Abstract: Processes for producing near net-shape panels and panels formed thereby. The processes include forming a preform to comprise a stack of multiple plies that contain an uncured expandable foam material. The preform has regions that differ from each other by the number and/or volume of the plies therein. The preform and its plies are then cured within a restricted volume to produce a near net-shape panel. The curing step causes the expandable foam material to expand, and the restricted volume is sized so that the number and volume of the plies within the regions of the preform cause zones within the panel to have different densities and/or thicknesses.

Abstract: Processes for producing near net-shape panels and panels formed thereby. The processes include forming a preform to comprise a stack of multiple plies that contain an uncured expandable foam material. The preform has regions that differ from each other by the number and/or volume of the plies therein. The preform and its plies are then cured within a restricted volume to produce a near net-shape panel. The curing step causes the expandable foam material to expand, and the restricted volume is sized so that the number and volume of the plies within the regions of the preform cause zones within the panel to have different densities and/or thicknesses.

Abstract: A fairing is disclosed, comprising a surface capable of bounding a fluid on the surface and a seal located at an edge portion on the fairing wherein the seal has at least one support flange and a contact face capable of engaging with an adjacent component to facilitate reducing a leakage of the fluid. A stator assembly is disclosed comprising a vane, a first fairing having a first seal and a second fairing having a second seal, wherein the first seal engages with an adjacent component to facilitate reducing leakage of a fluid in the stator assembly.

Abstract: A method of manufacturing an integrated seal on a component is disclosed, comprising the steps of supplying a component having an edge portion, forming a profile on the edge portion, supplying a seal, applying a bond preparation on a surface on the edge portion, applying a bonding material on the seal, mounting the seal to the edge portion, and curing the bond. A method of assembling a stator assembly is disclosed comprising the steps of providing a vane, providing a first fairing located near a first side of the vane, the first fairing having a first seal coupled to a first edge portion of the first fairing, providing a second fairing located near a second side of the vane, the second fairing having a second seal coupled to a second edge portion of the second fairing and engaging a portion of the first seal with a portion of the second seal.