US20040067139A1 - Fiber reinforced composite article - Google Patents
Fiber reinforced composite article Download PDFInfo
- Publication number
- US20040067139A1 US20040067139A1 US10/601,754 US60175403A US2004067139A1 US 20040067139 A1 US20040067139 A1 US 20040067139A1 US 60175403 A US60175403 A US 60175403A US 2004067139 A1 US2004067139 A1 US 2004067139A1
- Authority
- US
- United States
- Prior art keywords
- layers
- reinforcing
- fibers
- preform
- reinforcing fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/603—Composites; e.g. fibre-reinforced
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49316—Impeller making
- Y10T29/49336—Blade making
- Y10T29/49337—Composite blade
Definitions
- This invention relates to a fiber reinforced composite article and its manufacture. More particularly, it relates to a fiber reinforced composite article such as a composite blading member including an airfoil, the article including generally transverse or angled reinforcing members.
- Components for sections of gas turbine engines for example a fan and/or a compressor, operating at relatively lower temperatures than sections downstream of the combustion section have been made of resin matrix composites including stacked, laminated layers.
- resin matrix composites including stacked, laminated layers.
- fibers include within it meaning filaments in a variety of configurations and lay-up directions, sometimes about a core and/or with local metal reinforcement or surface shielding.
- a variety of materials are used for such fibers, including carbon, graphite, glass, metals (forms of which sometimes are called boron fibers), etc., as is well known in the art.
- the present invention in one form, provides a method for making a fiber reinforced composite article comprising a plurality of stacked layers and including additional reinforcing members disposed at an angle, for example generally transverse, to planes of the stacked layers without damage to in-plane fibers reinforcing the layers.
- the method comprises providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers, herein sometimes called in-plane fibers.
- first reinforcing fibers generally are aligned with one another in the layers.
- Such layers are stacked generally upon one another into a preform of a stack of layers.
- a plurality of spaced apart additional or second reinforcing members is inserted into the preform at an angle to the stack of the layers.
- One preferred example is an angle generally transverse to such stack of layers of the preform.
- the preform is impregnated with a matrix about the first reinforcing fibers and the second reinforcing members.
- the present invention provides a fiber reinforced composite article.
- Such article includes a plurality of stacked layers of first reinforcing fibers and a plurality of second reinforcing members disposed into the article at an angle to the stack of layers.
- the second reinforcing members are disposed beside or adjacent to the first reinforcing fibers.
- a substantially solid matrix is disposed about the first reinforcing fibers and second reinforcing members.
- FIG. 1 is a diagrammatic side view of a turbine engine blading member, such as a fan blade, including a fiber reinforced composite airfoil.
- FIG. 2 is an enlarged, diagrammatic, fragmentary, partially sectional view of a portion through a thickness of the airfoil of the composite airfoil of FIG. 1 showing stacked, fiber reinforced layers and reinforcing members generally transverse to the layers.
- FIGS. 3 and 4 are diagrammatic, fragmentary sectional views of prior art arrangements of reinforcing members within a fiber reinforced, layered structure.
- FIG. 5 is a diagrammatic, fragmentary, partially sectional view of an arrangement of layers and reinforcing members in the practice of a form of the present invention.
- FIG. 6 is a diagrammatic, fragmentary, partially sectional view of a form of the article of the present invention showing the disposition of the stacked layers, the reinforcing members, and the fixed matrix.
- Disposition of in-plane fiber reinforced, stacked layers within a cured resin matrix has provided strength and an amount of resistance to material loss in such articles as gas turbine engine blading members.
- a typical example is an aircraft gas turbine engine fan blade.
- Such composite structure is lighter in weight than a comparable metal article. Therefore, use of the reinforced composite article has contributed to improvement in operation of a gas turbine engine.
- an impact on the article, typically on the airfoil of a blading member can cause layers to separate or delaminate.
- Forms of the present invention provide a stacked layered, fiber reinforced composite article, and method for making the article, with angled, for example generally transverse, reinforcement which avoids damage to in-plane type reinforcing fibers.
- FIG. 1 is a diagrammatic side view of a typical gas turbine engine composite, laminated, fiber reinforced fan blade shown generally at 10 including an airfoil 12 , a base 14 , and an airfoil tip 20 .
- Airfoil 12 includes a thickness 22 , shown in more detail in FIG. 2, and which can vary across airfoil 12 as a function of its design.
- Airfoil 12 includes additional or second reinforcement in the form of reinforcing pins, some of which are shown at 24 , disposed in a selected pattern or arrangement within region 26 of airfoil 12 included within broken line 28 .
- FIG. 2 is an enlarged, fragmentary, partially sectional view through a portion of thickness 22 of airfoil 12 within region 26 .
- Reinforcing pins 24 are disposed within and, in this example, substantially transversely to a plurality of typical stacked, reinforcing fiber planes or layers 30 , sometimes called in-plane fibers, in airfoil 12 .
- layers 30 are fiber reinforced composite layers impregnated with a resin.
- FIGS. 3 and 4 are typical diagrammatic, fragmentary sectional representations of prior art arrangements.
- additional reinforcement such as pins 24 were introduced transversely to in-plane layer reinforcing fibers 32 into a substantially fixed structure: fibers 32 were held in a substantially fixed, immobile position by at least partially cured matrix resin 34 .
- additional reinforcement members such as stitches, staples, or pins 24 were introduced into such a fixed structure, a variety of detrimental or damaging interference conditions occurred between fixed in-plane fibers 32 and moving reinforcing members or pins 24 .
- interference resulted in tearing or abrading of fibers 32 , for example as shown diagrammatically at 36 in FIG. 3.
- Other types of interference resulted in complete or virtual fracture or separation of in-plane reinforcing fiber 32 , for example as shown diagrammatically at 38 in FIG. 4.
- Such detrimental, damaging interference conditions reduced the strength and operating life of the article.
- Forms of the present invention avoid occurrence of such detrimental, damaging interference conditions in a fiber reinforced composite article comprising a plurality of stacked layers having in-plane fiber reinforcement, for example in a first direction, further reinforced with a plurality of additional reinforcing members disposed at an angle to the stacked layers, for example in a second direction.
- a plurality of stacked layers of fibers similar to layers 30 in FIG. 2, generally define a preform shown generally at 40 in the diagrammatic, fragmentary, partially sectional view of FIG. 5.
- FIG. 5 In the embodiment of FIG.
- each layer or plane of fibers in preform 40 includes first, substantially dry, unimpregnated reinforcing in-plane fibers 42 disposed generally in each layer of preform 40 .
- fibers 42 substantially are aligned with one another in the layer.
- the in-plane fibers thus used in the present invention are defined herein to be in a dry, unimpregnated condition in that they are not impregnated with a resin that is in a partially cured, prepreg condition or in the fully cured condition.
- individual in-plane fibers can include a lightly tacky surface material that enables the individual fibers to maintain a position or relationship with adjoining in-plane fibers in a layer. Nevertheless, such tacky condition does not inhibit individual fibers from being moved away from one another or from another member applying a force toward the in-plane fiber. For example, such a moving force can result from an angled reinforcing member introduced into the type of layered preform described above.
- reinforcing members 46 are inserted into preform 40 .
- Reinforcing members 46 herein conveniently called pins, can be in the form of a unitary structure such as a single rod or fiber; but preferably member 46 is in the form of a bundle of fibers, sometimes referred to as filaments.
- in-plane fibers 42 as well as reinforcing members 46 are of at least one material selected from carbon, graphite, glass, and metal, one example of which is referred to in the art as boron fibers.
- a plurality of second reinforcing members 46 were inserted at an angle, in this example substantially transversely as shown in FIG. 2, to the stack of layers 30 of in-plane reinforcing fibers 42 . In the event members 46 contact in-plane fibers 42 , loosely held fibers 42 were moved away from or beside members 46 . Such free movement capability enables avoiding detrimental damage, for example abrasion, cracking, tearing, or completely fracturing, to in-plane reinforcing fibers 42 .
- a matrix 48 for example a commercially available epoxy resin, was disposed to impregnate, for example as by injection, preform 40 as shown in the diagrammatic, fragmentary sectional view of FIG. 6.
- matrix resin 48 was disposed in voids 44 about the first, in-plane reinforcing fibers 42 and the second reinforcing members 46 .
- the matrix resin in the impregnated preform was cured as practiced in the art to provide a fiber reinforced composite article.
- a plurality of shaped layers of dry, unimpregnated, substantially unidirectionally aligned carbon fiber bundles commercially available as IM-7 12K tow tapes from Hexel Company, were used as the first, in-plane reinforcing fibers disposed in a first direction.
- the layers of in-plane carbon fibers were disposed in a stack as layers of a preform in the cavity of a commercial resin transfer mold, with typical amounts of intermediate wicking felt as used in the art.
- the mold cavity was in the shape of a turbine engine blade including an airfoil, similar to that shown in FIG. 1, and included typical resin ports and vents.
- the preform and its layers then were inspected for any detrimental alignment conditions, such as wrinkling. Any such conditions were removed by redraping or smoothing the individual layers while the preform was in the dry, unimpregnated state.
- a plurality of dry, spaced apart bundles of carbon fibers were provided as the second, additional reinforcing members.
- Various forms and types of such bundles of fibers commercially are available, for example from prepreg manufacturers.
- Each such bundle in this example was about 0.020′′ in general diameter.
- the bundles were disposed into the preform in a second direction at an angle, in this example substantially transversely, to the in-plane first direction of the first reinforcing fibers in a selected region of the airfoil, for example as shown by region 26 in FIG. 1.
- each bundle first was placed inside a hollow needle. Then the needle was driven into the preform. When the needle was retracted, it left the bundle in the preform.
- the mold cavity was closed and a vacuum was provided in the cavity to remove ambient air from the cavity and from about the preform including its reinforcing members.
- an ordinary, commercially available curable epoxy resin was injected into the mold cavity about the stacked layers and the reinforcing fibers and members, wetting and saturating the preform including the reinforcements with the resin.
- the epoxy resin used was commercially available as Dow Chemical TACTIX 123 epoxy resin system. Curing of the resin was conducted at a temperature of about 350° F. for about 120 minutes before the mold was cooled then opened and the contents of the mold removed.
- the resulting article was a near net shape molded substantially solid epoxy resin matrix reinforced, laminated composite article including an airfoil and a base.
- the airfoil included stacked layers of in-plane carbon fiber reinforcement and angled carbon fiber bundle reinforcement. Cross sectional inspection of the airfoil showed that the angled, second reinforcement had avoided detrimental interference with the in-plane reinforcing fibers in a structure similar to that shown in FIG. 6.
Abstract
A fiber reinforced composite article is made by providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers, sometimes called in-plane fibers. Such layers are stacked into a preform of a stack of layers. While in the dry, unimpregnated condition, a plurality of spaced apart second reinforcing members are inserted into the preform at an angle, for example transversely, to the stack of layers. In this condition, the preform is impregnated with a matrix about the first reinforcing fibers and the second reinforcing members. The article product comprises the plurality of stacked layers of the first reinforcing fibers and the plurality of the spaced apart second reinforcing members disposed beside or adjacent the first reinforcing fibers, with a substantially solid matrix disposed about the reinforcing fibers and members.
Description
- This invention relates to a fiber reinforced composite article and its manufacture. More particularly, it relates to a fiber reinforced composite article such as a composite blading member including an airfoil, the article including generally transverse or angled reinforcing members.
- Components for sections of gas turbine engines, for example a fan and/or a compressor, operating at relatively lower temperatures than sections downstream of the combustion section have been made of resin matrix composites including stacked, laminated layers. Generally such primarily non-metallic composite structures, which replaced heavier predominantly metal structures, include superimposed layers, sometimes called plies, reinforced with fibers substantially in the plane of the layer. As used herein, fibers include within it meaning filaments in a variety of configurations and lay-up directions, sometimes about a core and/or with local metal reinforcement or surface shielding. For elevated temperature applications, a variety of materials are used for such fibers, including carbon, graphite, glass, metals (forms of which sometimes are called boron fibers), etc., as is well known in the art. Typical examples of such components made primarily of non-metallic composites are reported in such U.S. patents as U.S. Pat. No. 3,892,612—Carlson et al. (patented Jul. 1, 1975); U.S. Pat. No. 4,022,547—Stanley (patented May 10, 1977); U.S. Pat. No. 5,279,892—Baldwin et al. (patented Jan. 18, 1994); U.S. Pat. No. 5,308,228—Benoit et al. (patented May 3, 1994); and U.S. Pat. No. 5,375,978—Evans et al. (patented Dec. 27, 1994).
- As has been discussed in detail in such patents as the above-identified Evans et al. patent, such non-metallic composites in an aircraft gas turbine engine are subject to damage from ingestion into the engine and impact on components of foreign objects. Such objects can be airborne or drawn into the engine inlet. These include various types and sizes of birds as well as inanimate objects such as hailstones, sand, land ice, and runway debris. Impact damage to the airfoil of blading members, including fan and compressor blades, as well as damage to strut type members in the air stream, has been observed to cause loss of material and/or delamination of the stacked layers. Such a condition in a rotating blade can cause the engine to become unbalanced resulting in potentially severe, detrimental vibration.
- The above identified and other prior art have reported various arrangements and structures to avoid such material loss and/or delamination of layers. Some arrangements, for example U.S. Pat. No. 3,834,832—Mallinder et al. (patented Sep. 10, 1974) and the above-identified Benoit et al. patent, include use of seams or fastening devices disposed transversely through an at least partially solidified, reinforced resin matrix that fixes reinforcing fibers in a position. Their purpose is to avoid delamination of laminated composite structures using ordinary commercial resin systems as the composite matrix. It has been observed, however, that disposition of such transverse reinforcement through a generally solidified or at least partially cured resin reinforced layer or preform of an article, with reinforcing fibers held by a resin in a fixed position, can fracture, tear or otherwise damage the fibers reinforcing the layer. Such damage can reduce the operating integrity and life of a composite article.
- The present invention, in one form, provides a method for making a fiber reinforced composite article comprising a plurality of stacked layers and including additional reinforcing members disposed at an angle, for example generally transverse, to planes of the stacked layers without damage to in-plane fibers reinforcing the layers. The method comprises providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers, herein sometimes called in-plane fibers. In a preferred form, such first reinforcing fibers generally are aligned with one another in the layers. Such layers are stacked generally upon one another into a preform of a stack of layers. While in the dry, unimpregnated condition, a plurality of spaced apart additional or second reinforcing members is inserted into the preform at an angle to the stack of the layers. One preferred example is an angle generally transverse to such stack of layers of the preform. Then the preform is impregnated with a matrix about the first reinforcing fibers and the second reinforcing members.
- In another form, the present invention provides a fiber reinforced composite article. Such article includes a plurality of stacked layers of first reinforcing fibers and a plurality of second reinforcing members disposed into the article at an angle to the stack of layers. The second reinforcing members are disposed beside or adjacent to the first reinforcing fibers. A substantially solid matrix is disposed about the first reinforcing fibers and second reinforcing members.
- FIG. 1 is a diagrammatic side view of a turbine engine blading member, such as a fan blade, including a fiber reinforced composite airfoil.
- FIG. 2 is an enlarged, diagrammatic, fragmentary, partially sectional view of a portion through a thickness of the airfoil of the composite airfoil of FIG. 1 showing stacked, fiber reinforced layers and reinforcing members generally transverse to the layers.
- FIGS. 3 and 4 are diagrammatic, fragmentary sectional views of prior art arrangements of reinforcing members within a fiber reinforced, layered structure.
- FIG. 5 is a diagrammatic, fragmentary, partially sectional view of an arrangement of layers and reinforcing members in the practice of a form of the present invention.
- FIG. 6 is a diagrammatic, fragmentary, partially sectional view of a form of the article of the present invention showing the disposition of the stacked layers, the reinforcing members, and the fixed matrix.
- Disposition of in-plane fiber reinforced, stacked layers within a cured resin matrix has provided strength and an amount of resistance to material loss in such articles as gas turbine engine blading members. A typical example is an aircraft gas turbine engine fan blade. Such composite structure is lighter in weight than a comparable metal article. Therefore, use of the reinforced composite article has contributed to improvement in operation of a gas turbine engine. However, because such a structure includes stacked layers or laminations, an impact on the article, typically on the airfoil of a blading member, can cause layers to separate or delaminate.
- As was mentioned above, prior additional reinforcement of the layers has been disposed generally transverse to the layers of the stacked composite article. For example, such arrangements are described in the above-identified Mallinder et al. and Benoit et al patents. However, as described in those patents, such additional, generally transverse reinforcement or fastening devices, such as stitches, seams, pins, and staples, has been disposed into the stacked layers while the layers and their reinforcing fibers are in a substantially fixed, immobile position. Such fixed relationship was established at least by a partially cured or pre-impregnated resin disposed about the generally in-plane reinforcing fibers in the layer, prior to introduction of the additional reinforcement. It has been observed that disposing such additional, generally transverse reinforcement into such a fixed structure can result in abrading, tearing, or complete fracture of the relatively immobile fiber reinforcement of the layers of the composite structure. Damage of that nature can adversely affect the strength and/or operating life of a composite article including torn or damaged fiber reinforcement within at least one lamination. Forms of the present invention provide a stacked layered, fiber reinforced composite article, and method for making the article, with angled, for example generally transverse, reinforcement which avoids damage to in-plane type reinforcing fibers. This is accomplished according to forms of the present invention by disposing the angled reinforcing fibers beside, meaning not in damaging interference with, the in-plane reinforcing fibers, avoiding at least partial penetration into or through in-plane fibers reinforcing the layers
- The present invention will be more fully understood by reference to the drawings. FIG. 1 is a diagrammatic side view of a typical gas turbine engine composite, laminated, fiber reinforced fan blade shown generally at10 including an
airfoil 12, abase 14, and anairfoil tip 20. Airfoil 12 includes athickness 22, shown in more detail in FIG. 2, and which can vary acrossairfoil 12 as a function of its design.Airfoil 12 includes additional or second reinforcement in the form of reinforcing pins, some of which are shown at 24, disposed in a selected pattern or arrangement withinregion 26 ofairfoil 12 included withinbroken line 28. - FIG. 2 is an enlarged, fragmentary, partially sectional view through a portion of
thickness 22 ofairfoil 12 withinregion 26. Reinforcing pins 24, one shown as protruding from the fragmentary section, are disposed within and, in this example, substantially transversely to a plurality of typical stacked, reinforcing fiber planes orlayers 30, sometimes called in-plane fibers, inairfoil 12. In the embodiment of FIG. 2, layers 30 are fiber reinforced composite layers impregnated with a resin. - As was mentioned above, prior publications have shown such transverse reinforcement disposed in the airfoil of a blading member. FIGS. 3 and 4 are typical diagrammatic, fragmentary sectional representations of prior art arrangements. In each prior arrangement, additional reinforcement such as
pins 24 were introduced transversely to in-planelayer reinforcing fibers 32 into a substantially fixed structure:fibers 32 were held in a substantially fixed, immobile position by at least partially curedmatrix resin 34. As additional reinforcement members such as stitches, staples, or pins 24 were introduced into such a fixed structure, a variety of detrimental or damaging interference conditions occurred between fixed in-plane fibers 32 and moving reinforcing members or pins 24. Some of such interference resulted in tearing or abrading offibers 32, for example as shown diagrammatically at 36 in FIG. 3. Other types of interference resulted in complete or virtual fracture or separation of in-plane reinforcing fiber 32, for example as shown diagrammatically at 38 in FIG. 4. Such detrimental, damaging interference conditions reduced the strength and operating life of the article. - Forms of the present invention avoid occurrence of such detrimental, damaging interference conditions in a fiber reinforced composite article comprising a plurality of stacked layers having in-plane fiber reinforcement, for example in a first direction, further reinforced with a plurality of additional reinforcing members disposed at an angle to the stacked layers, for example in a second direction. In the practice of a form of the method of the present invention, a plurality of stacked layers of fibers, similar to
layers 30 in FIG. 2, generally define a preform shown generally at 40 in the diagrammatic, fragmentary, partially sectional view of FIG. 5. In the embodiment of FIG. 5, each layer or plane of fibers inpreform 40 includes first, substantially dry, unimpregnated reinforcing in-plane fibers 42 disposed generally in each layer ofpreform 40. In a preferred form,fibers 42 substantially are aligned with one another in the layer. - The in-plane fibers thus used in the present invention are defined herein to be in a dry, unimpregnated condition in that they are not impregnated with a resin that is in a partially cured, prepreg condition or in the fully cured condition. However, in some examples of practice of the present invention, individual in-plane fibers can include a lightly tacky surface material that enables the individual fibers to maintain a position or relationship with adjoining in-plane fibers in a layer. Nevertheless, such tacky condition does not inhibit individual fibers from being moved away from one another or from another member applying a force toward the in-plane fiber. For example, such a moving force can result from an angled reinforcing member introduced into the type of layered preform described above.
- While
fibers 42 are in the dry, unimpregnated condition and relationship shown in FIG. 5, including voids orspaces 44 betweenadjacent fibers 42, a plurality of additional or second reinforcingmembers 46 are inserted intopreform 40. Reinforcingmembers 46, herein conveniently called pins, can be in the form of a unitary structure such as a single rod or fiber; but preferablymember 46 is in the form of a bundle of fibers, sometimes referred to as filaments. In a preferred form, in-plane fibers 42 as well as reinforcingmembers 46 are of at least one material selected from carbon, graphite, glass, and metal, one example of which is referred to in the art as boron fibers. A plurality of second reinforcingmembers 46 were inserted at an angle, in this example substantially transversely as shown in FIG. 2, to the stack oflayers 30 of in-plane reinforcing fibers 42. In theevent members 46 contact in-plane fibers 42, loosely heldfibers 42 were moved away from or besidemembers 46. Such free movement capability enables avoiding detrimental damage, for example abrasion, cracking, tearing, or completely fracturing, to in-plane reinforcing fibers 42. - After reinforcing
members 46 had been inserted between dry, unimpregnated in-plane reinforcing fibers 42, amatrix 48, for example a commercially available epoxy resin, was disposed to impregnate, for example as by injection, preform 40 as shown in the diagrammatic, fragmentary sectional view of FIG. 6. In this embodiment,matrix resin 48 was disposed invoids 44 about the first, in-plane reinforcing fibers 42 and the second reinforcingmembers 46. Thereafter, the matrix resin in the impregnated preform was cured as practiced in the art to provide a fiber reinforced composite article. - During one series of evaluations of the present invention, a plurality of shaped layers of dry, unimpregnated, substantially unidirectionally aligned carbon fiber bundles, commercially available as IM-7 12K tow tapes from Hexel Company, were used as the first, in-plane reinforcing fibers disposed in a first direction. The layers of in-plane carbon fibers were disposed in a stack as layers of a preform in the cavity of a commercial resin transfer mold, with typical amounts of intermediate wicking felt as used in the art. The mold cavity was in the shape of a turbine engine blade including an airfoil, similar to that shown in FIG. 1, and included typical resin ports and vents. The preform and its layers then were inspected for any detrimental alignment conditions, such as wrinkling. Any such conditions were removed by redraping or smoothing the individual layers while the preform was in the dry, unimpregnated state.
- With the layers of the preform in the mold cavity and before closing the mold for matrix resin injection, a plurality of dry, spaced apart bundles of carbon fibers were provided as the second, additional reinforcing members. Various forms and types of such bundles of fibers commercially are available, for example from prepreg manufacturers. Each such bundle in this example was about 0.020″ in general diameter. The bundles were disposed into the preform in a second direction at an angle, in this example substantially transversely, to the in-plane first direction of the first reinforcing fibers in a selected region of the airfoil, for example as shown by
region 26 in FIG. 1. The spaced-apart bundles were inserted into the preform by holding the bundles at an appropriate angle to the surface of the preform to be penetrated. Then the bundles were inserted into the preform. In one example, each bundle first was placed inside a hollow needle. Then the needle was driven into the preform. When the needle was retracted, it left the bundle in the preform. - After the substantially transverse bundles were inserted, the mold cavity was closed and a vacuum was provided in the cavity to remove ambient air from the cavity and from about the preform including its reinforcing members. Then an ordinary, commercially available curable epoxy resin was injected into the mold cavity about the stacked layers and the reinforcing fibers and members, wetting and saturating the preform including the reinforcements with the resin. In this example, the epoxy resin used was commercially available as Dow Chemical TACTIX123 epoxy resin system. Curing of the resin was conducted at a temperature of about 350° F. for about 120 minutes before the mold was cooled then opened and the contents of the mold removed.
- The resulting article was a near net shape molded substantially solid epoxy resin matrix reinforced, laminated composite article including an airfoil and a base. The airfoil included stacked layers of in-plane carbon fiber reinforcement and angled carbon fiber bundle reinforcement. Cross sectional inspection of the airfoil showed that the angled, second reinforcement had avoided detrimental interference with the in-plane reinforcing fibers in a structure similar to that shown in FIG. 6.
- The present invention has been described in connection with specific examples and combinations of materials and structures. However, it should be understood that they are intended to be typical of rather than in any way limiting on the scope of the invention. Those skilled in the various arts involved with the methods, materials and structures will understand that the present invention is capable of variations and modifications without departing from the scope of the appended claims.
Claims (10)
1. A method for making a fiber reinforced composite article comprising the steps of:
providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers;
stacking the layers generally one upon another into a preform of a stack of layers;
while in the substantially dry, unimpregnated condition, inserting into the preform at an angle to the stack of layers a plurality of spaced apart second reinforcing members; and,
impregnating the preform with a matrix about the first reinforcing fibers and the second reinforcing members.
2. The method of claim 1 in which:
the first and second reinforcing fibers comprise at least one material selected from the group consisting of carbon, graphite, glass, and metal; and,
the matrix is a curable resin.
3. The method of claim 1 in which the second reinforcing members extend substantially through the plurality layers of the preform.
4. The method of claim 1 in which the first reinforcing fibers in a layer substantially are aligned with one another.
5. The method of claim 2 in which the second reinforcing members comprise at least one member selected from the group consisting of bundles of fibers, single fibers and rods.
6. The method of claim 1 for making at least an airfoil of a turbine engine blading member comprising the steps of:
providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers comprising at least one material selected from the group consisting of carbon, graphite, glass, and metal;
stacking the layers generally one upon another into a preform of a stack of layers;
while in the substantially dry, unimpregnated condition, inserting into the preform at an angle to the stack of layers a plurality of spaced apart second reinforcing members each comprising a bundle of fibers of at least one material selected from the group consisting of carbon, graphite glass and metal; and,
impregnating the preform with a matrix of a curable resin about the first reinforcing fibers and the second reinforcing members.
7. The method of claim 6 in which the first reinforcing fibers substantially are aligned with one another.
8. (amended) A fiber reinforced composite article comprising:
a plurality of stacked layers of first reinforcing fibers comprising a stack of layers; and,
a plurality of unconnected spaced apart second reinforcing pins, each comprising a bundle of rods, disposed into the article at an angle to stack of layers;
the second reinforcing pins being disposed beside the first reinforcing fibers; and,
a substantially solid matrix disposed about the first reinforcing fibers and the second reinforcing members.
9. (amended) The article of claim 8 in which the first reinforcing fibers and the second reinforcing pins comprise at least one material selected from the group consisting of carbon, graphite, glass, and metal.
10. (amended) The article of claim 9 in the form of a turbine engine article comprising:
an airfoil including the stack of layers and the speed apart second reinforcing pins;
the first reinforcing fibers in a layer being substantially aligned with one another.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/601,754 US20040067139A1 (en) | 2001-07-18 | 2003-06-23 | Fiber reinforced composite article |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/907,982 US6613392B2 (en) | 2001-07-18 | 2001-07-18 | Method for making a fiber reinforced composite article and product |
US10/601,754 US20040067139A1 (en) | 2001-07-18 | 2003-06-23 | Fiber reinforced composite article |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/907,982 Division US6613392B2 (en) | 2001-07-18 | 2001-07-18 | Method for making a fiber reinforced composite article and product |
Publications (1)
Publication Number | Publication Date |
---|---|
US20040067139A1 true US20040067139A1 (en) | 2004-04-08 |
Family
ID=25424961
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/907,982 Expired - Lifetime US6613392B2 (en) | 2001-07-18 | 2001-07-18 | Method for making a fiber reinforced composite article and product |
US10/601,754 Abandoned US20040067139A1 (en) | 2001-07-18 | 2003-06-23 | Fiber reinforced composite article |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/907,982 Expired - Lifetime US6613392B2 (en) | 2001-07-18 | 2001-07-18 | Method for making a fiber reinforced composite article and product |
Country Status (1)
Country | Link |
---|---|
US (2) | US6613392B2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2012012287A3 (en) * | 2010-07-23 | 2013-04-25 | Easton Sports, Inc. | Co-molded, focused weighted, dimple arrayed hockey sticks and other composite structures |
US20170261002A1 (en) * | 2016-03-08 | 2017-09-14 | Rolls-Royce Plc | Composite component |
Families Citing this family (29)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP4322062B2 (en) * | 2003-07-23 | 2009-08-26 | 日本発條株式会社 | Engine block and manufacturing method thereof |
GB0327002D0 (en) * | 2003-11-20 | 2003-12-24 | Rolls Royce Plc | A method of manufacturing a fibre reinforced metal matrix composite article |
US6865826B1 (en) | 2004-01-21 | 2005-03-15 | Lakin General Corporation | Impeller blade for snowblower |
EP2302170A1 (en) * | 2004-11-12 | 2011-03-30 | Board of Trustees of Michigan State University | Turbomachine system and method of operation |
US7563497B2 (en) | 2004-12-27 | 2009-07-21 | Mkp Structural Design Associates, Inc. | Lightweight, rigid composite structures |
US7278830B2 (en) | 2005-05-18 | 2007-10-09 | Allison Advanced Development Company, Inc. | Composite filled gas turbine engine blade with gas film damper |
US7694621B1 (en) | 2005-07-22 | 2010-04-13 | Mkp Structural Design Associates, Inc. | Lightweight composite armor |
US7490539B2 (en) | 2005-07-22 | 2009-02-17 | Mkp Structural Design Associates, Inc. | Lightweight composite armor |
US7547194B2 (en) * | 2006-07-31 | 2009-06-16 | General Electric Company | Rotor blade and method of fabricating the same |
FR2933422B1 (en) * | 2008-07-04 | 2011-05-13 | Messier Dowty Sa | METHOD FOR MANUFACTURING A METAL PIECE COMPRISING INTERNAL REINFORCEMENTS FORMED OF CERAMIC FIBERS |
US20110052405A1 (en) * | 2009-09-02 | 2011-03-03 | United Technologies Corporation | Composite airfoil with locally reinforced tip region |
GB0916758D0 (en) * | 2009-09-24 | 2009-11-04 | Rolls Royce Plc | A hybrid component |
US20110176927A1 (en) * | 2010-01-20 | 2011-07-21 | United Technologies Corporation | Composite fan blade |
US8499450B2 (en) * | 2010-01-26 | 2013-08-06 | United Technologies Corporation | Three-dimensionally woven composite blade with spanwise weft yarns |
US20110229334A1 (en) * | 2010-03-16 | 2011-09-22 | United Technologies Corporation | Composite leading edge sheath and dovetail root undercut |
FR2975037B1 (en) * | 2011-05-13 | 2014-05-09 | Snecma Propulsion Solide | COMPOSITE TURBOMACHINE VANE WITH INTEGRATED LEG |
GB201111598D0 (en) * | 2011-07-07 | 2011-08-24 | Rolls Royce Plc | Layered composite component |
DE102011056088B4 (en) * | 2011-12-06 | 2013-07-04 | Deutsches Zentrum für Luft- und Raumfahrt e.V. | repair procedures |
US9115584B2 (en) * | 2012-04-24 | 2015-08-25 | General Electric Company | Resistive band for turbomachine blade |
DE102013201963A1 (en) * | 2013-02-07 | 2014-08-07 | Bayerische Motoren Werke Aktiengesellschaft | Process for producing a fiber-reinforced plastic component |
GB201306479D0 (en) * | 2013-04-10 | 2013-05-22 | Rolls Royce Plc | A method of through-thickness reinforcing a laminated material |
GB201306481D0 (en) * | 2013-04-10 | 2013-05-22 | Rolls Royce Plc | A method of manufacturing a composite material including a thermoplastic coated reinforcing element |
DE102013210934A1 (en) | 2013-06-12 | 2014-12-18 | Bayerische Motoren Werke Aktiengesellschaft | Method and device for producing a fiber composite component and fiber composite component |
WO2014204573A1 (en) | 2013-06-17 | 2014-12-24 | United Technologies Corporation | Composite airfoil bonded to a metallic root |
GB201418581D0 (en) * | 2014-10-20 | 2014-12-03 | Rolls Royce Plc | Composite component |
FR3039839B1 (en) * | 2015-08-06 | 2019-12-20 | Safran Aircraft Engines | PROCESS FOR MANUFACTURING A PART OF COMPOSITE MATERIAL |
DE102018105246B4 (en) | 2017-04-25 | 2024-02-15 | Deutsches Zentrum für Luft- und Raumfahrt e.V. | Method for producing a reinforced fiber composite material, fiber composite material and aircraft or spacecraft |
US11149553B2 (en) * | 2019-08-02 | 2021-10-19 | Rolls-Royce Plc | Ceramic matrix composite components with heat transfer augmentation features |
CN113677179A (en) * | 2021-09-28 | 2021-11-19 | 郑州佛光发电设备有限公司 | Electromagnetic shielding composite material and preparation method thereof |
Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3834832A (en) * | 1971-12-21 | 1974-09-10 | Rolls Royce 1971 Ltd | Fibre reinforced composite structures |
US3892612A (en) * | 1971-07-02 | 1975-07-01 | Gen Electric | Method for fabricating foreign object damage protection for rotar blades |
US4022547A (en) * | 1975-10-02 | 1977-05-10 | General Electric Company | Composite blade employing biased layup |
US4622091A (en) * | 1984-11-29 | 1986-11-11 | The Boeing Company | Resin film infusion process and apparatus |
US4622254A (en) * | 1981-08-31 | 1986-11-11 | Toray Industries, Inc. | Fiber material for reinforcing plastics |
US5279892A (en) * | 1992-06-26 | 1994-01-18 | General Electric Company | Composite airfoil with woven insert |
US5308228A (en) * | 1991-12-04 | 1994-05-03 | Societe Nationale d'Etude et de Construction de Moteurs d`Aviation "S.N.E.C.M.A." | Gas turbine blade comprising layers of composite material |
US5375978A (en) * | 1992-05-01 | 1994-12-27 | General Electric Company | Foreign object damage resistant composite blade and manufacture |
US5733404A (en) * | 1992-10-27 | 1998-03-31 | Foster Miller, Inc. | Translaminar reinforcement system for Z-direction reinforcement of a fiber matrix structure |
US6099906A (en) * | 1998-06-22 | 2000-08-08 | Mcdonnell Douglas Corporation | Immersion process for impregnation of resin into preforms |
-
2001
- 2001-07-18 US US09/907,982 patent/US6613392B2/en not_active Expired - Lifetime
-
2003
- 2003-06-23 US US10/601,754 patent/US20040067139A1/en not_active Abandoned
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3892612A (en) * | 1971-07-02 | 1975-07-01 | Gen Electric | Method for fabricating foreign object damage protection for rotar blades |
US3834832A (en) * | 1971-12-21 | 1974-09-10 | Rolls Royce 1971 Ltd | Fibre reinforced composite structures |
US4022547A (en) * | 1975-10-02 | 1977-05-10 | General Electric Company | Composite blade employing biased layup |
US4622254A (en) * | 1981-08-31 | 1986-11-11 | Toray Industries, Inc. | Fiber material for reinforcing plastics |
US4622091A (en) * | 1984-11-29 | 1986-11-11 | The Boeing Company | Resin film infusion process and apparatus |
US5308228A (en) * | 1991-12-04 | 1994-05-03 | Societe Nationale d'Etude et de Construction de Moteurs d`Aviation "S.N.E.C.M.A." | Gas turbine blade comprising layers of composite material |
US5375978A (en) * | 1992-05-01 | 1994-12-27 | General Electric Company | Foreign object damage resistant composite blade and manufacture |
US5279892A (en) * | 1992-06-26 | 1994-01-18 | General Electric Company | Composite airfoil with woven insert |
US5733404A (en) * | 1992-10-27 | 1998-03-31 | Foster Miller, Inc. | Translaminar reinforcement system for Z-direction reinforcement of a fiber matrix structure |
US6099906A (en) * | 1998-06-22 | 2000-08-08 | Mcdonnell Douglas Corporation | Immersion process for impregnation of resin into preforms |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2012012287A3 (en) * | 2010-07-23 | 2013-04-25 | Easton Sports, Inc. | Co-molded, focused weighted, dimple arrayed hockey sticks and other composite structures |
CN103260712A (en) * | 2010-07-23 | 2013-08-21 | 伊士登运动公司 | Co-molded, focused weighted, dimple arrayed hockey sticks and other composite structures |
US20170261002A1 (en) * | 2016-03-08 | 2017-09-14 | Rolls-Royce Plc | Composite component |
US10385869B2 (en) * | 2016-03-08 | 2019-08-20 | Rolls-Royce Plc | Composite component |
Also Published As
Publication number | Publication date |
---|---|
US20030017053A1 (en) | 2003-01-23 |
US6613392B2 (en) | 2003-09-02 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US6613392B2 (en) | Method for making a fiber reinforced composite article and product | |
US7008689B2 (en) | Pin reinforced, crack resistant fiber reinforced composite article | |
JP5974111B2 (en) | Composite storage case for gas turbine fan and manufacturing method thereof | |
US8109734B2 (en) | Article formed from a composite material | |
EP3292991B1 (en) | Fiber composite material for a fan blade | |
US5279892A (en) | Composite airfoil with woven insert | |
EP2768658B1 (en) | High pressure molding of composite parts | |
US20100077721A1 (en) | Composite fan case with integral containment zone | |
US20090151142A1 (en) | Methods for repairing composite containment casings | |
US20140294594A1 (en) | Hybrid turbine blade including multiple insert sections | |
EP3058199B1 (en) | Compression molded fiber reinforced fan case ice panel | |
US20130224035A1 (en) | Composite airfoil with local tailoring of material properties | |
US20160186774A1 (en) | Process of producing a thermoplastic-fiber composite and fan blades formed therefrom | |
Chawla et al. | Polymer matrix composites | |
EP2543506B1 (en) | Layered composite component | |
US10717109B2 (en) | Nanotube enhancement of interlaminar performance for a composite component | |
US20030203178A1 (en) | Toughened, crack resistant fiber reinforced composite article and method for making | |
US11549391B2 (en) | Component formed from hybrid material | |
US20230003132A1 (en) | Frangible airfoil | |
US20230029918A1 (en) | Frangible airfoil with shape memory alloy | |
CN115539441A (en) | Composite airfoil with frangible tip | |
CN116892416A (en) | Component having composite laminate with co-cured chopped fibers | |
CN115680783A (en) | Fragile airfoil with shape memory alloy |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |