Abstract: A static guide vane for use in a fan section of a gas turbine engine includes an outer platform and an inner platform. The inner and outer platforms are connected by an airfoil. The airfoil have channels extending into a main body of the airfoil to reduce the weight of the vane. A cover closes off the channels with the cover providing a portion of the airfoil.

Abstract: An airfoil array includes a plurality of airfoils that differ in geometry over a plurality of geometry classes. An airfoil can include an airfoil body that has a first distinct piece and a second distinct piece that seats together with the first distinct piece. The first distinct piece and the second distinct piece include a mistake-proof feature configured such that the second distinct piece fully seats with the first distinct piece.

Abstract: A seal for use with a static guide vane of a gas turbine engine has a strap member extending to a generally cylindrical bulb. The bulb forms a diameter, and is spaced a distance defined between an end of the strap remote from the bulb, to a point on the bulb furthest from the end. A ratio of the diameter to the distance is between 0.2 and 0.5. A static guide vane and a gas turbine engine are also disclosed.

Abstract: A disclosed structural guide vane for a gas turbine engine includes a strut defining a plurality of channels and a cover attached over the plurality of channels. The strut includes a first side defining a first surface of an airfoil and a second side including a plurality of channels. At least one of the plurality of channels defines a wall thickness of a portion of the first side that varies in a chord wise direction.

Abstract: A composite fan blade having an airfoil with a leading edge and a trailing edge and a dovetail root includes a first pressure face and second pressure face, a lower horizontal face connecting the pressure faces at the bottom of the dovetail and a first and a second dovetail runout fillet connecting the pressure faces to the airfoil. The pressure faces are each angled outward at about 65 degrees to about 75 degrees from horizontal.

Abstract: The disclosed composite airfoil includes a three-dimensional composite core extending longitudinally and having a chord-wise direction. The core has a core in-plane thickness extending between opposing sides in a through-plane direction generally perpendicular to the chord-wise and longitudinal directions. A composite skin covers the opposing sides and has an exterior surface providing an airfoil contour. The skin includes a total skin in-plane thickness corresponding to a sum of thicknesses through the skin in the through-plane direction from each of the opposing sides to their adjoining exterior surface. A sum of the core in-plane and total skin in-plane thicknesses at a central portion of the composite airfoil is a total in-plane thickness. The total skin in-plane thickness at the central portion is less than 50% of the total in-plane thickness.

Abstract: A method of forming an airfoil includes forming a metal portion of the airfoil including a tip, a leading edge, a trailing edge, a pressure side and a suction side; forming a plurality of grooves into one side of the airfoil; and filling the plurality of grooves with composite material.

Abstract: A sheath for a fan airfoil having a leading edge, a trailing edge, a tip, a root, a suction side and a pressure side includes a solid portion to wrap around the airfoil lead edge and over the airfoil tip and means for securing the solid portion to the airfoil.

Abstract: Gas turbine engine systems involving fairings with locating data are provided. In this regard, a representative a fairing assembly for a gas turbine engine includes: a first locating component having a leading edge, first and second sides extending from the leading edge, and a recess oriented parallel to the leading edge, the recess having a first datum surface, the first locating component being operative to be positioned between a portion of a strut and a portion of an interior surface of a fairing sheath such that the first datum surface establishes a desired orientation of the fairing sheath relative to the strut.

Abstract: A composite airfoil includes a core that has a three-dimensional network of fibers. The core defines an airfoil section and a root section. A composite skin covers a portion of the core excluding the root section.

Abstract: An intermediate-manufactured composite airfoil includes first and second composite skins each having a plurality of fibers in a polymer matrix. A composite core is removably located between the first and second composite skins. The composite core includes a dry, three-dimensional, woven fiber network. The composite core may alternatively include a three-dimensional, woven fiber network in a fully cured polymer matrix.

Abstract: A sheath for a fan airfoil having a leading edge, a trailing edge, a tip, a root, a suction side and a pressure side includes a solid portion to wrap around the airfoil lead edge and over the airfoil tip and means for securing the solid portion to the airfoil.

Abstract: A method of forming a composite airfoil having a suction side and pressure side includes the steps of designing a mold, designing a woven core, designing a plurality of plies and assembling the designed mold, core and plies to create the composite airfoil. The hollow mold has an inner surface which defines the surface profile of the composite airfoil. The plurality of plies is designed to fit between the inner surface of the mold and an outer surface of the woven core. The plurality of plies is designed after the step of designing the woven core.

Abstract: The disclosed composite airfoil includes a three-dimensional composite core extending longitudinally and having a chord-wise direction. The core has a core in-plane thickness extending between opposing sides in a through-plane direction generally perpendicular to the chord-wise and longitudinal directions. A composite skin covers the opposing sides and has an exterior surface providing an airfoil contour. The skin includes a total skin in-plane thickness corresponding to a sum of thicknesses through the skin in the through-plane direction from each of the opposing sides to their adjoining exterior surface. A sum of the core in-plane and total skin in-plane thicknesses at a central portion of the composite airfoil is a total in-plane thickness. The total skin in-plane thickness at the central portion is less than 50% of the total in-plane thickness.

Abstract: A fan blade includes an airfoil and a dovetail at a radially inner end of the airfoil. The dovetail extends between first and second axial ends, and has outer circumferential faces. The dovetail is formed of relatively rigid composite material. Compliant material is placed on each outer circumferential face of the dovetail. The compliant material is less rigid than the composite material for forming the dovetail. In a second embodiment, the compliant layer may be positioned within the disk slots in a disk, such that the compliant layer will come in contact with circumferentially outer faces of the dovetail.

Abstract: A mandrel comprising a rigid inner core and an elastomeric outer layer that at least partially surrounds the rigid inner core, wherein the elastomeric outer layer is adapted to expand during a molding process to seal a cavity to prevent incursion of material injected during the molding process.

Abstract: An intermediate-manufactured composite airfoil includes first and second composite skins each having a plurality of fibers in a polymer matrix. A composite core is removably located between the first and second composite skins. The composite core includes a dry, three-dimensional, woven fiber network. The composite core may alternatively include a three-dimensional, woven fiber network in a fully cured polymer matrix.

Abstract: Gas turbine engine systems involving fairings with locating data are provided. In this regard, a representative a fairing assembly for a gas turbine engine includes: a first locating component having a leading edge, first and second sides extending from the leading edge, and a recess oriented parallel to the leading edge, the recess having a first datum surface, the first locating component being operative to be positioned between a portion of a strut and a portion of an interior surface of a fairing sheath such that the first datum surface establishes a desired orientation of the fairing sheath relative to the strut.

Abstract: An inlet guide vane provides improved, smooth airflow and avoids separation of flow even at high incidence angles. The inlet guide vane includes a strut having opposite side surfaces that are continuously curved to provide a controlled velocity distribution at the trailing edge of the strut. The inlet guide vane further includes a flap having a leading edge aligned behind the trailing edge of the strut. Generally, the strut and the flap are designed together so that low momentum air in the gap between the strut and the flap will be energized and entrained in the boundary layer of the flap. The airflow from the gap will remain attached to the flap to improve the flow from the flap.

Abstract: A mandrel comprising a rigid inner core and an elastomeric outer layer that at least partially surrounds the rigid inner core, wherein the elastomeric outer layer is adapted to expand during a molding process to seal a cavity to prevent incursion of material injected during the molding process.