Abstract: A method for compression molding a resin-impregnated preform to fabricate an impact-resistance, fiber-reinforced composite fan blade for use in a high bypass turbofan engine. The method is compatible with the use of high viscosity resin systems that contribute greater impact resistance to the fan blade, but whose flow through the fan blade during molding would cause unacceptable movement of the reinforcing fibers. The method entails restricting the flow of the resin system within the preform through selective placement of a resin-impervious material on certain surfaces of the preform, so as to prevent resin loss and fiber movement during the compression molding operation.

Abstract: The present invention provides a composite airfoil particularly useful as a fan blade, having a high degree of twist, in a large high bypass ratio turbofan engine. The composite airfoil of the present invention has a progression of filament reinforced airfoil laminations of varying span, arranged in order by span, and interrupted by at least one filament reinforced airfoil lamination having a span out of height order to form what is called a confused or broken shear plane where radially outer tips of the laminations end.

Abstract: A composite fastener member, in one form, having integral head and shank portions is defined by a plurality of superimposed composite fiber reinforced sheets spirally wound about a longitudinal axis. A plurality of fastener members, oppositely disposed within an opening in an article, define a fastener especially useful in joining lightweight composite structures such as aircraft or aircraft engine components. In another form, the ends of a single spirally wound composite fastener member are splayed to fasten a plurality of sheets.

Abstract: A method for making a fiber reinforced composite article includes placing in a forming mold article cavity a preform which includes at least a fiber reinforcement arrangement, such as stacked piles of resin bonded sheets. Closure of the mold defines a matrix reservoir for excess matrix material in fluid flow relationship with the article cavity. Gas pressure applied to the excess matrix material while in the fluid condition forces that material back into the article cavity to nominally eliminate voids, pores and other internal and surface discontinuities from the article.

Abstract: A hollow composite airfoil with an integral internal support rib of fluoroelastomer rubber is formed by bracketing the rib between two silicone rubber mandrels to form a core assembly having a desired aerodynamic shape, then building up on opposite sides of the core assembly separate stacks of laminae of a composite material of graphite (or carbon) and glass fibers impregnated with an epoxy resin, with the two stacks overlapping adjacent to the leading and trailing edges of the core assembly. Heat and pressure are then applied to the core assembly with the laminae thereon to bond together the laminae of each stack, then to bond the two stacks together along the overlapping portions thereof and to bond the two stacks to the rib to form a continuous shell around the core assembly. The mandrels are then removed. One open end of the resulting hollow airfoil is plugged and that end is inserted into a recess in a mounting platform with a predetermined clearance space therebetween.

Abstract: A composite fabric preform and article made of both structural and thermoplastic fibrous materials and a method of making such preform and article, the method improving the handling properties of the composite. A plurality of layers of fabric made from structural fibrous material are disposed in a stacked assembly with layers sequentially adjacent each other. At least each of alternate layers of the alternate layers of fabric include within its weave thermoplastic fibrous material intermixed with the structural fibrous material. The layers of fabric, preferably under pressure, are heated at a temperature sufficient to promote bonding action by the thermoplastic fibers at junctures between fibrous materials.

Abstract: A composite fabric preform and article made of both structural and thermoplastic fibrous materials and a method of making such preform and article, the method improving the handling properties of the composite. A plurality of layers of fabric made from structural fibrous material are disposed in a stacked assembly with layers sequentially adjacent each other. At least each of alternate layers of the alternate layers of fabric include within its weave thermoplastic fibrous material intermixed with the structural fibrous material. The layers of fabric, preferably under pressure, are heated at a temperature sufficient to promote bonding action by the thermoplastic fibers at junctures between fibrous materials.