Turbine Engine and Method of Assembling

Abstract

A turbine engine that includes a stationary assembly, and a rotor assembly configured to rotate relative to the stationary assembly. The rotor assembly includes a plurality of unitary turbine and fan blades. Each unitary turbine and fan blade includes a single turbine airfoil, a single fan airfoil positioned radially outward from the single turbine airfoil, and a midspan shroud segment defined between the single turbine airfoil and the single fan airfoil.

What is claimed is: 
     
         1 . A turbine engine comprising:
 a stationary assembly; and   a rotor assembly configured to rotate relative to said stationary assembly, said rotor assembly comprising:
 a plurality of unitary turbine and fan blades, wherein each unitary turbine and fan blade comprises a single turbine airfoil, a single fan airfoil positioned radially outward from said single turbine airfoil, and a midspan shroud segment extending between said single turbine airfoil and said single fan airfoil; and 
 a rotor disk formed unitarily with the plurality of unitary turbine and fan blades as a unitary structure, 
 wherein said each unitary turbine and fan blade comprises at least one reinforcing support member extending through said single turbine airfoil, across said midspan shroud segment, and through said single fan airfoil. 
   
     
     
         2 . The turbine engine in accordance with  claim 1 , wherein said single turbine airfoil is fabricated from a first material and said single fan airfoil is fabricated from a second material different from the first material. 
     
     
         3 . The turbine engine in accordance with  claim 1 , wherein said each unitary turbine and fan blade comprises at least one reinforcing support member extending through said single turbine airfoil, across said midspan shroud segment, and through said single fan airfoil. 
     
     
         4 . The turbine engine in accordance with  claim 1 , wherein said at least one reinforcing support member extends longitudinally along thickest portions of said single turbine airfoil and said single fan airfoil. 
     
     
         5 . The turbine engine in accordance with  claim 1 , wherein said at least one reinforcing support member comprises a first reinforcing support member and a second reinforcing support member, said first reinforcing support member extending longitudinally along leading edges of said single turbine airfoil and said single fan airfoil, and said second reinforcing support member extending longitudinally along trailing edges of said single turbine airfoil and said single fan airfoil. 
     
     
         6 . A rotor assembly for use in a turbine engine, said rotor assembly comprising:
 at least one unitary turbine and fan blade comprising:
 a single turbine airfoil; 
 a single fan airfoil; and 
 a midspan shroud segment extending between said single turbine airfoil and said single fan airfoil; and 
 a rotor disk formed unitarily with the plurality of unitary turbine and fan blades as a unitary structure, 
 wherein said at least one unitary turbine and fan blade comprises at least one reinforcing support member extending through said single turbine airfoil, across said midspan shroud segment, and through said single fan airfoil. 
   
     
     
         7 . The rotor assembly in accordance with  claim 6 , wherein said single turbine airfoil is fabricated from a first material and said single fan airfoil is fabricated from a second material different from the first material. 
     
     
         8 . The rotor assembly in accordance with  claim 6 , wherein said at least one reinforcing support member extends longitudinally along thickest portions of said single turbine airfoil and said single fan airfoil. 
     
     
         9 . The rotor assembly in accordance with  claim 6 , wherein said at least one reinforcing support member comprises a first reinforcing support member and a second reinforcing support member, said first reinforcing support member extending longitudinally along leading edges of said single turbine airfoil and said single fan airfoil, and said second reinforcing support member extending longitudinally along trailing edges of said single turbine airfoil and said single fan airfoil. 
     
     
         10 . A method of assembling a turbine engine, said method comprising:
 unitarily forming a plurality of unitary turbine and fan blades and a rotor disk together as a unitary structure, wherein each unitarily formed turbine and fan blade includes a single turbine airfoil, a single fan airfoil, and a midspan shroud segment defined between the single turbine airfoil and the single fan airfoil;   orienting the plurality of unitarily formed turbine and fan blades such that the single fan airfoil is positioned radially outward from the single turbine airfoil; and   reinforcing each unitarily formed turbine and fan blade utilizing at least one reinforcing support member extending through said single turbine airfoil, across said midspan shroud segment, and through said single fan airfoil.   
     
     
         11 . The method in accordance with  claim 10 , wherein coupling a plurality of unitary turbine and fan blades and a rotor disk together comprises forming the plurality of unitary turbine and fan blades and the rotor disk in an additive manufacturing process. 
     
     
         12 . The method in accordance with  claim 10 , further comprising orienting the plurality of unitary turbine and fan blades such that each midspan shroud segment is radially aligned with each other. 
     
     
         13 . The method in accordance with  claim 10 , wherein the at least one support member extends longitudinally along thickest portions of said single turbine airfoil and said single fan airfoil. 
     
     
         14 . The method in accordance with  claim 10 , wherein reinforcing each unitarily formed turbine and fan blade utilizing the at least one reinforcing support member comprises reinforcing each unitarily formed turbine and fan blade utilizing a first reinforcing support member and a second reinforcing support member, said first reinforcing support member extending longitudinally along leading edges of said single turbine airfoil and said single fan airfoil, and said second reinforcing support member extending longitudinally along trailing edges of said single turbine airfoil and said single fan airfoil. 
     
     
         15 . The method of  claim 10 , wherein unitarily forming the plurality of unitary turbine and fan blades and a rotor disk together as a unitary structure comprising forming said single turbine airfoil from a first material and said single fan airfoil from a second material different from the first material of each unitarily formed turbine and fan blade.