Hybrid metal leading edge part and method for making the same

1. A method for forming a part for use as a leading edge reinforcement on a blade or airfoil part comprising:

a. providing a first main body, said first main body including first and second leg sections, said first and section leg sections each being a preformed component, said first and second leg sections each having a front and back end and a side edge;

b. bonding together said front end of each of said first and second leg sections at a bond region by a weld bead or diffusion bond to form a bond region on a nose portion of said first main body prior to a metal deposition layer being applied to said nose portion; and,

c. depositing a coating of metal on said first main body to build up a thickness of metal on said first main body to form a leading edge having a customized outer end portion, said metal deposition layer forming a complete outer end portion of the leading edge, said metal deposition layer applied to said front end of each of said first and second leg sections, said back end of said first and second leg sections spaced from one another, at least 80% of said front end of said first and second leg sections covered by said metal deposition layer, a majority of said first and second leg sections absent said metal deposition layer, said metal deposition layer covers said weld metal or diffusion bonded region on said nose portion, said metal deposition coating covering at least 80% of said bond region on a top surface of said nose portion, said metal deposition layer extending upwardly from said bond region.

2. The method as defined in claim 1 , further including one or more processing steps selected from the group consisting of a) hot forming/super plastic forming one or more portions of the leading edge, b) machining at least portion of said first main body to obtain a desired tapered profile of one or more pieces of said first main body, c) deburr at least portion of said first main body, d) machine at least a portion of said first main body, e) bench at least a portion of said leading edge to remove burrs or surface anomalies from said leading edge, f) conduct X-ray or Ultrasonic NDT one or more portions of said leading edge, g) hot isostatic press one or more portions of said leading edge, h) heat treat or hot size the leading edge, I) machine an inner nose region weld root of said first main body, k) trim at least a portion of said leading edge, l) etch, prime and combinations thereof at least a portion of said leading edge, m) cut one or more portions of said first main body by a laser cutter, and n) clean one or more portions of the leading edge.

3. The method as defined in claim 1 , wherein said metal deposition layer deposited on said first and second leg sections forming a sole bond between said front ends of said first and section leg sections, said metal deposition layer deposited over 80% of said front ends of said first and second leg sections, said metal deposition layer extending upwardly top edges of said first and second leg sections.

4. The method as defined in claim 1 , further including the processing steps of a) hot forming/super plastic forming one or more portions of the leading edge, b) machining at least a portion of said first main body to obtain a desired tapered profile of one or more pieces of said first main body, c) deburr at least a portion of said first main body, d) machine at least a portion of said first main body, e) bench at least a portion of said leading edge to remove burrs or surface anomalies from said leading edge, f) conduct X-ray or Ultrasonic NDT testing on one or more portions of said leading edge, g) hot isostatic press one or more portions of said leading edge, h) heat treat or hot size the leading edge, i) machine an inner nose region weld root of said first main body, j) trim at least a portion of said leading edge, k) etch, prime and combinations thereof at least a portion of said leading edge, l) cut one or more portions of said first main body by a laser cutter, and m) clean one or more portions of the leading edge.

5. A method for forming a part for use as a leading edge reinforcement on a blade or airfoil part comprising:

a. providing a first main body and a second main body, said first main body including first and second leg sections, said first and second leg sections of said first main body each being a preformed component, said first and second leg sections of said first main body each having a front and back end and a side edge, said second main body having first and second leg sections and a metal deposition layer that is applied to said second main body, said first and section leg sections of said second main body each being a preformed component, said first and second leg sections of said second main body each having a front and back end and a side edge;

b. bonding together said side edges of said first and second main bodies at a bond region by a weld bead or diffusion bond prior to a metal deposition layer being applied to said first and second main bodies, said bond region formed along one of said leg sections of said first and second main bodies; and,

c. depositing a coating of metal on said first main body and said second main body to build up a thickness of metal on said first main body and said second main body to form a leading edge having a customized outer end portion, said metal deposition layer forming a complete outer end portion of the leading edge, said metal deposition layer applied to said front end of each of said first and second leg sections of said first main body, said back end of said first and second leg sections of said first main body spaced from one another, said metal deposition layer deposited over 80% of said bond region between said first and second main bodies, said metal deposition layer deposited over 80% of said front ends of said first and second leg sections of said first and second main bodies, said metal deposition layer extending upwardly from said first and second leg sections of said first and second main bodies, a majority of said first and second leg sections of said first and second main bodies absent said metal deposition layer.

6. A method for forming a part for use as a leading edge reinforcement on a blade or airfoil part comprising:

a. providing a first main body, said first main body including first and second leg sections, said first and second leg sections each being a preformed component, said first and second leg sections each having a front and back end and a side edge, said main body includes a preformed nose portion, and further including the step of bonding said nose portion to said first and second leg sections by weld metal or a diffusion bond, said step of bonding performed prior to a metal deposition layer being applied to said nose portion; and,

b. depositing a coating of metal on said first main body to build up a thickness of metal on said first main body to form a leading edge having a customized outer end portion, said metal deposition layer forming a complete outer end portion of the leading edge, said metal deposition layer applied to said front end of each of said first and second leg sections, said back end of said first and second leg sections spaced from one another, at least 80% of said front end of said first and second leg sections covered by said metal deposition layer, a majority of said first and second leg sections absent said metal deposition layer, said metal deposition layer deposited over 80% of a bond region on a top surface between said nose portion and said first and second leg sections, said metal deposition layer deposited over 80% of said nose portion, said metal deposition layer extending upwardly from said nose portion.

7. A method for forming a reinforced metal component for use on a leading edge of a blade or airfoil part comprising:

a. providing a first main body, said main body including first and second leg sections, said first and second leg sections each being a preformed component, said first and second leg sections each having a front and back end;

b. bonding together said front end of each of said first and second leg sections at a bond region by a weld bead or diffusion bond to form a bond region on a nose portion of said first main body prior to a metal deposition layer being applied to said nose portion; and,

c. depositing a coating of metal on said first main body to build up a thickness of metal on said main body to form a leading edge having a customized outer end portion, said metal deposition layer forming a complete outer end portion of the leading edge, said metal deposition layer applied to said front end of each of said first and second leg sections, said back end of said first and second leg sections spaced from one another, at least 80% of said front end of said first and second leg sections covered by said metal deposition layer, a majority of said first and second leg sections absent said metal deposition layer, said metal deposition layer covers said weld metal or diffusion bonded region on said nose portion, said metal deposition coating covering at least 80% of said bond region on a top surface of said nose portion, said metal deposition layer extending upwardly from said bond region; and,

c. securing a leading edge reinforcement component to said leading edge of said metal component.

8. The method as defined in claim 7 , further including one or more processing steps selected from the group consisting of a) hot forming/super plastic forming one or more portions of the leading edge, b) machining at least a portion of said first main body to obtain a desired tapered profile of one or more pieces of said first main body, c) deburr at least a portion of said first main body, d) machine at least a portion of said first main body, e) bench at least a portion of said leading edge to remove burrs or surface anomalies from said leading edge, f) conduct X-ray or Ultrasonic NDT testing on one or more portions of said leading edge, g) hot isostatic press one or more portions of said leading edge, h) heat treat or hot size the leading edge, i) machine an inner nose region weld root of said first main body, j) trim at least a portion of said leading edge, k) etch, prime and combinations thereof at least a portion of said leading edge, l) cut one or more portions of said first main body by a laser cutter, and m) clean one or more portions of the leading edge.

9. The method as defined in claim 7 , further including the processing steps of a) hot forming/super plastic forming one or more portions of the leading edge, b) machining at least a portion of said first main body to obtain a desired tapered profile of one or more pieces of said first main body, c) deburr at least a portion of said first main body, d) machine at least a portion of said first main body, e) bench at least a portion of said leading edge to remove burrs or surface anomalies from said leading edge, f) conduct X-ray or Ultrasonic NDT testing on one or more portions of said leading edge, g) hot isostatic press one or more portions of said leading edge, h) heat treat or hot size the leading edge, i) machine an inner nose region weld root of said first main body, j) trim at least a portion of said leading edge, k) etch, prime and combinations thereof at least a portion of said leading edge, l) cut one or more portions of said first main body by a laser cutter, and m) clean one or more portions of the leading edge.

10. A method for forming a reinforced metal component for use on a leading edge of a blade or airfoil part comprising:

a. providing a first main body, said main body including first and second leg sections, said first and second leg sections each being a preformed component, said first and second leg sections each having a front and back end, said main body includes a preformed nose portion, and further including the step of bonding said nose portion to said first and second leg sections by weld metal or a diffusion bond, said step of bonding performed prior to said a metal deposition layer being applied to said nose portion;

b. depositing a coating of metal on said first main body to build up a thickness of metal on said main body to form a leading edge having a customized outer end portion, said metal deposition layer forming a complete outer end portion of the leading edge, said metal deposition layer applied to said front end of each of said first and second leg sections, said back end of said first and second leg sections spaced from one another, at least 80% of said front end of said first and second leg sections covered by said metal deposition layer, a majority of said first and second leg sections absent said metal deposition layer, said metal deposition layer deposited over 80% of a bond region on a top surface between said nose portion and said first and second leg sections, said metal deposition layer deposited over 80% of said nose portion, said metal deposition layer extending upwardly from said nose portion; and,

c. securing a leading edge reinforcement component to said leading edge of said metal component.