A method of fabricating an airfoil includes providing an airfoil core tube that is made of a rigidized ceramic fabric, using the airfoil core tube as a mandrel by braiding a plurality of ceramic fiber tows around the airfoil core tube to form one or more braided layers, where the airfoil core tube and the one or more braided layers forming an airfoil preform, and densifying the airfoil preform with a ceramic matrix material to thereby form a ceramic matrix composite airfoil.

A method of fabricating an airfoil includes providing an airfoil core tube that is made of a rigidized ceramic fabric, using the airfoil core tube as a mandrel by braiding a plurality of ceramic fiber tows around the airfoil core tube to form one or more braided layers, where the airfoil core tube and the one or more braided layers forming an airfoil preform, and densifying the airfoil preform with a ceramic matrix material to thereby form a ceramic matrix composite airfoil.

A system for forming multiple braided preform segments includes a mandrel assembly disposed along a mandrel axis, a radial braider for winding fibers onto the mandrel assembly to form a continuous braided article, an applicator for applying a polymer binder to the braided article while mounted on the mandrel assembly, and a debulking tool for debulking the braided article while mounted on the mandrel assembly. The mandrel assembly includes a lead-in extension defining a first end, an end extension defining a second end, and a plurality of mandrels removably connected to a plurality of transition pieces and disposed axially between the lead-in extension and the end extension.

A method of fabricating an airfoil includes providing an airfoil core tube that is made of a rigidized ceramic fabric, using the airfoil core tube as a mandrel by braiding a plurality of ceramic fiber tows around the airfoil core tube to form one or more braided layers, where the airfoil core tube and the one or more braided layers forming an airfoil preform, and densifying the airfoil preform with a ceramic matrix material to thereby form a ceramic matrix composite airfoil.

A method of fabricating an airfoil includes providing an airfoil core tube that is made of a rigidized ceramic fabric, using the airfoil core tube as a mandrel by braiding a plurality of ceramic fiber tows around the airfoil core tube to form one or more braided layers, where the airfoil core tube and the one or more braided layers forming an airfoil preform, and densifying the airfoil preform with a ceramic matrix material to thereby form a ceramic matrix composite airfoil.

A mandrel suitable for supporting an airfoil preform includes a first piece extending along a longitudinal axis of the mandrel, and a second piece in physical contact with the first piece at first interface region and extending along the longitudinal axis of the mandrel. The first piece is formed from a first material, and the second piece is formed from a second material.

A mandrel suitable for supporting an airfoil preform includes a first piece extending along a longitudinal axis of the mandrel, and a second piece in physical contact with the first piece at first interface region and extending along the longitudinal axis of the mandrel. The first piece is formed from a first material, and the second piece is formed from a second material.