Abstract: A composite component for a gas turbine engine includes a body including a composite material. Furthermore, the composite component includes a connection feature integrally woven to the body. Additionally, the connection portion includes a composite material. Moreover, the composite material of the body and the composite material of the connection feature include alternating layers of fiber tows integrally woven together.

Abstract: An airfoil assembly and a method of forming the airfoil assembly, the airfoil assembly having a trunnion, a spar, and a set of inserts. The trunnion having a flared socket with an open top. The spar extending from the flared socket and through the open top. The spar having a first end located within the flared socket.

Abstract: A containment assembly for use in a turbine engine includes a fan case formed from a composite material. The fan case includes a forward end, an aft end, and an opening defined through the fan case between the forward and aft ends. The containment assembly further includes a structural attachment member formed from a metallic material and coupled to the fan case. The structural attachment member is positioned within the opening in the fan case and is configured to receive at least one fastener to couple a component to the structural attachment member.

Abstract: A method is provided for forming a composite article to have a primary composite structure and an integral secondary composite structure that extends out of a plane defined by the primary composite structure. The method includes laying-up first plies to construct the primary composite structure. The first plies contain continuous reinforcement material and extend from a first zone that will define the primary composite structure into a second zone that will define the secondary composite structure. During laying-up of the first plies, additional plies are interleaved with the first plies within the second zone but not the first zone. The additional plies originate within a build-up zone between the first and second zones and extend therefrom into the second zone. After interleaving the plies, the build-up zone is deformed to orient the second zone and form the secondary composite structure that extends out of the plane defined by the continuous reinforcement material of the first plies.

Abstract: Composite fan blade platform includes forward and aft portions and transition portion therebetween. Platform mounting holes extend through increased section thickness in transition portion and conical countersinks centered about centerlines of mounting holes extend into transition portion. Bolts include bolt shanks extending away from boltheads through center bolt holes in conical load spreaders in conical countersink. Boltheads engage conical load spreader. Bolthead is disposed entirely within cylindrical counterbore into top of load spreader and engages shoulder at bottom of cylindrical counterbore. Radial gap between bolthead and cylindrical counterbore surface of cylindrical counterbore may be filled by filler or filler ring. Bolts may join platform supports to disk hooks attached, fixed or joined to, or integral with disk posts of disk. Nuts threaded on threaded inner end of bolt shank may secure bases attached to platform supports to fan blade platform.

Abstract: A containment assembly for use in a turbine engine includes a fan case formed from a composite material. The fan case includes a forward end, an aft end, and an opening defined through the fan case between the forward and aft ends. The containment assembly further includes a structural attachment member formed from a metallic material and coupled to the fan case. The structural attachment member is positioned within the opening in the fan case and is configured to receive at least one fastener to couple a component to the structural attachment member.

Abstract: Composite fan blade platform includes forward and aft portions and transition portion therebetween. Platform mounting holes extend through increased section thickness in transition portion and conical countersinks centered about centerlines of mounting holes extend into transition portion. Bolts include bolt shanks extending away from boltheads through center bolt holes in conical load spreaders in conical countersink. Boltheads engage conical load spreader. Bolthead is disposed entirely within cylindrical counterbore into top of load spreader and engages shoulder at bottom of cylindrical counterbore. Radial gap between bolthead and cylindrical counterbore surface of cylindrical counterbore may be filled by filler or filler ring. Bolts may join platform supports to disk hooks attached, fixed or joined to, or integral with disk posts of disk. Nuts threaded on threaded inner end of bolt shank may secure bases attached to platform supports to fan blade platform.

Abstract: A method is provided for forming a composite article to have a primary composite structure and an integral secondary composite structure that extends out of a plane defined by the primary composite structure. The method includes laying-up first plies to construct the primary composite structure. The first plies contain continuous reinforcement material and extend from a first zone that will define the primary composite structure into a second zone that will define the secondary composite structure. During laying-up of the first plies, additional plies are interleaved with the first plies within the second zone but not the first zone. The additional plies originate within a build-up zone between the first and second zones and extend therefrom into the second zone. After interleaving the plies, the build-up zone is deformed to orient the second zone and form the secondary composite structure that extends out of the plane defined by the continuous reinforcement material of the first plies.

Abstract: An apparatus and methods for manufacturing a flanged component from a composite lay-up are provided. The apparatus includes a support structure coupled to the composite lay-up and a mold ring coupled to the support structure. The mold ring includes a ring guide surface and a radial contact surface that is configured to couple to the composite lay-up. The apparatus further includes a mold plate coupled to the mold ring. The mold plate includes a recessed surface and a plate guide surface, where the recessed surface is configured to couple to the composite lay-up and the plate guide surface is configured to couple to the ring guide surface. The apparatus also includes an autoclave that applies pressure to the mold ring and the mold plate to move the plate guide surface along the ring guide surface to apply pressure to the composite lay-up.