Abstract: A method of forming a composite article involves the steps of: providing a formed article, the formed article comprising a plurality of non-crimp fibre fabrics with each non-crimp fibre fabric comprising at least two dry-fibre layers; stabilising the plurality of non-crimp fibre fabrics; machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops; positioning the machined formed article in a second mould; infiltrating the second mould with a polymer matrix resin; and curing the machined formed article to form the composite article.

Abstract: A method of manufacturing a composite fan blade with an outer part and a core includes laying up a plurality of continuous plies to achieve a stack, placing the core on a central portion of the stack of continuous plies to achieve an unfolded preform; folding the contin-uous plies about the core, such that the central portion of the stack folds about the core and the first portion is superimposed to the second portion, to achieve a folded preform; apply-ing pressure to the folded preform to achieve a consolidated curved folded preform; curing the consolidated curved folded preform to achieve the composite fan blade.

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: There is disclosed a method of manufacturing a fan blade for a gas turbine engine, the method comprising: providing a root insert comprising quasi-isotropic short fibre reinforced resin, providing a first sub-laminate of a fibre-reinforcement pre-form for the fan blade on a first mould surface, placing the root insert on the first sub-laminate at a position corresponding to a root of the fan blade, providing a second sub-laminate of the pre-form over the root insert and the first-sub-laminate, so that the root insert is at an intermediate position between the first and second sub-laminates; and applying heat and pressure to form the pre-form.

Abstract: There is disclosed a method of manufacturing a fan blade for a gas turbine engine, the method comprising: providing a root insert comprising quasi-isotropic short fibre reinforced resin, providing a first sub-laminate of a fibre-reinforcement pre-form for the fan blade on a first mould surface, placing the root insert on the first sub-laminate at a position corresponding to a root of the fan blade, providing a second sub-laminate of the pre-form over the root insert and the first-sub-laminate, so that the root insert is at an intermediate position between the first and second sub-laminates; and applying heat and pressure to form the pre-form.

Abstract: A method of forming a composite article involves the steps of: providing a formed article, the formed article comprising a plurality of non-crimp fibre fabrics with each non-crimp fibre fabric comprising at least two dry-fibre layers; stabilising the plurality of non-crimp fibre fabrics; machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops; positioning the machined formed article in a second mould; infiltrating the second mould with a polymer matrix resin; and curing the machined formed article to form the composite article.

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: A method of manufacturing a composite fan blade with an outer part and a core includes laying up a plurality of continuous plies to achieve a stack, placing the core on a central portion of the stack of continuous plies to achieve an unfolded preform; folding the contin-uous plies about the core, such that the central portion of the stack folds about the core and the first portion is superimposed to the second portion, to achieve a folded preform; apply-ing pressure to the folded preform to achieve a consolidated curved folded preform; curing the consolidated curved folded preform to achieve the composite fan blade.

Abstract: A housing for a mud motor is disclosed. The housing comprises a female member comprising a female mating section and a male member comprising a male mating section and a housing section. The male mating section is matingly received within the female mating section. The collar is positioned on the housing section. The collar is made up of a framework with a plurality of discrete bodies spaced about the framework and a portion of each of the discrete bodies protrudes above the framework.

Abstract: A mud motor has integrated rotatable reamer elements. The reamer elements may be located directly radially outwardly of a rotor of the mud motor on an outer surface of the mud motor. The reamer elements may be applied to provide one or more of sizing a wellbore, smoothing a wellbore and stabilizing a bottom hole assembly and/or drill bit during drilling. The reamer elements may project from pockets formed in an outside surface of the mud motor. Axes of rotation of the reamer elements may be parallel to and/or skewed relative to a longitudinal centerline of the mud motor. Reamer devices that connect at couplings between drill string sections may be used together with the mud motor or applied separately of the mud motor. The reamer devices include inwardly-projecting elements that engage gaps between the drill string sections.

Abstract: A mud motor has integrated rotatable reamer elements. The reamer elements may be located directly radially outwardly of a rotor of the mud motor on an outer surface of the mud motor. The reamer elements may be applied to provide one or more of sizing a wellbore, smoothing a wellbore and stabilizing a bottom hole assembly and/or drill bit during drilling. The reamer elements may project from pockets formed in an outside surface of the mud motor. Axes of rotation of the reamer elements may be parallel to and/or skewed relative to a longitudinal centerline of the mud motor. Reamer devices that connect at couplings between drill string sections may be used together with the mud motor or applied separately of the mud motor. The reamer devices include inwardly-projecting elements that engage gaps between the drill string sections.

Abstract: A housing for a mud motor is disclosed. The housing comprises a female member comprising a female mating section and a male member comprising a male mating section and a housing section. The male mating section is matingly received within the female mating section. The collar is positioned on the housing section. The collar is made up of a framework with a plurality of discrete bodies spaced about the framework and a portion of each of the discrete bodies protrudes above the framework.