Embodiments are directed to systems and methods for creating a tubular composite structure. In one embodiment, a device comprises multiple layers of cured composite fabric bonded together to form a tubular composite structure, wherein alternating groups of the multiple layers comprise on-axis fabric and off-axis fabric. The tubular composite structure may form a spar for an aerodynamic component. The composite fabric may comprise one or more of carbon, fiberglass, or other composite materials, or a combination of materials. One or more stacks of the fabric wrap completely around the tubular composite structure, and other stacks of fabric may not wrap completely around the tubular composite structure.

A method of forming an airfoil includes the steps of (a) providing an airfoil body with a hollow having at least one rib extending to an outer surface, and forming the outer surface of the rib to have at least one groove connecting a hollow pocket within a boundary defined by the rib to a location outwardly of the rib, (b) placing a cover over the hollow, and (c) welding the cover to the airfoil body, and such that the rib is welded to the blade cover. An intermediate airfoil body is also disclosed.

A propulsion engine for an aeronautical vehicle defines a radial direction and a cooling air flowpath. The propulsion engine includes a power source; and a fan including a fan blade rotatable by the power source and extending generally along the radial direction, the fan blade defining an inlet, an outlet, and a cooling air passage extending between the inlet and the outlet and in airflow communication with the cooling air flowpath, the inlet being positioned inward from the outlet along the radial direction to provide a cooling airflow through the cooling air flowpath.

Embodiments are directed to systems and methods for manufacturing composite assemblies comprising laying up composite plies on molds for two or more uncured components, joining the molds for the two or more uncured components to form a tubular body, and curing the joined components simultaneously to create a single composite assembly. The single composite assembly may form a spar for an aerodynamic component. The method may further comprise forming at least one axial edge having a sloped shape on the uncured components and mating the sloped axial edges together when joining the uncured components. The molds for the two or more uncured components may comprise female tools or both female tools and male tools. The two or more cured composite assemblies may comprise one or more of carbon and fiberglass composite materials.

A rotating airfoil assembly including a rotation axis and a plurality of rotating airfoils configured to rotate about the rotation axis. Each rotating airfoil of the rotating airfoils includes a leading edge, a trailing edge, a suction surface between the leading edge and the trailing edge, and a pressure surface between the leading edge and the trailing edge. The suction surface and the pressure surface are positioned on opposite sides of the rotating airfoil such that, when airflows over the suction surface and the pressure surface of the rotating airfoil as the rotating airfoil rotates about the rotation axis, the rotating airfoil generates lift. At least one opening is located on one of the suction surface or the pressure surface. The at least one opening is configured to eject air or to draw air into the opening.

A rotating airfoil assembly including a rotation axis and a plurality of rotating airfoils configured to rotate about the rotation axis. Each rotating airfoil of the rotating airfoils includes a leading edge, a trailing edge, a suction surface between the leading edge and the trailing edge, and a pressure surface between the leading edge and the trailing edge. The suction surface and the pressure surface are positioned on opposite sides of the rotating airfoil such that, when airflows over the suction surface and the pressure surface of the rotating airfoil as the rotating airfoil rotates about the rotation axis, the rotating airfoil generates lift. At least one opening is located on one of the suction surface or the pressure surface. The at least one opening is configured to eject air or to draw air into the opening.

The present invention provides a power device generating greater propelling force and finds that traditional power devices do not include all propelling forces based on the fundamental core propelling force source problem. External pressure is guided to the traditional power devices since the inner speed is higher the outer speed, power consumption for overcoming fluid resistance is high, and mutual contradiction results are obtained. The unique difference between the present invention and general common sense lies in opposite fluid pressure directions; inner fluid channels and outer fluid channels with higher flow speeds are formed to generate pressure differences which guides the fluid pressure to the outside and serve as propelling force, thus the present invention creatively finds three propelling force sources, two lifting force or propelling force sources of helicopters or airplanes driven by propellers and two propelling force sources for sufficient burning of fuel in combustion chambers of engines.

The present invention provides a power device generating greater propelling force and finds that traditional power devices do not include all propelling forces based on the fundamental core propelling force source problem. External pressure is guided to the traditional power devices since the inner speed is higher the outer speed, power consumption for overcoming fluid resistance is high, and mutual contradiction results are obtained. The unique difference between the present invention and general common sense lies in opposite fluid pressure directions; inner fluid channels and outer fluid channels with higher flow speeds are formed to generate pressure differences which guides the fluid pressure to the outside and serve as propelling force, thus the present invention creatively finds three propelling force sources, two lifting force or propelling force sources of helicopters or airplanes driven by propellers and two propelling force sources for sufficient burning of fuel in combustion chambers of engines.

A method of forming an airfoil includes the steps of (a) providing an airfoil body with a hollow having at least one rib extending to an outer surface, and forming the outer surface of the rib to have at least one groove connecting a hollow pocket within a boundary defined by the rib to a location outwardly of the rib, (b) placing a cover over the hollow, and (c) welding the cover to the airfoil body, and such that the rib is welded to the blade cover. An intermediate airfoil body is also disclosed.

A blade for a propulsion apparatus that includes a body formed of a first material. The body includes opposed pressure and suction sides and extends in span between a root and a tip. The body extends in court between a leading edge and a trailing edge. A tension element is positioned within the body and extends between the root and the tip. The tension element includes at least one string that is configured to be under tension such that at least a portion of the blade between the root and the tip is under compression.