Alliedsignal Inc.

Steven C Stenard

Bruce D Wilson

Mani Janakiram

Donald R Schuyler

Mohsen Sohi

James Thompson

Devinder N Katariya

Frank Heydrich

Forest H Hover

Ronald J Rich

Ellen White

Steven G Mackin

Ian Little

John P Furseth

A unitary composite stator vane for a gas turbine engine comprising an aerodynamically configured airfoil section, a foot extending substantially perpendicularly from one end of the airfoil section, and a smoothly contoured transition section interconnecting the airfoil section with the foot. The stator vane is comprised of a composite material including a plurality of compression molded, heat cured plies. The plies include a plurality of centrally located internal plies of reinforcement material of continuous yarns of para-aramid fibers. On each side of the internal plies are plies of resin impregnated graphite fiber material. The graphite fibers are protected by an external steel wire mesh ply covering the leading edges of the vanes. Substantially all of the internal para-aramid reinforcement fibers are discontinuous proximate the transition section between the airfoil section and foot.

Tear-away composite fan stator vane

A composite stator vane for a gas turbine engine comprising a plurality of compression molded, heat cured plies, the plies including a plurality of centrally located internal plies of reinforcement material of unidirectional yarns of para-aramid fibers, a plurality of plies of resin impregnated graphite fiber material on each side of the centrally located plies of reinforcement material, and an external steel wire mesh ply on the leading edge of the vane.

Insertable stator vane assembly

A method for preparing a machined surface of a composite article for diffusion bonding is provided. The method includes removing most of the exposed fibers by shot peening followed by acid etching. The acid etch may be followed by grit blasting and then another acid etch. After the method is applied to the surface, the article can be diffusion bonded to other composite article to form complex shapes.

Method for preparing a composite surface for diffusion bonding

A composite article is manufactured by preparing a machined surface of the composite article for diffusion bonding. The method includes removing most of the exposed fibers by shot peening followed by acid etching. The acid etch may be followed by grit blasting and then another acid etch. After the method is applied to the surface, the article can be diffusion bonded to other composite article to form complex shapes.

Composite article having a surface prepared for diffusion bonding

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Scottsdale, AZ, United States of America

Steven C Stenard