Abstract: There is disclosed a self-heating tool (10) for manufacturing a composite component, comprising: a support structure (24); a mandrel (26) onto which composite material can be applied; a heater (58) for heating the mandrel (26) during a curing operation; and a plurality of extendible support members (28) extending between the support structure (24) and the mandrel (26) to support the mandrel (26). Each extendible support member (28) is configured to change in length in response to thermal expansion of the mandrel (28) during a curing operation. A method of manufacturing a composite component using a self-heating tool is also disclosed.

Abstract: There is disclosed a method of forming a composite component having a curved body and an integral flange from a pre-form (200) using forming apparatus comprising: a tool (102) comprising a curved body portion (104) having a lay-up surface (110) and a forming assembly (105) comprising a plurality of forming elements (106) each having a lay-up surface (120) and a primary flange-forming surface (122); and a plurality of filler elements (107) each having a secondary flange-forming surface (156).

Abstract: A method of assembling and shaping a laminate panel. An intermediate member is mounted on a lay-up table and a lay-up is assembling by laying a series of plies onto the intermediate member on the lay-up table. The intermediate member and the lay-up are then removed from the lay-up table and placed them on a shaped surface. The lay-up is then forced against the shaped surface, via the intermediate member, in a manner that modifies the shape of the lay-up to form a shaped laminate panel. Finally the shaped laminate panel is removed from the intermediate member. The lay-up table can thus support the flexible intermediate member during assembly, and can be relatively flat to enable the lay-up to assembled by an automated process.

Abstract: There is disclosed a self-heating tool (10) for manufacturing a composite component, comprising: a support structure (24); a mandrel (26) onto which composite material can be applied; a heater (58) for heating the mandrel (26) during a curing operation; and a plurality of extendible support members (28) extending between the support structure (24) and the mandrel (26) to support the mandrel (26). Each extendible support member (28) is configured to change in length in response to thermal expansion of the mandrel (28) during a curing operation. A method of manufacturing a composite component using a self-heating tool is also disclosed.

Abstract: Method forming a composite structure (9) comprising a main body and a flange. The composite structure is manufactured by laying-up a preform (7) on a mold (6). The preform (7) does not have the first and second bends and comprises a first part which corresponds to the main body of the composite structure and a second part which corresponds to the flange of the composite structure. The second part of the (preform (7) has a proximal portion which corresponds to the wall portion of the flange and a distal portion which corresponds to the lip portion of the flange. The preform (7) comprises a plurality of plies and uni-directional ply material extends from the first part of the preform (7) to the distal portion of the second part of the preform (7).

Abstract: A structure such as a containment case (2) for a gas turbine engine (1) comprises an annular housing (3) made of composite material. A sleeve-like flange unit (4) is fitted onto an end of the housing (3) and is mechanically joined thereto by a first portion (31, 32, 33) of the composite material of the housing which projects into a recess (411) of the flange unit (4). This reduces or eliminates the need to use mechanical fasteners to connect the housing (3) to the flange unit (4).

Abstract: A curable assembly which upon the application of curing conditions will form a completed component or part component comprises two pieces of composite fiber-reinforced, resin matrix material, with filler component of relatively rigid material arranged therebetween. The intermediate component is arranged to be secured between the two pieces. The filler component has a body with first and second opposing surface profiles. The filler component can be used to transmit or react a consolidating load during curing.

Abstract: A method of assembling and shaping a laminate panel. An intermediate member is mounted on a lay-up table and a lay-up is assembling by laying a series of plies onto the intermediate member on the lay-up table. The intermediate member and the lay-up are then removed from the lay-up table and placed them on a shaped surface. The lay-up is then forced against the shaped surface, via the intermediate member, in a manner that modifies the shape of the lay-up to form a shaped laminate panel. Finally the shaped laminate panel is removed from the intermediate member. The lay-up table can thus support the flexible intermediate member during assembly, and can be relatively flat to enable the lay-up to assembled by an automated process.

Abstract: A method of assembling and shaping a laminate panel. An intermediate member is mounted on a lay-up table and a lay-up is assembling by laying a series of plies onto the intermediate member on the lay-up table. The intermediate member and the lay-up are then removed from the lay-up table and placed them on a shaped surface. The lay-up is then forced against the shaped surface, via the intermediate member, in a manner that modifies the shape of the lay-up to form a shaped laminate panel. Finally the shaped laminate panel is removed from the intermediate member. The lay-up table can thus support the flexible intermediate member during assembly, and can be relatively flat to enable the lay-up to assembled by an automated process.

Abstract: Method forming a composite structure (9) comprising a main body and a flange. The composite structure is manufactured by laying-up a preform (7) on a mould (6). The preform (7) does not have the first and second bends and comprises a first part which corresponds to the main body of the composite structure and a second part which corresponds to the flange of the composite structure. The second part of the (preform (7) has a proximal portion which corresponds to the wall portion of the flange and a distal portion which corresponds to the lip portion of the flange. The preform (7) comprises a plurality of plies and uni-directional ply material extends from the first part of the preform (7) to the distal portion of the second part of the preform (7).

Abstract: A structure such as a containment case (2) for a gas turbine engine (1) comprises an annular housing (3) made of composite material. A sleeve-like flange unit (4) is fitted onto an end of the housing (3) and is mechanically joined thereto by a first portion (31, 32, 33) of the composite material of the housing which projects into a recess (411) of the flange unit (4). This reduces or eliminates the need to use mechanical fasteners to connect the housing (3) to the flange unit (4).

Abstract: A curable assembly which upon the application of curing conditions will form a completed component or part component comprises two pieces of composite fibre-reinforced, resin matrix material, with filler component of relatively rigid material arranged therebetween. The intermediate component is arranged to be secured between the two pieces. The filler component has a body with first and second opposing surface profiles. The filler component can be used to transmit or react a consolidating load during curing.

Abstract: A method of assembling and shaping a laminate panel. An intermediate member is mounted on a lay-up table and a lay-up is assembling by laying a series of plies onto the intermediate member on the lay-up table. The intermediate member and the lay-up are then removed from the lay-up table and placed them on a shaped surface. The lay-up is then forced against the shaped surface, via the intermediate member, in a manner that modifies the shape of the lay-up to form a shaped laminate panel. Finally the shaped laminate panel is removed from the intermediate member. The lay-up table can thus support the flexible intermediate member during assembly, and can be relatively flat to enable the lay-up to assembled by an automated process.