Abstract: Collar support assemblies are provided. For example, a collar support assembly for an airfoil comprises a collar that includes a first surface shaped complementary to a fillet of the airfoil and a planar second surface. The first surface is disposed adjacent the fillet of the airfoil. The collar support assembly further comprises a shim material disposed between the second surface and an airfoil support structure and a filler material inserted between the first surface and the fillet of the airfoil to provide a tight fit between the collar and the airfoil. In other embodiments, the collar support assembly comprises a pair of collars and supports an airfoil doublet. The airfoil doublets may be part of an outlet guide vane assembly of a gas turbine engine, and methods for assembling outlet guide vane assemblies also are provided.

Abstract: Collar support assemblies are provided. For example, a collar support assembly for an airfoil comprises a collar that includes a first surface shaped complementary to a fillet of the airfoil and a planar second surface. The first surface is disposed adjacent the fillet of the airfoil. The collar support assembly further comprises a shim material disposed between the second surface and an airfoil support structure and a filler material inserted between the first surface and the fillet of the airfoil to provide a tight fit between the collar and the airfoil. In other embodiments, the collar support assembly comprises a pair of collars and supports an airfoil doublet. The airfoil doublets may be part of an outlet guide vane assembly of a gas turbine engine, and methods for assembling outlet guide vane assemblies also are provided.

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: Articles having substantially cylindrical bodies including a plurality of circumferential layers, each layer having at least one ply of material, the material comprising a weave fabric, a non-crimp fabric, or a combination thereof.

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 containment case comprises a composite core, with an inner surface, and at least one ceramic layer integrated with the composite core. The at least one ceramic layer is bonded to the inner surface of the composite core with a resin. In another embodiment, a containment case comprises a composite core, with an inner surface, and a hybrid material comprising at least one ceramic material and at least one non-ceramic material. The hybrid material is disposed on the inner surface of the composite core. The hybrid material is bonded to the inner surface of the composite core with a resin. A method of fabricating a containment case includes the steps of disposing one or more layers of ceramic fabric on an inner surface of a composite core, infusing the composite core and the one or more layers of ceramic fabric with resin, and curing the resin.

Abstract: Methods for making articles having a substantially cylindrical body including providing a substantially cylindrical tool, providing at least one ply of a material, the material being a weave fabric, a non-crimp fabric, or a combination thereof, wrapping the at least one ply of material about the tool to produce an article preform having a plurality of circumferential layers, applying a resin to the article preform, and curing the article preform to produce an article having a substantially cylindrical body.

Abstract: Methods for making a structure having an integral mounting flange involving providing a primary composite structure having a circumference, applying at least one circumferentially oriented core fiber about the circumference of the primary composite structure, applying at least one layer of attachment fibers to operably connect the core fiber to the primary composite structure about the circumference to obtain an integral mounting flange preform, and curing the mounting flange preform to obtain an integral mounting flange.

Abstract: Tethered flange corners including at least one ply of barrier fibers and at least one fiber tow wrapped about the barrier fibers. Also included are flanges having a tethered corner containing at least one ply of barrier fibers, at least one fiber tow wrapped about the barrier fibers, at least one ply of filler fibers applied over the fiber tow, and at least one ply of flange fibers applied over the filler fibers. Additionally included are articles incorporating a composite structure having a flange with a tethered corner containing at least one ply of barrier fibers and at least one fiber tow wrapped about the barrier fibers.

Abstract: A containment case comprises a composite core, with an inner surface, and at least one ceramic layer integrated with the composite core. The at least one ceramic layer is bonded to the inner surface of the composite core with a resin. In another embodiment, a containment case comprises a composite core, with an inner surface, and a hybrid material comprising at least one ceramic material and at least one non-ceramic material. The hybrid material is disposed on the inner surface of the composite core. The hybrid material is bonded to the inner surface of the composite core with a resin. A method of fabricating a containment case includes the steps of disposing one or more layers of ceramic fabric on an inner surface of a composite core, infusing the composite core and the one or more layers of ceramic fabric with resin, and curing the resin.

Abstract: Articles having substantially cylindrical bodies including a plurality of circumferential layers, each layer having at least one ply of material, the material comprising a weave fabric, a non-crimp fabric, or a combination thereof.

Abstract: Methods for making articles having a substantially cylindrical body including providing a substantially cylindrical tool, providing at least one ply of a material, the material being a weave fabric, a non-crimp fabric, or a combination thereof, wrapping the at least one ply of material about the tool to produce an article preform having a plurality of circumferential layers, applying a resin to the article preform, and curing the article preform to produce an article having a substantially cylindrical body.

Abstract: Continuous debulking methods involving providing a spool of fabric, heating the fabric to produce a heated fabric while concurrently transferring the heated fabric to a composite structure forming tool, wrapping the heated fabric about the composite structure forming tool, applying resin to the heated fabric to obtain a resin rich fabric surface, applying a subsequent ply of heated fabric to the resin rich fabric surface to obtain an impregnated composite material, and debulking and cooling the impregnated composite to obtain a composite structure preform.

Abstract: Continuous debulking systems including in combination a spool for providing a fabric, a heating apparatus for heating the fabric as the fabric is unrolled from the spool to produce a heated fabric, a composite structure forming tool for wrapping the heated fabric thereabout, a resin applicator for applying resin to the heated fabric as the heated fabric is wrapped about the composite structure forming tool to produce a resin rich fabric surface to which a subsequent ply of heated fabric is applied to produce an impregnated composite material, and a pressure roller for concurrently debulking and cooling the impregnated composite material to produce a composite structure preform.

Abstract: Tethered flange comers including at least one ply of barrier fibers and at least one fiber tow wrapped about the barrier fibers. Also included are flanges having a tethered corner containing at least one ply of barrier fibers, at least one fiber tow wrapped about the barrier fibers, at least one ply of filler fibers applied over the fiber tow, and at least one ply of flange fibers applied over the filler fibers. Additionally included are articles incorporating a composite structure having a flange with a tethered corner containing at least one ply of barrier fibers and at least one fiber tow wrapped about the barrier fibers.

Abstract: Methods for fabricating a composite structure with a flange having a tethered corner involving providing a composite structure forming tool including a first endplate and a second endplate and having a composite structure formed thereabout, applying at least one ply of barrier fibers about the composite structure adjacent to the first endplate of the composite structure forming tool, and wrapping at least one fiber tow about the barrier fibers.

Abstract: A method for fabricating a turbine engine composite containment casing is provided. The method comprising impregnating a plurality of fiber-reinforced layers with a resin to form a preform, heating the preform to a first temperature, applying a vacuum to the preform, varying an amount of pressure applied to the preform when the temperature reaches the first temperature, heating the preform from the first temperature to a second temperature at a first temperature rate, and heating the preform from the second temperature to a third temperature at a second temperature rate to facilitate curing of the preform.

Abstract: Methods for fabricating a composite structure having at least one mounting flange involving providing a composite structure forming tool having a first endplate and a second endplate, fabricating a composite structure preform about the tool, the composite structure preform having at least one mounting flange preform circumferentially oriented thereabout, placing at least one extended flange shoe having a first side and a second side circumferentially about the composite structure preform so that the first side lies adjacent to the first endplate, removeably coupling the first endplate to the first extended flange shoe, placing at least one flange shoe circumferentially about the composite structure preform adjacent to the second end of the extended flange shoe, removeably coupling the flange shoe to the extended flange shoe to form a cavity about the mounting flange preform, and curing the composite structure preform having the at least one mounting flange preform to obtain a composite structure having at lea

Abstract: An apparatus including a composite structure forming tool having a circumferential core, a first endplate and a second endplate, at least one extended flange shoe having a first side and a second side, the first side removeably coupled to the first endplate, and at least one flange shoe removeably coupled to the second side of the extended flange shoe such that when a composite structure preform having at least one mounting flange preform is fabricated about the composite structure forming tool and the extended flange shoe and flange shoe are removeably coupled, a cavity is formed about the mounting flange preform by the extended flange shoe and flange shoe.

Abstract: Methods for making a structure having an integral mounting flange involving providing a primary composite structure having a circumference, applying at least one circumferentially oriented core fiber about the circumference of the primary composite structure, applying at least one layer of attachment fibers to operably connect the core fiber to the primary composite structure about the circumference to obtain an integral mounting flange preform, and curing the mounting flange preform to obtain an integral mounting flange.