Methods and apparatus for turbine engine rotors

Abstract

A method for welding two sections of a rotor together, wherein each rotor section includes a welding surface, is provided. The method includes positioning the welding surface of the first rotor section substantially flush against the welding surface of the second rotor section. The method also includes positioning the second section substantially flush against a flange circumscribing the first section such that a rabbeted joint is defined therebetween.

1 . A method for welding two sections of a rotor together, wherein each rotor section includes a welding surface, said method comprising: 
 positioning the welding surface of the first rotor section substantially flush against the welding surface of the second rotor section such that a welding joint is defined therebetween; and    positioning the second rotor section substantially flush against a flange circumscribing the first rotor section such that a rabbeted joint is defined therebetween.    
   
   
       2 . A method in accordance with  claim 1  further comprising: 
 coupling a casing to the rotor such that a chamber defined by the casing circumscribes the welding joint;    removing air from the chamber to create a vacuum therein; and    welding the welding joint with an electron beam generator.    
   
   
       3 . A method in accordance with  claim 2  wherein welding the welding joint further comprises welding the welding joint during a single rotation of the electron beam generator around the welding joint.  
   
   
       4 . A method in accordance with  claim 3  wherein welding the welding joint further comprises adjusting an intensity of the electron beam as the electron beam generator is rotated about the welding joint.  
   
   
       5 . A method in accordance with  claim 1  wherein positioning the second rotor section substantially flush against a flange circumscribing the first rotor section further comprises positioning the second rotor section substantially flush against the flange such that a cavity is defined between the first rotor section and the second rotor section.  
   
   
       6 . A method in accordance with  claim 1  wherein the first rotor section and the second rotor section are fabricated from different materials, said method further comprising inserting a shim between the first rotor section surface and the second rotor section surface to facilitate coupling the first rotor section and the second rotor section.  
   
   
       7 . A method in accordance with  claim 6  further comprising: 
 heating the first rotor section surface and the second rotor section surface to facilitate producing welded metal at each welding surface; and    melting the shim to facilitate mixing the material of the shim with the welded metal to facilitate coupling the first rotor section and the second rotor section.    
   
   
       8 . A rotor for a turbine engine, said rotor comprising: 
 a first rotor section comprising a welding surface and a flange;    a second rotor section comprising a welding surface, said first rotor welding surface is positioned substantially flush against said second rotor welding surface such that a welding joint is defined therebetween, said second rotor section is substantially flush against said flange such that a rabbeted joint is defined therebetween, said rabbeted joint facilitates coupling said first rotor section and said second rotor section.    
   
   
       9 . A rotor in accordance with  claim 8  wherein a casing is coupled to said rotor such that a chamber defined by the casing substantially circumscribes said welding joint, said chamber configured to maintain a vacuum pressure therein, said welding joint configured to be welded with an electron beam generator within said chamber.  
   
   
       10 . A rotor in accordance with  claim 9  wherein said welding joint is configured to be welded by the electron beam generator during a single rotation of the electron beam generator around said welding joint.  
   
   
       11 . A rotor in accordance with  claim 9  further comprising a shim inserted substantially flush between said first rotor section surface and said second rotor section surface, said shim facilitates coupling said first rotor section and said second rotor section.  
   
   
       12 . A rotor in accordance with  claim 11  wherein said shim comprises an alloy material.  
   
   
       13 . A rotor in accordance with  claim 8  wherein a cavity is defined between said first rotor section and said second rotor section.  
   
   
       14 . A system for welding two sections of a rotor, wherein each rotor section includes a welding surface, said system comprising: 
 a welding joint defined between the first rotor section welding surface and the second rotor section welding surface;    a rabbeted joint defined between the second rotor section and a flange circumscribing the first rotor section;    a casing coupled to the rotor such that a chamber defined by said casing substantially circumscribes the welding joint, said chamber configured to maintain a vacuum pressure therein; and    an electron beam generator configured to weld said welding joint within said chamber.    
   
   
       15 . A system in accordance with  claim 14  wherein said electron beam generator is configured to weld said welding joint during a single rotation around said welding joint.  
   
   
       16 . A system in accordance with  claim 14  wherein an intensity of said electron beam generator is adjustable to facilitate welding said welding joint.  
   
   
       17 . A system in accordance with  claim 14  wherein said welding joint includes an inner portion, an intensity of said electron beam generator is adjustable to facilitate welding said inner portion.  
   
   
       18 . A system in accordance with  claim 14  further comprising a shim positioned substantially flush between said first rotor section surface and said second rotor section surface, said shim facilitates coupling said first rotor section and said second rotor section.  
   
   
       19 . A system in accordance with  claim 18  wherein said shim comprises an alloy material.  
   
   
       20 . A system in accordance with  claim 14  further comprising a cavity defined between said first rotor section and said second rotor section.