Method of forming gas turbine engine components

1. A method of forming a gas turbine engine component comprising:

welding a cover skin to an airfoil body to define an airfoil, the airfoil body extending from a root section to a tip portion to define a stagger angle such that the airfoil body is twisted;

moving the airfoil in a forming line subsequent to the welding step, the forming line including a set of heating stations and a deforming station; and

wherein the moving step includes positioning the airfoil in the set of heating stations to progressively increase a temperature of the airfoil, and then positioning the airfoil in the deforming station including causing the airfoil to deform between first and second dies.

2. The method as recited in claim 1 , wherein:

wherein the airfoil body extends from a root section to a tip portion, the tip portion defines a stagger angle relative to the root section, and the stagger angle is greater than or equal to 10 degrees, absolute, prior to the welding step; and

the step of causing the airfoil to deform between the first and second dies occurs such that a change in the stagger angle of the airfoil presented to the deforming station is no more than 1 degree, absolute.

3. The method as recited in claim 1 , further comprising forming a plurality of internal cavities in the airfoil body, and wherein the welding step includes trapping an inert gas in the plurality of internal cavities.

4. A method as recited in claim 1 , wherein the forming line includes a set of cool down stations, and wherein the moving step includes positioning the airfoil in the set of cool down stations to progressively decrease the temperature of the airfoil subsequent to the step of positioning the airfoil in the deforming station.

5. A method of forming a gas turbine engine component comprising:

attaching a cover skin to an airfoil body, the airfoil body and the cover skin cooperating to define pressure and suction sides of an airfoil;

moving the airfoil in a forming line including a plurality of stations, the plurality of stations including a set of heating stations, a deforming station and a set of cool down stations; and

wherein the moving step includes positioning the airfoil in the set of heating stations to progressively increase a temperature of the airfoil, then positioning the airfoil in the deforming station including causing the airfoil to deform between first and second dies, and then positioning the airfoil in the set of cool down stations to progressively decrease the temperature of the airfoil.

6. The method as recited in claim 5 , wherein the attaching step includes welding at least a perimeter of the cover skin to the airfoil body.

7. The method as recited in claim 6 , wherein the cover skin is dimensioned to enclose at least one internal cavity in the airfoil body, and the attaching step includes trapping an inert gas in the at least one internal cavity.

8. The method as recited in claim 7 , wherein the inert gas comprises argon.

9. The method as recited in claim 5 , wherein the set of heating stations includes two or more heating stations arranged in series.

10. The method as recited in claim 9 , wherein the temperature of the airfoil in at least one heating station of the set of heating stations is greater than a temperature of the first and second dies.

11. The method as recited in claim 5 , wherein the step of positioning the airfoil in the deforming station includes moving the first and second dies towards and into abutment with respective ones of the pressure and suction sides.

12. The method as recited in claim 11 , wherein the step of positioning the airfoil in the deforming station includes heating the first and second dies to a temperature of at least 1200 degrees Fahrenheit.

13. The method as recited in claim 5 , wherein the airfoil body extends from a root section to a tip portion, the tip portion defines a stagger angle relative to the root section, and the stagger angle is greater than or equal to 10 degrees, absolute, prior to the attaching step.

14. The method as recited in claim 13 , wherein the step of causing the airfoil to deform occurs such that a change in the stagger angle of the airfoil presented to the deforming station is no more than 2 degrees, absolute.

15. The method as recited in claim 5 , wherein the airfoil includes a plurality of airfoils, and the moving step includes moving the plurality of airfoils together as an airfoil set in each of the plurality of stations.

16. The method as recited in claim 15 , further comprising positioning the airfoil set in a common support fixture, and wherein the moving step includes moving the common support fixture together with the airfoil set in the plurality of stations.

17. The method as recited in claim 5 , wherein the airfoil is a fan blade.

18. The method as recited in claim 5 , wherein the airfoil is metallic.

19. The method as recited in claim 5 , wherein each heating station of the set of heating stations includes one or more infrared heating elements.

20. The method as recited in claim 5 , wherein the forming line includes a loading station upstream of the set of heating stations, and further comprising positioning the airfoil in the loading station at a loading temperature between 50 degrees and 150 degrees Fahrenheit.