Airfoil Textron Inc.

Textron Corporation

Raymond G Spain

Carlos Bailey

Susan M DeGrood

A multi-dimensional (e.g., 3D braided) preform formed of reinforcement strands or filaments is rigidized by impregnating the preform with a resin solution (e.g., silicone resin solution), curing the resin to impart a selected shape to the preform and then heating the shaped preform to convert the cured resin to inorganic solids (e.g., silica solids) so dispersed in an effective amount between the strands as to rigidize the preform. The rigidized preform is then infiltrated with an inorganic matrix (e.g., a ceramic material) to form a composite article.

Composite preforms and articles and methods for their manufacture

A composite gas turbine engine blade is made by braiding a plurality of fibers to form a preform having an airfoil precursor portion and an integral root precursor portion. A plurality of fiber shaping inserts are positioned in the root precursor portion, either by braiding the root precursor portion around the inserts or inserting the fiber shaping inserts into the root precursor portion after braiding, to impart an enlarged, divergent shape (e.g., dovetail precursor shape) to the braided root precursor portion. The braided preform with the enlarged, shaped root precursor portion is infiltrated with matrix material and shaped to near net shape to provide the composite blade with a dovetail shaped root.

Composite blade with divergent root and method for making same

An annular fluid seal is provided between a pair of spaced apart machine components, such as a rotor and a stator. The rotatable component includes an annular sealing surface of increasing diameter in a given direction (e.g., along its length or along a radially extending shoulder). An annular fibrous sealing element is disposed proximate the clearance space between the components in such a manner that a sealing portion thereof engaging the other component moves in the direction of increasing diameter as the sealing portion may wear so as to maintain sealing contact with the annular sealing surface. A fluid seal is thereby maintained between the components.

Fluid seal structure

Method of making a composite blade with divergent root

A braided gas turbine engine blade preform includes an airfoil precursor portion and an integral root precursor portion. A plurality of fiber shaping inserts are disposed in the root precursor portion, to impart an enlarged, divergent shape (e.g., dovetail precursor shape) to the braided root precursor portion. The braided preform with the enlarged, shaped root precursor portion is infiltrated with matrix material and shaped to near net shape to provide a composite blade with a dovetail shaped root.

Composite blade perform with divergent root

The method involves braiding a plurality of fiber bundles, each comprising a reinforcing fiber overwrapped by a plurality of glass or metal matrix-forming fibers, to form a 3D braided preform having stuffer fiber bundles extending longitudinally therethrough and heating the preform at a temperature and applying pressure to form the matrix-forming fibers into a bonded matrix in which the reinforcing fibers are disposed in a 3D braided pattern and in a longitudinal (stuffer) pattern.

Braided preform

The apparatus includes a plurality of fiber strand carrier members that are movable on a carrier surface defined by multiple, movable, side-by-side support members and a plurality of fiber guides affixed on the support members for dispensing axial stuffer fiber strands as the carrier members move along predetermined paths to intertwine the fiber strands from the fiber guides. The carrier members are disposed on the support members for movement therewith and for movement from one support member to abother. The fiber guides are affixed on the support members for movement only with the respective support member. The stuffer fiber strand for each fiber guide is dispensed from a spool that is carried on a respective support member or is mounted on a stationary base.

Apparatus and method for braiding fiber strands and stuffer fiber strands

Method for making 3D fiber reinforced metal/glass matrix composite

A composite article is made by braiding a 3D article shaped preform including non-fugative braider reinforcing fibers and fugative fibers and removing the fugative fibers to form a plurality of matrix-ingress passages in the braided preform. During impregnation of the braided preform with a matrix material, matrix material is supplied to the interior of the preform via the passages. The fugative fibers typically comprise fugative monofilaments which are substantially larger in size than the non-fugative fibers to permit one or more dimensions of the preform and thus the composite article to be increased beyond the capacity of the particular braiding apparatus employed.

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Farmington Hills, MI, United States of America

Raymond G Spain