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1. WO2014163667 - STRUCTURAL GUIDE VANE SONIC SHAPE AND INSPECTION

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[ EN ]

CLAIMS

What is claimed is:

1. A method of forming a guide vane, comprising:

forming a vane blank with sufficient material to fabricate the guide vane in accordance with any one of a plurality of different vane classes;

inspecting the vane blank for material inconsistences; and

removing material from the vane blank to form the guide vane in accordance with a desired one of the plurality of vane classes, wherein inspecting the vane blank includes defining a first portion of the vane blank in which a material inconsistency is acceptable and a second portion of the vane blank where a material inconsistency is not acceptable.

2. The method as recited in claim 1 , wherein the step of defining the first portion and the second portion comprises defining a plurality of zones within the vane blank and depths within which are permitted material inconsistences.

3. The method as recited in claim 2, wherein material depths are defined within each of the plurality of zones within which material inconsistences are permitted within the vane blank for a desired one of the plurality of vane classes.

4. The method as recited in claim 2, wherein the plurality of zones includes at least three separate zones defined vertically and horizontally within the vane blank.

5. The method as recited in claim 3, wherein each of the plurality of zones defines different depths within the vane blank that may include material inconsistences.

6. The method as recited in claim 5, wherein the different depths include a first depth from a surface of the blank within which material inconsistences are acceptable, and a second depth within which material inconsistences are not acceptable, with the second depth being greater than the first depth.

7. The method as recited in claim 1, wherein removing material from the vane blank includes machining the vane blank.

8. The method as recited in claim 1, wherein the guide vane formed in accordance with the desired one of the plurality of vane classes includes an airfoil configured and adapted to be operatively positioned between an outer platform mounted to a fan case and an inner platform mounted to a static engine case of a gas turbine engine.

9. The method as recited in claim 8, wherein each of the inner platform and the outer platform includes features that maintain a particular desired orientation of the vane.

10. A guide vane assembly for a gas turbine engine, comprising:

an outer platform mountable to a fan case of a gas turbine engine;

an inner platform mountable to a static engine case of the gas turbine engine; and an airfoil extending between the inner platform and the outer platform, wherein the airfoil is fabricated from a vane blank having sufficient material to fabricate the airfoil in accordance with any one of a plurality of guide vane classes, wherein each guide vane class corresponds to a different airfoil configuration, and vane blank includes at least one material inconsistency within a region of the vane blank removed to form the airfoil.

11. The guide vane assembly as recited in claim 10, wherein each of the inner platform and outer platform includes features that are fabricated to maintain an orientation of the airfoil.

12. The guide vane assembly as recited in claim 10, wherein the vane blank includes sufficient material to form the airfoil in accordance with any one of the plurality of guide vane classes.

13. The structural guide vane as recited in claim 10, wherein the airfoil is disposed at an angle relative to the inner and outer platforms.