Abstract: A woven composite component for an aerospace structure or machine, comprising: a compound member extending from a junction with a feeder member, a noodle element extending in a weft direction through the junction. The feeder member comprises first and second feeder portions either side of the junction, each feeder portion comprising warp tows extending towards the junction. There is a compound set of warp tows extending from the first and second feeder portions, each turning at the junction to define warp tows for the compound member. There is a crossing set of warp tows belonging to the compound set, the crossing set comprising warp tows from the first feeder portion and warp tows from the second portion which cross each other at the junction to pass around the noodle element. There is also disclosed a method of manufacturing a preform for a woven composite component.

Abstract: An apparatus for manufacturing an annular or semi-annular composite component having a circumferentially-extending base and a flange, the apparatus including: a loom for weaving a woven preform of fibre reinforcement material for the composite component; a rotatable mandrel configured to receive and draw the woven preform through the loom for weaving; and a guide disposed between the loom and the rotatable mandrel, configured so that a woven preform drawn by the rotatable mandrel along a guide path under tension engages the guide to transition to a flanged profile at a lip of the guide before being received on the mandrel.

Abstract: A storage tank for liquid hydrogen comprises first and second shells each constructed of laminate material, the second shell being disposed outwardly of the first shell with respect to the centre of the storage tank. The first and second shells are mechanically connected by a first plurality of pins each of which passes through at least some layers of the second shell and at least some layers of the first shell. The storage tank may be constructed using a simpler manufacturing process involving less tooling and fewer process steps than is the case for known tanks for storing liquid hydrogen. The storage tank has also has a lower mass and reduced thermal losses compared to tanks of the prior art. The plurality of pins allows for the shells to be thinner, and hence lighter, than similar shells in tanks of the prior art.

Abstract: A method of manufacturing a composite laminate. The method comprises providing a base layer, providing a discontinuous reinforcing patch on the base layer, and providing a top layer over the base layer and discontinuous reinforcing patch. Also, a composite laminate having a discontinuous reinforcing patch interposed between a base layer and a top layer. The discontinuous reinforcing patch comprises a patterned nanomaterial layer with nanomaterial-filled zones and vacant zones.

Abstract: A storage tank for liquid hydrogen comprises first and second shells each constructed of laminate material, the second shell being disposed outwardly of the first shell with respect to the centre of the storage tank. The first and second shells are mechanically connected by a first plurality of pins each of which passes through at least some layers of the second shell and at least some layers of the first shell. The storage tank may be constructed using a simpler manufacturing process involving less tooling and fewer process steps than is the case for known tanks for storing liquid hydrogen. The storage tank has also has a lower mass and reduced thermal losses compared to tanks of the prior art. The plurality of pins allows for the shells to be thinner, and hence lighter, than similar shells in tanks of the prior art.

Abstract: The present disclosure relates to a variable stator vane and a method of fabricating the variable stator vane of a gas turbine engine. The method includes providing at least one fibre sheet. The method further includes rolling the at least one fibre sheet around a mandrel to form a spindle section of the variable stator vane. An excess of material of the at least one fibre sheet remains after forming the spindle section. The method further includes using the excess of material of the at least one fibre sheet to form the at least one aerofoil section of the variable stator vane.

Abstract: There is disclosed a vane for a gas turbine engine, the vane comprising a three-dimensional weave of composite material. The vane is hollow to define a hollow core, wherein the vane has a maximum thickness (T), and a maximum wall thickness (WT) between an inner surface and an outer surface in a direction normal to the outer surface, wherein WT?0.1T. Also disclosed is a method of manufacturing a composite vane for a gas turbine engine, the method comprising: forming a preform for the vane comprising a three-dimensional weave of composite material; and curing the preform. The preform has an internal hollow region, and the cured vane has a maximum thickness (T), and a maximum wall thickness (WT) between an inner surface and an outer surface in a direction normal to the outer surface, wherein WT?0.1T.

Abstract: Tool arrangement for compacting a composite preform assembly comprising a support structure preform and an array of component preforms each extending from the support structure preform and spaced apart along the support structure preform. The tool arrangement comprises a support tool defining a lay-up surface for laying up the support structure preform; a plurality of component moulds, each component mould comprising a pair of blocks configured to cooperate with one another to receive and compact a respective component preform extending from the support structure therebetween, each block having a compaction surface for engaging the component preform and a driving surface.

Abstract: A storage tank for storing gaseous hydrogen comprises a boundary wall having a laminate composite structure which includes a resin-rich layer forming an internal surface of the boundary wall, a glass-fibre composite layer in contact with the resin-rich layer and a carbon fibre composite layer in contact with the glass-fibre composite layer on a side thereof remote from the resin-rich layer. The laminate structure provides a high level of hydrogen impermeability and resistance to micro-cracking as a result of pressure cycling, providing the tank with a gravimetric efficiency appropriate to aeronautical applications.

Abstract: A method of manufacturing a fan blade for a gas turbine engine. The method includes providing a compression mould having an internal mould surface corresponding to an outer profile of a fan blade, providing opposing first and second laminates to form a shell corresponding to the mould surface, each laminate comprising a lay-up of plies of fibre reinforcement material, applying a core material comprising quasi-isotropic short fibre reinforced resin in the compression mould so that with the compression mould in a moulding configuration the core material is enclosed by the shell, the core material and the shell forming a pre-form for the fan blade, applying pressure to compress the pre-form so that it conforms to the mould surface, and applying heat to cure the pre-form.

Abstract: The present disclosure relates to a variable stator vane and a method of fabricating the variable stator vane of a gas turbine engine. The method includes providing at least one fibre sheet. The method further includes rolling the at least one fibre sheet around a mandrel to form a spindle section of the variable stator vane. An excess of material of the at least one fibre sheet remains after forming the spindle section. The method further includes using the excess of material of the at least one fibre sheet to form the at least one aerofoil section of the variable stator vane.

Abstract: Tool arrangement for compacting a composite preform assembly comprising a support structure preform and an array of component preforms each extending from the support structure preform and spaced apart along the support structure preform. The tool arrangement comprises a support tool defining a lay-up surface for laying up the support structure preform; a plurality of component moulds, each component mould comprising a pair of blocks configured to cooperate with one another to receive and compact a respective component preform extending from the support structure therebetween, each block having a compaction surface for engaging the component preform and a driving surface.

Abstract: Method of manufacturing an integral thermoset infused fibre reinforced composite, structural stator vane ring for a core inlet, a bypass duct, or an air intake of a gas turbine engine. The method comprises winding fibre reinforcement material around a mandrel to form an inner annulus preform; providing a plurality of vane preforms comprising fibre reinforcement material, arranging the plurality of vane preforms around the inner annulus preform, and connecting each of the plurality of vane preforms to the inner annulus preform using a fibre jointing method; winding fibre reinforcement material around the plurality of vane preforms to form an outer annulus preform and connecting the outer annulus preform to each of the plurality of vane preforms using a fibre jointing method to produce a stator vane ring preform; and infusing a thermoset resin into the stator vane ring preform and curing the resin to form the integral stator vane ring.

Abstract: There is disclosed a vane for a gas turbine engine, the vane comprising a three-dimensional weave of composite material. The vane is hollow to define a hollow core, wherein the vane has a maximum thickness (T), and a maximum wall thickness (WT) between an inner surface and an outer surface in a direction normal to the outer surface, wherein WT?0.1T. Also disclosed is a method of manufacturing a composite vane for a gas turbine engine, the method comprising: forming a preform for the vane comprising a three-dimensional weave of composite material; and curing the preform. The preform has an internal hollow region, and the cured vane has a maximum thickness (T), and a maximum wall thickness (WT) between an inner surface and an outer surface in a direction normal to the outer surface, wherein WT?0.1T.

Abstract: A composite component comprising fibres embedded in a matrix material. A plurality of pins extend through the matrix material. Each pin of the plurality of pins comprises a hollow bore such that the bore of each pin defines a plurality of holes in the composite component.

Abstract: The application describes methods of making composite bodies including fibre-reinforced composite material with carbon fibre reinforcement and also a metal-containing portion (4). The metal-containing portion (4) is formed by laying up metal reinforcement elements, such as tapes of titanium alloy, among the carbon fibre reinforcement tapes which make up the composite body. The proportion of metal reinforcement may increase progressively towards the surface and/or towards an edge (14) of the composite body. In an example, metal leading and trailing edges (14,15) of a fan blade (1) are integrally formed in this way.

Abstract: A method of manufacturing a fan blade for a gas turbine engine. The method includes providing a compression mould having an internal mould surface corresponding to an outer profile of a fan blade, providing opposing first and second laminates to form a shell corresponding to the mould surface, each laminate comprising a lay-up of plies of fibre reinforcement material, applying a core material comprising quasi-isotropic short fibre reinforced resin in the compression mould so that with the compression mould in a moulding configuration the core material is enclosed by the shell, the core material and the shell forming a pre-form for the fan blade, applying pressure to compress the pre-form so that it conforms to the mould surface, and applying heat to cure the pre-form.

Abstract: This disclosure concerns a composite product having first and second components. At least one intermediate binding layer is located between the first and second components, and at least one electrically conductive member is located within the at least one intermediate layer. The at least one electrically conductive member is configured to generate thermal energy upon the application of an electrical current to the at least one electrically conductive member. The at least one intermediate layer is configured such that at least one characteristic of the at least one intermediate layer is altered where the thermal energy generated by the at least one electrically conductive member is above a pre-determined threshold.

Abstract: A composite component comprising fibres embedded in a matrix material. A plurality of pins extend through the matrix material. Each pin of the plurality of pins comprises a hollow bore such that the bore of each pin defines a plurality of holes in the composite component.

Abstract: The application describes methods of making composite bodies including fibre-reinforced composite material with carbon fibre reinforcement and also a metal-containing portion (4). The metal-containing portion (4) is formed by laying up metal reinforcement elements, such as tapes of titanium alloy, among the carbon fibre reinforcement tapes which make up the composite body. The proportion of metal reinforcement may increase progressively towards the surface and/or towards an edge (14) of the composite body. In an example, metal leading and trailing edges (14,15) of a fan blade (1) are integrally formed in this way.