Turbine blade and method of fabricating same

Abstract

A method for fabricating a turbine blade includes casting at least one turbine blade that includes a blade tip shroud and at least one seal tooth coupled to the blade tip shroud, and removing at least a portion of the turbine blade such that a radially outer surface of the blade tip shroud has at least two substantially flat surfaces.

1 . A method for fabricating a turbine blade for a gas turbine engine, wherein the gas turbine engine includes a turbine including a plurality of turbine blades, said method comprising: 
 casting at least one turbine blade that includes a blade tip shroud and at least one seal tooth coupled to the blade tip shroud; and    removing at least a portion of the turbine blade such that a radially outer surface of the blade tip shroud has at least two substantially flat surfaces.    
   
   
       2 . A method in accordance with  claim 1  wherein removing at least a portion of the turbine blade further comprises removing at least a portion of the turbine blade such that a radially outer surface of the blade tip shroud has substantially V-shaped cross-sectional profile.  
   
   
       3 . A method in accordance with  claim 1  wherein casting a turbine blade further comprises casting a turbine blade utilizing a titanium aluminide material.  
   
   
       4 . A method in accordance with  claim 1  further comprising machining the turbine blade such that an outer surface of the at least one seal tooth has a substantially V-shaped cross-sectional profile.  
   
   
       5 . A method in accordance with  claim 4  wherein the turbine blade includes two seal teeth, said method further comprising machining the turbine blade such that an outer surface of each seal tooth has a substantially V-shaped cross-sectional profile.  
   
   
       6 . A method in accordance with  claim 1  wherein casting a turbine blade further comprises casting a low pressure turbine blade utilizing a titanium aluminide material.  
   
   
       7 . A method in accordance with  claim 1  wherein removing at least a portion of the turbine blade further comprises removing at least a portion of the turbine blade utilizing an electron discharge machining (EDM) apparatus.  
   
   
       8 . A turbine rotor blade comprising: 
 a blade tip shroud comprising a radially outer surface having at least two substantially flat surfaces; and    at least one seal tooth coupled to said blade tip shroud.    
   
   
       9 . A turbine rotor blade in accordance with  claim 8  wherein said blade tip shroud has a substantially V-shaped cross-sectional profile.  
   
   
       10 . A turbine rotor blade in accordance with  claim 8  wherein each blade tip shroud flat surface spans approximately half the circumferential width of said blade tip shroud.  
   
   
       11 . A turbine rotor blade in accordance with  claim 8  further comprising two seal teeth, wherein each seal tooth comprises a radially outer surface having at least two substantially flat surfaces.  
   
   
       12 . A turbine rotor blade in accordance with  claim 8  further comprising two seal teeth, wherein each seal tooth has a substantially V-shaped cross-sectional profile.  
   
   
       13 . A turbine rotor blade in accordance with  claim 8  wherein said turbine blade comprises a titanium aluminide material.  
   
   
       14 . A turbine rotor blade in accordance with  claim 8  wherein said turbine blade is coupled to a low pressure turbine.  
   
   
       15 . A gas turbine engine rotor assembly comprising: 
 a low pressure turbine rotor; and    a plurality of circumferentially-spaced rotor blades coupled to said low pressure turbine rotor, each said rotor blade comprising:    a blade tip shroud comprising a radially outer surface having at least two substantially flat surfaces; and    at least one seal tooth coupled to said blade tip shroud.    
   
   
       16 . A gas turbine engine rotor assembly in accordance with  claim 15  wherein said blade tip shroud has a substantially V-shaped cross-sectional profile.  
   
   
       17 . A gas turbine engine rotor assembly in accordance with  claim 15  wherein each blade tip shroud flat surface spans approximately half the circumferential width of said blade tip shroud.  
   
   
       18 . A gas turbine engine rotor assembly in accordance with  claim 15  wherein said turbine blade further comprises two seal teeth, wherein each seal tooth comprises a radially outer surface having at least two substantially flat surfaces.  
   
   
       19 . A gas turbine engine rotor assembly in accordance with  claim 15  wherein said turbine blade further comprises two seal teeth, wherein each seal tooth has a substantially V-shaped cross-sectional profile.  
   
   
       20 . A gas turbine engine rotor assembly in accordance with  claim 15  wherein said turbine blade comprises a titanium aluminide material.