A composite stringer assembly includes a composite stringer and a radius filler. The composite stringer includes a skin flange, a web, a corner portion extending from the skin flange to the web, an inner surface, and an outer surface. At the corner portion, the outer surface is defined by a first radius of curvature, which is substantially constant between the skin flange and the web. The support structure includes at least one of a skin of a vehicle or a base charge. The radius filler includes a first surface coupled to the inner surface at the corner portion, a second surface configured to couple to the support structure, and a third surface extending between the first surface and the second surface. The first surface of the radius filler is defined by a second radius of curvature, which is substantially constant between the second surface and the third surface.

A composite stringer assembly includes a composite stringer and a radius filler. The composite stringer includes a skin flange, a web, a corner portion extending from the skin flange to the web, an inner surface, and an outer surface. At the corner portion, the outer surface is defined by a first radius of curvature, which is substantially constant between the skin flange and the web. The support structure includes at least one of a skin of a vehicle or a base charge. The radius filler includes a first surface coupled to the inner surface at the corner portion, a second surface configured to couple to the support structure, and a third surface extending between the first surface and the second surface. The first surface of the radius filler is defined by a second radius of curvature, which is substantially constant between the second surface and the third surface.

Composite components having a T or L-shaped configuration that include features that reduce void defects between abutting laminate portions and provide improved mechanical properties are provided. Methods for forming such components are also provided. In one exemplary aspect, a composite component defines a first direction and a second direction and includes a wedged-shaped noodle at a joint interface between an abutting first laminate portion extending along the first direction and a second laminate portion extending along the second direction. The noodle has a first surface that is angled with respect to the second direction. At least one of the plies of the second laminate portion terminate and attach to the angled first surface of the noodle.

Systems and methods are provided for forming composite parts. One embodiment is a method that includes receiving flat unidirectional tape that is continuous and fiber-reinforced, and drawing the tape through a fixed die that heats and plastically deforms the tape into a gap filler having a non-flat cross section.

A method of forming a composite structure including coupling a plurality of components together forming a joint: wherein the plurality of components are oriented to form a radius gap therebetween: forming a filler structure that includes a closed cell foam core that has a porosity within a range defined between about 20 percent and about 40 percent by volume of the closed cell foam core and wherein the closed cell foam core is formed from a silicone-based material. The method also includes positioning the filler structure in the radius gap: and applying at least one of heat or pressure to the plurality of components and the filler structure.

A composite radius filler material is provided. The composite radius filler includes a resin, a first group of fibers dispersed within the resin, and a second group of fibers dispersed within the resin. The first group of fibers has a first length configured to facilitate orientation in a longitudinal direction. The second group of fibers has a second length that is shorter than the first length, with the second group of fibers configured to facilitate random orientation in a transverse direction.

A composite shaping apparatus includes at least one first roller that loads a prepreg with pressure, at least one second roller that loads the prepreg with pressure, and at least one motor that rotates at least one of the first roller or the second roller. The at least one first roller and the at least one second roller are rotated while at least one of rotation speed, roller diameter, or presence/absence of rotating power is made different between at least one of the first roller and at least one of the second roller.

An assembly for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil that has an airfoil section extending from a root section. The airfoil section extends between a leading edge and a trailing edge in a chordwise direction and extending between a tip portion and the root section in a radial direction. The airfoil section defines a pressure side and a suction side separated in a thickness direction. A platform is dimensioned to receive a retention pin to mount the platform to a rotatable hub. At least one of the airfoil and the platform includes a plurality of composite layers that define an internal cavity. A lattice structure in the internal cavity extends between the plurality of composite layers. The lattice structure has a plurality of branches that extend from a plurality of nodes.

A plurality of segments of radius filler is positioned onto a radius filler forming tool. The plurality of segments of radius filler is applied to a stringer in a single placement step.

A method of manufacturing a noodle of a structural joint that comprises pulling a first composite sheet through a first splitting station to cut the first composite sheet into a plurality of first composite plies, pulling the plurality of first composite plies through a first alignment station to stack the plurality of first composite plies on top of each other to form a first stacked composite layup, pulling the first stacked composite layup through a first heating station to heat the first stacked composite layup to form a first heated composite layup, pulling the first heated composite layup through a first forming station to shape the first heated composite layup into a first pre-selected cross-sectional shape to form at least a first portion of a continuous noodle, and pulling at least the first portion of the continuous noodle through a cutting station to cut at least the first portion of the continuous noodle to a pre-selected length.