A method of fabricating a gas turbine casing out of composite material of varying thickness, the method including making a strip-shaped fiber texture by three-dimensional weaving; winding the fiber texture as a plurality of superposed layers onto a mandrel of profile corresponding to the profile of the casing that is to be fabricated, so as to obtain a fiber preform of shape corresponding to the shape of the casing that is to be fabricated; and densifying the fiber preform with a matrix; wherein, before beginning to wind the fiber texture onto the mandrel, a reinforcing band of width smaller than the width of the fiber texture is placed on the mandrel in a zone that is to form a retention zone of the casing.

An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.

A manufacturing method contemplates performing vacuum-assisted resin infusion to enclose an elongated core within a cured composite laminate without employing a mold. Not relying upon an external mold enables the process to be efficiently performed for core shapes that are manufactured in low volumes. Typical resin infusion processes utilize flow media that induces bag bridging during vacuum draw in order to provide gaps facilitating resin flow. However, popular flow media also tends to impart directional aggregate forces during vacuum draw, which forces can deform the core since no mold is being used. To avoid unequal and non-dispersed directional forces from deforming the elongated core, a flow media is employed that is configured to disperse and/or reduce such forces. Some such flow media may be knitted so as to allow overlapping strands to slide over one another. Other flow media may ensure that strands are interleaved so that no one strand or group of strands is disposed outwardly of other strands along a substantial length of the strands, thus dispersing bag bridging forces in several directions and avoiding directional aggregate forces. However, such flow media may have inhibited resin flow relative to popular high-flow flow media, and thus new strategies have been developed to ensure appropriate wetting of fibrous reinforcement. An adjustable brace can also be employed to restrain the elongated core from deflecting during application of vacuum and/or resin infusion.

A tie rod suitable for use with known concrete forming systems is constructed from a non-metal fiber, such as fiberglass, that is wound about a pair of opposed thimble elements. The resultant tie rod is as strong as a metal tie rod without the drawbacks of conventional metal tie rods. Each of the thimble elements has a main body having a channel formed in an outer surface of the main body, and the fiberglass fiber is disposed within the channel when wound thereabout.

A process for manufacturing a blade made of composite material for a turbomachine. The blade includes an airfoil having a pressure side and a suction side which extend from a leading edge to a trailing edge of the airfoil. The blade further includes a metal sheath that extends along the leading edge of the airfoil. The process includes the steps of: placing a preform, produced by three-dimensionally weaving fibers, in a mold, the sheath being positioned on an edge of the preform intended to form the leading edge of the airfoil; and injecting polymerizable resin into the mold to impregnate the preform so as to form the airfoil after solidifying. At least one double-sided adhesive film may be inserted between the sheath and the edge of the preform prior to injection of the resin.

A method for preparing a part using a rigid tool surface having a shape. The method includes applying a breather sheet comprising gas-permeable material over the rigid tool surface. A vacuum bag is applied over the breather sheet, and a vacuum pressure is applied underneath the vacuum bag to conform the breather sheet and the vacuum bag to the shape of the rigid tool surface. A resin pre-impregnated ply is applied over the vacuum bag, and the part is positioned over the ply.

A device for moulding at least one bladed part of a turbomachine, including a base, a mould formed from several parts that are interlocked with each other, this mould being applied to the base and first sealing means being mounted between the mould and the base, a bell-shaped dome mounted on the mould and around the mould, this bell-shaped dome being applied to the base and second sealing means being mounted between the bell-shaped dome and the base, this bell-shaped dome being configured to be held clamped against the base and including inner surfaces cooperating by corner effect with complementary outer surfaces of the mould in order to apply a clamping force on the parts of this mould.

Provided herein is a wind turbine blade mold system having built in precision pins to locate structural components (e.g. spar caps) during layup of composite segments. A plurality of pins can be inserted through the layers of composite layups and into apertures within the mold, with spar caps positioned against the pins to ensure precise positioning, thereby preventing/inhibiting movement of the spar cap relative to the mold. A plurality of pins can be inserted through the layers of composite layups and into apertures within the mold, with cams attached to the pins and moveable to engage spar caps to ensure precise positioning of the spar cap, as well as preventing any drift during subsequent operations. The pins can remain embedded within the final molded part.

A polar end ring mechanism for use with composite pressure vessels. The end ring is designed to support a pressure vessel during its formation via filament winding. The end ring helps define an opening at one of the polar ends of a tank. Spikes positioned along a portion of the end ring help prevent rotation or translation of the tank during formation and provide an improved mechanical lock with the tank body. A cap may then be secured to the polar end ring after formation in order to close the pressure vessel.

A vane for a turbine engine includes a body in the form of an aerodynamic profile formed by a shell produced from a composite material formed from a three-dimensional textile of reinforcement fibres consolidated by a hardened resin. The shell forms a pressure surface and a suction surface of the vane connected to each other while forming on one side a leading edge and on the opposite side a trailing edge of the vane, and a core including a core body surrounded by the shell. The core is produced from non-porous plastics material, and the core body is in the form of an aerodynamic profile and delimits at least one closed cavity of the core.