Uber-cooled multi-alloy integrally bladed rotor

Abstract

Uber-cooled multi-alloy integrally bladed rotors (IBR) are made having blades with internal cooling passages with a cavity in the root portion attached to a disk having a protrusion on the periphery of the disk. The blades are put on the protrusion and the blade and disk are forced together, followed by locally heating the blade cavity/disk protrusion to a temperature between the blade and disk material softening temperatures, causing the protrusion to deform against the blade cavity, and holding them in place until bonding occurs. Subsequent to bonding the portion of the blade that defines the cavity is removed.

1 . A method of making an integrally bladed rotor (IBR) having blades with internal cooling passages attached to a disk, the method comprising:
 forming a cavity in a root portion of at least one blade having internal cooling passages;   forming a protrusion on a periphery of the disk for each at least one blade having internal cooling passages;   assembling the at least one blade having internal cooling passages on the at least one protrusion on the periphery of the disk;   forcing the blade and disk together,   locally heating the blade cavity/disk protrusion to an elevated temperature between the blade and disk material softening temperatures, causing the protrusion to deform against the blade cavity;   holding the disk-blade assembly together under conditions of heat and pressure until bonding occurs; and   subsequent to bonding remove a portion of the blade that defines the cavity.   
     
     
         2 . The method of  claim 1 , wherein bonding is performed at a temperature range of 1700° F. to 2300° F. (927° C. to 1260° C.). 
     
     
         3 . The method of  claim 1 , wherein local heating is provided by flowing current between the blade and the protrusion. 
     
     
         4 . The method of  claim 3 , wherein the current flow to provide the heating is about 3,600 to 4,000 amps for a time of about 0.5 to 4 hours. 
     
     
         5 . The method of  claim 1 , wherein the bonding force ranges from 3-15 ksi (20.7-103.4 mpa). 
     
     
         6 . An integrally bladed rotor (IBR) having blades with internal cooling passages attached to a disk, comprising:
 at least one blade having internal cooling passages, the at least one blade having a cavity in the root portion thereof;   at least one protrusion on a periphery of the disk for at least one blade having internal cooling passages; and   the at least one blade having internal cooling passages bonded to at least one protrusion on the periphery of the disk.   
     
     
         7 . The IBR of  claim 6 , wherein bonding is performed at a temperature range of 1700° F. to 2300° F. (927° C. to 1260° C.). 
     
     
         8 . The IBR of  claim 6 , wherein local heating is provided by flowing current between the blade and the protrusion. 
     
     
         9 . The IBR of  claim 3 , wherein the current flow to provide the necessary heating is about 3,600 to 4,000 amps for a time of about 0.5 to 4 hours. 
     
     
         10 . The IBR of  claim 6 , wherein the bonding force ranges from 3-15 ksi (20.7-103.4 mpa). 
     
     
         11 . A method of making an integrally bladed rotor (IBR) having blades with internal cooling passages and having a cavity in the root portion attached to a disk having a protrusion on the periphery of the disk for each blade having internal cooling passages, the method comprising:
 assembling the blades having internal cooling passages on the protrusion on the periphery of the disk;   forcing the blade and disk together,   locally heating the blade cavity/disk protrusion to an elevated temperature between the blade and disk material softening temperatures, causing the protrusion to deform against the blade cavity;   holding the disk-blade assembly together under conditions of heat and pressure until bonding occurs; and   subsequent to bonding remove a portion of the blade that defines the cavity.   
     
     
         12 . The method of  claim 11 , wherein bonding is performed at a temperature range of 1700° F. to 2300° F. (927° C. to 1260° C.). 
     
     
         13 . The method of  claim 11 , wherein local heating is provided by flowing current between the blade and the protrusion. 
     
     
         14 . The method of  claim 13 , wherein the current flow to provide the heating is about 3,600 to 4,000 amps for a time of about 0.5 to 4 hours. 
     
     
         15 . The method of  claim 11 , wherein the bonding force ranges from 3-15 ksi (20.7-103.4 mpa).