Patent Description:
Gas turbine engines can include a fan for propulsion air and to cool components. The fan also delivers air into a core engine where it is compressed. The compressed air is then delivered into a combustion section, where it is mixed with fuel and ignited. The combustion gas expands downstream over and drives turbine blades. Static vanes are positioned adjacent to the turbine blades to control the flow of the products of combustion.

Some fans include hollow fan blades made of a metallic or composite material. The fan blade may be formed between a set of dies at an elevated temperature.

An example of forming gas turbine engine components is described in <CIT>. In that document, a press device which can cool a metal mold is described. That device includes a pump which is connected to first and second annular cooling bodies. Each of the cooling bodies has a flow passage therein. The pump is used for circulating water through the flow passages to cause heat exchange between the water and the metal mold. The press device also comprises a control board <NUM> which is so configured as to output an operation signal to the pump thereby controlling circulation of water in the flow passages.

In a first aspect of the present invention there is provided a mounting plate for forming a gas turbine engine component comprising a plate body defining an abutment dimensioned to mate with a forming die. The plate body defines at least one internal cooling circuit. The at least one internal cooling circuit includes a passageway having an intermediate portion interconnecting inlet and outlet portions. The intermediate portion is dimensioned to follow a perimeter of the abutment. The intermediate portion includes a plurality of fins extending partially from a first sidewall towards a second sidewall opposed to the first sidewall. The at least one internal cooling circuit includes a first circuit and a second circuit fluidly isolated from the first circuit within the plate body, and the intermediate portion of the first circuit and the intermediate portion of the second circuit are defined on opposed sides of the abutment.

In an embodiment of the above embodiment, the plurality of fins are integrally formed with the plate body, and each fin of the plurality of fins extends at least a majority of a distance between the first and second sidewalls.

In an embodiment of any of the above embodiments, the plurality of fins are uniformly distributed along the first sidewall such that the intermediate portion has a substantially constant cross-sectional area.

In an embodiment of any of the above embodiments, the plurality of fins are substantially parallel to each other.

In an embodiment of any of the above embodiments, a cross-sectional geometry of the inlet and outlet portions differs from a cross-sectional geometry of the intermediate portion.

In an embodiment of any of the above embodiments, the inlet and outlet portions have an elliptical cross-sectional geometry.

In an embodiment of any of the above embodiments, the passageway includes first and second transition sections that respectively taper inwardly from the intermediate portion to the inlet and outlet portions.

In an embodiment of any of the above embodiments, the plurality of fins of the first circuit extend in a first direction away from the abutment, and the plurality of fins of the second circuit extend in a second, opposed direction away from the abutment.

In an embodiment of any of the above embodiments, the plate body extends between top and bottom surfaces. The top surface defines the abutment, and the intermediate portion is spaced apart from the abutment for at least a majority of positions along the intermediate portion such that the plate body defines a direct load path between the abutment and the bottom surface.

In an embodiment of any of the above embodiments, the plate body extends between top and bottom surfaces, and the plate body defines at least one recess extending inwardly from at least one of the top and bottom surfaces.

In an embodiment of any of the above embodiments, the at least one recess extends inwardly from an opening along the top surface. The opening is surrounded by the abutment.

In a second aspect of the present invention there is provided a die assembly for forming a gas turbine engine component comprising a support that has a pair of structural plates coupled to a base, a pair of forming dies dimensioned with respect to a predefined contour of a gas turbine engine component, and a pair of mounting plates. Each mounting plate includes a plate body defining an abutment dimensioned to mate with a forming die. The plate body defines at least one internal cooling circuit. The at least one internal cooling circuit includes a passageway having an intermediate portion interconnecting inlet and outlet portions. The intermediate portion is dimensioned to follow a perimeter of the abutment. The intermediate portion includes a plurality of fins extending partially from a first sidewall towards a second sidewall opposed to the first sidewall. The at least one internal cooling circuit includes a first circuit and a second circuit fluidly isolated from the first circuit within the plate body, and the intermediate portion of the first circuit and the intermediate portion of the second circuit are defined on opposed sides of the abutment. Each mounting plate is mechanically attached to respective ones of the pair of forming dies along respective abutments such that the pair of forming dies oppose each other and such that the pair of forming dies are spaced apart from the pair of structural plates. Each one of the pair of mounting plates has a plate body defining at least one internal cooling circuit. The at least one internal cooling circuit has a passageway that follows a perimeter of a respective one of the abutments, and a plurality of fins extend across the passageway.

In an embodiment of any of the above embodiment, the at least one internal cooling circuit includes inlet and outlet portions dimensioned to fluidly couple the passageway to a coolant source. A pair of actuators move respective ones of the pair of mounting plates relative to the base. A pair of heating elements each are coupled to a respective one of the pair of forming dies.

In an embodiment of any of the above embodiments, the pair of forming dies are made of a first material, and the pair of mounting plates are made of a second material that differs from the first material.

In a third aspect of the present invention there is provided a method of forming a gas turbine engine component comprising mounting a forming die to a mounting plate along an abutment, the mounting plate having a plate body defining the abutment and at least one internal cooling circuit, the at least one cooling circuit having a passageway that follows a perimeter of the abutment, and a plurality of fins extend across the passageway, heating the forming die to a predetermined temperature threshold, moving the forming die toward an adjacent forming die to deform a gas turbine engine component with respect to a predefined contour, and communicating fluid to the passageway to decrease a temperature of the mounting plate. The at least one internal cooling circuit has a first circuit and a second circuit fluidly isolated from the first circuit within the plate body. The plurality of fins of the first and second circuits arranged on opposed sides of the abutment.

In an embodiment of the above embodiment, the communicating step occurs during the heating step.

In an embodiment of any of the above embodiments, the step of moving the forming die includes moving an actuator to cause the mounting plate to move towards the gas turbine engine component.

In an embodiment of any of the above embodiments, the gas turbine engine component is an airfoil, and the moving step includes moving the forming die towards and into abutment with a pressure side or a suction side of the airfoil.

Although depicted as a two-spool turbofan gas turbine engine in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to use with two-spool turbofans as the teachings may be applied to other types of turbine engines including but not limited to three-spool architectures.

The low pressure turbine <NUM> pressure ratio is pressure measured prior to the inlet of low pressure turbine <NUM> as related to the pressure at the outlet of the low pressure turbine <NUM> prior to an exhaust nozzle. The geared architecture <NUM> may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about <NUM>: <NUM> and less than about <NUM>:<NUM>.

"Low corrected fan tip speed" is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tram °R) / (<NUM> °R)]<NUM> (where °R = K × <NUM>/<NUM>).

<FIG> illustrates a gas turbine engine component <NUM> according to an example. The component <NUM> can be incorporated in the gas turbine engine <NUM> of <FIG>, for example. In the illustrated example of <FIG>, the component <NUM> is an airfoil <NUM>. The airfoil <NUM> can be a fan blade 42A for the fan <NUM> of <FIG>, for example. Other types of airfoils, including blades, vanes and struts in the fan, compressor and turbine sections <NUM>, <NUM>, <NUM>, mid-turbine frame <NUM> and turbine exhaust case (TEC) <NUM> (<FIG>) may benefit from the examples disclosed herein which are not limited to the design shown. Other parts of the gas turbine engine <NUM> may benefit from the examples disclosed herein, including industrial turbines.

The airfoil <NUM> includes an airfoil section <NUM> extending in a spanwise or radial direction R from a root section <NUM>. The root section <NUM> is a shape that is configured to mount the fan blade 42A in the engine <NUM>, such as a dovetail shape. Generally, one side of the airfoil section <NUM> is a suction side SS and the other side is a pressure side PS (<FIG>) separated in a thickness direction T. The pressure side PS has a generally concave profile, and the suction side SS has a generally convex profile. The airfoil section <NUM> extends in the thickness direction T between the pressure and suction sides PS, SS to define an aerodynamic surface contour of the airfoil section <NUM>, as illustrated in <FIG>. The airfoil <NUM> is rotatable about an axis of rotation RR. The axis of rotation RR can be collinear or parallel to the engine axis A (<FIG>).

The airfoil section <NUM> includes a first skin or airfoil body <NUM> that extends in the radial direction R from the root section <NUM> to a tip portion <NUM> (<FIG>). The tip portion <NUM> is a terminal end of the airfoil <NUM>. The airfoil body <NUM> extends in a chordwise direction X between a leading edge LE and a trailing edge TE. The airfoil body <NUM> defines at least one of the pressure and suction sides PS, SS. In the illustrated example of <FIG> and <FIG>, the airfoil body <NUM> defines both the pressure and suction sides PS, SS.

The airfoil <NUM> includes a cover (or second) skin <NUM> disposed on a surface of the airfoil body <NUM> and is arranged to provide a continuous surface with the suction side SS of the airfoil <NUM>, as illustrated by <FIG>. In another example, the cover skin <NUM> is disposed on the pressure side PS of the airfoil <NUM>. The cover skin <NUM> is shown in an uninstalled position in <FIG> for illustrative purposes. The component <NUM> can include two or more cover skins along each of the pressure and/or suction sides PS, SS of the airfoil section <NUM>.

The airfoil body <NUM> and cover skin <NUM> can be made out of metallic materials such as titanium or aluminum. Other materials for the airfoil body <NUM> and cover skin <NUM> can be utilized, including metals or alloys and metal matrix composites.

Referring to <FIG> with continuing reference to <FIG>, the airfoil <NUM> includes at least one internal cavity <NUM> defined in the airfoil section <NUM>. In other examples, the internal cavities <NUM> are omitted such that the airfoil section <NUM> is substantially or completely solid. In the illustrative example of <FIG>, the airfoil body <NUM> includes one or more ribs <NUM> that define a plurality of internal cavities <NUM>. The airfoil <NUM> can include fewer or more than three internal cavities <NUM>, such as only one internal cavity <NUM>. Each internal cavity <NUM> can be defined having different dimensions, shapes and at other orientations than illustrated by <FIG> and <FIG>. The internal cavities <NUM> can substantially or completely free of any material such that the airfoil section <NUM> is hollow.

In the illustrated example of <FIG>, ribs 74A have a generally circular or otherwise elliptical geometry, ribs 74B have generally elongated, oblong or racetrack shaped geometry, and ribs 74C are generally linear or curvilinear. Ribs 74A, 74B and 74C have a thickness TA, TB and TC, respectively. In examples, thicknesses TA, TB are greater than or equal to about <NUM> inches (<NUM>) and less than or equal to about <NUM> inches (<NUM>), or more narrowly between <NUM> and <NUM> inches (<NUM> and <NUM>). Thickness TC can be greater than thicknesses TA, TB, such as between <NUM> and <NUM> inches (<NUM> and <NUM>), for example. Ribs 74A, 74B can be attached to the cover skin <NUM> utilizing any of the techniques disclosed herein, including laser or electron beam welding, brazing, diffusion bonding or other fastening techniques. At least some of the ribs <NUM> can be spaced apart from the cover skin <NUM> to define a gap GG when in an assembled position, as illustrated by rib 74C of <FIG>.

Walls <NUM> of the component <NUM> bound the internal cavities <NUM>. The walls <NUM> can be internal or external walls of the component <NUM>. The airfoil body <NUM> and cover skin <NUM> define one or more of the walls <NUM>. The cover skin <NUM> is attached to the airfoil body <NUM> to enclose or otherwise bound the internal cavities <NUM>, with the airfoil body <NUM> and cover skin <NUM> cooperating to define the pressure and suction sides PS, SS of the airfoil section <NUM>.

Referring to <FIG>, span positions of the airfoil section <NUM> are schematically illustrated from <NUM>% to <NUM>% in <NUM>% increments to define a plurality of sections <NUM>. Each section <NUM> at a given span position is provided by a conical cut that corresponds to the shape of segments a flowpath (e.g., bypass flowpath B or core flow path C of <FIG>), as shown by the large dashed lines. In the case of an airfoil <NUM> such as with an integral platform <NUM>, the <NUM>% span position corresponds to the radially innermost location where the airfoil section <NUM> meets the fillet joining the airfoil <NUM> to the platform <NUM> (see also <FIG> illustrating platform <NUM>). In the case of an airfoil <NUM> without an integral platform, the <NUM>% span position corresponds to the radially innermost location where the discrete platform <NUM> meets the exterior surface of the airfoil section <NUM>. A <NUM>% span position corresponds to a section of the airfoil section <NUM> at the tip portion <NUM>.

Referring to <FIG> with continuing reference to <FIG>, the airfoil section <NUM> is sectioned at a radial position between the root section <NUM> and tip portion <NUM>. In examples, each airfoil section <NUM> is specifically twisted about a spanwise axis in the radial direction R with a corresponding stagger angle α at each span position. Chord CD, which is a length between the leading and trailing edges LE, TE, forms stagger angle α relative to the chordwise direction X or a plane parallel to the axis or rotation RR. The stagger angle α can vary along the span of the airfoil section <NUM> to define a twist. For example, the tip portion <NUM> can define a stagger angle α relative to the root section <NUM> that is greater than or equal to <NUM> degrees or <NUM> degrees, absolute. In some examples, the stagger angle α at the tip portion <NUM> relative to the root section <NUM> is between <NUM>-<NUM> degrees, absolute, or more narrowly between <NUM>-<NUM> degrees, absolute, such that the airfoil section <NUM> is twisted about a spanwise axis as illustrated by the airfoil <NUM> of <FIG> and <FIG>. The airfoil section <NUM> can be three-dimensionally twisted about the spanwise axis.

<FIG> illustrates a process of constructing or forming a gas turbine engine component in a flow chart <NUM>. The process can be utilized to form the component <NUM> of <FIG> and <FIG>, including an airfoil <NUM> such as fan blade 42A, another hollow airfoil, or a solid airfoil, for example. In this disclosure, like reference numerals designate like elements where appropriate and reference numerals with the addition of one-hundred or multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding original elements. Reference is made to component <NUM> of <FIG> for illustrative purposes, which disclose exemplary conditions or states of the component <NUM> in the process <NUM>. In the illustrative example of <FIG>, the component <NUM> is a hollow airfoil <NUM> or fan blade including a metallic airfoil section <NUM>. The techniques disclosed herein can be utilized to form a new component or to repair a previously fielded component.

Referring to <FIG>, one or more portions of the component <NUM> can be prepared or otherwise provided at steps 176A-176E (shown in dashed lines). The component <NUM> includes a first skin or airfoil/main body <NUM> and a cover (or second) skin <NUM> that define one or more walls <NUM> of the component <NUM>.

At step 176A, airfoil body <NUM> is formed with respect to a predefined blade geometry, which can be defined with respect to one or more design criteria. The airfoil body <NUM> can be forged, cast, or produced by additive manufacturing from a metal or metal alloy, for example. At step 176B, internal and/or external surfaces of the airfoil body <NUM> are machined with respect to the predefined blade geometry. At step 176C, cover skin <NUM> is hot formed with respect to a predefined cover geometry. The cover skin <NUM> can be formed from sheet metal, for example. At step 176D, the cover skin <NUM> is chemically milled with respect to the predefined cover geometry. At step 176E, the cover skin <NUM> is cleaned to remove surface contaminants using a laser cleaning technique, for example.

One or more internal cavities <NUM> are formed in the airfoil body <NUM> and/or the cover skin <NUM> (internal cavities <NUM>' defined in cover skin <NUM> shown in dashed lines for illustrative purposes). Ribs <NUM> can be arranged to define various geometries of the internal cavities <NUM>, including any of the geometries of ribs <NUM> of <FIG>.

Various techniques can be utilized to form the internal cavities <NUM>, including casting, machining or additive manufacturing techniques. The internal cavities <NUM> can be defined in the airfoil body <NUM> and/or cover skin <NUM> during steps 176A-176C, for example. The cover skin <NUM> is dimensioned to enclose at least one, or more than one, internal cavity <NUM> in the airfoil body <NUM> when in an installed position.

At step 176F, cover skin <NUM>' is positioned relative to the airfoil body <NUM>. Cover skin <NUM>' is shown in dashed lines in <FIG> at a distance away from the airfoil body <NUM> for illustrative purposes. The positioning can include moving the cover skin <NUM>' in a direction DA and into abutment with ribs <NUM> of the airfoil body <NUM> to define a pre-finished state of the airfoil section <NUM>, as illustrated by cover skin <NUM>.

At step <NUM>, the cover skin <NUM> is attached to the airfoil body <NUM> to define the airfoil <NUM>. In examples, a perimeter P (see also <FIG>) of the cover skin <NUM> and/or locations of the cover skin <NUM> abutting the ribs <NUM> are attached to the airfoil body <NUM> to enclose or otherwise bound the internal cavities <NUM>. Various techniques can be utilized to attach the cover skin <NUM> to the airfoil body <NUM>, including laser or electron beam welding, brazing, diffusion bonding or other fastening techniques. The predefined blade and cover geometries can be set with respect to an expected distortion in the airfoil <NUM> caused by attachment of the airfoil body <NUM> and cover skin <NUM> during the attaching step <NUM>.

In examples, the airfoil body <NUM> extends from a root section to a tip portion (e.g., root section <NUM> and tip portion <NUM> of <FIG>) to define a stagger angle α (<FIG>) such that the airfoil body <NUM> is twisted. The stagger angle α of the airfoil section <NUM> can include any of the stagger angles α disclosed herein, such as being greater than or equal to <NUM> degrees, absolute, at the airfoil tip relative to the root section prior to attaching the cover skin <NUM> at step <NUM>.

Attaching the cover skin <NUM> can include trapping an inert gas in each internal cavity <NUM>. In the illustrated example of <FIG>, the component <NUM> can be situated in a controlled environment E (shown in dashed lines) prior to and during the attaching step <NUM>. A fluid source FS (shown in dashed lines) is operable to convey an amount of fluid F to the environment E. Example fluids F include inert gases such as argon or helium. The fluid F circulates in the environment E and is communicated to the internal cavities <NUM>. Attaching the cover skin <NUM> to the airfoil body <NUM> can cause an amount of the fluid F to be trapped in the internal cavities <NUM>. In other examples, fluid F is communicated to the internal cavities via passages in the root section (see, e.g., root section <NUM>, cavities <NUM> and fluid source FS of <FIG>). Walls of the ribs <NUM> can include one or more vent holes <NUM> (shown in dashed lines in <FIG>) at approximately mid-point within the rib <NUM>, for example, to permit equalization of pressure of the trapped inert gases between adjacent internal cavities <NUM> during attaching step <NUM>.

Referring to <FIG> and <FIG>, at step <NUM> at least one component <NUM> such as airfoil <NUM> is moved or otherwise positioned in a forming assembly or machine <NUM> subsequent to the attaching step <NUM>. The machine <NUM> includes a support <NUM> dimensioned to at least partially receive the component(s) <NUM>. The support <NUM> includes a base 179A and a pair of structural plates 179B fixedly attached or otherwise coupled to the base 179A. The base 179A is mounted to a static structure <NUM> (shown in dashed lines for illustrative purposes), which may be a factory floor, for example, utilizing one or more fasteners. The structural plates 179B have a generally rectangular geometry and extend substantially perpendicular to the base 179A such that the structural plates 179B oppose each other.

The machine <NUM> includes one or more pairs of forming dies (or die halves) <NUM>, <NUM> and one or more pairs of mounting plates <NUM>. The dies <NUM>, <NUM> include respective die surfaces DS (<FIG>, <FIG> and <FIG>) dimensioned with respect to a predefined contour of the component <NUM>. The die surfaces DS are dimensioned according to respective portions of the predefined contour. In examples, the die surfaces DS are contoured to respectively mate with pressure and suction sides PS, SS of the airfoil <NUM>, as illustrated by <FIG>.

The mounting plates <NUM> are mechanically attached to the respective dies <NUM>, <NUM> along respective interfaces <NUM> such that the dies <NUM>, <NUM> in each pair of oppose one another. In the illustrative example of <FIG>, each mounting plate <NUM> is mechanically attached to one of the dies <NUM>, <NUM>. In other examples, each mounting plate <NUM> is attached to more than one of the dies <NUM>, <NUM>. The mounting plates <NUM> are dimensioned to space apart the dies <NUM>, <NUM> from the structural plates 179B.

The support <NUM> can include gusseted supports or shelves 179C extending outwardly from the structural plates 179B. In the illustrative example of <FIG> and <FIG>, rollers <NUM> are fixedly attached to a bottom of each mounting plate <NUM> to support the mounting plate <NUM> on the shelf 179C. Each die <NUM>, <NUM> is movable in opposed directions D1, D2 between a first position and a second position (indicated by dashed lines at <NUM>'/<NUM>' in <FIG> for illustrative purposes) in response to movement of the mounting plate <NUM> relative to the respective shelf 179C.

Each airfoil <NUM> can be positioned in a support fixture <NUM> (shown in dashed lines for illustrative purposes). The support fixture <NUM> is moved in a direction FD to position the airfoil section <NUM> between respective a pair of the dies <NUM>, <NUM>.

The airfoil <NUM> can be positioned in a root upward orientation in the machine <NUM>, as illustrated by <FIG>. The airfoils <NUM> are suspended or otherwise supported by respective root sections <NUM> in the support fixture <NUM> generally residing above the machine <NUM> such that the airfoils <NUM> are oriented substantially vertically between the dies <NUM>, <NUM>. Tip portions <NUM> of the airfoils <NUM> are positioned downward or otherwise below respective root section <NUM>. Vertically orienting the airfoils <NUM> in a root upward orientation can reduce spanwise distortions such as buckling during heating and cooling of the airfoils <NUM>.

The machine <NUM> includes one or more actuators <NUM> (e.g., two pairs) each coupled to one of the mounting plates <NUM>. A housing of each actuator <NUM> is mounted to one of the structural plates 179B. The actuators <NUM> are operable to move the mounting plates <NUM> together with the dies <NUM>, <NUM> relative to the base 179A and structural plates 179B in response to signal(s) from a controller CONT (shown in dashed lines).

The dies <NUM>, <NUM> are moved in opposed directions D1, D2 (<FIG> and <FIG>) towards and into abutment with respective pressure and suction sides PS, SS of the airfoil <NUM> such that the component <NUM> is held between the dies <NUM>, <NUM>, as illustrated by <FIG>. The dies <NUM>, <NUM> are operable to heat the components <NUM> to a predefined or predetermined temperature threshold during holding the components <NUM> under compression by applying pressure from the actuators <NUM>. For example, the dies <NUM>, <NUM> can be heated to and continuously operated at a temperature of at least <NUM> degrees Fahrenheit (F) (<NUM> degrees Centigrade (C)), or more narrowly between approximately <NUM> and <NUM> degrees Fahrenheit (F) (<NUM> to <NUM> degrees Centigrade (C)). The dies <NUM>, <NUM> can be pre-heated prior to moving the dies <NUM>, <NUM> into contact with the component <NUM>.

<FIG> illustrates a backside of one of the dies <NUM>/<NUM> according to an example. One or more heating elements HE are coupled to the die <NUM>/<NUM>. Each heating element HE can positioned in a backside cavity of the die <NUM>/<NUM> to conductively heat the die <NUM>/<NUM>, as illustrated in <FIG>. Each die <NUM>/<NUM> can be made of metal or a metal alloy, such as a cast nickel alloy which can improve the ability of continuously operating the dies <NUM>, <NUM> at or above the predetermined temperature threshold.

A non-metallic heat conductive layer CL such as cloth can be situated between the heating elements HE and surfaces of the die <NUM>/<NUM> to reduce a likelihood of arcing. At least one coating CC can be deposited on surfaces of the die <NUM>/<NUM>. Example coatings include diffused aluminide which can provide oxidation protection.

Each heating element HE can be a heating coil that is coupled to an energy source ES (shown in dashed lines). The energy source ES can be a power supply operable to communicate electrical current to the heating element HE in response to controller CONT to heat the respective die <NUM>/<NUM> to the predetermined temperature threshold. The controller CONT can be coupled to at least one sensor SNS (shown in dashed lines), such as a thermocouple, to monitor surface temperatures of the respective die <NUM>/<NUM>. The controller CONT is operable to adjust the temperature of the die <NUM>/<NUM> to maintain or otherwise approach the predetermined temperature threshold. One would understand how to program or configure the controller CONT with logic to communicate with and control the actuators <NUM>, energy source ES and sensor(s) SNS according to the teachings disclosed herein.

The machine <NUM> is operable to cause the airfoil section <NUM> of each airfoil <NUM> to deform or resize between the dies <NUM>, <NUM>. Referring to <FIG>, <FIG> and <FIG>, at step 176I the component <NUM> undergoes permanent deformation to vary a geometry of the walls <NUM> of the airfoil body <NUM> and/or cover skin <NUM> (<FIG> and <FIG>). Subsequent to bringing the dies <NUM>, <NUM> into abutment with the component <NUM>, the dies <NUM>, <NUM> can be moved to exert a pressure on surfaces of the airfoil section <NUM> sufficient to cause a predetermined amount of deformation to occur.

Each airfoil section <NUM> is clamped or held in compression between the dies <NUM>, <NUM> approximately at or above the predetermined temperature threshold for a predetermined duration, such as approximately <NUM>-<NUM> minutes, to cause the airfoil section <NUM> to permanently deform between the dies <NUM>, <NUM> with respect to the predefined contour. The predetermined duration can be set to cause the airfoil section <NUM> to undergo creep deformation or hot sizing, to minimize or otherwise reduce the residual stresses in the component <NUM> that may be caused during the attaching step <NUM>, and to allow the walls <NUM> of the component <NUM> to conform to the surface profile defined by the die surfaces DS of the dies <NUM>, <NUM>.

In examples, the deformation of the airfoil section <NUM> can occur such that a change in the stagger angle α (see <FIG>) of the of airfoil <NUM> that is presented to the machine <NUM> is no more than approximately <NUM> or <NUM> degrees, absolute, at the tip portion relative to the root section. The deformation due to hot sizing the component <NUM> can be less than about <NUM> inches (<NUM>), for example. For the purposes of this disclosure, the terms "approximately" and "substantially" mean ±<NUM>% of the value unless otherwise disclosed.

The dies <NUM>, <NUM> can serve as "gas sizing" dies that are utilized to cause at least a portion of the component <NUM> to undergo deformation. Creep deformation, hot sizing and gas sizing are generally known. However, utilization of such techniques to form the components in situ as disclosed herein are not known. For example, heating of the fluid F trapped in the internal cavities <NUM> (<FIG>) of the component <NUM> during the attaching step <NUM> causes the internal cavities <NUM> to pressurize and the walls <NUM> of the airfoil section <NUM> to move outwardly or otherwise deform during the deforming step <NUM>. The techniques disclosed herein can be utilized to rapidly dimensionally correct the components <NUM> subsequent to welding or otherwise attaching the various portions of the components <NUM>.

The components <NUM> are unloaded or removed from the machine <NUM> subsequent to step <NUM>. One or more finishing steps can be performed subsequent to unloading or removing the components <NUM> from the machine <NUM>. For example, an interior inspection of the component <NUM> can occur at step 176J. One or more final machining operations of the component <NUM> can occur at step <NUM>. A final inspection of the component <NUM> can occur at step <NUM>.

As previously discussed, the dies <NUM>, <NUM> are subject to elevated temperatures during formation of the component <NUM>. The mounting plates <NUM> can provide a thermal path between the dies <NUM>, <NUM> and other portions of the machine <NUM>, including the actuators <NUM> and support <NUM>, which may otherwise need to be designed to withstand the elevated temperatures during operation.

<FIG> illustrate a mounting plate <NUM> for forming a gas turbine engine component according to an example. <FIG> illustrate a forming die <NUM>/<NUM> mechanically attached to the mounting plate <NUM>. The mounting plate <NUM> can be incorporated into the forming machine <NUM> of <FIG> and process <NUM> of <FIG>, for example. Reference is made to the machine <NUM> including dies <NUM>/<NUM> and process <NUM> for illustrative purposes. The mounting plate <NUM> includes one or more features that at least partially thermally isolate or reduce elevated temperatures from being communicated from the dies <NUM>, <NUM> to other portions of the machine <NUM>, which can reduce cost and complexity. The mounting plates <NUM> disclosed herein can be utilized to form gas turbine engine components, including any of the components disclosed herein. Other systems can benefit from the teachings disclosed herein, including systems that form components at elevated temperatures.

Referring to <FIG>, the mounting plate <NUM> includes a plate body 280A that extends between a top (or first) surface 280B and a bottom (or second) surface 280C (<FIG>) opposed to the top surface 280B. The plate body 280A extends between opposed sidewalls 280D (<FIG>). The plate body 280A defines an abutment 280E along the top surface 280B that cooperates with the die <NUM>/<NUM> to establish an interface <NUM> (<FIG>). The abutment 280E is dimensioned to mate with, and have a complementary geometry with, outer wall <NUM> defining a perimeter or footprint of the die <NUM>/<NUM> along the interface <NUM>, as illustrated in <FIG> (see also <FIG>). The respective die <NUM>/<NUM> is mounted to the mounting plate <NUM> along the abutment 280E.

The die <NUM>/<NUM> can be mounted to the mounting plate <NUM> utilizing various techniques. In the illustrative example of <FIG>, fasteners <NUM> (one shown for illustrative purposes, see also <FIG>) are received in a respective throughbore <NUM> defined in the mounting block <NUM> and in a respective inner bore <NUM> defined in a protruding portion <NUM> (see also <FIG> and <FIG>) of the outer wall <NUM> of the die <NUM>/<NUM>. In other examples, the protruding portions <NUM> are omitted, and fasteners are received in a thickness of the outer wall <NUM>.

Various techniques can be utilized to attach the mounting plate <NUM> to the actuator <NUM> (<FIG>). In the illustrative example of <FIG>, the mounting plate <NUM> is mechanically attached to a moveable portion of the actuator <NUM>. The actuator <NUM> includes a translatable actuator rod 181A, locknut 181B and uniball rod end 181C. The actuator rod 181A is dimensioned to extend through an access hole or opening <NUM> in the structural plate 179B. A clevis <NUM> (also shown in dashed lines in <FIG> for illustrative purposes) is mechanically attached to the rod end 181C utilizing a fastener <NUM>. The clevis <NUM> is mechanically attached to the plate body 280A utilizing fastener(s) <NUM>.

Referring back to <FIG> and <FIG>, the bottom 280C of the mounting plate <NUM> can be dimensioned to abut or rest against the structural plate 179B (shown in dashed lines in <FIG> for illustrative purposes) prior to moving the mounting plate <NUM> towards the component to be formed. Heating the die <NUM>/<NUM> causes conductive heating of adjacent portions of the mounting plate <NUM> due to direct contact between the outer wall <NUM> of the die <NUM>/<NUM> and the top surface 280B of the mounting plate <NUM>.

The plate body 280A can define at least one recess 280F extending inwardly from at least one of the top and bottom surfaces 280B, 280C. In the illustrative example of <FIG>, the plate body 280A defines two recesses 280F (indicated at 280F-<NUM>, 280F-<NUM>) on opposed sides of the plate body 280A. Recess 280F-<NUM> extends inwardly from an opening along the top surface 280B, and recess 280F-<NUM> extends inwardly from an opening along the bottom surface 280C. Each opening of the recesses 280F can be surrounded by the abutment 280E or interface <NUM>, as illustrated by <FIG>. The recesses 280F reduce a mass of the mounting plate <NUM> and reduce direct contact between surfaces of the die <NUM>/<NUM> and mounting plate <NUM>, which can reduce communication of heat from the die <NUM>/<NUM> to other portions of the machine <NUM> (<FIG>), including the structural plate 179B and actuators <NUM>. The recesses 280F can be at least partially or completely filled with insulation material <NUM> such as a ceramic-based material, as illustrated by recess 280F-<NUM> of <FIG>, to further thermally isolate the die <NUM>/<NUM>.

In examples, each die <NUM>/<NUM> is made of a first material, and each mounting plate <NUM> is made of a second material, which can be the same or can differ from the first material. Example materials of the mounting plate <NUM> can include metals and alloys such as stainless steel and nickel-based alloys. The structural plate 179B can be made of a metal material such as steel, for example. Although the materials of the die <NUM>/<NUM>, mounting plate <NUM> and/or structural plate 179B can differ, the materials can be selected to match or otherwise reduce a difference in thermal expansion rates.

The mounting plate <NUM> defines a cooling scheme <NUM> to cool portions of the plate body 280A and surrounding structure. The cooling scheme <NUM> includes at least one internal cooling circuit <NUM> defined in a thickness of the plate body 280A. In the illustrative example of <FIG> and <FIG>, the cooling scheme <NUM> includes inner and outer (or first and second) circuits (indicated at <NUM>-<NUM>, <NUM>-<NUM>) fluidly isolated from each other within the plate body 280A.

Each cooling circuit <NUM> includes a passageway <NUM> in communication with a coolant (or fluid) source CS. The coolant source CS is operable to convey or communicate an amount of coolant or fluid F to each passageway <NUM> to cool or decrease a temperature of adj acent portions of the mounting plate <NUM> to a steady-state temperature or threshold. Example coolant or fluid F can include water or a water-based coolant with chemical additive(s) to increase conductivity, reduce mold and/or reduce corrosion. In examples, the coolant source CS is a recirculation system including a pump, one or more flexible conduits, and a chiller to reduce a temperature of the fluid F.

The coolant source CS can be coupled to controller CONT (shown in dashed lines in <FIG> for illustrative purposes). The controller CONT can be programmed with logic to cause the coolant source CS to modulate the flow of fluid F through each cooling circuit <NUM> based on one or more criterion, such as the predetermined temperature threshold and surface temperature of the respective die <NUM>/<NUM>. Communication of the fluid F to each passageway <NUM> can occur prior to, during and/or after heating the die <NUM>/<NUM> during the deforming step 176I (<FIG>).

The passageway <NUM> includes an inlet portion 289A, an outlet portion 289B and an intermediate portion 289C that interconnects the inlet and outlet portions 289A, 289B. The inlet and outlet portions 289A, 289B are dimensioned to fluidly couple the passageway <NUM> to the coolant source CS. The inlet and outlet portions 289A, 289B can extend from respective openings or ports along one of the sidewalls 280D of the mounting plate <NUM>, as illustrated by <FIG> and <FIG>. Each circuit <NUM> can be dimensioned to have a substantially constant cross-sectional area along a length of the respective passageway <NUM>.

In the illustrated example of <FIG>, each intermediate portion 289C is dimensioned to follow a perimeter of the abutment 280E. The intermediate portion 289C includes a plurality of bends 289CB to form a loop between the inlet and outlet portions 289A, 289B. Each intermediate portion 289C includes four bends 289CB, although fewer or more than four bends 289CB can be utilized in accordance with the teachings disclosed herein. For example, the intermediate portion 289C can be free of any bends such that the intermediate portion 289C is substantially straight between the inlet and outlet portions 289A, 289B. Each bend 289CB can define an angle of at least <NUM> degrees, such as approximately <NUM> degrees. Each intermediate portion 289C extends at least <NUM> degrees about a central axis CA of the mounting plate <NUM>, or more narrowly between <NUM> and <NUM> degrees about the central axis CA. The central axis CA extends through the top and bottom surfaces 280B, 280C and is defined relative to the sidewalls 280D of the mounting plate <NUM>.

The cooling scheme <NUM> is arranged in the plate body 280A such that the intermediate portions 289C of the inner and outer circuits <NUM>-<NUM>, <NUM>-<NUM> are arranged or defined on opposed sides of the abutment 280E, as illustrated in <FIG>. Each intermediate portion 289C is spaced apart from a center of the abutment 280E for at least a majority of positions along the intermediate portion 289C such that the plate body 280A provides or defines a direct, rigid load path LP (<FIG>) between the abutment 280E and the bottom 280C of the mounting plate <NUM>. As illustrated in <FIG>, the outer wall <NUM> of the die <NUM>/<NUM> defines a thickness or distance T1. The intermediate portions 289C of the cooling circuits <NUM> are spaced apart by a distance T2. The distances T1, T2 can be the same or can differ. In the illustrative example of <FIG>, the distance T2 is greater than or equal to the distance T1 to provide the load path LP. In examples, the distance T2 is no more than twice the distance T1.

The cooling circuits <NUM> are coupled to the coolant source CS such that fluid F circulates in the inner cooling circuit <NUM>-<NUM> in a direction DF1 and circulates in the outer cooling circuit <NUM>-<NUM> in a direction DF2 (<FIG>). The direction DF1 (e.g., clockwise) can be generally opposed to the direction DF2 (e.g., counterclockwise) about the central axis CA such that the cooling scheme <NUM> defines a counter-flow arrangement, as illustrated by <FIG>. In other examples, directions DF1, DF2 are generally the same about the central axis CA such that the cooling scheme <NUM> defines a co-flow arrangement.

A cross-sectional geometry of the inlet and outlet portions 289A, 289B can differ from a cross-sectional geometry of the intermediate portion 289C. In the illustrative example of <FIG>, the intermediate portion 289C has a generally rectangular geometry. In the illustrative example of <FIG>, each of the inlet and outlet portions 289A, 289B has a generally elliptical, circular cross-sectional geometry. However, it should be appreciated that other geometries can be utilized in accordance with the teachings disclosed herein.

A portion of the inner cooling circuit <NUM>-<NUM> can pass above or below a portion of the outer cooling circuit <NUM>-<NUM> at transition region <NUM>, as illustrated by <FIG> and <FIG>. Each passageway <NUM> can have a generally elliptical, non-circular geometry at the transition region <NUM> to provide clearance between the adjacent passageway <NUM>, as illustrated by the passageway <NUM> of outer circuit <NUM>-<NUM> in <FIG>, which can reduce an overall thickness of the plate body 280A.

Referring to <FIG> and <FIG>, each passageway <NUM> can include first and second transition sections 289D, 289E that interconnect the intermediate portion 289C and respective ones of the inlet and outlet portions 289A, 289B. The transition sections 289D, 289E can respectively taper inwardly from the intermediate portion 289C to the inlet and outlet portions 289B, 289C, as illustrated by <FIG>. The transition sections 289D, 289E are contoured to provide a relatively smooth transition to reduce turbulence of fluid F and hydraulic jumps in the passageway <NUM>. In the illustrative example of <FIG>, the transition sections 289D, 289E have a generally elliptical, non-circular geometry. The inlet and outlet portions 289A, 289B can have threading to couple the passageway <NUM> to respective conduits in communication with the coolant source CS.

Referring to <FIG>, with continuing reference to <FIG>, the intermediate portion 289C includes a plurality of elongated fins (or heat augmentation features) <NUM> that extend across the passageway <NUM>. The fins <NUM> are arranged to interact with fluid F in the passageway <NUM> to cool adjacent portions of the mounting plate <NUM>. The fins <NUM> extend partially from a first sidewall 280F towards a second sidewall <NUM> of the passageway <NUM> opposed to the first sidewall 280F. The fins <NUM> are dimensioned such that a terminal end of each fin <NUM> is spaced apart from the second sidewall <NUM>, and can be dimensioned such that each fin <NUM> extends at least a majority of a distance between the first and second sidewalls <NUM>, <NUM>, as illustrated by <FIG>.

The fins <NUM> can be dimensioned to provide approximately <NUM>-<NUM> times more surface area along the passageway <NUM> than a tubular or rectangular passageway lacking any fins. Circulation of fluid F across the fins <NUM> can reduce a steady-state temperature of the mounting plate <NUM> along the bottom surface 280C below <NUM> degrees Fahrenheit (F) (<NUM> degrees Centigrade (C)) or approximately ambient, for example.

The fins <NUM> can be arranged at various orientations. The fins <NUM> can be arranged substantially parallel to a general direction of flow of fluid F in the passageway <NUM>. The fins <NUM> can have a generally planar geometry and can be arranged substantially parallel to each other, as illustrated by <FIG>. The fins <NUM> can be uniformly distributed along the first sidewall 280F such that the intermediate portion 289C has a substantially constant cross-sectional area for at least a majority, or each, position along a length of the intermediate portion 289C, as illustrated by <FIG>. In the illustrative example of <FIG>, passage <NUM> includes a plurality of fins <NUM> arranged in a fanned array such that an angle β differs for at least some of the fins <NUM> relative to wall <NUM>. The angle β of each fin <NUM> can be between <NUM>-<NUM> degrees relative to the wall <NUM> with some of the fins <NUM> defining an increasing angle β, one of the intermediate fins <NUM> defining a perpendicular angle β, and other fins <NUM> defining a decreasing angle β, for example.

The fins <NUM> can be arranged at various orientations relative to the abutment 280E. In the illustrative example of <FIG>, the fins <NUM> of the inner circuit <NUM>-<NUM> extend in a third direction D3 away the abutment 280E, and the fins <NUM> of the outer circuit <NUM>-<NUM> extend in a fourth direction D4 away the abutment 280E such that the third direction D3 is opposed to the fourth direction D4. Arranging the fins <NUM> to extend in opposed directions can increase uniformity of cooling and can reduce thermal gradients and a likelihood of warpage of the mounting plate <NUM>. Arranging the fins <NUM> to extend in opposed directions can increase an amount of material between the cooling circuits <NUM>, which can provide a relatively wider load path LP through the mounting block <NUM>. In other examples, the fins <NUM> of the inner and outer circuits <NUM>-<NUM>, <NUM>-<NUM> generally face in the same direction and extend towards the abutment 280E.

Various techniques can be utilized to form the fins <NUM>. In examples, the mounting plate <NUM> has a unitary construction, and the fins <NUM> integrally formed with the plate body 280A utilizing a casting, machine or additive manufacturing technique. In other examples, the fins <NUM> are separate and distinct components mechanically attached to the plate body 280A. The cooling scheme <NUM> can be formed such that the circuits <NUM> are substantially free of sharp corners that may otherwise cause turbulent flow, and which can improve the ability to remove powder particles that are not consumed during formation of the cooling scheme <NUM> utilizing an additive manufacturing technique.

A coating <NUM> (shown in dashed lines in <FIG> for illustrative purposes) can be deposited on surfaces of the passageways <NUM> subsequent to formation of the cooling scheme <NUM>. Various techniques can be utilized to deposit the coating <NUM>, such as a gaseous process, an aluminum-based slurry process, or an electroless plating process to provide corrosion resistance and/or improve conductivity. In examples, the passageways <NUM> are electroless copper or nickel plated, which can improve conductivity.

Claim 1:
A mounting plate (<NUM>, <NUM>) for forming a gas turbine engine component (<NUM>) comprising:
a plate body (280A) defining an abutment (280E) dimensioned to mate with a forming die (<NUM>, <NUM>), and the plate body (280A) defining at least one internal cooling circuit (<NUM>); and
wherein the at least one internal cooling circuit (<NUM>) comprises:
a passageway (<NUM>) including an intermediate portion (289C) interconnecting inlet and outlet portions (289A, 289B), the intermediate portion (289C) dimensioned to follow a perimeter of the abutment (280E);
wherein the intermediate portion (289C) includes a plurality of fins (<NUM>) extending partially from a first sidewall (280F) towards a second sidewall (<NUM>) opposed to the first sidewall (280F);
characterised in that the at least one internal cooling circuit (<NUM>) includes a first circuit (<NUM>-<NUM>) and a second circuit (<NUM>-<NUM>) fluidly isolated from the first circuit (<NUM>-<NUM>) within the plate body (280A), and the intermediate portion (289C) of the first circuit (<NUM>-<NUM>) and the intermediate portion (289C) of the second circuit (<NUM>-<NUM>) are defined on opposed sides of the abutment (280E).