TURBOMACHINE AND METHOD OF ASSEMBLY

Abstract

A turbomachine includes an annular casing and a fan disposed inside the annular casing and mounted for rotation about an axial centerline. The fan includes fan blades that extend radially outwardly toward the annular casing. The fan has an average chord fan width according to a first performance factor. The fan has a quantity of fan blades according to a second performance factor.

Description

FIELD

The present disclosure relates generally to jet engines and, more particularly, to jet engine fans.

BACKGROUND

In one form, a gas turbine engine can include a fan and a core arranged in flow communication with one another. The core generally includes, in serial flow order, a compressor section, a combustion section, a turbine section, and an exhaust section. The fan and the core may be partially surrounded by an outer nacelle. In such approaches, the outer nacelle defines a bypass airflow passage with the core.

In operation, air is provided from the fan to an inlet of the compressor section where one or more axial compressors progressively compress the air until it reaches the combustion section. Fuel is mixed with the compressed air using one or more fuel nozzles within the combustion section and burned to provide combustion gases. The combustion gases are routed from the combustion section to the turbine section. The flow of combustion gases through the turbine section drives the turbine section and is then routed through the exhaust section to atmosphere.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, with reference to the appended figures, in which:

FIG. 1 is a schematic, cross-sectional view of a gas turbine engine in accordance with exemplary aspects of the present disclosure;

FIG. 2 is a sectional view of a fan blade in accordance with exemplary aspects of the present disclosure;

FIG. 3 shows first example engines arranged on a first plot in accordance with a first performance factor for a fan module according to the present disclosure;

FIG. 4 shows second example engines arranged on a second plot in accordance with a second performance factor for a fan module according to the present disclosure;

FIG. 5 shows third example engines arranged on a third plot in accordance with the first performance factor for a fan module according to the present disclosure;

FIG. 6 shows fourth example engines arranged on a fourth plot in accordance with the second performance factor for a fan module according to the present disclosure;

FIG. 7 shows an exemplary fan blade of the gas turbine engine of FIG. 1;

FIG. 8 shows a cross-sectional view of a leading edge of a fan blade in accordance with a first exemplary aspect;

FIG. 9 shows a cross-sectional view of a leading edge of a fan blade in accordance with a second exemplary aspect;

FIG. 10 shows a cross-sectional view of a leading edge of a fan blade in accordance with a third exemplary aspect;

FIG. 11 shows a cross-sectional view of a leading edge of a fan blade in accordance with a fourth exemplary aspect;

FIG. 12 shows a cross-sectional view of a fan blade depicting reinforcement placement in accordance with a first exemplary aspect;

FIG. 13 shows a cross-sectional view of a fan blade depicting reinforcement placement in accordance with a second exemplary aspect;

FIG. 14 shows a cross-sectional view of a fan blade depicting reinforcement placement in accordance with a third exemplary aspect;

FIG. 15 shows a cross-sectional view of a fan blade depicting reinforcement placement in accordance with a fourth exemplary aspect;

FIG. 16 is a cross-sectional view a leading edge of a fan blade in accordance with another exemplary aspect;

FIG. 17 is an exploded cross-sectional view of a leading edge of a fan blade in accordance with a first exemplary aspect;

FIG. 18 is an exploded cross-sectional view of a leading edge of a fan blade in accordance with a second exemplary aspect;

FIG. 19 is an exploded cross-sectional view of a leading edge of a fan blade in accordance with a third exemplary aspect; and

FIG. 20 is a perspective view of a fan blade having a leading edge reinforcement.

Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of variations of the present disclosure. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these variations of the present disclosure. Certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required.

DETAILED DESCRIPTION

Aspects and advantages of the present disclosure will be set forth in part in the following description or may be learned through practice of the present disclosure.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary.

As used herein, the terms “first” and “second” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

The terms “upstream” and “downstream” refer to the relative direction with respect to a flow in a pathway. For example, with respect to a fluid flow, “upstream” refers to the direction from which the fluid flows, and “downstream” refers to the direction to which the fluid flows.

The terms “radial” or “radially” refer to a direction away from a common center. For example, in the overall context of a turbine engine, radial refers to a direction along a ray extending between a center longitudinal axis of the engine and an outer engine circumference.

The term “composite,” as used herein is, refers to a material that includes non-metallic elements or materials. As used herein, a “composite component” or “composite material” refers to a structure or a component including any suitable composite material. A composite material can be a combination of at least two or more non-metallic elements or materials. Examples of a composite material can be, but not limited to, a polymer matrix composite (PMC), a ceramic matrix composite (CMC), a metal matrix composite (MMC), carbon fibers, a polymeric resin, a thermoplastic resin, bismaleimide (BMI) materials, polyimide materials, an epoxy resin, glass fibers, and silicon matrix materials. Composite components, such as a composite airfoil, can include several layers or plies of composite material. The layers or plies can vary in stiffness, material, and dimension to achieve the desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength. One or more layers of adhesive can be used in forming or coupling composite components. Adhesives can include resin and phenolics, wherein the adhesive can require curing at elevated temperatures or other hardening techniques.

As used herein, “PMC” refers to a class of materials. By way of example, the PMC material is defined in part by a prepreg, which is a reinforcement material pre-impregnated with a polymer matrix material, such as thermoplastic resin. Non-limiting examples of processes for producing thermoplastic prepregs include hot melt pre-pregging in which the fiber reinforcement material is drawn through a molten bath of resin and powder pre-pregging in which a resin is deposited onto the fiber reinforcement material, by way of non-limiting example electrostatically, and then adhered to the fiber, by way of non-limiting example, in an oven or with the assistance of heated rollers. The prepregs can be in the form of unidirectional tapes or woven fabrics, which are then stacked on top of one another to create the number of stacked plies desired for the part. Multiple layers of prepreg may be stacked to the proper thickness and orientation for the composite component and then the resin is cured and solidified to render a fiber reinforced composite part. Resins for matrix materials of PMCs can be generally classified as thermosets or thermoplastics. Thermoplastic resins are generally categorized as polymers that can be repeatedly softened and flowed when heated and hardened when sufficiently cooled due to physical rather than chemical changes. Notable example classes of thermoplastic resins include nylons, thermoplastic polyesters, polyaryletherketones, and polycarbonate resins. Specific example of high performance thermoplastic resins that have been contemplated for use in aerospace applications include, polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK), and polyphenylene sulfide (PPS). In contrast, once fully cured into a hard rigid solid, thermoset resins do not undergo significant softening when heated, but instead thermally decompose when sufficiently heated. Notable examples of thermoset resins include epoxy, bismaleimide (BMI), and polyimide resins.

Instead of using a prepreg, in another non-limiting example, with the use of thermoplastic polymers, it is possible to utilize a woven fabric. Woven fabric can include, but is not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg braided architectures can be made in a similar fashion. With this approach, it is possible to tailor the fiber volume of the part by dictating the relative concentrations of the thermoplastic fibers and reinforcement fibers that have been woven or braided together. Additionally, different types of reinforcement fibers can be braided or woven together in various concentrations to tailor the properties of the part. For example, glass fibers, carbon fibers, and thermoplastic fibers could all be woven together in various concentrations to tailor the properties of the part. The carbon fibers provide the strength of the system, the glass fibers can be incorporated to enhance the impact properties, which is a design characteristic for parts located near the inlet of the engine, and the thermoplastic fibers provide the binding for the reinforcement fibers.

In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of a composite component. Generally, RTM includes the application of dry fibers or matrix material to a mold or cavity. The dry fibers or matrix material can include prepreg, braided material, woven material, or any combination thereof.

Resin can be pumped into or otherwise provided to the mold or cavity to impregnate the dry fibers or matrix material. The combination of the impregnated fibers or matrix material and the resin are then cured and removed from the mold. When removed from the mold, the composite component can require post-curing processing.

It is contemplated that RTM can be a vacuum assisted process. That is, the air from the cavity or mold can be removed and replaced by the resin prior to heating or curing. It is further contemplated that the placement of the dry fibers or matrix material can be manual or automated.

The dry fibers or matrix material can be contoured to shape the composite component or direct the resin. Optionally, additional layers or reinforcing layers of material differing from the dry fiber or matrix material can also be included or added prior to heating or curing.

The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

The inventors have sought to maximize efficiency of turbine engines during in-flight propulsion of an aircraft, and correspondingly reduce fuel consumption. In particular, the inventors were focused on how the fan of a ducted turbine engine can be improved. The inventors, in consideration of several different engine architectures proposed, considered how the fan module would need to change to achieve mission requirements, and/or how the fan module could improve upon an existing engine efficiency and/or fuel consumption. The inventors looked at several engine architectures, then determined how the number of fan blades utilized with a fan, average chord width of the fan blades, diameter of the fan blade, fan pressure ratio, fan tip speed, and hub-to-tip ratio affect engine efficiency and/or fuel consumption.

The inventors found that in some engines, an excess number of fan blades may add unnecessary cost to the engine design without appreciable benefit, and may also add unnecessary weight to an aircraft, thereby reducing overall fuel efficiency (e.g., due to increased fuel burn). A reduction in fan blade quantity, however, was found to potentially lead to a reduction in total fan blade area desired for efficient propulsion, fan aeromechanical stability and operability, etc. The inventors considered increasing the width or fan chord of the fan blades to achieve a desired fan blade area with a lower fan blade count. Such considerations were found to be of particular interest when the engine had a higher bypass ratio (i.e., lower fan pressure ratio), and when the engine had a lower blade tip speed.

The determination of the fan blade count and average fan chord for achieving a desired efficiency often required a time consuming, iterative process. As explained in greater detail below, after evaluation of numerous turbine engine architectures having different fan blade counts and average fan chords, it was found, unexpectedly, that there exist certain relationships between a fan or fan blade diameter, a fan pressure ratio, and a redline corrected fan tip Mach number of the turbine engine that identify an average fan chord needed to produce improved results in terms of engine efficiency. It was further found, unexpectedly, that there exist certain relationships between turbine engine parameters including a hub-to-tip ratio of the fan, a fan pressure ratio, and a redline corrected fan tip Mach number of the turbine engine that identify a fan blade count needed to produce improved results in terms of engine efficiency.

Various aspects of the present disclosure describe aspects of an aircraft turbine engine characterized in part by an increased average fan chord width and a reduced blade count, which are believed to result in an improved engine aerodynamic efficiency and/or improved fuel efficiency. According to the disclosure, a turbomachine for powering an aircraft in flight comprises an annular casing and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing.

Reference will now be made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosure.

Referring now to the drawings, wherein identical numerals indicate the same elements throughout the figures, FIG. 1 is a schematic, cross-sectional view of a turbomachine, more specifically a gas turbine engine, in accordance with an exemplary embodiment of the present disclosure. More particularly, for the embodiment of FIG. 1, the gas turbine engine is a high-bypass turbofan jet engine 10, referred to herein as “turbofan jet engine 10.” As shown in FIG. 1, the turbofan jet engine 10 defines an axial direction A (extending parallel to a longitudinal centerline 12 provided for reference) and a radial direction R. In general, the turbofan jet engine 10 includes a fan section 14 and a core turbine engine 16 disposed downstream from the fan section 14.

The exemplary core turbine engine 16 depicted generally includes a substantially tubular outer casing 18 that defines an annular inlet 20. The outer casing 18 encases, in serial flow relationship, a compressor section including a booster or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; a turbine section including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and a jet exhaust nozzle section 32. A high pressure (HP) shaft or spool 34 drivingly connects the high pressure turbine 28 to the high pressure compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the low pressure turbine 30 to the low pressure compressor 22.

Fan blades 40 extend outwardly from disk 42 generally along the radial direction R. For the embodiment depicted, the fan section 14 includes a variable pitch fan 38 having a plurality of fan blades 40 coupled to a disk 42 in a spaced apart manner. One or more of the fan blades 40 may rotatable relative to the disk 42 about a pitch axis P by virtue of the fan blades 40 being operatively coupled to a suitable actuation member 44 configured to vary the pitch of the fan blades 40, typically collectively in unison. In some approaches, the fan is a fixed pitch fan and actuation member 44 is not present. The fan blades 40, disk 42, and actuation member 44 may be together rotatable about the longitudinal centerline 12 by low pressure spool 36 across a power gear box 46. The power gear box 46 includes a plurality of gears for stepping down the rotational speed of the low pressure spool 36 to a more efficient rotational fan speed. In some approaches, the low pressure spool 36 may directly drive the fan without power gear box 46.

The power gear box 46 can include a plurality of gears, including an input and an output, and may also include one or more intermediate gears disposed between and/or interconnecting the input and the output. The input can comprise a first rotational speed and the output can have a second rotational speed. In some examples, a gear ratio of the first rotational speed to the second rotational speed is equal to or greater than 3.2 and equal to or less than 5.0. The power gear box 46 can comprise various types and/or configurations. In some examples, the power gear box 46 is a single-stage gear box. In other examples, the power gear box 46 is a multi-stage gear box. In some examples, the power gear box 46 is an epicyclic gearbox. In some examples, the power gear box 46 is a non-epicyclic gear box (e.g., a compound gearbox). More particularly, in some instances, the power gear box 46 is an epicyclic gear box configured in a star gear configuration. Star gear configurations comprise a sun gear, a plurality of star gears (which can also be referred to as “planet gears”), and a ring gear. The sun gear is the input and is coupled to the power turbine (e.g., the low-pressure turbine) such that the sun gear and the power turbine rotate at the same rotational speed. The star gears are disposed between and interconnect the sun gear and the ring gear. The star gears are rotatably coupled to a fixed carrier. As such, the star gears can rotate about their respective axes but cannot collectively orbit relative to the sun gear or the ring gear. As another example, the power gear box 46 is an epicyclic gear box configured in a planet gear configuration. Planet gear configurations comprise a sun gear, a plurality of planet gears, and a ring gear. The sun gear is the input and is coupled to the power turbine. The planet gears are disposed between and interconnect the sun gear and the ring gear. The planet gears are rotatably coupled to a rotatable carrier. As such, the planet gears can rotate about their respective axes and also collectively rotate together with the carrier relative to the sun gear and the ring gear. The carrier is the output and is coupled to the fan assembly. The ring gear is fixed from rotation.

Referring still to the exemplary embodiment of FIG. 1, the disk 42 is covered by rotatable front hub 48 aerodynamically contoured to promote an airflow through the plurality of fan blades 40. Additionally, the exemplary fan section 14 includes an annular fan casing or outer nacelle 50 that circumferentially surrounds the variable pitch fan 38 and/or at least a portion of the core turbine engine 16. It should be appreciated that the outer nacelle 50 may be configured to be supported relative to the core turbine engine 16 by a plurality of circumferentially spaced outlet guide vanes 52. Moreover, a downstream section 54 of the outer nacelle 50 may extend over an outer portion of the core turbine engine 16 so as to define a bypass airflow passage 56 therebetween.

During operation of the turbofan jet engine 10, a volume of air 58 enters the turbofan jet engine 10 through an associated inlet 60 of the outer nacelle 50 and/or fan section 14. As the volume of air 58 passes across the fan blades 40, a first portion 62 of the air 58 as indicated by arrow 62 is directed or routed into the bypass airflow passage 56 and a second portion 64 of the air 58 as indicated by arrow 64 is directed or routed into the low pressure compressor 22. The ratio between the first portion 62 of air 58 and the second portion 64 of air 58 is commonly known as a bypass ratio. The pressure of the second portion 64 of air 58 is then increased as it is routed through the high pressure (HP) compressor 24 and into the combustion section 26, where it is mixed with fuel and burned to provide combustion gases 66. Subsequently, the combustion gases 66 are routed through the high pressure turbine 28 and the low pressure turbine 30, where a portion of thermal and/or kinetic energy from the combustion gases 66 is extracted.

The combustion gases 66 are then routed through the jet exhaust nozzle section 32 of the core turbine engine 16 to provide propulsive thrust. Simultaneously, the pressure of the first portion 62 of air 58 is substantially increased as the first portion 62 of air 58 is routed through the bypass airflow passage 56 before it is exhausted from a fan nozzle exhaust section 76 of the turbofan jet engine 10, also providing propulsive thrust.

It should be appreciated, however, that the turbofan jet engine 10 depicted in FIG. 1 is by way of example only, and that in other exemplary embodiments, aspects of the present disclosure may additionally, or alternatively, be applied to any other suitable gas turbine engine. For example, in other exemplary embodiments, the turbofan jet engine 10 may instead be any other suitable aeronautical gas turbine engine, such as a turbojet engine, turboshaft engine, turboprop engine, etc. Additionally, in still other exemplary embodiments, the turbofan jet engine 10 may include or be operably connected to any other suitable accessory systems. Additionally, or alternatively, the exemplary turbofan jet engine 10 may not include or be operably connected to one or more of the accessory systems discussed above.

The fan blades 40 of the jet engine 10 may be made from a PMC material with metal leading edges to protect the airfoil from foreign objects, such as bird strikes. A polymer matrix composite (PMC) material for the airfoil can be more durable and/or exhibit improved performance when the airfoil is subjected to flutter effects during operation. In some embodiments, engines with fewer fan blades (e.g., less than 25 fan blades) and wider chords (c), such as engines having a blade count (BC) from 14 and 18, or 16 to 20 fan blades and ratios of chord to diameter (c/D) of greater than 0.17, or greater than 0.19, and less than 0.3 (e.g., less than 0.21) have the fan blade airfoil made from a PMC material with metal leading edge.

FIG. 2 is a sectional view of a fan blade 40 viewed radially (e.g., towards the rotation axis). A first axis 100 is parallel to the axial direction A of FIG. 1, and a second axis 102 is parallel to the circumferential direction θ.

Fan blade 40 includes a low-pressure surface 110 and an opposite high-pressure surface 112 that each extend between a proximal end 40a and a distal end 40b of the fan blade 40 (shown in FIG. 1). Fan blade 40 further includes a leading edge 114 and a trailing edge 116.

The low-pressure surface 110, high-pressure surface 112, leading edge 114, and trailing edge 116 form a profile 118 of the fan blade 40. The profile 118 defines a mean camber 120 that extends from the leading edge 114 to the trailing edge 116 and that is equidistant from the low-pressure surface 110 and the high-pressure surface 112.

The profile 118 further defines a local chord 122 (relative to a specific cross section through the blade) that represents a straight-line distance from the leading edge 114 to the trailing edge 116.

In some approaches, a fan blade 40 may have a profile 118 that varies along a radial height of the fan blade 40 between the proximal end 40a and the distal end 40b. For example, in some fan blade designs, a distance between the leading edge 114 and the trailing edge 116 may be greater at the proximal end 40a of the fan blade 40 than at the distal end 40b. As such, the length of the chord line 122 may vary along the radial height of the fan blade 40. In this way, an average chord line length may be derived for the fan blade that accounts for the variation in chord line lengths 122 along the radial height of the fan blade 40.

As mentioned earlier, the inventors have discovered relationships between timescales that include a fan pressure ratio, fan diameter, and corrected fan tip Mach number during the course of improving upon the fan module portion of various engine architectures. More particularly, and as discussed in greater detail below, the inventors have discovered relationships between ratio of axial flow timescales to rotation timescales, and suitable parameters for implementing those relationships with an engine.

The aircraft turbine engine architectures developed by the inventors include as major components a fan module and an engine core. The core includes one or more compressor stages and turbine stages. Compressor stages typically include high pressure and low pressure compressor stages, and turbines similarly include high and low pressure stages. The fan module that provides for an improved efficiency is not independent of these other parts of the engine, because there is always a trade benefit when one part is improved or modified. Improved efficiency brought by the fan can be in terms of a reduction in weight, lower installed drag, load balancing or management (dynamic or static loading), aerodynamic efficiency through the fan duct/interaction of fan to output guide vanes, and other factors. In an effort to improve upon what the fan can deliver (positive benefit of fan design) there often times need to be sacrifices in other parts of the engine (negative benefit of fan design). Or the benefits of a new fan design when viewed independent of a particular core design or airframe requirement, often times requires revision or is unrealistic given the impact that such a fan design will have on other parts of the engine, e.g., compressor operating margin, balance of a fan and output guide vanes (OGV) along with a power gearbox, and location of a low pressure compressor (packaging impacts). The teachings described herein are also applicable to other engine architectures such as electrically-driven fans (which may or may not include a turbine) and hybrid electrically-driven fans (e.g., distributed electric propulsion systems in which a gas turbine drives multiple fans).

The inventors, proceeding in the manner of designing improved fan modules, accounting for the trade-offs between fan module improvements and other potentially negative or limitations on fan module design, unexpectedly found certain relationships that define an improved fan design, now described in detail.

In one aspect, the inventors have discovered a relationship between an average fan chord “c”, a fan diameter “D” (e.g., a tip-to-tip dimension of the fan), a fan pressure ratio “FPR” of a fan, and a corrected redline fan tip Mach number “M_tip,c^(RL)” according to the below relationship, referred to herein as the First Performance Factor (“FPF”) for a fan module:

$\begin{array}{cc}\mathrm{FPF}=\left[\frac{c}{0.15·D}\right]/\left[\left[\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right]/M_{\mathrm{tip},c}^{\left(RL\right)}\right]-1\text{.23}& \left(1\right)\end{array}$ $\begin{array}{cc}{m}_1·\left[M_{\mathrm{tip},c}^{\left(RL\right)}-1.1\right]+6>\mathrm{FPF}>m_1·\left[M_{\mathrm{tip},c}^{\left(RL\right)}-1.1\right]+\Delta y_1& \left(2\right)\end{array}$

The ratio of average fan chord “c” to fan diameter “D” is a nondimensionalized chord width ratio greater than 0.1 (e.g., greater than 0.15, greater than 0.17, or greater than 0.19), and less than 0.3 (e.g., less than 0.21).

As used herein, the “fan pressure ratio” (FPR) refers to a ratio of a stagnation pressure immediately downstream of the plurality of outlet guide vanes 52 during operation of the fan 38 to a stagnation pressure immediately upstream of the plurality of fan blades 40 during the operation of the fan 38. The “√{square root over (FPR−1)}” portion of the average fan chord relationship may be utilized as a surrogate for referencing a proportionality to the increase in axial flow velocity through the fan. The fan pressure ratio is greater than 1.2 (e.g., greater than 1.3), and less than 1.5 (e.g., less than 1.45, less than 1.42, or less than 1.4).

As used herein, “M_tip,c^(RL)” is a corrected fan tip Mach number at redline (e.g., maximum permissible rotational speed of the fan at a redline shaft speed, which is either directly coupled to the fan or through a reduction gearbox). “Fan tip speed” refers to a linear speed of an outer tip of a fan blade 40 during operation of the fan 38. “Corrected fan tip speed” (referred to as “U_tip,c”) may be provided, for example, as ft/sec divided by an industry standard temperature correction. In an example approach, U_tip,c may be less than 1,500 ft/sec (e.g., less than 1,250 ft/sec or less than 1,100 ft/sec), and greater than 500 ft/sec. “Corrected fan tip Mach number” refers to a nondimensionalized value obtained by dividing U_tip,c by the generally accepted speed of sound at standard day sea level atmospheric conditions (i.e., 1,116.45 ft/sec). As such, M_tip,c^(RL) may be less than 1.34 (e.g., less than 1.12 or less than 0.99), and greater than 0.45.

FPF, as defined in (1), may be thought of as representing a ratio of speeds. When considered with the normalized chord width “c/D,” FPF may be thought of as a correlation of timescales of the blade rotation with the time taken for a flow particle to traverse a fan average chord length when the engine is operating at static conditions.

Referring to the inequality defined in (2) and to the plot of FIG. 3, example engine embodiments are shown having unique FPF values and corresponding redline corrected fan tip Mach number (M_tip,c^(RL)). FPF increases in value along the Y-axis, while the X-axis represents left-to-right increasing redline corrected fan tip Mach number (M_tip,c^(RL)). FIG. 3 also shows a first line 200 and a second line 202 that is offset from the first line 200 along the Y-axis. The first and second lines 200, 202 are defined by the “m₁·[M_tip,c^(RL)−1.1]+Δy₁” portion of inequality (2). As used herein, “m₁” refers to a slope of a line 200, 202, “1.1” refers to a reference corrected redline tip Mach number at which Y-intercept is defined in the FPF, and Δy₁ refers an offset from the Y-intercept along the Y-axis.

As shown in FIG. 3, the first and second lines 200, 202 are piecewise linear dividing curves; i.e., the first and second lines 200, 202 have different slopes “m₁” depending on the M_tip,c^(RL) along the X-axis. More particularly, when the value of M_tip,c^(RL) is equal to or greater than 1.1, the first and second lines 200, 202 have slopes “m₁” equal to 0.87. When the value of M_tip,c^(RL) is less than 1.1, the first and second lines 200, 202 have slopes “m” equal to 3.34. While depicted as piecewise linear dividing curves, the low-speed scaling is actually nonlinear and there are advantages to lower c/D designs toward the lower portion of the plot of FIG. 3 associated with lower FPR and lower M_tip,c^(RL).

As discussed, Δy₁ refers an offset from the Y-intercept along the Y-axis. The Δy₁ value can be 0.0125, 0.04, 0.07, 0.1, or 0.2, or can vary between 0 and 6, 0 and 0.0125, 0.0125 and 0.04, 0.04 and 0.07, 0.07 and 0.1, 0.1 and 0.2, or a value greater than 0.2 and less than 6.

FIG. 3 shows eight example engine embodiments, of which engines 210, 212, 214, 216 may be referred to as low speed engine designs (as indicated by subplot area 218), and engines 220, 222, 224, 226 may be referred to as high speed engine designs (as indicated by subplot area 228). Each of the engines 210, 212, 214, 216, 220, 222, 224, 226 have a gear ratio in a range equal to or greater than 3.2 and less than or equal to 5.0.

As represented by the FPF, which indicates a particular fan chord relationship, the inventors discovered a limited or narrowed selection of average fan chords that uniquely take into consideration other factors associated with the fan and engine type. For instance, the inventors determined that an engine having an FPF value for a given M_tip,c^(RL) value above line 200 (within plot area 240) may allow for relatively wider chord widths as compared to engines having an FPF value for a given M_tip,c^(RL) value below line 200 (within plot area 242). In this way, engines 214, 216, 224, and 226 may provide advantages over engines 210, 212, 220, and 222, such as a reduced fan blade count (discussed in greater detail below), increased aeromechanical stability and reduced fan lift coefficient C_L during takeoff of the aircraft. In some instances, such advantages may become more pronounced as FPF increases and M_tip,c^(RL) value decreases (for next generation ultra-high bypass ratio engines for instance). For example, the improvement in engine performance based on the redline tip Mach number may have FPF values greater than m₁·[M_tip,c^(RL)−1.1]+0.0125, greater than m₁·[M_tip,c^(RL)−1.1]+0.04, greater than m₁·[M_tip,c^(RL)−1.1]+0.07, greater than m₁·[M_tip,c^(RL)−1.1]+0.1, or greater than m₁·[M_tip,c^(RL)−1.1]+0.2 (these other examples are schematically represented by the phantom line 202).

In another aspect, the inventors have discovered a relationship between a fan blade count “BC”, a hub-to-tip ratio of a fan “HTR”, a fan pressure ratio “FPR” of a fan, and a corrected redline fan tip Mach number “M_tip,c^(RL)”, according to the below relationship, referred to herein as the Second Performance Factor (“SPF”) for a fan module:

$\begin{array}{cc}\mathrm{SPF}=\sqrt{\frac{\pi }{4}\left(1-{\mathrm{HTR}}^2\right)/\left(\frac{BC}{20}\right)}/\left(\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right)/M_{t\mathrm{ip},c}^{\left(RL\right)}-0.97& \left(3\right)\end{array}$ $\begin{array}{cc}{m}_2·\left[M_{t\mathrm{ip},c}^{\left(RL\right)}-1.1\right]+1.5>\mathrm{SPF}>m_2·\left[M_{t\mathrm{ip},c}^{\left(RL\right)}-1.1\right]+\Delta y_2& \left(4\right)\end{array}$

Regarding the hub-to-tip ratio “HTR,” a fan blade defines a hub radius (R_hub), which is the radius of the leading edge at the hub relative to a centerline of the fan, and a tip radius (R_tip), which is the radius of the leading edge at a tip of the fan blade relative to the centerline of the fan. HTR is the ratio of the hub radius to the tip radius (R_hub/R_tip). The ratio is greater than 0.1 and less than 0.5 (e.g., less than 0.275, less than 0.25, or less than 0.225).

Blade count “BC” corresponds to the number of fan blades circumferentially arranged about the fan hub. The blade count is between 10 fan blades and 40 fan blades. In certain example approaches, the blade count is less than or equal to 18 fan blades (e.g., 16 or fewer fan blades).

“FPR” and “M_tip,c^(RL)” refer to a fan pressure ratio and a redline corrected fan tip Mach number, respectively, as discussed with respect to the average fan chord relationship above. In this way, the values of one or more of the FPR and “M_tip,c^(RL)” may be the same as those discussed with respect to the average fan chord relationship.

Referring to the inequality defined in (4) and to the plot of FIG. 4, example engine embodiments are shown having unique SPF values and corresponding redline corrected fan tip Mach number (M_tip,c^(RL)). SPF increases in value along the Y-axis, while the X-axis represents left-to-right increasing redline corrected fan tip Mach number (M_tip,c^(RL)). FIG. 4 also shows a first line 300 and a second line 302 that is offset from the first line 300 along the Y-axis. The first and second lines 300, 302 are defined by the “m₂·[M_tip,c^(RL)−1.1]+Δy₂” portion of inequality (4).

As shown in FIG. 4, the first and second lines 300, 302 are piecewise linear dividing curves; i.e., the first and second lines 300, 302 have different slopes “m₂” depending on the M_tip,c^(RL) along the X-axis. More particularly, when the value of M_tip,c^(RL) is equal to or greater than 1.1, the first and second lines 300, 302 have slopes “m₂” equal to 0.41. When the value of M_tip,c^(RL) is less than 1.1, the first and second lines 300, 302 have slopes “m₂” equal to 0.55.

As used herein, “m₂” refers to a slope of a line 300, 302, which as shown, is equal to 1. “1.1” refers to a reference corrected redline tip Mach number at which the Y-intercept is defined, and Δy₂ refers an offset from the Y-intercept along the Y-axis. The Δy₂ value can be 0.0075, 0.01, 0.02, 0.024, 0.037, 0.04, or 0.06, or can vary between 0 and 1.5, 0 and 0.0075, 0.0075 and 0.01, 0.01 and 0.2, 0.2 and 0.024, 0.024 and 0.037, 0.037 and 0.04, 0.04 and 0.6, or a value greater than 0.6 and less than 1.5.

FIG. 4 shows eight example engine embodiments, of which engines 310, 312, 314, 316 may be referred to as low speed engine designs (as indicated by subplot area 318), and engines 320, 322, 324, 326 may be referred to as high speed engine designs (as indicated by subplot area 328). Each of the engines 310, 312, 314, 316, 320, 322, 324, 326 have a gear ratio a range equal to or greater than 3.2 and less than or equal to 5.0.

As represented by the SPF, which indicates a particular fan blade count relationship, the inventors discovered a limited or narrowed selection of fan blade count that uniquely take into consideration other factors associated with the fan and engine type. For instance, the inventors determined that an engine having an SPF value for a given M_tip,c^(RL) value above line 300 (within plot area 340) may allow for reduced fan blade counts as compared to engines having an SPF value for a given M_tip,c^(RL) value below line 300 (within plot area 342). In this way, engines 314, 316, 324, and 326 may provide advantages over engines 310, 312, 320, and 322, such as a reduced cost and weight. In some instances, such advantages may become more pronounced as the SPF value increases and the M_tip,c^(RL) value decreases (for next generation ultra-high bypass ratio engines for instance). For example, the improvement in engine performance based on the redline tip Mach number may have SPF values greater than m₂·[M_tip,c^(RL)−1.1]+0.0075, greater than m₂·[M_tip,c^(RL)−1.1]+0.01, greater than m₂·[M_tip,c^(RL)−1.1]+0.02, greater than m₂·[M_tip,c^(RL)−1.1]+0.024, greater than m₂·[M_tip,c^(RL)−1.1]+0.037, greater than m₂·[M_tip,c^(RL)−1.1]+0.04, or greater than m₂·[M_tip,c^(RL)−1.1]+0.06 (these other examples are schematically represented by the phantom line 302).

FIG. 5 shows additional example engine embodiments 402, 404, 406, 408 having First Performance Factor (FPF) values, as similarly described herein. Line 400 is a piecewise linear dividing curve having different slopes “m₁” depending on the M_tip,c^(RL) along the X-axis. More particularly, when the value of M_tip,c^(RL) is equal to or greater than 1.1, line 400 has a slope “m₁” equal to 9.43. When the value of M_tip,c^(RL) is less than 1.1, line 400 has a slope “m₁” equal to 27.02.

Line 420 corresponds to line 200 of FIG. 3 and is similarly a piecewise linear dividing curve having different slopes “m₂” depending on the M_tip,c^(RL) along the X-axis. As with FIG. 3, when the value of M_tip,c^(RL) is equal to or greater than 1.1, the line 420 has a slope “m₂” equal to 0.87. When the value of M_tip,c^(RL) is less than 1.1, line 420 has a slope “m₂” equal to 3.34.

In this approach, the First Performance Factor (FPF) is as provided:

$\begin{array}{cc}\mathrm{FPF}=\left[\frac{c}{0.15·D}\right]/\left[\left[\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right]/M_{t\mathrm{ip},c}^{\left(RL\right)}\right]-1\text{.23}& \left(5\right)\end{array}$ $\begin{array}{cc}{m}_1·\left[M_{t\mathrm{ip},c}^{\left(RL\right)}-1.1\right]+9\text{.14}>\mathrm{FPF}>m_2·\left[M_{t\mathrm{ip},c}^{\left(RL\right)}-1.1\right]& \left(6\right)\end{array}$

The First Performance Factor (FPF) values may be in the range, for example, equal to or greater than −0.8 and equal to or less than 8.4, equal to or greater than 0 and equal to or less than 6, or equal to or greater than 1 and equal to or less than 2. M_tip,c^(RL) values may be within a range equal to or greater than 0.8 and equal to or less than 1.5, or equal to or greater than 0.9 and equal to or less than 1.4. FPR values may be within a range equal to or greater than 1.2 and equal to or less than 1.6, equal to or greater than 1.3 and equal to or less than 1.5, or equal to or greater than 1.35 and equal to or less than 1.45.

FIG. 6 shows additional example engine embodiments 452, 454, 456, 458 having Second Performance Factor (SPF) values, as similarly described herein. Line 450 is a linear curve having slope “m₃” of 3.17. Line 470 corresponds to line 300 of FIG. 4 and is similarly a piecewise linear dividing curve having different slopes “m₄” depending on the M_tip,c^(RL) along the X-axis. More particularly, when the value of M_tip,c^(RL) is equal to or greater than 1.1, line 470 has a slope “m₄” equal to 0.41. When the value of M_tip,c^(RL) is less than 1.1, line 420 has a slope “m₄” equal to 0.55.

In this approach, the Second Performance Factor (SPF) is as provided:

$\begin{array}{cc}\mathrm{SPF}=\sqrt{\frac{\pi }{4}\left(1-{\mathrm{HTR}}^2\right)/(\frac{BC}{20}})/\left(\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right)/M_{t\mathrm{ip},c}^{\left(RL\right)}-0\text{.97}& \left(7\right)\end{array}$ $\begin{array}{cc}{m}_3·\left[M_{t\mathrm{ip},c}^{\left(RL\right)}-1.1\right]+2\text{.52}>\mathrm{SPF}>m_4·\left[M_{t\mathrm{ip},c}^{\left(RL\right)}-1.1\right]& \left(8\right)\end{array}$

The Second Performance Factor (SPF) values may be in the range, for example, equal to or greater than 0.087 and equal to or less than 2.4, or equal to or greater than 1 and equal to or less than 2. M_tip,c^(RL) values may be within a range equal to or greater than 0.8 and equal to or less than 1.5, or equal to or greater than 0.9 and equal to or less than 1.4. HTR values may be within a range equal to or greater than 0.2 and equal to or less than 0.4, or equal to or greater than 0.25 and equal to or less than 0.35.

The inventors have discovered a relationship between the First Performance Factor and Second Performance Factor described herein. More particularly, the inventors have discovered that engine designs achieving each of the First Performance Factor and Second Performance Factor, while maintaining relatively-constant solidity, provide improved engine performance. Blade solidity is defined as the ratio of the blade chord length to the distance of space between the blades.

Example engine parameters and corresponding First Performance Factors and Second Performance Factors are presented in Table 1 below.

	TABLE 1
	Example	HTR	FPR	Mtip,c(RL)	SPF	FPF
	1	0.206	1.522	1.417	1.782	2.374
	2	0.400	1.376	1.421	0.981	0.976
	3	0.260	1.204	1.177	0.823	2.722
	4	0.224	1.595	0.976	0.646	−0.359
	5	0.213	1.517	0.815	0.613	−0.823
	6	0.265	1.448	1.497	1.152	1.161
	7	0.352	1.250	0.962	0.087	−0.445
	8	0.394	1.328	1.228	2.403	6.606
	9	0.213	1.517	0.815	0.613	−0.823
	10	0.235	1.240	1.231	2.053	8.398

In this way, using fan parameters such as fan pressure ratios, corrected fan tip Mach number, fan diameters, and hub-to-tip ratios, the inventors discovered approaches that utilize the above-described average fan chord relationship to obtain an average chord width, and the above-described fan blade count relationship to obtain a fan blade count. These obtained constraints guide one to select fan chord width, blade count, or both suited for the particularized engine architectures and mission requirements, informed by engine-unique environments and trade-offs in design (as discussed above), which are believed to result in an improved engine.

In another aspect, the FPF and SPF may also be useful as a design tool for down-selecting, or providing a guideline for reducing the number of candidate designs for fan blade counts and average fan chords from which to design a fan module for a particular architecture. In this way, an engine architecture is improved overall by knowing, early in the design process, what constraints or limitations would be imposed by a fan module given the mission objectives.

In another aspect method of assembly is provided. The method includes mounting a fan inside an annular casing for rotation about an axial centerline. The fan including fan blades that extend radially outwardly toward the annular casing. The fan further includes an average fan chord width according to the First Performance Factor (“FPF”) and/or a quantity of fan blades according to the Second Performance Factor (“SPF”) discussed above.

As will be appreciated from the description provided herein, a fan blade having reduced weight along with increased stiffness can improve aerodynamic efficiency, fuel efficiency, and durability. A combination of high elongation fiber composite strips used in conjunction with fiber composite layers can provide increased mechanical integrity. Such a hybridized material system can increase the interlaminar fracture resistance relative to single material systems. High elongation fiber composite strips are relatively lightweight, providing a reduced airfoil thickness that results in better aerodynamic performance and improved foreign object damage resistance.

Furthermore, a metal leading edge for a fan blade, as disclosed herein, when combined with a fan module contemplated by the above relationships (1) through (4), can enable the reduced radius ratios noted above to result in compounded performance gains. In particular, by including the metal leading edge disclosed herein, the fan module can define a lower radius ratio while avoiding the unexpected issues noted above associated with a reduced radius ratio. The metal leading edge can therefore be integrated into the fan module contemplated by the above relationships (1) through (4) to further improve performance of the gas turbine engine. For example, the metal leading edge may improve aerodynamic flow through the fan, thereby improving fuel consumption. The metal leading edge may also protect the fan blades from foreign object damage. Additionally, at lower fan pressure ratios (FPR), the First Performance Factor (FPF) and the Second Performance Factor (SPF) parameters drive the fan blade design towards a lower corrected fan tip speed or corrected tip fan tip Mach number, which in turn allows for the selection of a lower fan chord and potentially a reduced blade count (BC). Such a reduction in fan chord and/or tip speed can enable the use of a lighter metal leading edge, which synergistically improves the efficiency of the engine (with FPF and SPF) by reducing the aerodynamic losses and overall system weight and enhancing fuel efficiency.

Accordingly, the inventors of the present disclosure found that the integration of high elongation fiber composite strips used in conjunction with fiber composite layers, as well as metallic leading edge undulations, when incorporated according to the relationships (1) through (4) discussed hereinabove, results in a gas turbine engine synergistic engine improvement in terms of aerodynamic efficiency, fuel efficiency, and durability.

Referring to FIG. 7, as discussed, a fan blade 40 has a low-pressure surface 110, also referred to as a suction side 110, and an opposite high-pressure surface 112, also referred to herein as a pressure side 112. The fan blade 40 extends in a chordwise direction from a leading edge 114 to a trailing edge 116, and extends in a spanwise or radial direction from a root 500 (which may be in the form of a dovetail root) to a tip 502.

FIGS. 8-11 are cross-sectional views of a leading edge 114 of a fan blade 40. A fan blade 40 may be composed of fiber composite or fiber composite layers 504 (e.g., carbon fiber layers) that extend chordwise between the leading edge 114 and the trailing edge 116, and spanwise from the root 500 to the tip 502. The fiber composite may be a material having any (metal or non-metal) fiber filament embedded in any (metal or non-metal) matrix binder. In one embodiment of the invention, the majority of the fan blade is a lay-up of discrete fiber composite laminations. In an exemplary embodiment, the fiber composite is comprised of graphite fiber filaments embedded in an epoxy (e.g., epoxy resin) matrix binder with the resulting composite layer having an elastic modulus of between 124,110 megapascals (MPa) and 165,480 megapascals (MPa) and tensile elongation of between 1.3% and 1.5%, both measured parallel to the fibers. Other choices for the matrix resin include, but are not limited to, bismaleimide, polyimide, polyetherimide, polyetheretherketone, poly(aryl sulfone), polyethersulfone and cyante ester and combinations thereof. In one embodiment the matrix binder includes toughening materials such as rubber particles.

A number of high elongation fiber composite strips 510, 512, and 514 are used to reinforce in areas prone to damage, such as at the leading edge 114, trailing edge 116, both edges 114, 116, or along an outer perimeter of a fan blade 40, including the leading edge 114, trailing edge 116, suction side 110, and pressure side 112. The high elongation fiber composite strips 510, 512, and 514 are layered inwardly from outer surfaces of sides 110, 112. The high elongation fiber composite strips 510, 512, and 514 allow fan blade 10 to deform prior to failure, and also facilitate load distribution over a larger area, reducing the likelihood of local damage.

In FIG. 8, a leading section 520 of the composite fiber 504 is left exposed at the leading edge 114. The high elongation fiber composite strips 510, 512, and 514 have fibers arranged in different orientations. High elongation fiber composite strips 510 have fibers oriented in a direction parallel to the spanwise direction of the blade 40. High elongation fiber composite strips 512 have fibers oriented in a direction 45 degrees relative to the spanwise direction of the blade 40. High elongation fiber composite strips 514 have fibers oriented in a direction −45 degrees relative to the spanwise direction of the blade 40.

In the approach of FIG. 8, the ends of the high elongation fiber composite strips 510, 512, and 514 distanced from leading edge 114 are staggered. That is, the length of each high elongation fiber composite strip 510, 512, and 514 decreases as position from surface of sides 110 and 112 increases. In one approach, the difference d in length between adjacent high elongation fiber composite strips 510, 512, and 514 is at least about 0.1 inches. Alternatively, the difference d may be expressed as a function of strip thickness; e.g., at least 15 times the strip thickness. This tapers the high elongation fiber composite strips 510, 512, and 514 such that the compliant region is longer near the pressure and suction surfaces than in the middle of the fan blade.

The high elongation fiber composite strips 510, 512, and 514 meet the fiber composite layers 504 at a joint 522. The joint may be a butt joint or a small overlap. The high elongation fiber composite strips 510, 512, and 514 may be incorporated in blade 40 during the layup process in which layers of fiber composite and high elongation fiber composite are adhesively bonded or co-cured. The fan blade 40 is constructed from the interior outwards to the suction side 110 and pressure side 112. The fiber composite layers 504 are joined using techniques such as adhesives or co-curing. Once the reinforcement locations are reached, strips of high elongation fiber composite 510, 512, and 514 are joined to the layers of fiber composite 504 using techniques such as adhesives or co-curing.

FIG. 9 is a cross-sectional view of a leading edge 114 of fan blade 40 according to another approach. In the approach of FIG. 9, the high elongation fiber composite strips 510, 512, and 514 wrap around leading edge 114 to cover the leading edge 114. High elongation fiber composite strips 510 have fibers oriented in a direction parallel to the spanwise direction of the blade 40. High elongation fiber composite strips 512 have fibers oriented in a direction 45 degrees relative to the spanwise direction of the blade 40. High elongation fiber composite strips 514 have fibers oriented in a direction −45 degrees relative to the spanwise direction of the blade 40. The high elongation fiber composite strips 510, 512, and 514 meet the fiber composite layers at a joint as described above with reference to FIG. 8.

FIG. 10 is a cross-sectional view of a leading edge 114 of fan blade 40 according to another approach. In the approach of FIG. 10, the ends of the high elongation fiber composite strips 510, 512, and 514 are staggered such that adjacent high elongation fiber composite strips 510, 512, and 514 may have different lengths, but the lengths do not decrease as position from surface of sides 110 and 112 increases. High elongation fiber composite strips 510 have fibers oriented in a direction parallel to the spanwise direction of the blade 40. High elongation fiber composite strips 512 have fibers oriented in a direction 45 degrees relative to the spanwise direction of the blade 40. High elongation fiber composite strips 514 have fibers oriented in a direction −45 degrees relative to the spanwise direction of the blade 40. The high elongation fiber composite strips 20, 22 and 24 meet the fiber composite layers at a joint as described above with reference to FIG. 8.

FIG. 11 is a cross-sectional view of a leading edge 114 of fan blade 40 according to another approach. The approach of FIG. 11 is similar to that in FIG. 10, but only selected fiber composite layers are replaced with high elongation fiber composite strips 512. Thus, a fiber composite layer 504 is interposed between the high elongation fiber composite strips 512 rather than contiguous high elongation fiber composite strips of FIGS. 8-10. High elongation fiber composite strips 512 have fibers oriented in a direction 45 degrees relative to the spanwise direction of the blade 40. The high elongation fiber composite strips 512 meet the fiber composite layers 504 at a joint as described above with reference to FIG. 8.

FIGS. 12-15 are cross-sectional views of fan blade 40 depicting different positions for the high elongation fiber composite strips (e.g., strips 510, 512, and 514). FIG. 12 depicts the high elongation fiber composite strips at the leading edge 114 of fan blade 40. FIG. 13 depicts the high elongation fiber composite strips at the leading edge 114 and trailing edge 116 of fan blade 40. FIG. 14 depicts the high elongation fiber composite strips at the trailing edge 116 of fan blade 40. FIG. 15 depicts the high elongation fiber composite strips across the entire surface of fan blade 40. The thickness of the high elongation fiber composite strips may vary over the surface of the fan blade.

FIG. 16 is a cross-sectional view of a leading edge 114 of a fan blade 40 according to another approach. Fan blade 40 includes a reinforcement 530, which may be a metal guard secured to the leading edge 114. It understood that the reinforcement 530 may be positioned at one or more of the leading edge 114 and trailing edge 116, and may be made from materials other than metal. In addition a coating 532 is shown on the surface of suction side 110, but may be applied on one or both of the surfaces of the suction side 110 and pressure side 112. Coating 532 may be an erosion protection coating, paint, etc.

FIGS. 17-19 show connections of the reinforcement 530 with a composite body 600 of a fan blade 40. In the approach shown, the reinforcement 530 is a leading edge element, and the composite body 600 is a trailing edge element. However, it is to be appreciated that the reinforcement 530 may also or instead be a trailing edge element.

As illustrated in FIG. 17, the fan blade 40 is an assembly that includes reinforcement 530a and composite body 600a. Reinforcement 530a and composite body 600a are brought together by a connection 602, which secures a projection 610 of the composite body 600a and the reinforcement 530 by bonding the projection 610 within a recess 612 of the reinforcement 530a; for example, by an adhesive bond. In the approach shown, the connection 602 includes the recess 612 formed along an aft edge in the reinforcement 530a to receive the projection 612 of the composite body 600a. In another approach, the recess is formed in the composite body 600a, and the projection extends from the reinforcement 530a.

Other exemplary embodiments of securing the reinforcement 530 to the composite body 600 are illustrated in FIGS. 18 and 19. In FIG. 18, a T-shaped end 620 is formed on the composite body 600b to connect with a T-shaped recess 622 in aft edge of the reinforcement 530b. In FIG. 19, a channel 632 is formed in the composite body 600c, and a projection 634 is formed at the aft edge of the reinforcement 530c to fit into the channel 632.

FIG. 20 is a perspective view of an airfoil assembly, referred to herein as airfoil 700, of a fan blade 40. In an exemplary embodiment the airfoil 700 is an outlet guide vane 52 of FIG. 1. Alternatively, the airfoil 700 may be used with, but not limited to, rotor blades, and/or stator vanes/blades.

Similar to the approaches discussed with respect to FIGS. 17-19, the airfoil 700 includes a physically separate leading edge element 710, including a leading edge 712, and trailing edge element 720, having a trailing edge 722. The airfoil includes a pressure side 730 and a suction side 732, where the suction side 732 has a length that is greater than the pressure side 730. The airfoil 700 is further characterized by a chord 740 defined as a length of a straight line from the leading edge 712 to the trailing edge and a camber 742 defined as a length of a line connecting a collection of points midway between the suction side 732 and pressure side 730 of the airfoil 700.

While not necessary, it is contemplated that the leading edge element 710 and the trailing edge element 720 are made of different materials, with the different materials being selected for the different utility of the leading and trailing edge elements 710, 720. The trailing edge element 720 can be formed from a composite into a body having a mounting edge 724 that tapers into the trailing edge; for example, as discussed with respect to FIG. 17. The leading edge element 710 can be made of a metal element.

More particularly, the leading edge element 710 can be made of a metal element machined or case into a 3-D leading edge geometry 750 having both chord 740 and camber 742 variation that includes a plurality of undulations 752 and secured to the mounting edge 724. The undulations 752 can be symmetrical or asymmetrical and can extend partially or fully along the span of the airfoil. Further, the undulations 752 can have any suitable shape, including a wave shape when viewed in planform.

The undulations 752 cause the length of the chord 740 to vary. This variation is dependent on a length y having a distance defined as the length of a line running from a tip to an end of the mounting edge 724. The tip can be anywhere along the leading edge 712. To illustrate, the variations the chord 740 is depicted as two differing lengths, one from the trailing edge 722 to a maximum 760 of the undulation 752, and one from the trailing edge 722 to a minimum 762 of the undulation 752. While the length of the chord 740 changes due to these variations, the length ψ is a variation only within the 3-D leading edge geometry 750 of the leading edge element 710.

Bonding the metal leading edge element 710 to the composite trailing edge element 720 enables the entire contact surface to participate in load management. This increases the efficiency of the load allowing for the thickness and weight of both the metal and composite materials to be reduced.

The metal forming the leading edge element 712 is easily shaped to make the 3-D leading edge geometry 750, and while it is not necessary that the leading edge element 712 be removable after installation, it is beneficial for it to be so, as it provides for replacement of just the leading edge element 712, not the entire blade assembly, when there is impact damage on the leading edge 712. Removing the leading edge element 710 in a scenario where damage has occurred to the leading edge 712 is possible without damaging the trailing edge element 720. That is, the leading edge element 710 is designed to be taken off and replaced without damaging any surrounding parts. Such design also allows for application of 3-D geometric features to composite airfoils without having to modify ply orientations. Further, the 3-D features, which include both camber and chord variation as a function of radial span, are effective in reducing noise and increasing performance.

This written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Further aspects are provided by the subject matter of the following clauses:

A turbomachine for an aircraft, comprising: an annular casing; and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing; wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“M_tip,c^(RL)”), according to a First Performance Factor; wherein

$\mathrm{FPF}=\left[\frac{c}{0.15·D}\right]/\left[\left[\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right]/M_{t\mathrm{ip},c}^{\left(RL\right)}\right]-1.23,$

and wherein m₁·[M_tip,c^(RL)−1.1]+6>FPF>m₁·[M_tip,c^(RL)−1.1]+Δy₁, and wherein 0<Δy₁<6.

The turbomachine of one or more of these clauses wherein M_tip,c^(RL) is within a range equal to or greater than 0.45 and equal to or less than 1.34.

The turbomachine of one or more of these clauses wherein M_tip,c^(RL) is within a range equal to or greater than 0.45 and equal to or less than 1.12.

The turbomachine of one or more of these clauses wherein m₁ is equal to 0.87 when M_tip,c^(RL) is greater than or equal to 1.1.

The turbomachine of one or more of these clauses wherein m₁ is equal to 1.0 when M_tip,c^(RL) is greater than or equal to 1.1.

The turbomachine of one or more of these clauses wherein m₁ is equal to 2.5 when M_tip,c^(RL) is less than 1.1.

The turbomachine of one or more of these clauses wherein m₁ is equal to 3.34 when M_tip,c^(RL) is less than 1.1.

The turbomachine of one or more of these clauses wherein Δy₁ is equal to or greater than 0.0125 and less than 6.

The turbomachine of one or more of these clauses wherein Δy₁ is equal to or greater than 0.04 and less than 6.

The turbomachine of one or more of these clauses wherein Δy₁ is equal to or greater than 0.07 and less than 6.

The turbomachine of one or more of these clauses wherein Δy₁ is equal to or greater than 0.1 and less than 6.

The turbomachine of one or more of these clauses wherein Δy₁ is equal to or greater than 0.2 and less than 6.

The turbomachine of one or more of these clauses wherein the turbomachine has a gear ratio within a range equal to or greater than 3.2 and equal to or less than 5.0.

The turbomachine of one or more of these clauses wherein the fan blade includes an airfoil portion made from a polymer matrix composite (PMC) material, a metallic leading edge, the ratio c/D is between 0.16 and 0.21, and the fan has between 16 and 25 fan blades.

The turbomachine of one or more of these clauses wherein ratio c/D is within a range equal to or greater than 0.1 and equal to or less than 0.3.

The turbomachine of one or more of these clauses wherein ratio c/D is within a range equal to or greater than 0.15 and equal to or less than 0.21.

The turbomachine of one or more of these clauses wherein ratio c/D is equal to or greater than 0.1.

The turbomachine of one or more of these clauses wherein ratio c/D is equal to or less than 0.3.

The turbomachine of one or more of these clauses wherein FPR is within a range equal to or greater than 1.2 and equal to or less than 1.5.

The turbomachine of one or more of these clauses wherein FPR is within a range equal to or greater than 1.3 and equal to or less than 1.45.

The turbomachine of one or more of these clauses wherein FPR is equal to or greater than 1.2.

The turbomachine of one or more of these clauses wherein FPR is equal to or greater than 1.3.

The turbomachine of one or more of these clauses wherein FPR is equal to or less than 1.5.

The turbomachine of one or more of these clauses wherein FPR is equal to or less than 1.45.

The turbomachine of one or more of these clauses wherein U_c(tip) is within a range equal to or greater than 500 ft/sec and equal to or less than 1,500 ft/sec.

The turbomachine of one or more of these clauses wherein U_c(tip) is within a range equal to or greater than 500 ft/sec and equal to or less than 1,250 ft/sec.

A turbomachine comprising: an annular casing; and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing; wherein the fan includes a fan hub-to-tip ratio (“HTR”), a fan blade count (“BC”), a fan pressure ratio (“FPR”), and a redline corrected redline fan tip Mach number (“M_tip,c^(RL)”) according to a Second Performance Factor (“SPF”),

$\mathrm{SPF}=\sqrt{\frac{\pi }{4}\left(1-{\mathrm{HTR}}^2\right)\left(\frac{\mathrm{BC}}{20}\right)}/\left(\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right)/M_{\mathrm{tip},c}^{\left(\mathrm{RL}\right)}-0.97,$

wherein m₂·[M_tip,c^(RL)−1.1]+1.5>SPF>m₂·[M_tip,c^(RL)−1.1]+Δy₂, and wherein 0<Δy₂<1.5.

The turbomachine of one or more of these clauses wherein Δy₂ is equal to or greater than 0.0075 and less than 1.5.

The turbomachine of one or more of these clauses wherein Δy₂ is equal to or greater than 0.01 and less than 1.5.

The turbomachine of one or more of these clauses wherein Δy₂ is equal to or greater than 0.02 and less than 1.5.

The turbomachine of one or more of these clauses wherein Δy₂ is equal to or greater than 0.024 and less than 1.5.

The turbomachine of one or more of these clauses wherein Δy₂ is equal to or greater than 0.037 and less than 1.5.

The turbomachine of one or more of these clauses wherein Δy₂ is equal to or greater than 0.04 and less than 1.5.

The turbomachine of one or more of these clauses wherein Δy₂ is equal to or greater than 0.06 and less than 1.5.

The turbomachine of one or more of these clauses wherein m₂ is equal to 0.41 when M_tip,c^(RL) is greater than or equal to 1.1.

The turbomachine of one or more of these clauses wherein m₂ is equal to 0.55 when M_tip,c^(RL) is less than 1.1.

The turbomachine of one or more of these clauses wherein HTR is within a range equal to or greater than 0.1 and equal to or less than 0.5.

The turbomachine of one or more of these clauses wherein HTR is within a range equal to or greater than 0.2 and equal to or less than 0.275.

The turbomachine of one or more of these clauses wherein HTR is within a range equal to or greater than 0.2 and equal to or less than 0.25.

The turbomachine of one or more of these clauses wherein HTR is equal to or greater than 0.1.

The turbomachine of one or more of these clauses wherein HTR is equal to or less than 0.5.

The turbomachine of one or more of these clauses wherein BC is within a range equal to or greater than 10 and equal to or less than 18.

The turbomachine of one or more of these clauses wherein FPR is within a range equal to or greater than 1.2 and equal to or less than 1.5.

The turbomachine of one or more of these clauses wherein FPR is within a range equal to or greater than 1.3 and equal to or less than 1.45.

A method of assembly, comprising: mounting a fan inside an annular casing for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing; wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip redline Mach number (“M_tip,c^(RL)”) according to a First Performance Factor (“FPF”), wherein.

$\mathrm{FPF}=\left[\frac{c}{0\text{.15}·D}\right]/\left[\left[\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right]/M_{t\mathrm{ip},c}^{\left(RL\right)}\right]-1\text{.23};$

m₁·[M_tip,c^(RL)−1.1]+6>FPF>m₁·[M_tip,c^(RL)−1.1]+Δy₁; and 0<Δy₁<6; or wherein the fan includes a fan hub-to-tip ratio (“HTR”), a fan blade count (“BC”), FPR, and M_tip,c^(RL) according to a Second Performance Factor (“SPF”), wherein:

$\mathrm{SPF}=\sqrt{\frac{\pi }{4}\left(1-{\mathrm{HTR}}^2\right)/\left(\frac{BC}{20}\right)}/\left(\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right)/M_{t\mathrm{ip},c}^{\left(RL\right)}-0.97;$

m₂·[M_tip,c^(RL)−1.1]+1.5>SPF>m₂·[M_tip,c^(RL)−1.1]+Δy₂; and 0<Δy₂<1.5.

A turbomachine for an aircraft, comprising: an annular casing; and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing; wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“M_tip,c^(RL)”), according to a First Performance Factor; wherein

$\mathrm{FPF}=\left[\frac{c}{0.15·D}\right]/\left[\left[\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right]/M_{\mathrm{tip},c}^{\left(\mathrm{RL}\right)}\right]-1.23,$

and wherein m₁·[M_tip,c^(RL)−1.1]+9.14>FPF>m₂·[M_tip,c^(RL)−1.1], wherein m₁ is equal to 9.43 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 27.02 when M_tip,c^(RL) is less than 1.1, and wherein m₂ is equal to 0.87 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 3.34 when M_tip,c^(RL) is less than 1.1.

The turbomachine of one or more of these clauses wherein FPF is within a range equal to or greater than −0.8 and equal to or less than 8.4.

The turbomachine of one or more of these clauses wherein FPF is within a range equal to or greater than 0 and equal to or less than 6.

The turbomachine of one or more of these clauses wherein FPF is within a range equal to or greater than 1 and equal to or less than 2.

The turbomachine of one or more of these clauses wherein M_tip,c^(RL) is within a range equal to or greater than 0.8 and equal to or less than 1.5.

The turbomachine of one or more of these clauses wherein M_tip,c^(RL) is within a range equal to or greater than 0.9 and equal to or less than 1.4.

The turbomachine of one or more of these clauses wherein ratio c/D is within a range equal to or greater than 0.1 and equal to or less than 0.3.

The turbomachine of one or more of these clauses wherein FPR is within a range equal to or greater than 1.2 and equal to or less than 1.6.

The turbomachine of one or more of these clauses wherein FPR is within a range equal to or greater than 1.3 and equal to or less than 1.5.

The turbomachine of one or more of these clauses wherein FPR is within a range equal to or greater than 1.35 and equal to or less than 1.45.

The turbomachine of one or more of these clauses wherein the turbomachine has a gear ratio within a range equal to or greater than 3.2 and equal to or less than 5.0.

The turbomachine of one or more of these clauses wherein the fan blade includes an airfoil portion made from a polymer matrix composite (PMC) material, a metallic leading edge, the ratio c/D is between 0.16 and 0.21, and the fan has between 16 and 25 fan blades.

A turbomachine comprising: an annular casing; and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing; wherein the fan includes a fan hub-to-tip ratio (“HTR”), a fan blade count (“BC”), a fan pressure ratio (“FPR”), and a redline corrected redline fan tip Mach number (“M_tip,c^(RL)”) according to a Second Performance Factor (“SPF”),

$\mathrm{SPF}=\mathrm{SPF}=\frac{\sqrt{\frac{\pi }{4}\left(1-{\mathrm{HTR}}^2\right)/\left(\frac{\mathrm{BC}}{20}\right)}}{\left(\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right)/M_{\mathrm{tip},c}^{\left(\mathrm{RL}\right)}}-0.97,$

wherein m₃·[M_tip,c^(RL)−1.1]+2.52>SPF>m₄·[M_tip,c^(RL)−1.1]wherein m₃ is equal to 3.17, and wherein m₄ is equal to 0.41 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 0.55 when M_tip,c^(RL) is less than 1.1.

The turbomachine of one or more of these clauses wherein SPF is within a range equal to or greater than 0.087 and equal to or less than 2.4.

The turbomachine of one or more of these clauses wherein SPF is within a range equal to or greater than 1 and equal to or less than 2.

A turbomachine for an aircraft, comprising: an annular casing; and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including a plurality of fiber composite layers, and at least one high elongation fiber composite strip joining one of the fiber composite layers at a joint; wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“M_tip,c^(RL)”), according to a First Performance Factor; wherein

$\mathrm{FPF}=\left[\frac{c}{0.15·D}\right]/\left[\left[\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right]/M_{\mathrm{tip},c}^{\left(\mathrm{RL}\right)}\right]-1.23,$

and wherein m₁·[M_tip,c^(RL)−1.1]+9.14>FPF>m₂·[M_tip,c^(RL)−1.1], wherein m₁ is equal to 9.43 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 27.02 when M_tip,c^(RL) is less than 1.1, and wherein m₂ is equal to 0.87 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 3.34 when M_tip,c^(RL) is less than 1.1.

The turbomachine of one or more of these clauses wherein the high elongation fiber composite strips include a first high elongation fiber composite strip having fibers oriented in a first direction, a second high elongation fiber composite strip having fibers oriented in a second direction different than the first direction, and a third high elongation fiber composite strip having fibers oriented in a third direction different than the first direction and the second direction.

The turbomachine of one or more of these clauses wherein the modulus of the high elongation fiber composite strips is from about 13,790 MPa to about 96,530 MPa.

The turbomachine of one or more of these clauses wherein the modulus of the high elongation fiber composite strips is from about 41,370 MPa to about 62,055 MPa.

The turbomachine of one or more of these clauses wherein the tensile elongation of the high elongation fiber composite strips is at least about 1.75%.

The turbomachine of one or more of these clauses wherein the tensile elongation of the high elongation fiber composite strips is at least about 3%.

The turbomachine of one or more of these clauses wherein at least one of the high elongation fiber composite strips is embedded within an interior surface of the fan blade.

The turbomachine of one or more of these clauses wherein the high elongation fiber composite strips are layered from a first outside surface of the fan blade towards an interior of the fan blade.

The turbomachine of one or more of these clauses wherein ends of the high elongation fiber composite strips are staggered such that a length of each high elongation fiber composite strip decreases as position from the first outside surface increases.

The turbomachine of one or more of these clauses wherein the high elongation fiber composite strips are contiguously layered from a first outside surface of the fan blade towards an interior of the fan blade.

The turbomachine of one or more of these clauses wherein the high elongation fiber composite strips extend around a leading edge of the fan blade to a second outside surface of the fan blade, the high elongation fiber composite strips layered from the second outside surface of the fan blade towards the interior of the fan blade.

The turbomachine of one or more of these clauses wherein the first direction is 45 degrees relative to a spanwise direction of the fan blade.

The turbomachine of one or more of these clauses wherein the second direction is parallel to the spanwise direction of the fan blade.

The turbomachine of one or more of these clauses wherein the first direction is 45 degrees relative to a spanwise direction of the fan blade; the second direction is parallel to the spanwise direction of the fan blade; and the third direction is −45 degrees relative to the spanwise direction of the fan blade.

The turbomachine of one or more of these clauses wherein at least one of the high elongation fiber composite strips is positioned at a leading edge of the fan blade.

The turbomachine of one or more of these clauses wherein at least one of the high elongation fiber composite strips is positioned at a leading edge, trailing edge and tip of the fan blade.

The turbomachine of one or more of these clauses wherein a plurality of fiber composite layers are interposed between respective ones of the high elongation fiber composite strips, such that at least a plurality of the high elongation fiber composite strips are not contiguous.

The turbomachine of one or more of these clauses wherein at least some of the high elongation fiber composite strips have fibers oriented in a direction of about 45 degrees relative to the spanwise direction of the blade.

The turbomachine of one or more of these clauses wherein ends of the high elongation fiber composite strips are staggered such that a length of at least one of the high elongation fiber composite strips differs relative to the respective length of other ones of the high elongation fiber composite strips, and the respective lengths of the high elongation fiber composite strips do not monotonically increase or monotonically decrease as position from the first outside surface increases.

The turbomachine of one or more of these clauses wherein the first direction is parallel to a spanwise direction of the fan blade, the second direction is 45 degrees relative to the spanwise direction of the fan blade, and the third direction is −45 degrees relative to the spanwise direction of the fan blade.

A turbomachine for an aircraft, comprising: an annular casing; and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including an airfoil including a body having a mounting edge and a trailing edge, and a leading edge element secured to the mounting edge and defining a 3-D leading edge geometry with both chord and camber variation; wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“M_tip,c^(RL)”), according to a First Performance Factor; wherein

$\mathrm{FPF}=\left[\frac{c}{0.15·D}\right]/\left[\left[\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right]/M_{\mathrm{tip},c}^{\left(\mathrm{RL}\right)}\right]-1.23,$

and wherein m₁·[M_tip,c^(RL)−1.1]+9.14>FPF>m₂·[M_tip,c^(RL)−1.1], wherein m₁ is equal to 9.43 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 27.02 when Mine is less than 1.1, and wherein m₂ is equal to 0.87 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 3.34 when M_tip,c^(RL) is less than 1.1.

A turbomachine comprising: an annular casing; and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including an airfoil including a body having a mounting edge and a trailing edge, and a leading edge element secured to the mounting edge and defining a 3-D leading edge geometry with both chord and camber variation; wherein the fan includes a fan hub-to-tip ratio (“HTR”), a fan blade count (“BC”), a fan pressure ratio (“FPR”), and a redline corrected redline fan tip Mach number (“M_tip,c^(RL)”) according to a Second Performance Factor (“SPF”),

$\mathrm{SPF}=\mathrm{SPF}=\frac{\sqrt{\frac{\pi }{4}\left(1-{\mathrm{HTR}}^2\right)/\left(\frac{\mathrm{BC}}{20}\right)}}{\left(\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right)/M_{\mathrm{tip},c}^{\left(\mathrm{RL}\right)}}-0.97,$

wherein m₃·[M_tip,c^(RL)−1.1]+2.52>SPF>m₄·[M_tip,c^(RL)−1.1] wherein m₃ is equal to 3.17, and wherein m₄ is equal to 0.41 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 0.55 when M_tip,c^(RL) is less than 1.1.

A turbomachine for an aircraft, comprising: an annular casing; and a fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including an airfoil including a body having a mounting edge and a trailing edge, and a leading edge element secured to the mounting edge and defining a 3-D leading edge geometry with both chord and camber variation; wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“M_tip,c^(RL)”), according to a First Performance Factor; wherein

$\mathrm{FPF}=\left[\frac{c}{0.15·D}\right]/\left[\left[\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right]/M_{\mathrm{tip},c}^{\left(\mathrm{RL}\right)}\right]-1.23,$

and wherein m₁·[M_tip,c^(RL)−1.1]+9.14>FPF>m₂·[M_tip,c^(RL)−1.1], wherein m₁ is equal to 9.43 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 27.02 when M_tip,c^(RL) is less than 1.1, and wherein m₂ is equal to 0.87 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 3.34 when M_tip,c^(RL) is less than 1.1; and wherein the fan includes a fan hub-to-tip ratio (“HTR”), a fan blade count (“BC”), a fan pressure ratio (“FPR”), and a redline corrected redline fan tip Mach number (“M_tip,c^(RL)”) according to a Second Performance Factor (“SPF”),

$\mathrm{SPF}=\mathrm{SPF}=\frac{\sqrt{\frac{\pi }{4}\left(1-{\mathrm{HTR}}^2\right)/\left(\frac{\mathrm{BC}}{20}\right)}}{\left(\frac{\sqrt{\mathrm{FPR}-1}}{\sqrt{0.4}}\right)/M_{\mathrm{tip},c}^{\left(\mathrm{RL}\right)}}-0.97,$

wherein m₃·[M_tip,c^(RL)−1.1]+2.52>SPF>m₄·[M_tip,c^(RL)−1.1]

• • wherein m₃ is equal to 3.17, and wherein m₄ is equal to 0.41 when M_tip,c^(RL) is greater than or equal to 1.1 and is equal to 0.55 when M_tip,c^(RL) is less than 1.1.

The turbomachine of one or more of these clauses wherein the at least one high elongation fiber composite strip includes a plurality of high elongation fiber strips that include a first high elongation fiber composite strip having fibers oriented in a first direction, a second high elongation fiber composite strip having fibers oriented in a second direction different than the first direction, and a third high elongation fiber composite strip having fibers oriented in a third direction different than the first direction and the second direction.

The turbomachine of one or more of these clauses wherein the modulus of the high elongation fiber composite strips is from about 13,790 MPa to about 96,530 MPa.

The turbomachine of one or more of these clauses wherein the tensile elongation of the high elongation fiber composite strips is at least about 1.75%.

The turbomachine of one or more of these clauses wherein the body comprises a composite body.

The turbomachine of one or more of these clauses wherein the leading edge element comprises a metal element machined into the 3-D leading edge geometry.

The turbomachine of one or more of these clauses wherein the undulations are asymmetrical in planform.

The turbomachine of one or more of these clauses wherein the undulations define a plurality of wave shaped projections in planform.

The turbomachine of one or more of these clauses further comprising a connection securing the mounting edge and the leading edge element.

The turbomachine of one or more of these clauses wherein the connection comprises a recess within one of the mounting edge or the leading edge element and a projection extending from the other of the mounting edge and the leading edge element, with the projection received within the recess.

The turbomachine of one or more of these clauses further comprising bonding the projection within the recess.

The turbomachine of one or more of these clauses wherein the projection extends from the body and the recess is formed within the leading edge element.

The turbomachine of one or more of these clauses wherein the recess is formed along an aft edge of the leading edge element.

The turbomachine of one or more of these clauses wherein blade assembly is a blade assembly for an outlet guide vane.

The turbomachine of one or more of these clauses wherein the leading edge element and trailing edge element are made from different materials.

The turbomachine of one or more of these clauses wherein the leading edge element is metal.

The turbomachine of one or more of these clauses wherein the trailing edge element is composite.

The turbomachine of one or more of these clauses wherein the projection extends from the trailing edge element and the recess is formed within the leading edge element.

The turbomachine of one or more of these clauses wherein the recess is formed along an aft edge of the leading edge element.

A method of forming an airfoil having a pressure side and a suction side and extending axially between a leading edge and a trailing edge to define a chord-wise direction, the method comprising securing a trailing edge element extending in the chord-wise direction from a mounting edge to the trailing edge to a leading edge element having a 3-D leading edge geometry comprising a plurality of undulations with both chord and camber variation and located along the leading edge; wherein the securing occurs at the mounting edge and in a location spaced from the leading edge to define a length in the chord-wise direction interior of both the pressure side and the suction side; wherein the length varies between a maximum and a minimum to define the undulations.

The method of one or more of these clauses wherein the securing comprises mechanically securing together the leading edge and trailing edge elements.

The method of one or more of these clauses wherein the securing comprises bonding together the leading edge and trailing edge elements.

Claims

1. A turbomachine for an aircraft comprising: an annular casing; anda fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including:a plurality of fiber composite layers; andat least one high elongation fiber composite strip joining one of the fiber composite layers at a joint;wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“Mtip,c(RL)”) according to a First Performance Factor (“FPF”),wherein

2. The turbomachine of claim 1, wherein the at least one high elongation fiber composite strip includes a plurality of high elongation fiber strips that include a first high elongation fiber composite strip having fibers oriented in a first direction, a second high elongation fiber composite strip having fibers oriented in a second direction different than the first direction, and a third high elongation fiber composite strip having fibers oriented in a third direction different than the first direction and the second direction.

3. The turbomachine of claim 1, wherein the modulus of the high elongation fiber composite strips is from about 13,790 MPa to about 96,530 MPa.

4. The turbomachine of claim 1, wherein the tensile elongation of the high elongation fiber composite strips is at least about 1.75%.

5. The turbomachine of claim 1, wherein: FPF is within a range equal to or greater than −0.8 and equal to or less than 8.4;Mtip,c(RL) is within a range equal to or greater than 0.8 and equal to or less than 1.5;ratio c/D is within a range equal to or greater than 0.1 and equal to or less than 0.3; andFPR is within a range equal to or greater than 1.2 and equal to or less than 1.6.

6. The turbomachine of claim 1, wherein the turbomachine has a gear ratio within a range equal to or greater than 3.2 and equal to or less than 5.0.

7. The turbomachine of claim 1, wherein the ratio c/D is between 0.16 and 0.21, and the fan has between 16 and 25 fan blades.

8. A turbomachine comprising: an annular casing; anda fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including:a plurality of fiber composite layers; andat least one high elongation fiber composite strip joining one of the fiber composite layers at a joint;wherein the fan includes a fan hub-to-tip ratio (“HTR”), a fan blade count (“BC”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“Mtip,c(RL)”) according to a Second Performance Factor (“SPF”),wherein

9. The turbomachine of claim 8, wherein the at least one high elongation fiber composite strip includes a plurality of high elongation fiber strips that include a first high elongation fiber composite strip having fibers oriented in a first direction, a second high elongation fiber composite strip having fibers oriented in a second direction different than the first direction, and a third high elongation fiber composite strip having fibers oriented in a third direction different than the first direction and the second direction.

10. The turbomachine of claim 8, wherein the modulus of the high elongation fiber composite strips is from about 13,790 MPa to about 96,530 MPa.

11. The turbomachine of claim 8, wherein the tensile elongation of the high elongation fiber composite strips is at least about 1.75%.

12. The turbomachine of claim 8, wherein: SPF is within a range equal to or greater than 0.087 and equal to or less than 2.4;Mtip,c(RL) is within a range equal to or greater than 0.8 and equal to or less than 1.5;HTR is within a range equal to or greater than 0.2 and equal to or less than 0.4;FPR is within a range equal to or greater than 1.2 and equal to or less than 1.6; andBC is within a range equal to or greater than 3 and equal to or less than 18.

13. The turbomachine of claim 8, wherein the turbomachine has a gear ratio within a range equal to or greater than 3.2 and equal to or less than 5.0.

14. A turbomachine for an aircraft comprising: an annular casing; anda fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including:a plurality of fiber composite layers; andat least one high elongation fiber composite strip joining one of the fiber composite layers at a joint;wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“Mtip,c(RL)”) according to a First Performance Factor (“FPF”),wherein

15. The turbomachine of claim 14, wherein the at least one high elongation fiber composite strip includes a plurality of high elongation fiber strips that include a first high elongation fiber composite strip having fibers oriented in a first direction, a second high elongation fiber composite strip having fibers oriented in a second direction different than the first direction, and a third high elongation fiber composite strip having fibers oriented in a third direction different than the first direction and the second direction.

16. The turbomachine of claim 14, wherein the modulus of the high elongation fiber composite strips is from about 13,790 MPa to about 96,530 MPa.

17. The turbomachine of claim 14, wherein the tensile elongation of the high elongation fiber composite strips is at least about 1.75%.

18. The turbomachine of claim 14, wherein: FPF is within a range equal to or greater than −0.8 and equal to or less than 8.4;SPF is within a range equal to or greater than 0.087 and equal to or less than 2.4;Mtip,c(RL) is within a range equal to or greater than 0.8 and equal to or less than 1.5; andFPR is within a range equal to or greater than 1.2 and equal to or less than 1.6.

19. The turbomachine of claim 14, wherein: ratio c/D is within a range equal to or greater than 0.1 and equal to or less than 0.3;HTR is within a range equal to or greater than 0.2 and equal to or less than 0.4; andBC is within a range equal to or greater than 3 and equal to or less than 18.

20. The turbomachine of claim 14, wherein the turbomachine has a gear ratio within a range equal to or greater than 3.2 and equal to or less than 5.0.

21. A turbomachine for an aircraft comprising: an annular casing; anda fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including an airfoil including a body having a mounting edge and a trailing edge, and a leading edge element secured to the mounting edge and defining a 3-D leading edge geometry with both chord and camber variation;wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“Mtip,c(RL)”) according to a First Performance Factor (“FPF”),wherein

22. The turbomachine of claim 21, wherein the airfoil extends axially between a leading edge and a trailing edge to define a chord-wise direction, wherein the mounting body is spaced from the leading edge in the chord-wise direction along a camber line and extends from the mounting edge to the trailing edge to define at least a portion of the airfoil, the leading edge extending element from the leading edge toward the mounting edge in the chord-wise direction to define a length of at least a portion of the airfoil, wherein the leading edge includes a plurality of undulations along the leading edge, and wherein the length varies between a maximum and a minimum to define the undulations.

23. The turbomachine of claim 21, wherein a connection secures the leading edge element to a trailing edge element, wherein the connection comprises a recess spaced from the leading edge in the chord-wise direction within one of the trailing edge element or the leading edge element and a projection extending from the other of the trailing edge element and the leading edge element, with the projection received within the recess.

24. The turbomachine of claim 22, wherein the undulations are asymmetrical and define a plurality of wave shaped projections in planform.

25. The turbomachine of claim 21, wherein: FPF is within a range equal to or greater than −0.8 and equal to or less than 8.4;Mtip,c(RL) is within a range equal to or greater than 0.8 and equal to or less than 1.5;ratio c/D is within a range equal to or greater than 0.1 and equal to or less than 0.3; andFPR is within a range equal to or greater than 1.2 and equal to or less than 1.6.

26. The turbomachine of claim 21, wherein the turbomachine has a gear ratio within a range equal to or greater than 3.2 and equal to or less than 5.0.

27. The turbomachine of claim 21, wherein the ratio c/D is between 0.16 and 0.21, and the fan has between 16 and 25 fan blades.

28. A turbomachine comprising: an annular casing; anda fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including an airfoil including a body having a mounting edge and a trailing edge, and a leading edge element secured to the mounting edge and defining a 3-D leading edge geometry with both chord and camber variation;wherein the fan includes a fan hub-to-tip ratio (“HTR”), a fan blade count (“BC”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“Mtip,c(RL)”) according to a Second Performance Factor (“SPF”),wherein

29. The turbomachine of claim 28, wherein the airfoil extends axially between a leading edge and a trailing edge to define a chord-wise direction, wherein the mounting body is spaced from the leading edge in the chord-wise direction along a camber line and extends from the mounting edge to the trailing edge to define at least a portion of the airfoil, the leading edge extending element from the leading edge toward the mounting edge in the chord-wise direction to define a length of at least a portion of the airfoil, wherein the leading edge includes a plurality of undulations along the leading edge, and wherein the length varies between a maximum and a minimum to define the undulations.

30. The turbomachine of claim 28, wherein a connection secures the leading edge element to a trailing edge element, wherein the connection comprises a recess spaced from the leading edge in the chord-wise direction within one of the trailing edge element or the leading edge element and a projection extending from the other of the trailing edge element and the leading edge element, with the projection received within the recess.

31. The turbomachine of claim 30, wherein the undulations are asymmetrical and define a plurality of wave shaped projections in planform.

32. The turbomachine of claim 8, wherein: SPF is within a range equal to or greater than 0.087 and equal to or less than 2.4;Mtip,c(RL) is within a range equal to or greater than 0.8 and equal to or less than 1.5;HTR is within a range equal to or greater than 0.2 and equal to or less than 0.4;FPR is within a range equal to or greater than 1.2 and equal to or less than 1.6; andBC is within a range equal to or greater than 3 and equal to or less than 18.

33. The turbomachine of claim 28, wherein the turbomachine has a gear ratio within a range equal to or greater than 3.2 and equal to or less than 5.0.

34. A turbomachine for an aircraft comprising: an annular casing; anda fan disposed inside the annular casing and mounted for rotation about an axial centerline, the fan including fan blades that extend radially outwardly toward the annular casing, a fan blade including an airfoil including a body having a mounting edge and a trailing edge, and a leading edge element secured to the mounting edge and defining a 3-D leading edge geometry with both chord and camber variation;wherein the fan includes an average fan chord width of the fan blades (“c”), a diameter of the fan (“D”), a fan pressure ratio (“FPR”), and a redline corrected fan tip Mach number (“Mtip,c(RL)”) according to a First Performance Factor (“FPF”),wherein

35. The turbomachine of claim 34, wherein the airfoil extends axially between a leading edge and a trailing edge to define a chord-wise direction, wherein the mounting body is spaced from the leading edge in the chord-wise direction along a camber line and extends from the mounting edge to the trailing edge to define at least a portion of the airfoil, the leading edge extending element from the leading edge toward the mounting edge in the chord-wise direction to define a length of at least a portion of the airfoil, wherein the leading edge includes a plurality of undulations along the leading edge, and wherein the length varies between a maximum and a minimum to define the undulations.

36. The turbomachine of claim 34, wherein a connection secures the leading edge element to a trailing edge element, wherein the connection comprises a recess spaced from the leading edge in the chord-wise direction within one of the trailing edge element or the leading edge element and a projection extending from the other of the trailing edge element and the leading edge element, with the projection received within the recess.

37. The turbomachine of claim 36, wherein the undulations are asymmetrical and define a plurality of wave shaped projections in planform.

38. The turbomachine of claim 34, wherein: FPF is within a range equal to or greater than −0.8 and equal to or less than 8.4;SPF is within a range equal to or greater than 0.087 and equal to or less than 2.4;Mtip,c(RL) is within a range equal to or greater than 0.8 and equal to or less than 1.5; andFPR is within a range equal to or greater than 1.2 and equal to or less than 1.6.

39. The turbomachine of claim 34, wherein: ratio c/D is within a range equal to or greater than 0.1 and equal to or less than 0.3;HTR is within a range equal to or greater than 0.2 and equal to or less than 0.4; andBC is within a range equal to or greater than 3 and equal to or less than 18.

40. The turbomachine of claim 34, wherein the turbomachine has a gear ratio within a range equal to or greater than 3.2 and equal to or less than 5.0.