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.

What is claimed is: 
     
         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.