Method of forming gas turbine engine components

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

forming a plurality of internal channels in a main body between one or more internal ribs;

forming a weld pattern in an external surface of a cover skin, the weld pattern based on at least a geometry of the one or more internal ribs;

positioning the cover skin along the main body to enclose the plurality of internal channels, wherein the positioning step occurs subsequent to the step of forming the weld pattern; and

welding the cover skin to the main body along the weld pattern subsequent to the positioning step.

2. The method as recited in claim 1 , wherein the one or more internal ribs are a plurality of internal ribs that are spaced apart along a wall of the main body.

3. The method as recited in claim 2 , wherein the weld pattern comprises a plurality of separate and distinct sub-patterns, each of the sub-patterns corresponding to a respective one of the plurality of internal ribs.

4. The method as recited in claim 3 , wherein each sub-pattern corresponds to a mean line defined between opposing sidewalls of a respective one of the plurality of internal ribs.

5. The method as recited in claim 3 , wherein each of the internal ribs has a first arcuate portion and a second arcuate portion opposed to the first arcuate portion such that the respective one of the internal ribs encircles a respective one of the plurality of internal channels.

6. The method as recited in claim 1 , wherein the main body and the external surface of the cover skin cooperate to define pressure and suction sides of an airfoil.

7. The method as recited in claim 6 , wherein the airfoil is a fan blade.

8. The method as recited in claim 1 , further comprising inspecting the one or more internal ribs to define the weld pattern.

9. The method as recited in claim 8 , wherein the inspecting step includes determining a set of edge curves corresponding to the geometry of the one or more internal ribs, and the weld pattern corresponds to the set of edge curves.

10. The method as recited in claim 1 , wherein the cover skin and the main body are metallic.

11. The method as recited in claim 1 , further comprising:

forming a recess in the main body that extends about the one or more internal ribs and that is dimensioned to mate with a perimeter of the cover skin;

wherein the weld pattern is based on a geometry of the recess; and

wherein the welding step includes welding the perimeter of the cover skin to surfaces of the recess along the weld pattern.

12. The method as recited in claim 1 , further comprising:

forming one or more pedestals in an internal surface of the cover skin;

positioning the one or more pedestals in abutment against respective ones of the one or more internal ribs; and

wherein the welding step includes welding the one or more internal ribs to respective ones of the one or more pedestals along the weld pattern.

13. The method as recited in claim 1 , further comprising:

deforming the cover skin with respect to a predefined contour subsequent to the step of forming the weld pattern; and

wherein the main body extends from a root section to a tip portion, and the step of deforming the cover skin occurs such that 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.

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

forming a plurality of internal channels in a main body between a plurality of internal ribs;

inspecting the main body to determine a rib pattern subsequent to forming the plurality of internal channels, the rib pattern corresponding to a geometry of the plurality of internal ribs;

forming a plurality of pedestals in an internal surface of a cover skin according to the rib pattern;

forming a weld pattern in an external surface of the cover skin, the weld pattern based on at least a geometry of the plurality of internal ribs;

positioning the cover skin along the main body to enclose the plurality of internal channels such that the plurality of pedestals abut against respective ones of the plurality of internal ribs, wherein the positioning step occurs subsequent to the step of forming the weld pattern; and

welding the plurality of pedestals to respective ones of the plurality of internal ribs subsequent to the positioning step.

15. The method as recited in claim 14 , further comprising:

welding the cover skin to the main body along the weld pattern subsequent to the positioning step.

16. The method as recited in claim 15 , wherein the weld pattern is offset from the rib pattern.

17. The method as recited in claim 15 , further comprising:

deforming the cover skin with respect to a predefined contour subsequent to the step of forming the plurality of pedestals, wherein the cover skin has a substantially planar geometry during the inspecting step;

forming a recess in the main body that is dimensioned to mate with a perimeter of the cover skin;

wherein the cover skin has a substantially planar geometry during the step of forming the plurality of pedestals; and

wherein the welding step includes welding a perimeter of the cover skin to the main body along the weld pattern subsequent to the positioning step.

18. The method as recited in claim 14 , wherein the cover skin and the main body are metallic.

19. The method as recited in claim 14 , wherein the inspecting step includes determining a set of edge curves corresponding to sidewalls of the plurality of internal ribs, and the rib pattern corresponds to the set of edge curves.

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

forming a plurality of internal channels in a main body between one or more internal ribs;

forming a weld pattern in an external surface of a cover skin, the weld pattern based on at least a geometry of the one or more internal ribs;

positioning the cover skin along the main body to enclose the plurality of internal channels;

welding the cover skin to the main body along the weld pattern subsequent to the positioning step; and

deforming the cover skin with respect to a predefined contour subsequent to the step of forming the weld pattern, and wherein the cover skin has a substantially planar geometry during the step of forming the weld pattern.

21. The method as recited in claim 20 , wherein the main body extends from a root section to a tip portion, and the step of deforming the cover skin occurs such that 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.