Method for forming a composite article

Abstract

A method of forming a composite article involves the steps of: providing a formed article, the formed article comprising a plurality of non-crimp fibre fabrics with each non-crimp fibre fabric comprising at least two dry-fibre layers; stabilising the plurality of non-crimp fibre fabrics; machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops; positioning the machined formed article in a second mould; infiltrating the second mould with a polymer matrix resin; and curing the machined formed article to form the composite article.

Claims

1. A method of forming a composite article, the method comprising the steps of: providing a formed article, the formed article comprising a plurality of non-crimp fibre fabrics with each non-crimp fibre fabric comprising at least two dry-fibre layers; stabilising the plurality of non-crimp fibre fabrics; arranging an insert at a first end of the plurality of non-crimp fibre fabrics such that at least a first plurality of non-crimp fibre fabrics are arranged directly adjacent to and contacting the insert; machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops; positioning the machined formed article in a second mould; infiltrating the second mould with a polymer matrix resin; and curing the machined formed article to form the composite article, wherein the step of infiltrating the machined preform article with a polymer matrix resin, comprises the additional previous step of applying a fibre fabric wrap layer to the machined formed article, the fibre fabric wrap layer extending over at least a part of the exterior surface of the machined formed article.

2. The method as claimed in claim 1, wherein the non-crimp fabric layers are multi-axial non-crimp fabric layers.

3. The method as claimed in claim 1, wherein the step of providing a formed article, comprises the steps of: providing a layup surface; sequentially positioning a plurality of non-crimp fibre fabrics onto the layup surface to form a first sub-section preform, and a second sub-section preform, each non-crimp fibre fabric being oriented in dependence on a geometry and load-carrying capability of the composite article; assembling the first sub-section preform and the second sub-section preform together to form a preformed article; positioning the preformed article in a first mould; and press-forming the preformed article in the first mould to create a formed article.

4. The method as claimed in claim 3, wherein the step of press-forming the preformed article in the first mould to consolidate the non-crimp fibre fabrics comprises the additional previous step of: lubricating the stack of non-crimp fibre fabrics with water.

5. The method as claimed in claim 3, wherein the step of sequentially positioning a plurality of non-crimp fibre fabrics onto the layup surface to form a sub-section preform, comprises the additional subsequent step of: applying a vacuum to the sub-section preform to debulk the plurality of non-crimp fibre fabrics.

6. The method as claimed in claim 3, wherein the step of assembling the first sub-section preform and the second sub-section preform together to form a preformed article comprises the additional subsequent step of: providing through-thickness reinforcement to the preformed article.

7. The method as claimed in claim 6, wherein the through-thickness reinforcement is provided by a technique selected from the group consisting of any of stitching, tufting, or pinning.

8. The method as claimed in claim 3, wherein the step of stabilising the plurality of non-crimp fibre fabrics, comprises the steps of: infiltrating the first mould with water; cooling the first mould to freeze the water; removing the formed article from the first mould; and the step of machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops, comprises the additional subsequent step of: heating the machined formed article to melt the residual ice.

9. The method as claimed in claim 3, wherein the step of stabilising the plurality of non-crimp fibre fabrics, comprises the steps of: applying a thermally activated binder to the plurality of non-crimp fibre fabrics; and the step of sequentially positioning a plurality of non-crimp fibre fabrics onto the layup surface to form a first sub-section preform, and a second sub-section preform, comprises the additional subsequent step of: heating the sub-section preform to thermally activate the thermally activated binder.

10. The method as claimed in claim 9, wherein the thermally activated binder is a thermally activated powder coating applied to the plurality of non-crimp fibre fabrics.

11. The method as claimed in claim 9, wherein the thermally activated binder is a thermally activated film interleaved between adjacent ones of the plurality of non-crimp fibre fabrics.

12. The method as claimed in claim 3, wherein the insert extends substantially perpendicularly to a longitudinal extent of each of the plurality of non-crimp fibre fabrics, wherein the plurality of non-crimp fibre fabrics includes at least one non-crimp fibre fabric arranged above the insert, and wherein a top surface of the insert is arranged adjacent to and contacts the at least one non-crimp fibre fabric arranged above the insert.

13. The method as claimed in claim 3, further comprising: prior to infiltrating the second mould with a polymer matrix resin, applying a vacuum to the second mould to remove any residual volatiles and to encourage the uptake of the polymer matrix resin.

14. The method as claimed in claim 3, wherein the step of sequentially positioning a plurality of non-crimp fibre fabrics onto the layup surface to form a sub-section preform, is performed by an automated fabric placement system.

Description

DESCRIPTION OF THE DRAWINGS

(1) There now follows a description of an embodiment of the disclosure, by way of non-limiting example, with reference being made to the accompanying drawings in which:

(2) FIG. 1 shows a flow chart illustrating a method according to a first aspect of the present disclosure;

(3) FIG. 2 shows a flow chart illustrating a method according to a second aspect of the present disclosure;

(4) FIG. 3 shows a schematic elevational view of a first embodiment of a sub-section preform produced by either of the methods of FIGS. 1 and 2;

(5) FIG. 4 shows a schematic elevational view of a second embodiment of a sub-section preform produced by either of the methods of FIGS. 1 and 2;

(6) FIG. 5 shows a schematic elevational view of a vacuum debulking operation from either of the methods of FIGS. 1 and 2;

(7) FIG. 6 shows a schematic elevational view of a water infiltration operation from the method of FIG. 1;

(8) FIG. 7 shows a schematic elevational view of a resin infiltration and curing operations from either of the methods of FIGS. 1 and 2; and

(9) FIG. 8 shows a perspective part-sectional view of a turbofan engine fan blade produced by either of the methods of FIGS. 1 and 2.

(10) It is noted that the drawings may not be to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering represents like elements between the drawings.

DETAILED DESCRIPTION

(11) FIG. 1 shows a flowchart for a method of forming a composite article according to a first embodiment of the disclosure. FIGS. 3 to 7 illustrate schematically the process steps of the method of the flowchart of FIG. 1.

(12) The method starts at step 10 with providing a layup surface 110. In the present embodiment, the layup surface 110 is a flat surface. In other embodiments, the layup surface 110 may be a curved surface. In this embodiment, the layup surface 110 is a geometric mid-plane 102 of the composite article 100, as illustrated in FIG. 3.

(13) At step 12 a plurality of non-crimp fibre fabrics 120 are sequentially positioned onto the layup surface 110 to thereby form a sub-section preform 130. Each of the non-crimp fibre fabrics 120 comprises at least two dry-fibre layers 122. Each of the non-crimp fibre fabrics 120 is oriented in dependence on a geometry and load-carrying capability of the composite article 100. In other words, the direction of the fibres within the various non-crimp fibre fabric 120 is chosen to best meet the loads and stresses that the composite article 100 will experience when in service.

(14) The sequential positioning of the non-crimp fibre fabrics 120 is repeated at step 12 so as to form a first sub-section preform 132 and a second sub-section preform 134.

(15) The method of the disclosure may include the use of tailored non-crimp fabrics to improve material characteristics such as drape and formability. This would allow the relatively thick and rigid fabric layers to better conform to the required geometry in the press forming operation. The fabrics may also be tailored in such a way that they are exhibit variable thickness, specific orientation sequences, optimal widths or pre-applied geometric features (twist and/or camber).

(16) In the present embodiment, an insert 123 is incorporated into one end of the sequential stack of non-crimp fibre fabrics 120. The insert 123 may be formed from a metallic material such as, for example, titanium alloy. The purpose of the insert 123 is to enable the finished composite article to be secured or mounted in another assembly or apparatus. The inclusion of an insert 123 may greatly accelerate the deposition of root material. Fabric layers 120 may also be folded around the insert 123.

(17) At step 14 (shown in FIG. 5), the sub-section preform 130 is enclosed in a vacuum bag and subjected to a vacuum de-bulking process 136. The vacuum debulking serves to consolidate the assembled non-crimp fibre fabrics 120. This makes the subsequent processing operations better able to be carried out without dislodging the fabric layers 120.

(18) The first sub-section preform 132 and the second sub-section preform 134 are then assembled at step 18 to form a preformed article 140.

(19) This assembly step may involve positioning the first sub-section preform 132 against the second sub-section preform 134 with the preform surfaces adjoining the layup surface being joined to one another.

(20) At step 20 through-thickness reinforcement 138 is applied to the preformed article 140. The through-thickness reinforcement 138 may be any one, or combination, of stitching, tufting or pinning.

(21) The preformed article 140 is then infused with water at step 22. The water acts as a lubricant to improve the formability of the dry fibre material in the subsequent press-forming operation.

(22) The preformed article 140 is then positioned in a first mould 150, at step 24 (shown in FIG. 6). Once in the first mould 150, the preformed article 140 is press-formed 151 to thereby further consolidate the stack of non-crimp fibre fabrics 120, and to introduce geometric features to the resulting formed article 143.

(23) The first mould 150 is then infiltrated with water at step 26 by an infiltration means 152. Sufficient water is added to the first mould 150 to completely fill any interstitial volumes between the formed article 143 and the mould cavity

(24) At step 28 the first mould 150 is then cooled by a cooling means 154. In the embodiment shown in the figures, the cooling means 154 takes the form of refrigerant coils embedded within the body of the first mould 150. In an alternative arrangement, the cooling means 154 may be entirely external to the first mould 150 such as, for example, a refrigeration unit sized to accommodate the entire first mould 150.

(25) At step 30 the ice encased formed article 143 is removed from the first mould 150. The ice encased formed article 143 is positioned in readiness to be machined using a machining means 160. The machining means 160 may be any suitable machining apparatus such as, for example, a laser cutter, a machining centre or a computer numerically controlled milling machine.

(26) At step 32 the outer surface 142 of the formed article 143 is machined to correspond to the finished geometry of the composite article 100.

(27) At step 34 an outer surface 163 of the machined formed article 162 may be enclosed with a wrap layer 164. In the embodiment shown on the right hand side of FIG. 2, the wrap layer 164 extends across the entire outer surface 163 of the machined formed article 162.

(28) The composite article 100 may have a metallic sheath or other attachment (not shown) fastened to the outer surface 163 prior to the curing step 42

(29) At step 36 the machined preform article 162 is positioned in a second mould 170. The second mould 170 conformally encloses the machined preform article 162. The second mould 170 is heated at step 38 to melt the residual water, after the machining operations have been completed.

(30) The second mould 170 is then infiltrated with a suitable resin material at step 40 (shown in FIG. 7). Examples of a suitable resin material include epoxy, polyethylene, polypropylene, polystyrene, acrylic, polyurethane, unsaturated polyesters, phenolics, and silicones.

(31) Prior to resin infiltration, a vacuum may be applied to the second mould 170 to remove any residual volatiles, and to encourage the uptake of the resin material. In a further alternative, the resin material is injected into the second mould 170.

(32) The machined formed article 162 is then cured at step 42 to form the composite article 100.

(33) FIG. 2, illustrates a flow chart showing a method according to a second embodiment of the disclosure. Method steps of the flow chart of FIG. 2 which correspond to those of the flow chart of FIG. 1 have been given corresponding reference numerals for ease of reference.

(34) As with the method of FIG. 1, the method of FIG. 2 starts at step 10 with providing a layup surface 110. The layup surface 110 is a geometric mid-plane 102 of the composite article 100, as illustrated in FIG. 3.

(35) The sequential positioning of the plurality of non-crimp fibre fabrics 120 then follows at step 12. As outlined above, this positioning is repeated in order to form a first sub-section preform 132 and a second sub-section preform 134.

(36) Each of the non-crimp fibre fabrics 120 comprises at least two dry-fibre layers 122. In this embodiment, each of the dry-fibre layers 122 is coated with a thermally activated powder 126. This powder coating 124 may be applied by any suitable means such as, for example, by a spray coating process. The thermally activated powder 126 is a material that when heated provides an adhesive connection between adjoining coated dry-fibre layers 122. Examples of suitable thermally activated powders 126 include TEXT.

(37) The thermally activated powder material may be selected from the group consisting of modified epoxies, polyester, polyamide, polyethylene, polypropylene, polyether sulfone and other thermoplastics.

(38) In an alternative embodiment, the adjoining dry-fibre layers 122 may be separated by an interleaved thermoplastic layer, or veil, which is also thermally activated. In other words, the thermoplastic layer melts upon application of thermal energy and provides intra-laminar adhesion through the dry-fibre layers 122.

(39) As mentioned above, each of the non-crimp fibre fabrics 120 is oriented in dependence on a geometry and load-carrying capability of the composite article 100.

(40) The use of tailored non-crimp fabrics may be employed as outlined above in order to improve material characteristics such as drape and formability, and so to allow the relatively thick and rigid fabric layers to better conform to the required geometry in the press forming operation.

(41) An insert 123 may be incorporated into the preformed article as outlined above in relation to the method of FIG. 1.

(42) The sub-section preform 130 is enclosed in a vacuum bag and subjected to a vacuum de-bulking process 136 at step 14 (shown in FIG. 5). The sub-section preform 130 is then heated, at step 15, to thermally activate the powder coating 124. Both the vacuum debulking and the thermal activation of the powder coating serve to consolidate the assembled non-crimp fibre fabrics 120. This makes the subsequent processing operations better able to be carried out without dislodging the fabric layers 120.

(43) The first sub-section preform 132 and the second sub-section preform 134 are then assembled at step 18 to form a preformed article 140, with through-thickness reinforcement 138 being applied to the preformed article 140 at step 20.

(44) The preformed article 140 is then positioned in a first mould 150, at step 24. Once in the first mould 150, the preformed article 140 is press-formed 151 to thereby further consolidate the stack of non-crimp fibre fabrics 120, and to introduce geometric features to the resulting formed article 143.

(45) The formed article 143 is positioned in readiness to be machined using a machining means 160. The machining means 160 may be any suitable machining apparatus such as, for example, a laser cutter, a machining centre or a computer numerically controlled milling machine.

(46) At step 32 the outer surface 145 of the formed article 143 is machined to correspond to the finished geometry of the composite article 100.

(47) At step 34 an outer surface 163 of the machined formed article 162 may be enclosed with a wrap layer 164. As indicated in FIG. 7, the wrap layer 164 extends across the entire outer surface 163 of the machined formed article 162.

(48) The composite article 100 may have a metallic sheath or other attachment (not shown) fastened to the outer surface 163 prior to the curing step 42

(49) At step 36 the machined formed article 162 is positioned in a second mould 170. The second mould 170 conformally encloses the machined formed article 162.

(50) The second mould 170 is then infiltrated with a suitable resin material at step 40 (shown in FIG. 7). Examples of a suitable resin material include epoxy, polyethylene, polypropylene, polystyrene, acrylic, polyurethane, unsaturated polyesters, phenolics, and silicones.

(51) Prior to resin infiltration, a vacuum may be applied to the second mould 170 to remove any residual volatiles, and to encourage the uptake of the resin material. In a further alternative, the resin material is injected into the second mould 170.

(52) The machined preform article in then cured at step 42 to form the composite article 100.

(53) The main view of FIG. 3 illustrates a single sub-section preform 130 together with some of the features of the assembled preformed article 140, and the machined formed article 162. Specifically, the outer surface 142, the through-thickness reinforcement 138, the machined portions 144, and the machined formed article 162.

(54) In the embodiment of FIG. 3, the ply deposition starts from the mid-plane of the composite article 100 and finishes at what will be the exterior surface of the composite article 100. This results in the plydrops being located at the exterior surface.

(55) In an alternative arrangement, shown in FIG. 4, the ply deposition starts from the exterior surface of the composite article 100 and finishes at what will be the mid-plane of the composite article 100. This alternative arrangement results in the plydrops being located at the mid-plane of the composite article 100.

(56) In the arrangement of FIG. 4 the layup surface 310 corresponds to the exterior surface of the composite article 100.

(57) At step 12 a plurality of non-crimp fibre fabrics 320 are sequentially positioned onto the layup surface 310 to thereby form a sub-section preform 330. Each of the non-crimp fibre fabrics 320 comprises at least two dry-fibre layers 322. Each of the non-crimp fibre fabrics 320 is oriented in dependence on a geometry and load-carrying capability of the composite article 100. In other words, the direction of the fibres within the various non-crimp fibre fabric 320 is chosen to best meet the loads and stresses that the composite article 100 will experience when in service.

(58) The sequential positioning of the non-crimp fibre fabrics 320 is repeated at step 12 so as to form a first sub-section preform 332 and a second sub-section preform 334.

(59) The method of the disclosure may include the use of tailored non-crimp fabrics to improve material characteristics such as drape and formability. This would allow the relatively thick and rigid fabric layers to better conform to the required geometry in the press forming operation. The fabrics may also be tailored in such a way that they are exhibit variable thickness, specific orientation sequences, optimal widths or pre-applied geometric features (twist and/or camber).

(60) At step 14 (shown in FIG. 5), the sub-section preform 330 is enclosed in a vacuum bag and subjected to a vacuum de-bulking process 136 as outlined above.

(61) The first sub-section preform 332 and the second sub-section preform 334 are then assembled at step 18 to form a preformed article 340 as outlined above.

(62) The preformed article 340 is then infused with water at step 22. The water acts as a lubricant to improve the formability of the dry fibre material in the subsequent press-forming operation.

(63) The preformed article 340 is then positioned in a first mould 150, at step 24 (shown in FIG. 6). Once in the first mould 150, the preformed article 340 is press-formed 151 to thereby further consolidate the stack of non-crimp fibre fabrics 320, and to introduce geometric features to the resulting formed article 343.

(64) The first mould 150 is then infiltrated with water at step 26 by an infiltration means 152. Sufficient water is added to the first mould 150 to completely fill any interstitial volumes between the formed article 343 and the mould cavity

(65) At step 30 the ice encased formed article 343 is removed from the first mould 150. The ice encased formed article 343 is positioned in readiness to be machined using a machining means 160.

(66) At step 32 the outer surface 342 of the formed article 343 is machined to correspond to the finished geometry of the composite article 100.

(67) At step 34 an outer surface 163 of the machined formed article 362 may be enclosed with a wrap layer 164.

(68) At step 36 the machined preform article 362 is positioned in a second mould 170. The second mould 170 conformally encloses the machined preform article 362. The second mould 170 is heated at step 38 to melt the residual water, after the machining operations have been completed. The second mould 170 is then infiltrated with a suitable resin material at step 40 (shown in FIG. 7).

(69) Prior to resin infiltration, a vacuum may be applied to the second mould 170 to remove any residual volatiles, and to encourage the uptake of the resin material. In a further alternative, the resin material is injected into the second mould 170.

(70) The machined formed article 362 is then cured at step 42 to form the composite article 100.

(71) In one or more examples, the operations described may be controlled in hardware, software, firmware, or any combination thereof. If controlled in software, the operations may be stored on or transmitted over, as one or more instructions or code, a computer-readable medium and executed by a hardware-based processing unit. Computer-readable media may include computer-readable storage media, which corresponds to a tangible medium such as data storage media, or communication media including any medium that facilitates transfer of a computer program from one place to another, e.g., according to a communication protocol. In this manner, computer-readable media generally may correspond to (1) tangible computer-readable storage media, which is non-transitory or (2) a communication medium such as a signal or carrier wave. Data storage media may be any available media that can be accessed by one or more computers or one or more processors to retrieve instructions, code and/or data structures for implementation of the techniques described in this disclosure. A computer program product may include a computer-readable medium.

(72) By way of example, and not limitation, such computer-readable storage media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage, or other magnetic storage devices, flash memory, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Also, any connection is properly termed a computer-readable medium. For example, if instructions are transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium. It should be understood, however, that computer-readable storage media and data storage media do not include connections, carrier waves, signals, or other transient media, but are instead directed to non-transient, tangible storage media. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray disc, where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media.

(73) Instructions may be executed by one or more processors, such as one or more DSPs, general purpose microprocessors, ASICs, FPGAs, or other equivalent integrated or discrete logic circuitry. Accordingly, the term “processor,” as used herein may refer to any of the foregoing structure or any other structure suitable for implementation of the techniques described herein. In addition, in some aspects, the functionality described herein may be provided within dedicated hardware and/or software modules. Also, the techniques could be fully implemented in one or more circuits or logic elements.

(74) The techniques of this disclosure may be implemented in a wide variety of devices or apparatuses, including a processor, an integrated circuit (IC) or a set of ICs (e.g., a chip set). Various components, modules, or units are described in this disclosure to emphasize functional aspects of devices configured to perform the disclosed techniques, but do not necessarily require realization by different hardware units. Rather, as described above, various units may be combined in a hardware unit or provided by a collection of interoperative hardware units, including one or more processors as described above, in conjunction with suitable software and/or firmware.

(75) Various example embodiments of the invention are described herein. Reference is made to these examples in a non-limiting sense. They are provided to illustrate more broadly applicable aspects of the invention. Various changes may be made to the invention described and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process act(s) or step(s) to the objective(s), spirit or scope of the present invention. Further, it will be appreciated by those with skill in the art that each of the individual variations described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope of the present inventions. All such modifications are intended to be within the scope of claims associated with this disclosure.

(76) The invention includes methods that may be performed using the subject devices. The methods may comprise the act of providing such a suitable device. Such provision may be performed by the end user. In other words, the “providing” act merely requires the end user obtain, access, approach, position, set-up, activate, power-up or otherwise

(77) act to provide the requisite device in the subject method. Methods recited herein may be carried out in any order of the recited events which is logically possible, as well as in the recited order of events.

(78) Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.

(79) The foregoing description of various aspects of the disclosure has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to a person of skill in the art are included within the scope of the disclosure as defined by the accompanying claims.