HYBRID TURBINE SHEET OF MULTIPLE COMPONENTS
BACKGROUND The present invention relates in general to both gas turbines and steam turbines, and more particularly to a turbine blade composed of several components made of different materials. Steam turbines include, but are not limited to, steam turbine power generation equipment and on-board steam turbine propulsion equipment. Gas turbines include, but are not limited to, gas turbine power generation equipment and gas turbine aircraft engines. An exemplary steam turbine typically includes a high pressure turbine section, a low pressure turbine section, or a combination thereof, which is rotated by the steam flow. An exemplary gas turbine typically includes a central engine, which has a high-pressure compressor to compress the flow of air entering the central engine, a combustor in which a mixture of fuel and compressed air is burned to generate a gas flow propeller, and a high pressure turbine that is rotated by the flow of propellant gas and which is connected by a larger diameter arrow to drive the high pressure compressor. A gas turbine aircraft engine with a typical front fan adds a low pressure turbine (located after the high pressure turbine) connected by a coaxial arrow of smaller diameter to drive the front fan (located forward of the high pressure compressor) ) and to drive an optional low pressure compressor (located between the front fan and the high pressure compressor). The low pressure compressor is sometimes called a lift compressor or simply a lift. In the exemplary gas turbine, typically the fan and the high and low pressure compressors and turbines have gas turbine blades each including a portion of the support surface attached to a handle portion. In the exemplary steam turbine, the high and low pressure turbine sections typically have steam turbine blades each including a bearing portion attached to a handle portion. The rotor blades are gas or steam turbine blades attached to rotating rotating gas or steam turbine discs, respectively. Stator pallets are gas turbine blades or steam turbine blades attached to non-rotating gas turbine or steam turbine stators, respectively. Typically, there are circumferential rows of rotor blades that extend radially outwardly and stator valves that extend radially inwardly. When present in the gas turbine configuration, a first and / or last row of stator pallets (also called inlet and outlet guide vanes) may have their radially inward ends also attached to a stator housing of a gas turbine. not rotating. "Stator" vanes that rotate against are also known in gas turbine designs. Conventional designs of gas and steam turbine blades typically have portions of the surface that are made entirely of metal, such as titanium, or are made entirely of a compound. The sheets of metal material, include expensive broad rope hollow leaves, are heavier, resulting in lower fuel efficiency and require more robust sheet joints. In an aircraft application with gas turbines, lighter composite sheets, without a metal front edge, are more susceptible to damage by bird ingestion events. Known hybrid sheets include a composite sheet whose front edge is protected by metal (the remainder of the sheet being covered by a non-metallic coating) from erosion and impact reasons of birds. Gas turbine fan blades are typically the largest (and therefore the heaviest) blades in a gas turbine aircraft engine and the front fan blades are the first to be hit by a bird strike. Composite sheets have typically been used in applications where weight is a major concern., the desire to reduce collateral damage during leaf loss events in addition to higher operating speeds has created the desire to reduce the weight of these leaves even more. In accordance with the foregoing, there is a need for a specifically improved turbine blade, what is needed is a gas turbine blade, and especially a gas turbine fan blade, which is lighter in weight than any of the traditional composite or hybrid sheets. What is also needed is a steam turbine blade that is lighter than any of the traditional composite or hybrid sheets. SUMMARY The present invention, in one embodiment, provides a multi-component hybrid turbine blade comprising a handle portion and a support surface portion. The supporting surface portion comprises a composite section having a first density. The composite section comprises a recess and an insertion section. The insertion section has a second density of mass, which is smaller than the first density of mass. The insertion section is arranged in the recess, and the insertion section is attached to the composite section. The composite section and the insertion section together define a shape of a supporting surface. A manufacturing method is provided, in another embodiment, comprising prefabricating the insertion section, and overlaying layers of composite material to form a portion of the composite section, wherein the portion of the composite section comprises a gap followed by arranging the section of the composite section. insert into the gap and overlay additional layers of composite material to achieve a desired final thickness of the composite section while covering the insertion section. Drawings These and other features, aspects, and advantages of the present invention will be better understood when reading the detailed description that follows with reference to the accompanying drawings in which like characters represent equal parts in all the drawings, wherein: Figure 1 is a schematic side elevational view of the pressure side of a hybrid turbine blade embodiment of the present invention. Fig. 2 is a schematic cross-sectional view of the supporting surface portion of a hybrid turbine blade embodiment of Fig. 1, taken along lines 2-2 of Fig. 1; Figure 3 is a schematic cross-sectional view of the support surface portion of a hybrid turbine blade embodiment of Figure 4, taken along lines 3-3 of Figure 4; Figure 4 is a schematic side elevational view of the pressure side of another embodiment of the turbine blade of the present invention; Figure 5 is a schematic side elevational view of the pressure side of another embodiment of the turbine blade of the present invention; Figure 6 is a schematic side elevational view of the pressure side of an alternative embodiment of the turbine blade of the present invention; Figure 7 provides a schematic front side view of pressure, a schematic side view of the front edge, a schematic side view of the rear edge, a schematic top view and a schematic bottom view of the insert section in one embodiment of the present invention; Figure 8 is a schematic cross-sectional view of the support surface portion of a hybrid turbine blade embodiment of Figure 1, taken along lines 2-2 of Figure 1; and Figure 9 is a schematic cross-sectional view of the support surface portion of a hybrid turbine blade embodiment of Figure 1, taken along lines 2-2 of Figure 1.
Description The multi-component hybrid turbine blade 10, according to one embodiment of the present invention, includes a handle portion 12 and a bearing surface portion 14 as depicted in Figures 1-6. The bearing surface portion 14 has a design operating temperature, a blade root 16 attached to the handle portion 12, a blade tip 18, and a radial axis 20 extending outward toward the blade tip 18 and inwards towards the root of the blade 16. As used in the present "radial shaft" 20 it refers to the reference axis and not to a physical part of the hybrid turbine blade 10. In a gas turbine application the temperature Design operation is the maximum temperature that the portion of the bearing surface 14 is expected to experience during normal operation of the gas turbine (not shown). An example of an operating temperature of a typical gas turbine and a typical steam turbine is, but is not limited to, generally between 18 and several hundred degrees centigrade. The middle direction arrows 26 in Figure 1 generally indicate the average direction. The average typically comprises air in a gas turbine application and typically comprises saturated steam or superheated steam in a steam turbine application. In a gas turbine application of the hybrid turbine blade 10, the handle portion 12 typically includes a swallow tail 22, for attachment of the hybrid turbine blade 10 with a rotor disk (not shown), and a platform of sheet 24, to help contain radially the air flow. The bearing surface portion has a leading edge 30 and a rear edge 32, wherein the middle direction 26 is generally from the leading edge 30 to the rear edge 32. The bearing surface portion 14 also has a pressure side 34 and a suction side 36 as shown in Figure 2, where the distance from the front edge 30 to the rear edge 32 through the suction side 36 is typically longer than the distance from the front edge 30 to the rear edge 32 a through the pressure side 34. In a gas turbine compressor application the hybrid turbine blade 10 typically rotates in a direction such that the pressure side 34 passes a reference point before the suction side 36 passes the same reference point. In a steam turbine application the hybrid turbine blade 10 typically rotates in a direction such that the suction side 36 passes a reference point before the pressure side 34 passes the same reference point. The supporting surface portion 14 also includes a composite section 28 as shown in Figures 2 and 3. As used herein, "composite section" is defined as a section comprising a composite material. The term "composite material" is defined as a material having any fiber filament (metallic or non-metallic) immersed in any matrix binder (metal or non-metal). In one embodiment of the present invention, the composite section 28 is a stacking of discrete composite laminations. The composite material is composed of fiber filaments immersed in a matrix binder. In an exemplary embodiment, the composite material is composed of graphite fiber filaments immersed in an epoxy matrix binder (i.e., epoxy resin). Other options for the fiber filaments in the composite include, but are not limited to, glass fibers, aramid fibers, carbon fibers, and boron fibers and combinations thereof. Other options for the matrix resin include, but are not limited to, bismaleimide, polyimide, polyetherimide, polyetheroterquetone, poly (aryl sulfone), polyether sulfone and ester ester and combinations thereof. In one embodiment the matrix binder includes reinforcing materials such as rubber particles. The composite section 28 has a first mass density and radially extends from generally the root 16 of the sheet to generally the tip 18 of the sheet. The first mass density of the compote section 28 is typically in a range from about 1.4 grams per cubic centimeter to about 2.0 grams per cubic centimeter. The composite section 28 extends in the direction of the length of the wing along the entire front edge 30 and the entire rear edge 32 between a leaf platform 24 and a leaf tip 18. The composite section 28 extends according to rope between the front and rear edges 30 and 32. In an exemplary construction, the composite section 28 has no holes in the surface and has no more voids than those containing one (i.e., at least one) insertion section 38, and without internal voids. The section 28 has a (i.e., at least one) hollow 40 and the hollow 40 comprises an inner front edge 42, an inner rear edge 44, an inner leaf tip edge 60 and an inner leaf root edge 62, the holding surface portion 14 further includes one (i.e., at least one) insertion section 38 (seen in Figures 1-6). in a gas turbine application, the insertion section 38 is located in the hybrid turbine blade 10 so that neither the resistance to bird strikes nor the frequency response of the hybrid turbine blade 10 are sacrificed. The insertion section 38 is incorporated in the process of overcoating and curing standard of the hybrid turbine blade 10 and does not require special tool other than that required to fabricate the same insertion section 38. In one embodiment of the present invention, the section of insert 38 comprises a first insertion section 138 and a second insertion section 238 that are not in physical contact with each other. In one embodiment of the present invention, "the insertion section" 38 has a second density of mass that is less than the first mass density of the composite section 28. In one embodiment of the present invention, the insertion section 38 is Composed of a base thermoplastic elastomer and lightweight filler particles. The lightweight filler particles are generally the same size, wherein the lightweight filler particles comprise a plurality of air-containing cavities. Each cavity in each lightweight filler particle has a volume of about 10"16 cubic millimeters As used herein, the term" light weight "is defined as a material having a density in a typical range from about 0.001 grams. / cubic centimeter to about 1.2 grams / cubic centimeter In one embodiment of the present invention, the lightweight filler particles are composed of polymer particles, wherein each polymer particle typically comprises the air-containing cavity and each polymer particle has a cell structure (regardless of size, shape, uniformity, or content). These lightweight filler particles are generally uniformly dispersed throughout the base elastomer in the insertion section 38. In one embodiment, the elastomeric material of Light weight in the insert section 38 is manufactured by inserting filled particles Light weight gums in the base elastomer before healing. The resulting density of the elastomeric material in the insertion section 38 is smaller than the reinforced composite fiber section 28. In another embodiment of the present invention, the insertion section 38 comprises a hollow portion 95 as shown in Figure 6. The Insertion section 38 is typically made of a thermoplastic material or alternatively a thermosetting material. Other choices of material for constructing the insertion section 38 comprising the hollow portion 95 include, but are not limited to, thermoplastic materials and thermosetting materials, metals, honeycomb ceramics, or silicones, and combinations thereof. In some embodiments of the present invention, the insertion section 38 comprising the hollow portion 95 is made by an injection molding process to produce an injection molded version of the insertion section 38. In some embodiments of the present invention the insert section 38 comprising hollow portion 95 further comprises internal ribs for improving the stiffness and overall strength of insertion section 38. The technician selects the number and orientation of internal ribs in insertion section 38. In another embodiment of the present invention the insertion section 38 is made with the hollow portion 95, wherein the insertion section 38 further comprises a port (not shown) and an inner tube (not shown). The inner tube is coupled from the port to the hollow portion 95 which allows the fluid to be added, pressurized or removed from the hollow portion 95 of the insertion section 38. In the embodiment where the insertion section 38 comprises the hollow portion 95. and the hollow portion 95 of the insertion section 38 can be filled and pressurized, the material of the insert section typically used is a flexible membrane material. In an alternative embodiment, the flexible membrane material has internal reinforcements, while in another embodiment of the present invention the flexible membrane material has external reinforcements. The number and orientation of the internal ribs or outer ribs in the insertion section 38 is left to the technician. During a manufacturing mode of the multi-component hybrid turbine blade 10 utilizing the insertion section 38 comprising the hollow portion 95, the port and the inner tube, the composite section 28 further comprises a fluid path coupled to the port of the section 38 at one end and coupled to an external surface of the composite section 28 in the other. In this embodiment, after a portion of the composite layers is over, the insertion section 38 is placed in the recess 40. The hollow portion 95 of the insertion section 38 is filled with fluid and pressurized so that the section of insert 38 achieves the desired shape. Additional composite layers are provided, which cover the insertion section 38, to produce a finished version of the composite section 28, while maintaining the fluid runoff path. In another embodiment, the hollow portion 95 of the insertion section 38 is filled with fluid and pressurized, so that the insertion section 38 achieves the desired shape, after which the additional composite layers are arranged to cover the insertion section 38. to produce the completed version of the composite section 28. Typically, fluid is drained from the hollow portion 95 of the insertion section 38 through the runoff path after the completed version of the composite section 28 is glued and consolidated . In one embodiment of the present invention, the second density resulting from the insertion section 38 produced by the present invention is generally in a typical range of about 0.01 grams per cubic centimeter to about 0.9 grams per cubic centimeter. In another embodiment of the present invention, the density of the insertion section 38 comprising the hollow portion 95 that has been drained of fluid after manufacture of the hybrid turbine sheet 10 is finished, is generally in a typical range from about 0.01. grams per cubic centimeter to approximately 0.9 grams per cubic centimeter. The second density of mass of the insertion section 38 is smaller than the first mass density of the composite section 28. The insertion section 38 further comprises an insertion front edge 43, an insertion rear edge 45, a tip edge of insert sheet 61, and a root edge of insert sheet 63. The high stretch capacity and low elastic modulus of the elastomer material in insert section 38 allows mechanical loads to be efficiently transferred around insertion section 38. instead of through the insertion section 38. In one embodiment, the elastomer material in the insertion section 38 has an elongation capacity of at least about 20% and has an elastic modulus range from about 3500 kPa to about 350000 kPa. The elastic modulus and the stretchability of the material of the insertion section is selected, so that the material of the insertion section has little deformation during the processing of the insertion section 38 and the strength to withstand the fracture during manufacture .
In addition, the insertion material is selected, so that the material of the insertion section is able to withstand fatigue in the low cycle and in the high cycle. Low-cycle fatigue is typically represented by approximately 30,000 cycles of pick-up and stop, while high-cycle fatigue typically is represented by more than 1,000,000 spin cycles. In one embodiment of the present invention, the insertion section 38 is formed so as to have sufficient stiffness and dimensional stability to maintain the shape of the supporting surface during the manufacture of the composite section 28. In one embodiment of the present invention, the insertion section 38 is formed to retain sufficient elasticity and flexibility, so that the insertion section conforms to the recess 40. The technician chooses the number and location of the insertion sections 38. The insertion section 38 is attached to the composite section 28. Bonding is carried out by adhesion between the material of the insertion section and the material of the composite section. Other examples of gluing include, without limitation, autoclave cycle cure, adhesive glue, and melt glue (film or adhesive paste). The insertion section 38 has a second volume, and in an alternative embodiment, the second volume is equal to at least generally ten percent of a first volume of the composite section 28. The composite section 28 and the insertion section 38 ( which in one embodiment comprises two or more insertion sections, as shown in Figures 3, 4 and 5, by a first insertion section 138, a second insertion section 238, and a third insertion section 338) together typically define a form of surface sustentadora. The composite section 28 comprises a recess 40 as shown in Figures 1 and 2 of one embodiment of the present invention, whereby a major axis 80 of the recess 40 is parallel to the radial axis 20 The recess 40 has an inner leading edge 42, an inner rear edge 44, an inner blade tip edge 60, and an inner blade root edge 62. The insertion section 38 is disposed in the recess 40 so that the insertion front edge 43 is disposed within the interior of the interior. the inner front edge 42, the insert rear edge 45 is disposed on the inner rear edge 44, the insert sheet tip edge 61 is disposed at the inner leaf tip edge 60 and the insert leaf root edge 63 is disposed at the root edge of inner sheet 62. In an exemplary embodiment, composite section 28 as depicted in Figures 3 and 4 includes a first recess 140, a second recess 240 and a third recess 340. A major axis of the first huec or 180, a major axis of the second recess 280 and a major axis of the third recess 380 of the recesses 140, 240, 340, respectively are parallel to the radial axis 20. The major axes 180, 280 and 380, respectively are oriented from typically the blade platform 24 towards the tip of the blade 18 along the span of the supporting surface portion 14. In one embodiment of the present invention the insertion sections 138, 238 and 338 are used and located in each of the corresponding first, second and third holes 140, 240 and 340, respectively. The first, second and third recesses 140, 240 and 340 have a first inner leading edge 142, a second inner leading edge 242, and a third inner leading edge 342, respectively; a first inner rear edge 144, a second inner rear edge 244 and a third inner rear edge 344, respectively; a first inner leaf tip edge 160, a second inner leaf tip edge 260, and a third inner leaf tip edge 360, respectively, and a first inner leaf root edge62, a second leaf root edge interior 262, and a third edge of inner leaf root 362, respectively. The first insertion section 138, the second insertion section 238 and the third insertion section 338 have a first insertion front edge 143, a second insertion front edge 243 and a third front edge 343, respectively, a first rear edge of insert 145, a second insertion rear edge 245 and a third rear edge 345, respectively, a first insert sheet tip edge 161, a second sheet tip edge 261 and a third sheet tip edge 361, respectively and a first edge of insertion leaf root 163, a second leaf root edge 263 and a third leaf root edge 363, respectively. The insertion sections 138, 238 and 338 are disposed in the recesses 140, 240, and 340, respectively so that the first insertion front edge 143, the second insertion front edge 243 and the third insertion front edge 343 are disposed on the first inner front edge 142, the second inner front edge 242, and the third inner nose edge 342, respectively; the first insert rear edge 145, the second insert rear edge 245, and the third insert rear edge 345 are disposed on the first inner back edge 144, the second inner rear edge 244 and the third inner rear edge 344, respectively, the first insert sheet tip edge 161, the second insert sheet tip edge 261 and the third insert sheet tip edge 361 are disposed on the first inner sheet tip edge 160, the second tip edge of inner sheet 260 and third inner leaf tip edge 360, respectively and the first insert sheet root edge 163, the second insert sheet edge 263 and the third insert sheet root edge are disposed in the first inner leaf root border 162, second inner leaf root edge 262 and third inner leaf root edge 362, respectively. In one embodiment of the present invention, when the first insertion section 138 and the second insertion section 238 (in other words, at least two insertion sections) are used, the composite section 28 includes a rib 46, typically composed of the same composite material than composite section 28. Rib 46 is disposed between, and glued to, first and second insert sections 138 and 238. Rib 46 extends between inner first back edge 144 and second inner front edge 242 as shown in Figure 4. A desired location for the first insertion section 138 and the second insertion section 238 is closer to the root of the sheet 16 than to the tip of the sheet 18. When the third section of insert 338 is used, an additional rib (such as the additional rib 48 as shown in Figures 3 and 4) is used to extend between the second inner back edge 244 and the third to inner front edge 342 in the portion of the lifting surface 14. Alternative embodiments of the present invention utilize additional numbers of insertion sections and additional ribs to preserve the strength of the hybrid turbine blade 10. The additional ribs provide improved rigidity and act to limit the development of fractures and delamination. The additional ribs are typically composed of the same composite material as the composite section 28 and the rib 46. The orientation of the ribs is left to the technician. In another embodiment of the present invention, the first insertion section 138 comprises a first hollow insert portion 195 and the second insert section 238 comprises a second hollow insert portion 295. In another embodiment of the present invention, the first section of insert 138 comprises first insertion hollow portion 195, second insert section 238 comprises second insertion hollow portion 295 and third insert section 338 comprises a third insertion section 338. The structure for the first insertion section 138 which comprises the first insertion hollow portion 195, the second insert section 238 comprising the second hollow portion 295 and the third insertion section 338 comprising the third insertion section is similar to that described above for the insertion section 38 comprising the hollow portion 95.
In an alternative embodiment, the composite section 28 as shown in Figure 5 includes the first recess 140, the second recess 240 and the third recess 340. The major axis of the first recess 180, the major axis of the second recess 280 and the axis greater of the third recess 380 of each recess 140, 240 and 340, respectively is perpendicular to the radial axis 20 (ie, the major axis 180, 280 and 380 of the recess 140, 240 and 340, respectively are oriented from the leading edge 30 towards the rear edge 32 along the rope of the supporting surface portion 14). The first recess 140, the second recess 240 and the third recess 340 are similar to the elements described above for Figures 3 and 4. The orientations of the first insertion section 138, the second insertion section 238, and the third section of insert 338 are similar to the elements described above for Figures 3 and 4. When more than one insert section 38 of Figure 5 is used, the composite section 28 typically includes a rib 46, of the same composite material as the composite section 28. The rib 46 is disposed between, and glued to, the first insertion section 138 and the second insertion section 238, where the rib 46 extends between a first inner leaf root edge 162 and a second end edge of the leaf. inner sheet 260. In an alternative embodiment of the present invention which utilizes the third insertion section 338, an additional rib (such as the additional rib 48) may be employed for extending between the second inner leaf root edge 262 and the third inner leaf tip edge 360 in the supporting surface portion 14. As discussed above, alternative embodiments of the present invention utilize additional numbers of insertion sections and ribs. additional to maintain the strength of hybrid turbine blade 10. Additional ribs are used to improve rigidity and to act as fracture / delamination stops. The orientation of the ribs is left to the technician. In one embodiment of the present invention a single insertion section 38 is connected to the composite section 28 as shown in Figures 1 and 6. In a more specific embodiment, as shown in Figure 7, a front edge decreased from the side pressure 81 is disposed between the pressure side 34 of the insertion section 38 and the insertion front edge 43 to form a first interior angle of the pressure side 100, wherein the first interior angle of the pressure side 100 is typically in a range from approximately 20 degrees to approximately 179 degrees. The first interior angle of the pressure side 100 is measured between the decreased front edge of the pressure side 81 and the pressure side 34 of the insertion section 38. A decreased front edge of the suction side 91 is disposed between the suction side 36 of the insert section 38 and the front edge 43 to form a first interior angle of the suction side 102, wherein the first interior angle of the suction side 102 is typically in a range from about 20 degrees to about 179 degrees. The first interior angle of the suction side 102 is measured between the decreased front edge of the suction side 91 and the suction side 36 of the insertion section 38. A decreased rear edge of the pressure side 82 is disposed between the pressure side 34 of the insertion section 38 and the insertion rear edge 45 to form a second interior angle of the pressure side 104, wherein the first (sic) interior angle of the pressure side 104 is typically in the range from about 20 degrees to Approximately 179 degrees. The second inner angle of the pressure side 104 is measured between the decreased rear edge of the pressure side 34 of the insertion section 38. A decreased rear edge of the suction side 92 is disposed between the suction side 36 of the insertion section 38 and the insertion rear edge 45 to form a second interior angle of the suction side 106, wherein the second interior angle of the suction side 106 is typically in a range from about 20 degrees to about 179 degrees. The second interior angle of the suction side 106 is measured between the diminished rear edge of the suction side 92 and the suction side 36 of the insertion section 38. A decreased blade tip edge of the pressure side 83 is disposed between the pressure side 34 of the insertion section 38 and the insert sheet tip edge 61 to form a third interior angle of the pressure side 108; wherein the third interior angle of the pressure side 108 is typically in a range from about 20 degrees to about 179 degrees. The third inner angle of the pressure side 108 is measured between the decreased blade tip edge of the pressure side 83 and the pressure side 34 of the insertion section 38. A decreased blade tip edge of the suction side 93 is disposes between the suction side 36 of the insertion section 38 and the tip edge of the insertion sheet 61 to form a third interior angle of the suction side 110; wherein the third interior angle of the suction side 110 is typically in a range from about 20 degrees to about 179 degrees. The third interior angle of the suction side 110 is measured between the reduced blade tip edge of the suction side 93 and the suction side 36 of the insertion section 38. A decreased blade root edge of the suction side 84 is disposes between the pressure side 34 of the insertion section 38 and the insert sheet root edge 63 to form a fourth interior angle of the pressure side 112, wherein the fourth interior angle of the pressure side 112 is typically in a range from 20 degrees to approximately 179 degrees. The fourth interior angle of the pressure side 112 is measured between the decreased leaf root edge of the pressure side 84 and the pressure side 34 of the insertion section 38. A decreased leaf root edge of the suction side 94 is disposes between the suction side 36 of the insertion section 38 and the root edge of the insertion sheet 63 to form a fourth interior angle of the suction side 114; wherein the fourth interior angle of the suction side 114 is typically in a range from about 20 degrees to about 179 degrees. The fourth interior angle of the suction side 114 is measured between the decreased leaf root edge of the suction side 94 and the suction side 36 of the insertion section 38. In the related embodiments of the present invention, at least two sections of insertion (shown in Figures 4 and 5 as the first insertion section 138, the second insertion section 238 and the third insertion section 338) and the interface with the composite section 28, and the insertion sections 138, 238 and 338 comprise the same internal angle configuration described for the insertion section 38 above and as shown in Figure 7.
In some embodiments of the present invention, the supporting surface portion 14 of Figures 2 and 6 includes a coating for erosion 52 as shown in Figures 1-3, 5-6 and 8-9. In one embodiment of the present invention, the erosion coating 52 of Figure 2 is disposed on at least a portion of the pressure side 34 and the erosion coating 52 is disposed on at least a portion of the suction side 36. In Another embodiment of the present invention, the erosion coating 52 of Figure 2 is disposed and glued on at least a portion of the pressure side 34 and the erosion coating 52 is disposed and glued in at least a portion of the Suction side 36. In one embodiment, the polyurethane was selected as the material for the erosion coating 52 of Figure 6 since the polyurethane provides greater resistance against erosion than the composite section 28. In another embodiment of the present invention , a front edge protective coating 70 is disposed on the front edge 30, at least on a pressure side portion 34, and at least on a portion of the front edge. suction 36. In an exemplary embodiment, titanium was selected as the material for the protective covering of the front edge 70, since titanium provides greater erosion resistance than the composite section 28. when titanium is used as the coating front edge protector 70, titanium provides a high proportion of resistance against weight, when titanium is used as the protective covering of the front edge 70, the titanium also provides increased roughness compared to the composite section 28 with respect to the ingestion of objects bizarre or shock events of birds that are likely to be experienced in aircraft engine fan blades. In another embodiment of the present invention, a protective rear edge cover 72 is provided on the rear edge 32, at least a portion of the pressure side 34 and at least a portion of the suction side 36. In an exemplary embodiment of the present Invention, a protective cover of the blade tip edge 53 of Figure 5 is disposed at the blade tip edge 18 of Figure 2, at least a portion of the pressure side 34, and at least a portion of the side of suction 36 (not shown in figure 5). In another embodiment of the present invention, titanium was used as the material for the protective coating of the tip of the sheet 53 of Figure 5. In another embodiment of the present invention, both the protective covering of the front edge 70 of the Figure 2 as the protective covering of the rear edge 72 are arranged as described above. In an exemplary embodiment of the present invention, titanium was used as the protective material for the rear edge 72 of Figure 6. In another embodiment of the present invention, the protective covering of the front edge 70, the protective coating of the rear edge 72 and the protective coating on the edge of the blade tip 53 of Figure 5 are arranged as described above. In another embodiment of the present invention, the erosion coating 52 of Figure 2 is disposed on and bonded to at least a portion of the pressure side 34 that is not covered by the protective covering of the front edge 70, the coating rear edge protector 72 and the protective covering of the blade tip edge 53 and a portion of the suction side 36, which is not covered by the protective covering of the front edge 70, the protective covering of the rear edge 72 and the protective covering of the blade tip edge 53, while the protective covering of the front edge 70, the protective covering of the rear edge 72 and the protective covering of the edge of the blade tip 53 of Figure 5 are arranged as described above. In another embodiment of the present invention, the erosion coating 52 of Figure 3 is disposed on and glued to at least a portion of the pressure side 34 and at least a portion of the suction side 36, and the protective covering of the front edge 70 is disposed at at least a portion of the erosion coating 52 along the front edge 30. In another embodiment of the present invention, the erosion coating 52 is disposed on and glued to at least a portion of the pressure side 34 and at least a portion of the suction side 36, and the protective covering of the rear edge 72 is provided in at least a portion of the erosion coating 52 along the rear edge 32. In another embodiment of the present invention, the Erosion coating 52 is disposed on and glued to at least a portion of the pressure side 34 and at least a portion of the suction side 36, and the protective coating of the tip edge of the blade. at 53 of Figure 5, at least one portion of the erosion coating 52 of Figure 3 is disposed along the edge of the sheet tip 18. In another embodiment of the present invention, the coating for erosion 52 is disposes on and sticks to at least a portion of the pressure side 34 and at least a portion of the suction side 36, the protective covering of the front edge 70 is disposed in at least a portion of the coating for erosion 52 a along the delaminating edge 30, and the protective covering of the rear edge 72 is provided in at least a portion of the erosion coating 52 along the rear edge 32. In another embodiment of the present invention, the coating for the erosion 52 is disposed in and sticks to at least a portion of the pressure side 34 and at least a portion of the suction side 36, the protective covering of the front edge 70 is disposed in at least one po of the erosion coating 52 along the front edge 30, the protective covering of the rear edge 72 is provided in at least a portion of the erosion coating 52 along the rear edge 32, and the protective coating from the tip edge edge 53 of Figure 5 there is provided at least a portion of the erosion coating 52 of Figure 3 along the edge of the sheet tip 18. In another embodiment of the present invention, the Erosion coating 52 of Figure 8 is disposed on and glued to at least a portion of the pressure side 34. In another embodiment of the present invention, the erosion coating 52 is disposed on and glued to at least one portion of the pressure side 34, and the protective covering of the front edge 70 is provided in at least a portion of the erosion coating 52 and at least a portion of the suction side 36 along the front rim 30. In another embodiment of the present invention, the erosion liner 52 is disposed on and glued to at least a portion of the pressure side 34, and the protective liner of the rear edge 72 is disposed on at least one portion of the erosion coating 52 and at least a portion of the suction side 36 along the rear edge 32. In another embodiment of the present invention, the erosion coating 52 is disposed at and glued to at least a portion of the pressure side 34, and the protective covering of the blade tip edge 53 of Figure 5 is provided in at least a portion of the erosion coating of Figure 8 and at least a portion of the suction side 36 along the tip edge edge 52. In another embodiment of the present invention, the erosion coating 52 is disposed on and glued to at least a portion of the pressure side 34, the coating Front edge guard 70 is provided in at least a portion of the erosion cover 52 and at least a portion of the suction side 36 along the front edge 30, and the protective covering of the rear edge 72 is provided in at least a portion of the erosion covering 52 and at least a portion of the suction side 36 that is not covered by the protective front edge covering 70 throughout of the back edge 32. In another embodiment of the present invention, the erosion coating 52 is disposed in and adheres to at least one pressure delineating portion 34, the protective covering of the leading edge 70 is disposed in at least one portion of the erosion coating 52 and at least a portion of the suction side 36 along the front edge 30, and the protective covering of the rear edge 72 is provided in at least a portion of the erosion coating 52 that is not covered by the protective covering of the front edge 70 and at least a portion of the suction side 36 along the rear edge 32 which is not covered The protective coating of the front edge 70, and the protective covering of the tip edge edge 53 of FIG. 5, is provided in at least a portion of the erosion coating 52, of FIG. 8, which is not covered by the protective covering of the front edge 70 and the protective covering of the leading edge 72 and at least a portion of the suction side 36 along the edge of the blade tip 52 that is not covered by the protective covering of the leading edge 70 and the protective covering of the leading edge 72. In another embodiment of the present invention, the protective covering of the leading edge 70 of Figure 9 is disposed in a portion of the pressure side 34 and a portion of the suction side 36 as described above. The erosion coating 52 is disposed on a pressure side portion 34 that is not covered by the protective covering of the front edge 70 and the erosion coating 52 is disposed on a portion of the suction side 36 that is not covered by the protective covering of the front edge 70. In another embodiment of the present invention, the protective covering of the front edge 70 and the protective covering of the rear edge 72 are arranged in a portion of the pressure side 34 and a portion of the side of suction 36 as described above. The erosion coating 52 is disposed on a portion of the pressure side 34 that is not covered by the protective covering of the front edge 70 and the protective covering of the rear edge 72 and the erosion coating 52 is disposed over a portion on the suction side 36 which is not covered by the protective covering of the front edge 70 and the protective covering of the rear edge 72. In another embodiment of the present invention, the protective covering of the front edge 70, the protective covering of the back edge 72 and protective sheet tip edge cover 53 of Figure 5 are disposed in a pressure side portion 34 of Figure 9 and a suction side portion 36 as described above. The erosion coating 52 is disposed on a portion of the pressure side that is not covered by the protective covering of the front edge 70, the protective covering of the rear edge 72 and the protective covering of the edge of the blade tip 53 of Figure 5 and the erosion coating 52 of Figure 9 is disposed on a portion of the suction side 36 that is not covered by the protective covering of the front edge 70, the protective covering of the rear edge 72, and the protective coating on the edge of the blade tip 53 of Figure 5. The handle portion 12 is typically a composite handle portion conveniently attached or otherwise affixed to the bearing surface portion. However, a metal handle portion (suitably glued or otherwise affixed to the composite bearing surface portion) can be employed in particular sheet designs. The swallow tail 22 of the handle portion 12 may be partially composite (not shown) on the pressure side (concave). Alternatively, swallow tail 22 may have a metal wedge system (also not shown) to positively capture by joining the insertion section and provide a swallowtail metal surface. In a gas turbine application of the present invention, the impact footprint of birds lies primarily on the area of the pressure side 34 along the front edge 30 of the hybrid turbine blade 10. In one embodiment of the present invention, the affected areas of the composite section 28, the insertion section 38, and the protective covering of the front edge 70 provide resistance to curling and fracture. In one embodiment of the present invention, the reduced mass of the hybrid turbine blade 10 compared to a similarly shaped non-hybrid turbine blade has the general effect of reducing the impact force of the broken blade on the containment structure and sheets backs (not shown) for a given blade rotational speed. In another gas turbine application of the present invention, the insertion section 38 is mechanically or thermally removable from the composite section 28 at a temperature below the melting point of the composite material. This allows the supporting surface portion 14 to be easily repairable if damaged due to bird collisions or impacts with foreign objects. If the portion of the bearing surface is damaged in the composite section 28 and the insertion section 38, the damaged insertion section would be thermally removed, the composite section 28 repaired, and a new insertion section 38 and reapplied composite material. Since most of these blade damages are to the front row of the hybrid turbine blades 10, typically the bearing portion 14 is a surface portion of a hybrid turbine blade 10 in a turbine aircraft engine. gas (or gas turbine aircraft engine compressor if the gas turbine engine does not have a fan). The insertion section 38 functions to facilitate stacking and autoclaving or other manufacturing methods of the hybrid turbine blade 10. In one embodiment, the insertion section 38 is wrapped by a (means at least one) layer of composite material 200. The composite layer 200 of Figure 9 wrapped around the insertion section 38 provides additional stability to the insertion section 38 of Figure 6 during manufacture. Wrapping the composite layer 200 of the Figure around the insertion section 38 of Figure 6 typically decreases the initiation of fractures within the insertion section 38. The composite layer 200 of Figure 9 wrapped around the section of insert 38 of Figure 6 allows more efficient load transfer around the gap 40 in the final application. in an alternative embodiment, an adhesive layer covers the insertion section 38. The adhesive layer can also be used to improve the bond between the composite section 28 and the insertion section 38 by improving adhesion between the insertion section 38 and the composite section 28. The hybrid turbine sheet 10 in its fully assembled condition has the insertion section 38 disposed in the recess 40 of the composite section 28, so that the surrounding composite layers 200 of Figure 9 in the composite section 28 of Figure 6 are able to satisfy all mechanical requirements, whereby no load transfer is necessary through the insertion section 38. When an elastomeric material is used to construct the insertion section 38, the high capacities of Elasticity and stretching of the elastomer material allow the composite section 28 to be deformed with little resistance of the section insertion 38 even in a severe impact load, such as could occur when a gas turbine engine ingests a foreign object. A typical method for making the hybrid turbine blade 10 of the invention includes, but is not limited to, manufacturing the composite section 28 and the insertion section 38 separately or as a unit (co-curing) using autoclave and compression molding techniques. In a manufacturing method of the present invention, the insertion section 38 is prefabricated. The plurality of composite layers 200 of Figure 9 are piled up to generate a portion of the composite section 28 of Figure 6, where the portion of the composite section 28 comprises the recess 40. The insertion section 28 is disposed therein. hollow 40; and the additional layers of composite material 200 are stacked, so that additional layers of composite material 200 cover the insertion section 38 and the desired final thickness of the composite section 28 is reached and a completed version of the composite section is produced, the completed version of the composite section 28 is then subjected to a process that consolidates and bonds the layers of composite material 200 together and the process also pastes the insertion section 38 to the adjacent layers of composite material 200. The consolidation process and Bonding is typically performed by an autoclave technique, alternatively the compression molding technique, and alternatively the resin molding technique. The autoclave technique, the compression molding technique, and the resin molding technique are provided only as examples of consolidation and bonding processes and do not imply a restriction on the present invention. In other embodiments of the present invention, multiple insertion sections (shown as 138 and 238 in Figure 4 and 138, 238 and 338 also in Figure 4 for example) are disposed in respective recesses, when multiple insertion sections are used in In the manufacturing process, a rib 46 is typically formed between the voids. In one embodiment of the present invention, the plurality of composite layers 200 of Figure 9 are stacked to generate a portion of the composite section 28 of Figure 1, wherein the portion of the composite section 28 comprises the recess 40. insertion section 38 is disposed in recess 40; and the additional layers of composite material 200 are stacked, so that additional layers of composite material 200 cover the insertion section 38 and the desired final thickness of the composite section 28 is achieved. In one embodiment of the present invention, the composite segment 28 is typically constructed by manual or machine layered or weaving around the composite section 28 and the insertion section 38. as previously mentioned, in the case of composite materials, modules fiber-filament and orientation will be chosen to maintain the overall stiffness of the supporting surface portion to reduce the structural bending of the sheet under centrifugal and aerodynamic loading, as it is within the skill level of the technician. The above description of various embodiments of the present invention has been presented for purposes of illustration. Although the invention has been described and illustrated in detail, it will be clearly understood that it is intended by way of illustration and example only and will not be taken by way of limitation. Obviously many modifications and variations of the present invention are possible in light of the above teachings. In accordance with the above, e esp. { The scope and scope of the present invention will be limited only by the terms of the appended claims.