Composite assemblies are described that include composite spars that are co-cured with one or more sacrificial members on their flanges, forming an integrated sacrificial surface for the composite spars. In one embodiment, the composite assembly includes a composite spar having a web and flanges that project from sides of the web. The composite assembly further includes a sacrificial member of composite materials co-cured with the composite spar on an outer surface of at least one of the flanges. In addition, the sacrificial member has an outer surface that has been machined into conformance with an inner surface of at least one skin panel for an aircraft structure to form a contact surface with the at least one skin panel.

Compaction systems and methods of compacting components are provided. In one aspect, a laminate of a component can be laid up on a tool of a compaction system. The laminate defines a cavity. A noodle is positioned relative to or in the cavity. A noodle ring is then positioned relative to the noodle. For instance, the noodle ring can be placed over the noodle. A cross section of the noodle ring can be shaped complementary to a cross section of the noodle. A plunger of the compaction system is moved so that it engages the noodle ring. Particularly, the plunger is moved in such a way that a force is applied on the noodle ring so that the noodle ring compacts the noodle into the cavity.

A mold assembly includes an injection mold configured to receive a woven preform. The preform has a principal direction with at least one edge extending substantially along the principal direction. The mold assembly is configured to allow the impregnation of the preform with a resin injected into the mold. The mold assembly further includes a removable longitudinal element for the injection mold, wherein said longitudinal element is configured to cooperate with the preform and conformed as a profiled member configured to be arranged in contact with the mold along at least the segment of the edge of the preform in order to prevent the pinching of free fibers extending from the edge of the preform between the two parts of the mold.

The polyurethane material is prepared from a polyol, butanediol, and an isocyanate. The protective cover is adapted to be attached along at least a part of a longitudinal edge of the wind turbine blade by adhesion of an inside of the protective cover to a surface of the longitudinal edge of the wind turbine blade. The protective cover is elongated in a longitudinal direction and has an at least substantially U-formed cross-section. The protective cover includes a central cover section extending in the longitudinal direction and two peripheral cover sections extending in the longitudinal direction at either side of the central cover section, respectively. The central cover section has a minimum thickness of at least 1 millimetre, and each peripheral cover section has a thickness decreasing from a maximum thickness of at least 1 millimetre to a minimum thickness of less than 1/2 millimetre.

A method of making a wind turbine blade (10) having a shear web (20, 22) bonded between first and second half shells (16, 18) is described. The method involves providing a web locator (40) on an inner surface of a half shell. The web locator has a fixed portion (42) and a spring portion (44) extending from the fixed portion. The spring portion is moveable relative to the fixed portion between compressed and relaxed states.

A composite article including composite component mounted on a spar including a shank extending heightwise from below component base up into composite component. Tab at an upper end of shank substantially or fully embedded in the composite component and at least one ply surface pattern of the composite component contacting and generally conforming to at least one spar surface pattern on the tab. Spar surface pattern may include spaced apart spar surface protrusions with spar surface spaces therebetween and spar surface protrusions extending outwardly from spar and disposed between tows in ply surface pattern. Tows may be layed up in spar surface spaces. Spar surface pattern may include continuous or segmented spaced spar surface protrusions and spar surface spaces therebetween with tows in ply surface pattern disposed in spar surface spaces. The composite article may be a composite blade or vane including a composite airfoil.

Single-airfoil vanes each having an inner platform, an outer platform, and an airfoil are obtained by three-dimensionally weaving a fiber blank in a single piece, by shaping the fiber blank to obtain a single-piece fiber preform, and by densifying the preform with a matrix to obtain a vane of composite material forming a single piece with inner and outer platforms incorporated therein. A plurality of vanes is assembled together at an intermediate stage of densification to form a multi-airfoil composite material guide vane sector for a turbine nozzle or a compressor diffuser and the assembled-together vanes are bonded together.

A molding apparatus for manufacturing a wind turbine blade component includes a main mold body (30) and a flexible bladder (38). The main mold body includes a shape defining surface (32) for receiving composite material forming the blade component and a heat reservoir (40) for heating the blade component during curing. The flexible bladder overlays and conforms to the shape of the blade component and is configured to receive heated liquid for heating the blade component during curing. One or both of the main mold body and the flexible bladder is divided into a plurality of zones (58, 66) that are independently controlled by a controller (70) to maintain a generally uniform temperature of the blade component at each zone.

A fiber preform for a turbine engine blade and also a single-piece blade suitable for being formed using such a preform, a rotor wheel, and a turbine engine including such a blade, the fiber preform being obtained by three-dimensional weaving and comprising a first longitudinal segment suitable for forming a blade root (21), a second longitudinal segment extending the first longitudinal segment upwards and suitable for forming an airfoil portion (22), a first transverse segment extending transversely from the junction between the first and second longitudinal segments and suitable for forming a first platform (23), and a first stiffener strip extending downwards from the distal edge of the first transverse portion and suitable for forming a first platform stiffener (25).

A method of manufacturing a control cuff for a rotor blade of a hinge and bearingless rotor. The method comprises at least the steps of: manufacturing an outer shell, manufacturing a stiffener member by means of an automated process, inserting the stiffener member into the outer shell, and bonding the stiffener member to the outer shell.