A method of manufacturing a composite component comprises forming a core, surrounding the circumference of the core with a first layer of fabric, applying a second layer of fabric having a different coefficient of thermal expansion from the first layer such that the second layer extends around at least a portion of the circumference of the core and curing the component such that the second layer imparts a compressive or tensile force on the core.

A method of fabricating a blade of composite material having an incorporated metal leading edge for a gas turbine aeroengine, the method including in succession placing a metal strip for making the leading edge of a blade in a cavity of an injection mold for making the blade, closing the injection mold, injecting a thermoplastic resin under pressure into the cavity of the mold so as to shape and overmold the metal strip, compacting the assembly, solidifying the resin by regulating the temperature of the injection mold, and unmolding the resulting blade.

A rotor blade is provided that includes an airfoil extending spanwise from a base to a tip. The airfoil extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil extends laterally between a first side and a second side. The airfoil includes a body and a weight. The body includes a plurality of body layers. Each of the body layers includes fiber reinforcement within a body thermoplastic matrix. The weight includes a weight layer embedded within the body. The weight layer includes metal powder within a weight thermoplastic matrix.

A system for manufacturing a rotor blade comprises a first tooling, positioned at a factory location and configured to assemble a first blade module, comprising a first-module skin and a first-module spar, each comprising a first thermoplastic polymer and a first reinforcement material. The system also comprises a second tooling, configured to assemble a second blade module, comprising a second-module skin and a second-module spar, each comprising a second thermoplastic polymer and a second reinforcement material. The system further comprises a first support, positioned at a field location and configured to receive the first blade module, and a second support, positioned at the field location and configured to receive the second blade module. The system also comprises a spar welding assembly, positioned at the field location and configured to join the first-module spar with the second-module spar.

Integrated pultruded composite profiles such as rotor wings and blades for electric vertical take-off and landing aircraft, light helicopters, wind turbines, and other rotor wing applications and integrated design and processing methods for making same are disclosed. The present invention provides a plurality of web ribs for stiffening and supporting an outer skin which can comprise fabric plies, a metallic skin, or a thermoplastic composite skin. A process and method to continuously pultrude integrated composite airfoil profile with variable aerodynamic twist is also disclosed. Utilization of a stranded metallic wire rope that enables the leading edge weight to be continuously in-situ fed into the pultrusion process and effectively retained in the pultruded product is also disclosed. Utilization of fiber reinforcement impregnated with matrix resin that is loaded with high density powder for the leading edge weight is also disclosed.

A method of repairing a composite structure includes providing an assembled composite structure comprising a substantially rigid outer component, wherein the composite structure comprises a void space at least partially bounded by the outer component. The method further includes forming an injection hole through the outer component to provide a path between the void space and space external to the composite structure. The method further includes injecting foam into the void space through the injection hole while the foam is in a substantially unexpanded state and expanding the foam within the void space.

The present invention relates to an adhesive, a preparation method and application thereof, particularly the application for bonding glass fiber composites, and a bonded article obtained by using the adhesive. The adhesive comprises: a polyisocyanate having an isocyanate functionality of not less than 2; an epoxy-modified polyether polyol; a hydroxyl-containing acrylate; a redox catalyst; a silane coupling agent; optionally a polyol containing bisphenol A structure; and optionally a polymer polyol different from the epoxy-modified polyether polyol. The adhesive according to the present invention has the advantages of being insensitive to moisture, good bonding properties and a long pot life.

The invention relates to a method for manufacturing a turbine engine blade from a preform (10) of composite material polymerised in a mould comprising a lower part (16) and an upper part, comprising at least one closure step, during which the upper part of said mould is placed on the lower part (16) of the mould containing the preform (10). The method comprises, prior to said closure step, at least one sub-step of inserting a position marker (28) into the preform (10), at least one sub-step of compacting the preform using an insert (34) intended to be received in the upper part of the mould (18), and at least one sub-step of checking the position of the marker (28) relative to a reference mark (30) of said insert (34).

A composite assembly has an outer spar component having an outer spar component inner profile, an inner spar component having an inner spar component outer profile substantially complementary to the outer spar component inner profile, and an adhesive disposed between the outer spar component and the inner spar component.

There is disclosed a method of manufacturing a fan blade for a gas turbine engine, the method comprising: providing a root insert comprising quasi-isotropic short fibre reinforced resin, providing a first sub-laminate of a fibre-reinforcement pre-form for the fan blade on a first mould surface, placing the root insert on the first sub-laminate at a position corresponding to a root of the fan blade, providing a second sub-laminate of the pre-form over the root insert and the first-sub-laminate, so that the root insert is at an intermediate position between the first and second sub-laminates; and applying heat and pressure to form the pre-form.