Abstract: A fiber-reinforced component is formed of a first composite member including a metal matrix with reinforcing fibers having a diameter and a length distributed therein in a selected orientation and a second composite member including a metal matrix with reinforcing fibers having a diameter and a length distributed therein in a selected orientation. The first composite member is bonded to the second composite member by a solid state bond along a predetermined joint path, such that an average volume fraction of the reinforcing fibers of the first composite member and the second composite member within the joint path is substantially the same as an average volume fraction of the reinforcing fibers of the first composite member and the second composite member within the remainder of the fiber-reinforced component.

Abstract: Including a disk, a plurality of circumferentially spaced apart airfoils extending radially outwardly from the disk, a plurality of shroud segments being disposed circumferentially between the plurality of airfoils and configured to attach to a corresponding airfoil of the plurality of airfoils and a plurality of wear surfaces, where at least one wear surface of the plurality of wear surfaces is configured and disposed to prevent excessive wear between the adjacent shroud segments. Each shroud segment of the plurality of shroud segments may be attached to a corresponding airfoil by weld connections to permit clearance during translation friction welding of the airfoil to the disk hub are located to avoid high stress areas.

Abstract: A fiber-reinforced component is formed of a first composite member including a metal matrix with reinforcing fibers having a diameter and a length distributed therein in a selected orientation and a second composite member including a metal matrix with reinforcing fibers having a diameter and a length distributed therein in a selected orientation. The first composite member is bonded to the second composite member by a solid state bond along a predetermined joint path, such that an average volume fraction of the reinforcing fibers of the first composite member and the second composite member within the joint path is substantially the same as an average volume fraction of the reinforcing fibers of the first composite member and the second composite member within the remainder of the fiber-reinforced component.

Abstract: A method of making a fiber-reinforced component includes: providing a first composite member having a metal matrix with reinforcing fibers distributed therein; providing a second composite member having a metal matrix with reinforcing fibers distributed therein; and joining the first member to the second member by friction stir welding along a predetermined joint path, such that an average volume fraction of the reinforcing fibers within the joint path is substantially the same as an average volume fraction thereof in the composite members before joining. A fiber-reinforced component includes: first and second members each having a metal matrix with reinforcing fibers distributed therein. The first member is bonded to the second member by a solid state bond along a predetermined joint path, such that an average volume fraction of the reinforcing fibers within the joint path is substantially the same as an average volume fraction thereof in remainder of the members.

Abstract: A method of making a fiber-reinforced component includes: providing a first composite member having a metal matrix with reinforcing fibers distributed therein; providing a second composite member having a metal matrix with reinforcing fibers distributed therein; and joining the first member to the second member by friction stir welding along a predetermined joint path, such that an average volume fraction of the reinforcing fibers within the joint path is substantially the same as an average volume fraction thereof in the composite members before joining. A fiber-reinforced component includes: first and second members each having a metal matrix with reinforcing fibers distributed therein. The first member is bonded to the second member by a solid state bond along a predetermined joint path, such that an average volume fraction of the reinforcing fibers within the joint path is substantially the same as an average volume fraction thereof in remainder of the members.

Abstract: Including a disk, a plurality of circumferentially spaced apart airfoils extending radially outwardly from the disk, a plurality of shroud segments being disposed circumferentially between the plurality of airfoils and configured to attach to a corresponding airfoil of the plurality of airfoils and a plurality of wear surfaces, where at least one wear surface of the plurality of wear surfaces is configured and disposed to prevent excessive wear between the adjacent shroud segments. Each shroud segment of the plurality of shroud segments may be attached to a corresponding airfoil by weld connections to permit clearance during translation friction welding of the airfoil to the disk hub are located to avoid high stress areas.

Abstract: Apparatus for cutting a sheet of material along a preselected line. The apparatus includes a table having an upper surface sized and shaped for receiving the sheet of material. In addition, the apparatus includes a wire positionable adjacent the upper surface of the table and generally vertically below the preselected line on the sheet of material when the sheet of material is received by the upper surface of the table. Further, the apparatus includes an elongate guide positionable above the sheet of material when the sheet is received by the upper surface of the table for holding the sheet of material in position with respect to the wire and the upper surface of the table. The apparatus also includes a device engageable with the wire for pulling the wire upward through the sheet of material to cut the sheet of material along the preselected line.

Abstract: Apparatus for cutting a sheet of material along a preselected line. The apparatus includes a table having an upper surface sized and shaped for receiving the sheet of material. In addition, the apparatus includes a wire positionable adjacent the upper surface of the table and generally vertically below the preselected line on the sheet of material when the sheet of material is received by the upper surface of the table. Further, the apparatus includes an elongate guide positionable above the sheet of material when the sheet is received by the upper surface of the table for holding the sheet of material in position with respect to the wire and the upper surface of the table. The apparatus also includes a device engageable with the wire for pulling the wire upward through the sheet of material to cut the sheet of material along the preselected line.

Abstract: A process is provided for producing high temperature composite components from a thermosetting polyimide resin system, and more particularly to an in-mold technique for impregnating a reinforcement fiber preform with the polyimide resin system, and thereafter imidizing the polyimide resin system in such a way that exposure to the uncured (nonimidized) polyimide resin system is minimized. The process entails an injection technique that ensures complete impregnation and wetting of the reinforcing fabric, and complete removal of the condensation byproducts formed during imidization. The imidized component is then cured by heating the component to a temperature sufficient to remelt the polyimide resin system, and then applying pressure and additional heat to cause the polyimide resin system to cross-link to produce the desired composite component. The process results in a fiber-reinforced polyimide matrix component characterized by a void content of less than about three percent.

Abstract: A multipurpose, automatic, self-contained device for manufacturing or repairing a workpiece made from a composite material includes a frame having an upper frame member and a lower frame member. A mechanical apparatus for providing a compressive force is mounted to the lower frame member and a lower platen is mounted to a movable member of the apparatus. An upper platen, positioned opposite to the lower platen, is mounted to the upper frame member. At least one heater is associated with at least one of the platens to apply heat to the workpiece and at least one temperature sensor is provided for mounting to the workpiece. The lower platen is moved toward and away from the upper platen by the mechanical apparatus to apply a compressive force to the workpiece disposed between the platens as a function of the temperature sensed from the workpiece and/or according to a predetermined schedule or plan.

Abstract: An in-jig assembly bond fixture for manufacturing a composite component having a plurality of parts includes at least one fixture for holding each of the plurality of parts in proper alignment relative to one another during a bonding operation. A mechanical mechanism is provided integral with the at least one fixture for applying a predetermined uniform compressive force to each bond line between each of the plurality of parts during the bonding operation. A plurality of heating elements is provided for applying heat directly to each bond joint and are each selectively located within the fixture for applying heat uniformly across each bond line during the bonding operation.