Abstract: The present invention provides a process for the lay-up of a composite laminate article, the article produced by this process, and the apparatus used to produce the composite laminate article. The composite laminate article may be, for example, an airfoil, particularly useful as a fan blade in a large high bypass ratio turbofan engine, wherein the blade is generally regarded as large and having a high degree of twist. In a preferred embodiment, the present invention provides a process for laying up a composite laminate article comprising a) reading a data set to enable the projection of an image of a ply section onto a work surface, the image indicating a ply section target point; b) laying up a ply section of composite laminating material within the image, wherein the ply section first contacts the work surface at the target point; and c) repeating steps (a)-(b) until the composite laminate article is complete.

Abstract: The present invention provides a process for the lay-up of a composite laminate article, the article produced by this process, and the apparatus used to produce the composite laminate article. The composite laminate article may be, for example, an airfoil, particularly useful as a fan blade in a large high bypass ratio turbofan engine, wherein the blade is generally regarded as large and having a high degree of twist. In a preferred embodiment, the present invention provides a process for laying up a composite laminate article comprising a) reading a data set to enable the projection of an image of a ply section onto a work surface, the image indicating a ply section target point; b) laying up a ply section of composite laminating material within the image, wherein the ply section first contacts the work surface at the target point; and c) repeating steps (a)-(b) until the composite laminate article is complete.

Abstract: A fan blade includes a spar having first and second opposite sides. The spar sides include a fatigue-life enhanced surface layer, with the spar first side having a cavity bounded in part by the surface layer. A skin closes the cavity and is bonded to the spar for maintaining the enhanced surface layer inside the cavity.

Abstract: A fan assembly for a gas turbine engine for aircraft has a stator casing made of a first material and an annular abradable seal structure made of a second material comprising an epoxy foam having heat expandable, thermoplastic microballoons filled with a chemical which expands when the second material is cured such that the second material bonds directly to the stator casing upon curing thereby minimizing the number of processing steps during manufacture.

Abstract: A composite article includes a plurality of laminates each having structural fibers bonded in a matrix, and an adhesive film disposed between and bonding together adjacent ones of the laminates. In an exemplary embodiment, the laminates and the interleaved adhesive films form a facesheet which is joined to a core for forming an impact resistant fan case impact liner for a gas turbine engine. The impact liner may be integrated with a sound suppression liner.

Abstract: Inserting a woven composite layer between laminates of composite material layers where the insert layer comprises composite, carbon fibers woven in a three dimensional weave. The woven insert is injected with a resin material and partially cured prior to deposition of the composite layers. The complete blade is then molded and cured as a unit.

Abstract: An air shroud device for a paint spray gun is provided with an improved air distributing arrangement which evenly distributes air about and also both toward and in the same direction as the paint spray issuing from the nozzle to form a uniform air shroud thereabout as well as prevent paint from building up on the air shroud device.

Abstract: For the application of humidity-sensitive, aqueous-based paint by spray gun, a compact air shroud assembly adapted to be attached to the spray apparatus about the air cap of the gun to envelope the spray with hot, dry air. The air shroud includes inner and outer annular members to define a passage therebetween. Hot, dry air enters the annular space from the bottom in a direction generally normal to the paint spray pattern and is divided into separate flow paths by a baffle below the inner annular member. From the baffle, the separated air flows pass to various segments of the annular space as directed by vanes in the annular passage. The vanes redirect the flow into a direction parallel with the spray pattern.