Patent ID: 12196106

DETAILED DESCRIPTION

Aspects and embodiments of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.

FIG.1illustrates a gas turbine engine10having a principal rotational axis9. The engine10comprises an air intake12and a propulsive fan23that generates two airflows: a core airflow A and a bypass airflow B. The gas turbine engine10comprises an engine core11that receives the core airflow A. The engine core11comprises, in axial flow series, a low pressure compressor14, a high pressure compressor15, combustion equipment16, a high pressure turbine17, a low pressure turbine19, and a core exhaust nozzle20. A nacelle21surrounds the gas turbine engine10and defines a bypass duct22and a bypass exhaust nozzle18. The bypass airflow B flows through the bypass duct22. The fan23is attached to and driven by the low pressure turbine19via a shaft26and an epicyclic gearbox30.

In use, the core airflow A is accelerated and compressed by the low pressure compressor14and directed into the high pressure compressor15where further compression takes place. The compressed air exhausted from the high pressure compressor15is directed into the combustion equipment16where it is mixed with fuel and the mixture is combusted. The resultant hot combustion products then expand through, and thereby drive, the high pressure and low pressure turbines17,19before being exhausted through the core exhaust nozzle20to provide some propulsive thrust. The high pressure turbine17drives the high pressure compressor15by a suitable interconnecting shaft27. The fan23generally provides the majority of the propulsive thrust. The epicyclic gearbox30is a reduction gearbox.

An exemplary arrangement for a geared fan gas turbine engine10is shown inFIG.2. The low pressure turbine19(seeFIG.1) drives the shaft26, which is coupled to a sun wheel, or a sun gear28of the epicyclic gearbox30. Radially outwardly of the sun gear28and intermeshing therewith is a plurality of planet gears32that are coupled together by a planet carrier34. The planet carrier34constrains the planet gears32to precess around the sun gear28in synchronicity whilst enabling each planet gear32to rotate about its own axis. The planet carrier34is coupled via linkages36to the fan23in order to drive its rotation about the principal rotational axis9. Radially outwardly of the planet gears32and intermeshing therewith is an annulus or ring gear38that is coupled, via linkages40, to a component100(a stationary supporting structure) of the gas turbine engine10.

In some embodiments, the component100is an engine section stator (ESS) vane or a core inlet stator vane. In some embodiments, the component100is provided at an inlet to the engine core11(shown inFIG.1) and rear of the fan23(shown inFIG.1). In some embodiments, the component100may guide the core airflow A entering the engine core11of the gas turbine engine10. In some embodiments, the gas turbine engine10includes multiple components100spaced circumferentially around the principal rotational axis9at the inlet to the engine core11of the gas turbine engine10.

Note that the terms “low pressure turbine” and “low pressure compressor” as used herein may be taken to mean the lowest pressure turbine stages and lowest pressure compressor stages (i.e., not including the fan23), respectively, and/or the turbine and compressor stages that are connected together by the interconnecting shaft26with the lowest rotational speed in the engine (i.e., not including the gearbox output shaft that drives the fan23). In some literature, the “low pressure turbine” and “low pressure compressor” referred to herein may alternatively be known as the “intermediate pressure turbine” and “intermediate pressure compressor”. Where such alternative nomenclature is used, the fan23may be referred to as a first, or lowest pressure, compression stage.

Accordingly, the present disclosure extends to a gas turbine engine having any arrangement of gearbox styles (for example, star or planetary), support structures, input and output shaft arrangement, and bearing locations. Optionally, the epicyclic gearbox30may drive additional and/or alternative components (e.g., the intermediate pressure compressor and/or a booster compressor).

Other gas turbine engines to which the present disclosure may be applied may have alternative configurations. For example, such engines may have an alternative number of compressors and/or turbines and/or an alternative number of interconnecting shafts. By way of further example, the gas turbine engine10shown inFIG.1has a split flow nozzle18,20meaning that the flow through the bypass duct22has its own nozzle18that is separate to and radially outside the core exhaust nozzle20. However, this is not limiting, and any aspect of the present disclosure may also apply to engines in which the flow through the bypass duct22and the flow through the engine core11are mixed, or combined, before (or upstream of) a single nozzle, which may be referred to as a mixed flow nozzle. One or both nozzles (whether mixed or split flow) may have a fixed or variable area. Whilst the described example relates to a turbofan engine, the disclosure may apply, for example, to any type of gas turbine engine, such as an open rotor (in which the fan stage is not surrounded by a nacelle), or turboprop engine, for example. In some arrangements, the gas turbine engine10may not comprise the epicyclic gearbox30.

The geometry of the gas turbine engine10, and components thereof, is defined by a conventional axis system, comprising an axial direction (which is aligned with the principal rotational axis9), a radial direction (in the bottom-to-top direction inFIG.1), and a circumferential direction (perpendicular to the page in theFIG.1view). The axial, radial and circumferential directions are mutually perpendicular.

FIG.3Ais a schematic side perspective view of the component100for the gas turbine engine10(shown inFIG.1). In some embodiments, the component100includes an aerofoil102including a radially inner end104, a radially outer end106, a leading edge108, and a trailing edge110. In some embodiments, the component100further includes an inner annulus wall112coupled to the radially inner end104of the aerofoil102and an outer annulus wall114coupled to the radially outer end106of the aerofoil102. The inner annulus walls112and the outer annulus walls114of multiple such components100may be arranged side by side around the principal rotational axis9(shown inFIGS.1and2) of the gas turbine engine10to form a ring (i.e., the engine section stator).

In some embodiments, the component100may be integrally manufactured using additive layer manufacturing (ALM), e.g., through electron beam melting. However, in alternative embodiments, any other manufacturing method may be utilized based on application requirements.

FIG.3Bis a schematic sectional view of the component100taken along a section line C-C′ shown inFIG.3A. Referring now toFIGS.3A and3B, the component100(or the aerofoil102) further includes a first wall116, a second wall118opposing the first wall116, and a fluid passageway120defined between the first wall116and the second wall118. In some embodiments, the fluid passageway120is configured to receive a fluid122(shown inFIG.3A) therein. For example, the fluid passageway120may be configured to receive gearbox and/or bearing chamber fluids, such as oil, air, etc.

The component100further includes at least one tie130disposed within the fluid passageway120. In the illustrated embodiment ofFIG.3B, the component100has multiple ties130. In some embodiments, the at least one tie130may provide vibration damping structural support to walls of the fluid passageway120, i.e., the first wall116and the second wall118. The term “at least one tie130” is interchangeably referred to hereinafter as the “tie130”. In some embodiments, the tie130is formed as a single unitary component by ALM. However, in alternative embodiments, any other manufacturing method may be utilized based on application requirements.

It should be understood that the component100may be any component of the gas turbine engine10(shown inFIG.1). For example, the gas turbine engine10may include the tie130disposed within other hollow components, e.g., pipes, ducts, vanes, etc., to support walls of such hollow components.

FIG.4is a schematic enlarged sectional view of a portion of the component100taken along the section line C-C′ shown inFIG.3A. In some embodiments, the tie130includes a body132defining a longitudinal axis X-X′ extending along its length L between the first wall116and the second wall118, a first longitudinal end134extending along the longitudinal axis X-X′, a second longitudinal end136opposing the first longitudinal end134and extending along the longitudinal axis X-X, a first transverse axis Y-Y′ perpendicular to the longitudinal axis X-X′ and extending between the first longitudinal end134and the second longitudinal end136, and a second transverse axis Z-Z′ perpendicular to each of the longitudinal axis X-X′ and the first transverse axis Y-Y′. In some embodiments, the fluid122(shown inFIG.3A) flows within the fluid passageway120in a flow direction F disposed along the second transverse axis Z-Z′ of the body132of the tie130.

The body132includes a first wide portion142fixedly coupled to the first wall116, a second wide portion144opposing the first wide portion142and fixedly coupled to the second wall118, and an elongate portion146extending between the first wide portion142and the second wide portion144along the longitudinal axis X-X′. The elongate portion146is disposed at the first longitudinal end134. In some embodiments, each of the first wide portion142and the second wide portion144tapers towards the elongate portion146. Thus, the first and second wide portions142,144may reduce flow disruption and pressure losses as the fluid122(shown inFIG.3A) flows through the fluid passageway120along the flow direction F. Reference numerals142and144are shown multiple times inFIG.4and subsequent Figures for the purpose of clarity.

In some embodiments, the first wide portion142, the second wide portion144, and the elongate portion146may be produced together with the component100through ALM. Thus, the first wide portion142may be integrally formed with the first wall116and the second wide portion144may be integrally formed with the second wall118.

The body132further includes an arch150disposed at the second longitudinal end136and adjacent to the elongate portion146. The arch150extends between the first wide portion142and the second wide portion144at least partially along the longitudinal axis X-X′. The arch150curves concavely towards the elongate portion146from each of the first wide portion142and the second wide portion144to an apex152of the arch150. In some embodiments, the arch150may be a gothic shaped arch.

In some embodiments, the arch150may ensure that the tie130is built correctly using ALM by supporting an overhanging material (i.e., the elongate portion146of the tie130) along a build direction BD of the tie130. Thus, the tie130of the present disclosure may not require use of additional support structures. Thus, the tie130of the present disclosure is suitably shaped such that the tie130is sufficiently supported to be printable using ALM.

FIG.5is a schematic perspective view of the tie130.FIGS.6A and6Bare schematic top and bottom sectional views of the tie130taken along a minimum cross-sectional plane140shown inFIG.4. Referring now toFIGS.4-6B, the arch150includes a pair of first outer curved surfaces154(shown inFIGS.5and6A) opposing each other and curving convexly from the first wide portion142at least partially along the second transverse axis Z-Z′. The arch150further includes a first middle surface156(shown inFIG.6A) extending between the pair of first outer curved surfaces154with respect to the second transverse axis Z-Z′. The first middle surface156includes a first minimum arch width158along the second transverse axis Z-Z′.

The arch150further includes a pair of second outer curved surfaces160(shown inFIGS.5and6B) opposing each other and curving convexly from the second wide portion144at least partially along the second transverse axis Z-Z′. The arch150further includes a second middle surface162(shown inFIG.6B) extending between the pair of second outer curved surfaces160with respect to the second transverse axis Z-Z′. The second middle surface162includes a second minimum arch width164along the second transverse axis Z-Z′. In some embodiments, each of the first middle surface156and the second middle surface162is at least piecewise planar. In some embodiments, the first minimum arch width158is equal to the second minimum arch width164.

The body132further defines the minimum cross-sectional plane140perpendicular to the longitudinal axis X-X′ and passing through the elongate portion146. In some embodiments, the minimum cross-sectional plane140forms a first plane of symmetry of the tie130. The apex152of the arch150lies within the minimum cross-sectional plane140. In some embodiments, a longitudinal plane138(shown inFIGS.4and5) orthogonal to the minimum cross-sectional plane140and containing the longitudinal axis X-X′ forms a second plane of symmetry of the tie130.

The body132further includes a minimum tie width148(shown inFIGS.6A and6B) at the minimum cross-sectional plane140along the second transverse axis Z-Z′. The minimum tie width148is greater than each of the first minimum arch width158and the second minimum arch width164by a width factor greater than or equal to 3 to less than or equal to 10. In some embodiments, the width factor is greater than or equal to 4, greater than or equal to 5, greater than or equal to 6, greater than or equal to 7, greater than or equal to 8, or greater than or equal to 9. In some embodiments, the width factor is equal to 6.

The tie130of the present disclosure may provide minimal flow disruption to the fluid122(shown inFIG.3A) received within the fluid passageway120since the width factor (i.e., a ratio of the minimum tie width148to the first minimum arch width158or the second minimum arch width164) is greater than or equal to 3 and less than or equal to 10. A larger value of the width factor may indicate that the portion of the tie130where the tie130has the largest cross-sectional area (i.e., the cross-sectional area of the tie130adjacent to the first and second middle surfaces156,162) may not extend as long in the flow direction F (shown inFIG.4) of the fluid122along the second transverse axis Z-Z′.

In some embodiments, the body132further includes a pair of first transition surfaces166(shown inFIGS.5and6A) extending from the first wide portion142towards the second wide portion144and disposed between the elongate portion146and respective opposing sides186of the arch150. In some embodiments, each of the pair of first transition surfaces166curves concavely from the elongate portion146to the respective opposing sides186of the arch150. In some embodiments, each of the pair of first transition surfaces166includes a first transition radius of curvature168(shown inFIG.5).

In some embodiments, the body132further includes a pair of second transition surfaces172(shown inFIGS.5and6B) extending from the second wide portion144towards the first wide portion142and disposed between the elongate portion146and the respective opposing sides186of the arch150. In some embodiments, each of the pair of second transition surfaces172curves concavely from the elongate portion146to the respective opposing sides186of the arch150. In some embodiments, each of the pair of second transition surfaces172includes a second transition radius of curvature174(shown inFIG.5). In some embodiments, the first transition radius of curvature168is equal to the second transition radius of curvature174.

In some embodiments, the body132further includes a minimum tie thickness170(shown inFIGS.6A and6B) at the minimum cross-sectional plane140along the first transverse axis Y-Y′. In some embodiments, the minimum tie thickness170is greater than each of the first transition radius of curvature168and the second transition radius of curvature174by a first thickness factor of greater than 1 and less than or equal to 3. In some embodiments, the first thickness factor is greater than 2 and less than or equal to 3. In some embodiments, the first thickness factor is equal to 2.67.

A lower value of the first thickness factor (i.e., a ratio of the minimum tie thickness170to the first transition radius of curvature168or the second transition radius of curvature174) may indicate a smoother transition of surfaces of the tie130along the flow direction F (shown inFIG.4) of the fluid122(shown inFIG.3A), thereby further reducing the fluid flow losses. In other words, the first thickness factor may indicate that edges of the tie130may be blended as smoothly as possible to minimise the flow disruption and the pressure losses.

In some embodiments, the arch150further includes a concave central surface176(shown inFIGS.6A and6B) extending between the first middle surface156(shown inFIG.6A) and the second middle surface162(shown inFIG.6B) and intersecting with the minimum cross-sectional plane140. In some embodiments, the arch150further includes a pair of first intermediate surfaces178(shown inFIGS.5and6A) disposed proximal to the first wide portion142. In some embodiments, each of the pair of first intermediate surfaces178extends between the concave central surface176and a corresponding first transition surface166from the pair of first transition surfaces166. In some embodiments, each of the pair of first intermediate surfaces178curves concavely from the corresponding first transition surface166to the concave central surface176. In some embodiments, each of the pair of first intermediate surfaces178incudes a first intermediate radius of curvature180(shown inFIG.5).

In some embodiments, the arch150further includes a pair of second intermediate surfaces182(shown inFIGS.5and6B) disposed proximal to the second wide portion144and spaced apart from the pair of first intermediate surfaces178. In some embodiments, each of the pair of second intermediate surfaces182extends between the concave central surface176and a corresponding second transition surface172from the pair of second transition surfaces172. In some embodiments, each of the pair of second intermediate surfaces182curves concavely from the corresponding second transition surface172to the concave central surface176. In some embodiments, each of the pair of second intermediate surfaces182includes a second intermediate radius of curvature184(shown inFIG.5). In some embodiments, the first intermediate radius of curvature180is equal to the second intermediate radius of curvature184.

It should be noted that the first and second transition radius of curvatures168,174are shown with a solid line since both the radius of curvatures are measured from outside the body132of the tie130while the first and second intermediate radius of curvatures180,184are shown with a dashed line since both the radius of curvatures are measured from inside the body132of the tie130.

In some embodiments, the minimum tie thickness170is greater than each of the first intermediate radius of curvature180and the second intermediate radius of curvature184by a second thickness factor of greater than 0.5 and less than or equal to 2. In some embodiments, the second thickness factor is equal to 1.6.

A lower value of the second thickness factor (i.e., a ratio of the minimum tie thickness170to the first intermediate radius of curvature180or the second intermediate radius of curvature184) may indicate a smoother transition of the surfaces of the tie130along the flow direction F (shown inFIG.4) of the fluid122(shown inFIG.3A), thereby further reducing the fluid flow losses. In other words, the second thickness factor may indicate that edges of the tie130may be blended as smoothly as possible to minimise the flow disruption and the pressure losses.

In some embodiments, a ratio between the minimum tie width148and the minimum tie thickness170is 3:2. This ratio between the minimum tie width148and the minimum tie thickness170may maximize a flow area within the fluid passageway120(shown inFIGS.3B and4) while allowing the tie130to be printed with an acceptable surface finish. The tie thickness itself is the primary factor in obtaining acceptable surface finish, the ratio between width and thickness is a secondary factor. Stress may become a limiting factor as the minimum tie thickness170is reduced. However, it should be understood that suitable dimensions for the tie130may be chosen based on application requirements.

In some embodiments, the elongate portion146curves concavely towards the arch150at the first longitudinal end134. In some embodiments, the body132further includes an oval cross-sectional shape at the minimum cross-sectional plane140. This may further reduce the flow disruption and the pressure losses associated with the fluid122(shown inFIG.3A) flowing though the fluid passageway120(shown inFIGS.3B and4).

FIG.7is a schematic left sectional perspective view of the tie130, according to another embodiment of the present disclosure. In the illustrated embodiment ofFIG.7, the body132further includes a tear-drop cross-sectional shape at the minimum cross-sectional plane140instead of an oval cross-sectional shape shown inFIGS.6A and6B. In some embodiments, the tear-drop cross-sectional shape of the body132may further reduce the flow disruption and the pressure losses associated with the fluid122(shown inFIG.3A).

FIG.8is a flow chart illustrating a method200of manufacturing the component100of the gas turbine engine10. The method200will be described hereinafter with reference to the component100and the tie130ofFIGS.3-7.

At step202, the method200includes forming the first wall116and the second wall118opposing the first wall116. In some embodiments, the first wall116and the second wall118define the fluid passageway120therebetween. At step204, the method200further includes forming the at least one tie130, such that the first wide portion142of the at least one tie130is fixedly coupled to the first wall116and the second wide portion144of the at least one tie130is fixedly coupled to the second wall118. In some embodiments, the at least one tie130is formed by additive layer manufacturing.

It will be understood that the invention is not limited to the embodiments above-described and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.