Manufacturing method

Abstract

The present invention provides a method of forming a leading edge for an aerofoil component e.g. an aerofoil blade. The method comprises forming a pre-form having a precursor edge and processing said precursor edge to form the leading edge. The pre-form is formed using metal injection molding. The leading edge may have an elliptical profile.

Claims

1. A method of forming a leading edge of an aerofoil component, the method comprising: forming a pre-form having a precursor edge; and processing the formed precursor edge of the pre-form to form the leading edge of the aerofoil component, wherein: the pre-form is formed using metal injection molding, and the formed precursor edge is sharper than the formed leading edge of the aerofoil component, which is formed as a result of the processing.

2. A method of forming an aerofoil component having a leading edge, the method comprising forming the leading edge according to the method of claim 1.

3. The method according to claim 1, wherein forming the pre-form includes: mixing powdered metal or metal alloy with a binder; shaping the mixture by injection into a die; removing the binder; and consolidating the metal/metal alloy powder using heat.

4. The method according to claim 3, wherein the binder is a thermoplastic plastic.

5. The method according to claim 3, further comprising removing the binder using a solvent.

6. The method according to claim 1, further comprising processing the precursor edge to form the leading edge having an elliptical profile.

7. The method according to claim 1, wherein the step of processing the precursor edge includes mechanical vibratory processing.

8. The method according to claim 1, wherein the aerofoil component is a blade for a fan, a compressor, or a turbine.

9. A method of manufacturing a fan, a compressor, or a turbine, the method comprising forming a leading edge of a blade of an aerofoil using the method of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:

(2) FIG. 1 shows a ducted fan gas turbine engine;

(3) FIG. 2 shows a cross-section through the leading edge of an aerofoil component formed according to the prior art; and

(4) FIG. 3 shows a cross-section through the leading edge of an aerofoil blade formed according to the present disclosure.

(5) FIG. 3 shows a cross-section through the leading edge of an aerofoil blade. The leading edge 27 extends along the join of the pressure surface 26 and suction surface 25.

DETAILED DESCRIPTION OF EMBODIMENTS

(6) The leading edge 27 is created by initially forming a pre-form having a sharp precursor edge 29. The pre-form is prepared by mixing powdered titanium alloy (or other suitable metal powder) with a thermoplastic plastic binder and injecting it into a die having the desired pre-form shape.

(7) The die is opened to retrieve a green component which is subjected to solvent and thermal de-binding to remove the binder. Next, the green component is heated to sinter and consolidate the metal/metal alloy powder to form the pre-form having the precursor edge 29.

(8) Next, the precursor edge 29 is processed using a mechanised vibratory finishing system to form the leading edge 27. The leading edge 27 may have an elliptical profile, as in the illustrated example.

(9) While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope of the invention.

(10) All references referred to above are hereby incorporated by reference.