Welding method for hollow airfoils and intermediate body

1. A method of forming an airfoil comprising the steps of:

providing an airfoil body with a hollow having at least one rib extending to an outer surface of said at least one rib, and forming said outer surface of said at least one rib to have at least one groove connecting a hollow pocket within a boundary defined by said at least one rib to a location outwardly of said at least one rib;

placing a cover over said hollow;

welding said cover to said airfoil body, and such that said outer surface of said at least one rib is welded to said cover; and

wherein a portion of said at least one rib is sacrificed during the welding step such that said at least one groove is sacrificed and is not part of said airfoil after said welding step.

2. The method as set forth in claim 1 , wherein said at least one groove includes a plurality of grooves.

3. The method as set forth in claim 2 , wherein said plurality of grooves extend in a plurality of locations across said outer surface of said at least one rib.

4. The method as set forth in claim 2 , wherein a cross section of said at least one rib is generally circular.

5. The method as set forth in claim 4 , wherein a groove depth is defined between an apex of said at least one groove to a bottom most depth of said at least one groove, with said groove depth being between 0.002-0.016 inches.

6. The method as set forth in claim 2 , wherein a groove depth is defined between an apex of said at least one groove to a bottom most depth of said at least one groove, with said groove depth being between 0.002-0.016 inches.

7. The method as set forth in claim 2 , wherein said welding step is laser welding.

8. The method as set forth in claim 7 , wherein said laser welding occurs in an inert gas environment.

9. The method as set forth in claim 8 , wherein said inert gas is an argon environment.

10. The method as set forth in claim 7 , wherein said airfoil body and said cover are formed of titanium alloys.

11. The method as set forth in claim 10 , wherein said at least one groove is formed into said outer surface of said at least one rib by a ball end mill tool.

12. The method as set forth in claim 1 , wherein a cross section of said at least one rib is generally circular.

13. The method as set forth in claim 12 , wherein a groove depth is defined between an apex of said at least one groove to a bottom most depth of said at least one groove, with said groove depth being between 0.002-0.016 inches.

14. The method as set forth in claim 13 , wherein said welding step is laser welding.

15. The method as set forth in claim 1 , wherein said airfoil body and said cover are formed of titanium alloys.

16. The method as set forth in claim 1 , wherein said welding step is laser welding.

17. The method as set forth in claim 1 , wherein said at least one groove is formed into said outer surface of said at least one rib by a ball end mill tool.

18. The method as set forth in claim 3 , wherein:

said at least one rib surrounds a perimeter of said hollow pocket; and

said at least one rib includes apices distributed along said outer surface of said at least one rib, and said plurality of grooves are established by a plurality of cusps between adjacent pairs of said apices;

said placing step occurs such that said cover contacts said apices;

said welding step includes welding said cover to said apices; and

said plurality of grooves extend in a common direction across said outer surface of said at least one rib and extend from said perimeter of said hollow pocket.

19. The method as set forth in claim 18 , wherein a cross section of said at least one rib is generally circular to establish said perimeter of said hollow pocket.