate that
denser materials may be needed near the axis of rotation of the
aircraft component Likewise, when a vibratory signature is modeled,
the model is mapped to materials that would influence the stiffness
of the aircraft component.
[0037] In a further example of this disclosure, the modeled
response is performed, at 12, using a computing device. The
computing device in this example is a known type of computer
including hardware, such as a hard drive and a processor, and is
capable of running software. The software in one example is a
finite element analysis (FEA) program capable of modeling a
response of a particular component to certain input conditions,
which here would be the operating conditions of the engine
(including exposure of the airfoil 18 to the flow 20). The step of
mapping materials, at 14, is further performed by the computing
device in this example. To perform this step, the computing device
includes, or has access to, a database of materials and is
configured to select certain materials based on cost and
performance constraints, or other constraints.
[0038] In still a further example of this disclosure, a plurality
of different models (e.g., a first model could indicate a thermal
response, and a second model could indicate the vibratory
signature) could be considered when mapping the materials to
specific regions. For example, the aircraft component 18 could be
modeled such that region 22a experiences a relatively high
temperature and relatively low vibration, compared to the remainder
of the airfoil 18, during operating conditions. Thus, the region
22a would be mapped to a material exhibiting a low thermal
coefficient and a low stiffness relative to the remainder of the
airfoil. Additionally, a weighting system could be used when
mapping materials to the particular regions of the component, if
desired, to account for relative importance of the particular
models.
[0039] Accordingly, this method can be used to provide an aircraft
component with locally tailored materials such that the materials
are provided in regions where they are most needed, thus using
these materials in a cost effective manner.
[0040] Once the materials are mapped to the regions generated using
the model, at 14, the aircraft component is fabricated with a
graded composition corresponding to the mapped materials. One
method specifically contemplated by this disclosure includes
additive manufacturing, although other fabricating methods may be
used. Additive manufacturing techniques enable one to fabricate a
single component out of a plurality of different materials, and can
be used to provide the component with a graded composition. Graded
components change in composition in a particular direction, for
example in the direction of the length or width of the
component.
[0041] An example additive manufacturing process 24 is illustrated
in FIG. 3. In the example process 24, powdered metal 26 used for
forming the aircraft component is provided within a machine 28.
With reference to the computer aided drafting (CAD) data 30, which
the aircraft component is produced at 32, by building up layers of
fused powdered metal. As the machine 28 builds the aircraft
component, the machine 28 can be provided with different materials,
to correspond to the mapped materials from 14. In this example, the
CAD data 30 represents a particular component design, and includes
instructions for adding a particular material into the machine 28
at a particular stage in the machining process.
[0042] FIG. 4 schematically illustrates an example additive
manufacturing machine 28. In the example, a powdered metal 26 is
provided on a bed 34 and is fused by an additive manufacturing
process. As illustrated, the additive manufacturing process is an
energy beam fusing process, including an energy beam source 36
which generates an energy beam 38. The energy beam could be one of
an electron beam and a laser beam.
[0043] As mentioned above, the bed 34 can be provided with
different powdered metals 26, depending upon the material desired
for a particular region of the aircraft component. Multiple beds
may be alternatively used with each bed 34 for a different powdered
metal. In this respect, a desired metal powder is added, as
schematically shown at 40, to the bed 34. When that particular
metal is no longer needed, the excess powder 42 is removed from the
bed 34, as represented at 42, and a new powdered metal of a
different composition is added.
[0044] Again, while powdered metal is specifically mentioned
relative to the additive manufacturing process, this disclosure
extends to other types of materials, such as ceramics and
polymers.
[0045] Although the different examples have the specific components
shown in the illustrations, embodiments of this disclosure are not
limited to those particular combinations. It is possible to use
some of the components or features from one of the examples in
combination with features or components from another one of the
examples.
[0046] One of ordinary skill in this art would understand that the
above-described embodiments are exemplary and non-limiting. That
is, modifications of this disclosure would come within the scope of
the claims. Accordingly, the following claims should be studied to
determine their true scope and content.
* * * * *