A method for manufacturing a turbine-engine blade from a preform made from polymerized composite material in a mold comprising a bottom part and a top part, comprising at least one closure step during which the top part of said mold is attached to the bottom part of the mold containing the preform, wherein it comprises, prior to said closure step, at least one insertion substep during which a first end of an immobilization element is inserted in a bottom part of the preform in a substantially transverse direction, and a positioning substep during which a second, opposite end of said element is disposed in a complementary reception cavity emerging in the bottom part of the mold.

A method is provided in one example embodiment and may include positioning at least one nozzle within a hollow portion of a rotor blade at a distance associated with a span of the rotor blade and providing, via the at least one nozzle, a liquid foam mixture in the hollow portion, wherein the liquid foam expands and becomes a solid foam material that fills the hollow portion of the rotor blade. Another method is provided in another example embodiment and may include providing a plurality of openings for a rotor blade that are positioned proximate to a hollow portion of the rotor blade and providing a liquid foam mixture in the hollow portion of the rotor blade through at least one opening of the rotor blade, wherein the liquid foam mixture expands and becomes a solid foam material that fills the hollow portion of the rotor blade.

An additive manufacturing technique includes depositing, via a filament delivery device, a filament onto a surface of a substrate. The filament includes a binder and a high entropy alloy powder. The technique also includes sacrificing the binder to form a preform and sintering the preform to form a component.

A manufacturing method of a turbomachine airfoil, such as an outlet guide vane airfoil, comprising positioning a first fibrous wall preform on a first mold portion, placing at least one core on the first wall preform, positioning a second fibrous wall preform on the core, assembling a second mold portion to the first mold portion so as to form a mold around the first and second wall preforms, applying a hardening treatment to the first and second wall preforms, removing the core, and positioning a reinforcing structure between the first wall preform and the second wall preform.

A fiber structure includes a plurality of weft layers and of warp layers interlinked by multilayer three-dimensional weaving, the fiber structure having at least first and second portions that are adjacent in the warp direction, the first portion presenting, in a direction perpendicular to the warp and weft directions, a thickness that is greater than the thickness of the second portion, wherein the first portion has at its core at least one fiber fabric obtained by three-dimensional weaving of warp yarns and weft yarns in the form of a Mock Leno weave grid, the at least one fabric being present between two skins present at the surface of the first portion and being linked to the skins by warp yarns belonging to the skins that are locally deflected into the fabric.

A light weight hybrid torque transfer joint trunnion has an integral metal hub spline fitting oriented on a center axis. This integral metal hub spline fitting may be made of steel, aluminum, titanium, or the like and may be generally cylindrical. The integral metal hub spline fitting defines an integral central internally-splined mast or driveshaft coupling opening centered about the center axis. A composite material body centrally retains, and is cured to, the metal hub spline fitting. Torque transfer joint link attachment pins extend from the composite material body and are rigidly linked to the metal hub spline fitting. In an example constant-velocity joint, a plurality of pivoting linkages may each be rotatably coupled to the torque transfer joint link attachment pins, and each of the plurality of pivoting linkages may, in turn be secured to a rotor yoke configured to mount a plurality of rotorcraft blades.

An airfoil having a wall structure including a plurality of spaced walls for improved cooling and lifetime is disclosed. The airfoil and walls are made by additive manufacturing. The airfoil includes an exterior wall, an intermediate wall, and an interior wall each separated from adjacent walls by a plurality of standoff members; a plurality of outer cooling chambers defined between the exterior and intermediate walls, the chambers partitioned by an outer partition; a plurality of intermediate cooling chambers defined between the intermediate and interior walls, the chambers partitioned by an intermediate partition; a thermal barrier coating on each of the exterior wall and the intermediate wall; a first plurality of impingement openings through the intermediate wall; a second plurality of impingement openings through the interior wall; and a plurality of cooling passages through the exterior wall.

A composite vane for a turbomachine, in particular an aircraft turbomachine, this vane including an aerofoil having a pressure side and a suction side connected together by a leading edge and by a trailing edge, the aerofoil been formed from a fibrous preform obtained by weaving fibres in three dimensions, which is embedded in a polymer matrix, the vane further including a first metal shield extending over and along the leading edge of the aerofoil, the vane further including at least one cover element extending over and along the trailing edge of the aerofoil.

A composite blade includes a composite blade body including reinforced fibers and resin; a metal layer provided on an outer side of a leading edge section including a leading edge that is a part of the composite blade body on an upstream side of an air stream, the metal layer having a thickness of equal to or larger than 5 micrometers and equal to or smaller than 100 micrometers; an adhesive layer provided between the composite blade body and the metal layer to bond the metal layer to the composite blade body; and an electric insulating layer provided in contact with a surface of the leading edge section of the composite blade body, the surface being on the side on which the metal layer is provided, the electric insulating layer having an electric insulating property.

In an implementation, a rotor blade (alternatively referred to herein as blade) for a helicopter or other aircraft may include an outer layer. The outer layer may define a cavity. The outer layer may at least partially correspond to an airfoil, e.g., a wing. One or more inserts may be included within the cavity and be encompassed thereby. The first insert may have a density of at least 0.6 pounds per cubic inch.