US-20260125988-A1 - METHOD OF MANUFACTURING A COMPOSITE COMPONENT FOR A GAS TURBINE ENGINE

US20260125988A1US 20260125988 A1US20260125988 A1US 20260125988A1US-20260125988-A1

Abstract

A method of manufacturing a composite component having an outer shell, an inner hub, and a plurality of struts connecting the outer shell and the inner hub. An outer shell frame preform is woven to include a plurality of outer shell strut preform portions, each including an outer shell strut leading edge preform portion and an outer shell strut trailing edge preform portion. An inner hub frame preform is woven to include a plurality of inner hub strut preform portions, each including an inner hub strut leading edge preform portion and an inner hub strut trailing edge preform portion. In forming a strut preform, the outer shell leading edge preform portion and the inner hub leading edge preform portion are connected together, and the outer shell trailing edge preform portion and the inner hub trailing edge preform portion are connected together.

Inventors

Nicholas J. Kray
Ming Xie
Douglas Lorrimer Armstrong
Wei Wu

Assignees

GENERAL ELECTRIC COMPANY

Dates

Publication Date: 20260507
Application Date: 20251031

Claims (20)

1 . A method of manufacturing a composite component for a gas turbine engine, the composite component including an outer shell, an inner hub, and a plurality of struts connecting the outer shell and the inner hub, the method comprising: weaving a three-dimensional outer shell frame preform to include: an outer shell frame portion having an inner side and an outer side, and a plurality of outer shell strut preform portions integrally woven in part connected with the outer shell frame portion, wherein each outer shell strut preform portion includes an outer shell strut leading edge lug preform portion having first and second bifurcated outer shell strut leading edge lug preform portions, an outer shell strut pi-leg preform portion having first and second bifurcated outer shell strut pi-leg preform portions, and an outer shell strut trailing edge lug preform portion having first and second bifurcated outer shell strut trailing edge lug preform portions; weaving a three-dimensional inner hub frame preform to include: an inner hub frame portion having an inner side and an outer side, and a plurality of inner hub strut preform portions integrally woven in part connected with the inner hub frame portion, wherein each inner hub strut preform portion includes an inner hub strut leading edge lug preform portion having first and second bifurcated inner hub strut leading edge lug preform portions, an inner hub strut pi-leg preform portion having first and second bifurcated inner hub strut pi-leg preform portions, and an inner hub strut trailing edge lug preform portion having first and second bifurcated inner hub strut trailing edge lug preform portions; forming a preform assembly including the outer shell frame preform, the inner hub frame preform, and a plurality of strut preforms connecting the outer shell frame preform and the inner hub frame preform, the plurality of strut preforms being formed from the plurality of outer shell preform portions and the plurality of inner hub strut preform portions by connecting each of the outer shell strut leading edge lug preform portions with a respective one of the inner hub strut leading edge lug preform portions, and by connecting each of the outer shell strut trailing edge lug preform portions with a respective one of the inner hub strut trailing edge lug preform portions; injecting a matrix material into a mold tooling structure upon which the preform assembly is formed; and applying a curing process to the mold tooling structure to obtain a cured molded composite structure.
2 . The method according to claim 1 , wherein each strut preform of the plurality of strut preforms further includes at least one additional layer extending to wrap around a periphery of the strut preform.
3 . The method according to claim 1 , wherein the composite component is one of an outlet guide vane structure, an inlet guide vane structure, or a stator vane structure.
4 . The method according to claim 1 , further comprising, in the forming of the preform assembly, connecting together a first outer shell frame preform connecting end and a second outer shell frame preform connecting end to form an outer shell hoop frame preform, and connecting together a first inner hub frame preform connecting end and a second inner hub frame preform connecting end to form an inner hub hoop frame preform.
5 . The method according to claim 1 , wherein the cured molded composite structure is further processed via machining to obtain the composite component.
6 . The method according to claim 1 , wherein: the outer shell strut leading edge lug preform portion further includes an outer shell strut leading edge connection portion arranged between the first and the second bifurcated outer shell strut leading edge lug preform portions and integrally woven with the outer shell frame preform, the outer shell strut pi-leg preform portion further includes an outer shell strut pi-leg connection portion arranged between the first and the second bifurcated outer shell strut pi-leg preform portions and integrally woven with the outer shell frame preform, and the outer shell strut trailing edge lug preform portion further includes an outer shell strut trailing edge connection portion arranged between the first and the second bifurcated outer shell strut trailing edge lug preform portions and integrally woven with the outer shell frame preform.
7 . The method according to claim 6 , wherein: the outer shell frame preform includes a plurality of outer shell frame warp fiber layers each having a plurality of outer shell frame warp fiber tows extending in a first direction, the outer shell strut preform portion includes a plurality of outer shell strut fiber layers each having a plurality of outer shell strut warp fiber tows extending in the first direction, the outer shell strut warp fiber tows in respective layers of the outer shell strut leading edge connection portion are interwoven with the outer shell frame warp fiber tows in respective layers of the outer shell frame preform, the outer shell strut warp fiber tows in respective layers of the outer shell strut trailing edge connection portion are interwoven with the outer shell frame warp fiber tows in respective layers of the outer shell frame preform, and the outer shell strut warp fiber tows in respective layers of the outer shell strut pi-leg connection portion are interwoven with the outer shell frame warp fiber tows in respective layers of the outer shell frame preform.
8 . The method according to claim 1 , wherein: the inner hub strut leading edge lug preform portion further includes an inner hub strut leading edge connection portion arranged between the first and the second bifurcated inner hub strut leading edge lug preform portions and integrally woven with the inner hub frame preform, the inner hub strut pi-leg preform portion further includes an inner hub strut pi-leg connection portion arranged between the first and the second bifurcated inner hub strut pi-leg preform portions and integrally woven with the inner hub frame preform, and the inner hub strut trailing edge lug preform portion further includes an inner hub strut trailing edge connection portion arranged between the first and the second bifurcated inner hub strut trailing edge lug preform portions and integrally woven with the inner hub frame preform.
9 . The method according to claim 8 , wherein: the inner hub frame preform includes a plurality of inner hub frame warp fiber layers each having a plurality of inner hub frame warp fiber tows extending in a first direction, the inner hub strut preform portion includes a plurality of inner hub strut fiber layers each having a plurality of inner hub strut warp fiber tows extending in the first direction, the inner hub strut warp fiber tows in respective layers of the inner hub strut leading edge connection portion are interwoven with the inner hub frame warp fiber tows in respective layers of the inner hub frame preform, the inner hub strut warp fiber tows in respective layers of the inner hub strut trailing edge connection portion are interwoven with the inner hub frame warp fiber tows in respective layers of the inner hub frame preform, and the inner hub strut warp fiber tows in respective layers of the inner hub strut pi-leg connection portion are interwoven with the inner hub frame warp fiber tows in respective layers of the inner hub frame preform.
10 . The method according to claim 1 , wherein the outer shell strut leading edge lug preform portion further includes a first outer shell strut leading edge preform portion connection portion woven integrally with the first bifurcated outer shell strut leading edge lug preform portion, and a second outer shell leading edge preform portion connection portion woven integrally with the second bifurcated outer shell strut leading edge lug preform portion, and the outer shell strut trailing edge lug preform portion includes a first outer shell strut trailing edge preform portion connection portion woven integrally with the first bifurcated outer shell strut trailing edge lug preform portion, and a second outer shell trailing edge preform portion connection portion woven integrally with the second bifurcated outer shell strut trailing edge lug preform portion.
11 . The method according to claim 10 , wherein the inner hub strut leading edge lug preform portion further includes a first inner hub strut leading edge preform portion connection portion woven integrally with the first bifurcated inner hub strut leading edge lug preform portion, and a second inner hub leading edge preform portion connection portion woven integrally with the second bifurcated inner hub strut leading edge lug preform portion, and the inner hub strut trailing edge lug preform portion includes a first inner hub strut trailing edge preform portion connection portion woven integrally with the first bifurcated inner hub strut trailing edge lug preform portion, and a second inner hub trailing edge preform portion connection portion woven integrally with the second bifurcated inner hub strut trailing edge lug preform portion.
12 . The method according to claim 11 , wherein, in the forming of the strut preform, a leading edge fiber insert is inserted to extend between the first and the second bifurcated outer shell strut leading edge lug preform portions, to extend between the first and the second bifurcated inner hub strut leading edge lug preform portions, and to extend between the outer shell frame portion and the inner hub frame portion, and a trailing edge fiber insert is inserted to extend between the first and the second bifurcated outer shell strut trailing edge lug preform portions, to extend between the first and the second bifurcated inner hub strut trailing edge lug preform portions, and to extend between the outer shell frame portion and the inner hub frame portion.
13 . The method according to claim 1 , wherein the connecting the outer shell strut leading edge lug preform portion and the inner hub strut leading edge lug preform portion together with each other includes: arranging the first and the second bifurcated outer shell strut leading edge lug preform portions to extend inward from the inner side of the outer shell frame preform, arranging the first and the second bifurcated inner hub strut leading edge lug preform portions to extend outward from the outer side of the inner hub frame preform, connecting the first bifurcated outer shell strut leading edge lug preform portion and the first bifurcated inner hub strut leading edge lug preform portion together, and connecting the second bifurcated outer shell strut leading edge lug preform portion and the second bifurcated inner hub strut leading edge lug preform portion together, and the connecting the outer shell strut trailing edge lug preform portion and the inner hub strut trailing edge lug preform portion together with each other includes: arranging the first and the second bifurcated outer shell strut trailing edge lug preform portions to extend inward from the inner side of the outer shell frame preform, arranging the first and the second bifurcated inner hub strut trailing edge lug preform portions to extend outward from the outer side of the inner hub frame preform, connecting the first bifurcated outer shell strut trailing edge lug preform portion and the first bifurcated inner hub strut trailing edge lug preform portion together, and connecting the second bifurcated outer shell strut trailing edge lug preform portion and the second bifurcated inner hub strut trailing edge lug preform portion together.
14 . The method according to claim 13 , wherein, in the arranging: the first and the second bifurcated outer shell strut leading edge lug preform portions are arranged to extend abutting against one another, the first and the second bifurcated inner hub strut leading edge lug preform portions are arranged to extend abutting against one another, the first and the second bifurcated outer shell strut trailing edge lug preform portions are arranged to extend abutting against one another, and the first and the second bifurcated inner hub strut trailing edge lug preform portions are arranged to extend abutting against one another.
15 . The method according to claim 13 , wherein, in the arranging: the first and the second bifurcated outer shell strut leading edge lug preform portions are arranged to extend with a first gap between each other and a filler material is inserted in the first gap, the first and the second bifurcated inner hub strut leading edge lug preform portions are arranged to extend with a second gap between each other and a filler material is inserted into the second gap, the first and the second bifurcated outer shell strut trailing edge lug preform portions are arranged to extend with a third gap between each other and a filler material is inserted into the third gap, and, the first and the second bifurcated inner hub strut trailing edge lug preform portions are arranged to extend with a fourth gap between each other and a filler material is inserted into the fourth gap.
16 . The method according to claim 13 , wherein: the first bifurcated outer shell strut leading edge lug preform portion includes a first connecting end, the second bifurcated outer shell strut leading edge lug preform portion includes a second connecting end, the first bifurcated outer shell strut trailing edge lug preform portion includes a third connecting end, the second bifurcated outer shell strut trailing edge lug preform portion includes a fourth connecting end, the first bifurcated inner hub strut leading edge lug preform portion includes a fifth connecting end, the second bifurcated inner hub strut leading edge lug preform portion includes a sixth connecting end, the first bifurcated inner hub strut trailing edge lug preform portion includes a seventh connecting end, the second bifurcated inner hub strut trailing edge lug preform portion includes an eighth connecting end, and the first connecting end is connected with the fifth connecting end, the second connecting end is connected with the sixth connecting end, the third connecting end is connected with the seventh connecting end, and the fourth connecting end is connected with the eighth connecting end.
17 . The method according to claim 16 , wherein each of the first connecting end, the second connecting end, the third connecting end, and the fourth connecting end include a first connection end configuration, and each of the fifth connecting end, the sixth connecting end, the seventh connecting end, and the eighth connecting end include a second connection end configuration arranged to connect with the first connection end configuration.
18 . The method according to claim 13 , wherein each strut preform of the plurality of strut preforms is further formed by: arranging the first and the second bifurcated outer shell strut pi-leg preform portions to extend inward from the inner side of the outer shell frame preform, and arranging the first and the second bifurcated inner hub strut pi-leg preform portions to extend outward from the outer side of the inner hub frame preform.
19 . The method according to claim 18 , wherein each strut preform of the plurality of strut preforms is further formed by inserting a filler material between the first and the second bifurcated outer shell strut pi-leg preform portions, and inserting a filler material between the first and the second bifurcated inner hub strut pi-leg preform portions.
20 . The method according to claim 19 , wherein each strut preform of the plurality of strut preforms is further formed by adding additional preform layers to form an airfoil-shaped strut preform.

Description

CROSS REFERENCE TO RELATED APPLICATIONS The present application claims the benefit of U.S. Provisional Patent Application No. 63/715,148, filed on Nov. 1, 2024, which is hereby incorporated by reference herein in its entirety. TECHNICAL FIELD The present disclosure relates to composite components and methods of forming the composite components, particularly, aircraft composite components for aircraft engines. BACKGROUND Turbine engines used in aircraft generally include a fan and a turbo-engine section arranged in flow communication with one another. A combustor is arranged in the turbo-engine to generate combustion gases for driving a turbine in the turbo-engine of the turbine engine, and the turbine may be used to drive the fan. A portion of air flowing into the fan flows through the turbo-engine as core air, and another portion of the air flowing into the fan bypasses the core section and flows through the turbine engine as bypass air. The turbo-engine section may include one or more compressors to compress the core air before the core air flows into the combustor. Composite materials may be used to manufacture various components of the turbine engine, particularly, when the turbine engine is a turbine engine for an aircraft. BRIEF DESCRIPTION OF THE DRAWINGS Features and advantages of the present disclosure will be apparent from the following description of various exemplary embodiments, as illustrated in the accompanying drawings, wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. FIG. 1 is a schematic, cross-sectional view of a turbine engine of for an aircraft, according to an aspect of the present disclosure. FIG. 2A is a schematic view of a three-dimensional fiber weave pattern, according to an aspect of the present disclosure. FIG. 2B is a schematic, cross-sectional view of the fiber weave pattern shown in FIG. 2A taken along line 2B-2B in FIG. 2A, according to an aspect of the present disclosure. FIG. 2C is a schematic, cross-sectional view of a fiber weave pattern similar to the fiber weave pattern shown in FIG. 2A, but with a different interlocking fiber pattern, according to an aspect of the present disclosure. FIG. 2D is a schematic, cross-sectional view of a fiber weave pattern similar to the fiber weave pattern shown in FIG. 2A, but with another interlocking fiber pattern, according to an aspect of the present disclosure. FIG. 3 is a flow chart of a general process of manufacturing a composite component that may be used in the turbine engine of FIG. 1, according to an aspect of the present disclosure. FIG. 4 is a schematic, forward aft-looking view of a vane structure, taken at plane 4-4 of FIG. 1, according to an aspect of the present disclosure. FIG. 5 is a schematic, elevational aft-looking perspective view of the vane structure of FIG. 4, according to an aspect of the present disclosure. FIG. 6 is a cross-sectional view, taken at plane 6-6 of FIG. 4, through the vane structure of FIG. 4, according to an aspect of the present disclosure. FIG. 7 is a schematic, aft-looking layout of a preform assembly used in manufacturing a composite component, according to an aspect of the present disclosure. FIG. 8 is a schematic, aft looking view of an outer shell frame preform that may be implemented in the preform assembly 300 of FIG. 7, according to an aspect of the present disclosure. FIG. 9 is a schematic, aft looking view of an inner hub frame preform that may be implemented in the preform assembly 300 of FIG. 7, according to an aspect of the present disclosure. FIG. 10 is an enlarged view of a first outer shell frame preform connecting end, according to an aspect of the present disclosure. FIG. 11 is an enlarged view of a second outer shell frame preform connecting end, according to an aspect of the present disclosure. FIG. 12 is an enlarged detail view of an outer shell connection, taken at detail view 356 of FIG. 7, according to an aspect of the present disclosure. FIG. 13 is an enlarged view of a first inner hub frame preform connecting end, according to an aspect of the present disclosure. FIG. 14 is an enlarged view of a second inner hub frame preform connecting end, according to an aspect of the present disclosure. FIG. 15 is an enlarged detail view of an inner hub connection, taken at detail view 364 of FIG. 7, according to an aspect of the present disclosure. FIG. 16 depicts an alternate outer shell frame connection to that shown in FIG. 12, according to an aspect of the present disclosure. FIG. 17 is an enlarged, detail view of a connection of an outer shell strut preform portion with the outer shell frame portion, taken at detail view 392 of FIG. 8, according to an aspect of the present disclosure. FIG. 18 is a bottom view of the connection of FIG. 17, taken at view 18-18 of FIG. 17, according to an aspect of the present disclosure. FIG. 19 is a cross-sectional view of the connection of FIG. 17, taken at plane 19-19