Abstract: There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising applying fibre-reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form comprising a body region and a longitudinally adjacent flange region. The pre-form extends generally longitudinally between two longitudinal ends; and a trailing ply of the pre-form extends generally longitudinally between the longitudinal end closest to the flange region and an inner ply end located in the flange region or partway into the body region. Relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion during a flange forming operation, thereby causing a tension force in at least the flange region of the pre-form of during forming of the flange.

Abstract: There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising applying fibre-reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form comprising a body region and a longitudinally adjacent flange region. The pre-form extends generally longitudinally between two longitudinal ends; and a trailing ply of the pre-form extends generally longitudinally between the longitudinal end closest to the flange region and an inner ply end located in the flange region or partway into the body region. Relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion during a flange forming operation, thereby causing a tension force in at least the flange region of the pre-form of during forming of the flange.

Abstract: There is disclosed a method of manufacturing a composite blade, and the composite blade. The method comprises a lay-up operation comprising laying up fibre reinforcement material on an untwisted lay-up surface to make a blade pre-form and a forming operation comprising forming the blade pre-form to introduce twist in the blade pre-form.

Abstract: There is disclosed bagging apparatus (20) for bagging a pre-form (12) for a composite component on a tool (10), the apparatus (20) comprising: a bag dispenser (22) having a store (28) for a tubular vacuum bag (30); and a bag guide (36). In use, a length of tubular vacuum bag material (30) can be drawn from the store (28) radially outwardly over the bag guide (36) and over the tool (10) to form a tube around the pre-form. There is also disclosed a method of bagging a pre-form (12) for a composite component on a tool using the bagging apparatus (20).

Abstract: The present disclosure relates to a method of manufacturing an aerofoil structure for a gas turbine engine, wherein the aerofoil structure includes a root configured to be received in a rotor disc of the gas turbine engine, the method including: providing a pre-moulded polymer insert; adding the polymer insert into a mould for forming the aerofoil structure; adding a composite constituent into the mould; and heating the composite constituent in the mould to bond the polymer insert to the composite constituent, the polymer insert being provided at a shoulder of the aerofoil structure root. The composite constituent is pre-impregnated with a resin and heating the composite constituent in the mould thermosets the resin. Heating the composite constituent in the mould to bond the polymer insert to the composite constituent forms an intermediate part and the method further comprises machining the intermediate part to remove excess material and form the aerofoil structure.

Abstract: There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising: applying fibre reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form having first, second and third contiguous regions, the first region corresponding to the main body of the component and the second region corresponding to the integral flange of the component; and causing relative movement between the flange-forming portion and the main body portion so that the second region of the pre-form deforms to form the flange; wherein the relative movement of the flange-forming portion and the main body portion causes sliding movement between the second and third regions of the pre-form and the flange-forming, thereby producing a tension force in at least the second region of the pre-form during forming of the flange.

Abstract: There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising applying fibre-reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form comprising a body region and a longitudinally adjacent flange region. The pre-form extends generally longitudinally between two longitudinal ends; and a trailing ply of the pre-form extends generally longitudinally between the longitudinal end closest to the flange region and an inner ply end located in the flange region or partway into the body region. Relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion during a flange forming operation, thereby causing a tension force in at least the flange region of the pre-form of during forming of the flange.

Abstract: There is disclosed a method of forming a composite component having a curved body and an integral flange from a pre-form (200) using forming apparatus comprising: a tool (102) comprising a curved body portion (104) having a lay-up surface (110) and a forming assembly (105) comprising a plurality of forming elements (106) each having a lay-up surface (120) and a primary flange-forming surface (122); and a plurality of filler elements (107) each having a secondary flange-forming surface (156).

Abstract: There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising: applying fibre reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form having first, second and third contiguous regions, the first region corresponding to the main body of the component and the second region corresponding to the integral flange of the component; and causing relative movement between the flange-forming portion and the main body portion so that the second region of the pre-form deforms to form the flange; wherein the relative movement of the flange-forming portion and the main body portion causes sliding movement between the second and third regions of the pre-form and the flange-forming, thereby producing a tension force in at least the second region of the pre-form during forming of the flange.

Abstract: There is disclosed bagging apparatus (20) for bagging a pre-form (12) for a composite component on a tool (10), the apparatus (20) comprising: a bag dispenser (22) having a store (28) for a tubular vacuum bag (30); and a bag guide (36). In use, a length of tubular vacuum bag material (30) can be drawn from the store (28) radially outwardly over the bag guide (36) and over the tool (10) to form a tube around the pre-form. There is also disclosed a method of bagging a pre-form (12) for a composite component on a tool using the bagging apparatus (20).

Abstract: Method forming a composite structure (9) comprising a main body and a flange. The composite structure is manufactured by laying-up a preform (7) on a mold (6). The preform (7) does not have the first and second bends and comprises a first part which corresponds to the main body of the composite structure and a second part which corresponds to the flange of the composite structure. The second part of the (preform (7) has a proximal portion which corresponds to the wall portion of the flange and a distal portion which corresponds to the lip portion of the flange. The preform (7) comprises a plurality of plies and uni-directional ply material extends from the first part of the preform (7) to the distal portion of the second part of the preform (7).

Abstract: A method for manufacturing a component comprising at least one layer having a fiber-reinforced composite material that absorbs microwaves is disclosed. The method comprises at least the following steps: a) arranging the at least one layer in a shape, b) treating a first surface section of the at least one layer with microwaves, wherein a temperature limiting mechanism of the at least one layer cooperate with at least one adjacent second surface section, at least part of the time. The method may be carried out in such that steps a) and b) are carried out for a plurality of components and that the components are further treated according to at least the following steps: c) positioning a plurality of components with respect to one another such that each second surface section forms at least one overlapping area at least partially, d) treating the at least one overlapping area with microwaves.

Abstract: Method forming a composite structure (9) comprising a main body and a flange. The composite structure is manufactured by laying-up a preform (7) on a mould (6). The preform (7) does not have the first and second bends and comprises a first part which corresponds to the main body of the composite structure and a second part which corresponds to the flange of the composite structure. The second part of the (preform (7) has a proximal portion which corresponds to the wall portion of the flange and a distal portion which corresponds to the lip portion of the flange. The preform (7) comprises a plurality of plies and uni-directional ply material extends from the first part of the preform (7) to the distal portion of the second part of the preform (7).

Abstract: A flange (1) made of composite material, a method of making the flange (1) and a mandrel (3) upon which the flange (1) is formed are provided. The flange (1) is a curved hollow member that has a substantially triangular cross-section. The method of making the flange (1) includes applying composite material to external surfaces of a curved mandrel (3). The mandrel (3) is curved and comprises a solid triangular cross-section. The method also includes curing the composite material to produce a flange (1) that is a curved hollow member that is substantially triangular in cross-section.

Abstract: A temperature sensor array comprises an optical fiber (16) on which are a plurality of Bragg gratings (18) on respective spaced apart portions of the fiber. Each portion is in a housing (14) which freely houses the said portion substantially without axial strain on the fiber within the housing and which also isolates the grating from strain imposed on the fiber outside the housing. Thus substantially only changes in temperature affect the Bragg grating of that portion. The array may be used to detect and control the temperature of a tool (12) for forming a composite component amongst other uses.

Abstract: A forming tool (100) for and a method of making a three dimensional composite component using double diaphragm forming. The forming tool (100) comprises a forming side having two or more regions of changing profile and one or more through holes associated with each region, the through holes exit on the forming side and are connectable to one or more vacuum sources such that vacuum can be selectively and discretely applied to each region.

Abstract: A flange (1) made of composite material, a method of making the flange (1) and a mandrel (3) upon which the flange (1) is formed are provided. The flange (1) is a curved hollow member that has a substantially triangular cross-section. The method of making the flange (1) includes applying composite material to external surfaces of a curved mandrel (3). The mandrel (3) is curved and comprises a solid triangular cross-section. The method also includes curing the composite material to produce a flange (1) that is a curved hollow member that is substantially triangular in cross-section.

Abstract: A method for manufacturing a component comprising at least one layer having a fiber-reinforced composite material that absorbs microwaves is disclosed. The method comprises at least the following steps: a) arranging the at least one layer in a shape, b) treating a first surface section of the at least one layer with microwaves, wherein a temperature limiting mechanism of the at least one layer cooperate with at least one adjacent second surface section, at least part of the time. The method may be carried out in such that steps a) and b) are carried out for a plurality of components and that the components are further treated according to at least the following steps: c) positioning a plurality of components with respect to one another such that each second surface section forms at least one overlapping area at least partially, d) treating the at least one overlapping area with microwaves.

Abstract: A forming tool (100) for and a method of making a three dimensional composite component using double diaphragm forming. The forming tool (100) comprises a forming side having two or more regions of changing profile and one or more through holes associated with each region, the through holes exit on the forming side and are connectable to one or more vacuum sources such that vacuum can be selectively and discretely applied to each region.

Abstract: A temperature sensor array comprises an optical fibre (16) on which are a plurality of Bragg gratings (18) on respective spaced apart portions of the fibre. Each portion is in a housing (14) which freely houses the said portion substantially without axial strain on the fibre within the housing and which also isolates the grating from strain imposed on the fibre outside the housing. Thus substantially only changes in temperature affect the Bragg grating of that portion. The array may be used to detect and control the temperature of a tool (12) for forming a composite component amongst other uses.