Turbine engine and composite airfoil assembly thereof

Abstract

A turbine engine includes a fan section, a compressor section, a combustion section, and a turbine section in a serial flow arrangement. The turbine engine further includes a composite airfoil assembly. The composite airfoil assembly has an outer wall, a composite body at least partially defining the outer wall, and a tip cap at least partially defining the outer wall.

Description

Technical Field

[0001] The present disclosure relates generally to turbine engines having airfoil assemblies and, more particularly, to turbine engines having composite airfoil assemblies. Background Art

[0002] A turbine engine (and in particular a gas or combustion turbine engine) is a rotating engine that extracts energy from a gas flow that passes through a fan having a plurality of fan blades, then enters the engine through a series of compressor stages (which include pairs of rotating blades and stationary vanes), through a combustor, and then through a series of turbine stages (which include pairs of rotating blades and stationary vanes). The blades are mounted to rotating disks, and the vanes are mounted to stator disks.

[0003] During operation, air enters the compressor section through the fan section, is then pressurized in the compressor, and is mixed with fuel and ignited in the combustor to generate hot combustion gases, which flow downstream through the turbine stage, where the air expands and is discharged from the exhaust section. The expansion of the air in the turbine section is used to drive the rotating sections of the fan section and the compressor section. The intake of air, the pressurization of air, and the expansion of air are accomplished in part by the rotation of various rotating blades mounted to corresponding disks throughout the fan section, the compressor section, and the turbine section, respectively. The rotation of the rotating blades applies mechanical stresses along various portions of the blades; in particular, mechanical stresses are applied where the blades are mounted to the disks. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] A full and enabling disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0005] Figure 1 is a schematic cross-sectional view of a turbine engine, which is a non-ducted or open rotor turbine engine according to an exemplary embodiment of the present disclosure.

[0006] Figure 2 Is suitable for Figure 1 Schematic diagram of an airfoil assembly for use within a turbine engine of FIG. 1 , the airfoil assembly comprising a composite body, a tip, and a tip cap.

[0007] Figure 3 yes Figure 2 Schematic exploded isometric view of an airfoil assembly.

[0008] Figure 4 yes Figure 2 A top-down schematic diagram of an airfoil assembly further illustrating the pressure side, suction side, and camber line.

[0009] Figure 5 is from Figure 2 A schematic cross-sectional view of the airfoil assembly as seen through section line VV, further illustrating a tip cap covering a portion of the tip.

[0010] Figure 6 Suitable for use as Figure 2 A schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating a tip cap including a first body, a second body, and at least one internal rib.

[0011] Figure 7 yes Figure 6 A schematic isometric view of a tip cap further illustrating a first body of the tip cap.

[0012] Figure 8 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating a tip cap including a butt joint formed along the tip.

[0013] Fig. 9 Suitable for use as Figure 2 A schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating a tip cap including a lap joint formed along the tip.

[0014] Fig.10 Suitable for use as Figure 2 A schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating a tip cap including a first butt joint and a second butt joint.

[0015] Fig.11 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating an asymmetric tip cap including external ribs.

[0016] Fig.12 yes Fig.11 A schematic isometric view of the tip cap, further showing the external ribs.

[0017] Fig.13 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating a tip cap including at least two external ribs.

[0018] Fig.14 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating an asymmetric tip cap including a semicircular external rib.

[0019] Fig.15 Suitable for use as Figure 2Schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating an asymmetric tip cap including external ribs.

[0020] Fig.16 Is suitable for use as Figure 2 A schematic cross-sectional view of an exemplary airfoil assembly of an airfoil assembly further illustrating a set of external ribs disposed along the tip cap. DETAILED DESCRIPTION

[0021] Various aspects disclosed herein relate to an airfoil assembly for a turbine engine. The airfoil assembly includes an outer wall, a tip cap, and a body. The outer wall is at least partially defined by the tip cap and the body. The outer wall defines a pressure side and a suction side of the airfoil assembly. The tip cap is disposed along at least a portion of the suction side, the pressure side, and the tip of the airfoil assembly. The body may be a composite body such that the airfoil assembly may be a composite airfoil assembly.

[0022] The tip cap is used to provide additional rigidity along the tip of the airfoil assembly to reduce tip deflection and strain during the operation of the airfoil assembly. The tip cap can be designed in a lightweight manner so as not to make the airfoil assembly too heavy at the tip, thereby causing imbalance of the airfoil assembly. The tip cap can further enhance the aerodynamic properties of the airfoil assembly. For the purpose of illustration, the present disclosure will be described with respect to the airfoil assembly of a turbine engine, in particular the fan blades of a turbine engine. However, it will be understood that the various aspects of the present disclosure described herein are not limited thereto and may have general applicability in other engines or in other parts of a turbine engine. For example, the present disclosure may be applicable to airfoil assemblies in other engines or vehicles, and may be used to provide benefits in industrial, commercial and residential applications.

[0023] As used herein, the term "upstream" refers to the direction opposite to the direction of fluid flow, while the term "downstream" refers to the direction in the same direction as the direction of fluid flow. The terms "front" or "forward" mean in front of something, and "rear" or "rearward" mean behind something. For example, when used in relation to fluid flow, front / forward may mean upstream, while rear / rearward may mean downstream.

[0024] Additionally, as used herein, the term "radial" or "radially" refers to a direction away from a common center. For example, in the overall context of a turbine engine, radial refers to a direction along a ray extending between a central longitudinal axis of the engine and an outer periphery of the engine. Additionally, as used herein, the term "group" or a "group" of elements may be any number of elements, including only one.

[0025] Furthermore, as used herein, the term "fluid" or iterations thereof may refer to any suitable fluid within a gas turbine engine, at least a portion of which is exposed to, for example, but not limited to, combustion gases, ambient air, a pressurized gas stream, a working gas stream, or any combination thereof. It is further contemplated that the gas turbine engine may be other suitable turbine engines, such as, but not limited to, a steam turbine engine or a supercritical carbon dioxide turbine engine. As non-limiting examples, the term "fluid" may refer to steam in a steam turbine engine, or to carbon dioxide in a supercritical carbon dioxide turbine engine.

[0026] All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, backward, etc.) are only used for identification purposes to help the reader understand the present disclosure, and do not create limitations, especially limitations on the position, orientation or use of the aspects of the present disclosure described herein. Unless otherwise stated, connection references (e.g., attachment, connection, fixing, fastening, connection and engagement) will be broadly interpreted and may include intermediate members between element sets and relative movement between elements. Therefore, connection references do not necessarily infer that two elements are directly connected and have a fixed relationship to each other. The exemplary drawings are only for illustrative purposes, and the dimensions, positions, orders and relative sizes reflected in the attached drawings may vary.

[0027] As used herein, the term "composite" refers to a component having two or more materials. A composite can be a combination of at least two or more metals, non-metals, or a combination of metal and non-metal elements or materials. Examples of composite materials can be, but are not limited to, polymer matrix composites (PMC), ceramic matrix composites (CMC), metal matrix composites (MMC), carbon fibers, polymer resins, thermoplastic resins, bismaleimide (BMI) materials, polyimide materials, epoxy resins, glass fibers, and silicon matrix materials.

[0028] As used herein, a "composite" component refers to a structure or component that includes any suitable composite material. A composite component, such as a composite airfoil, may include several layers or several layups of composite materials. The stiffness, material, and dimensions of the layers or layups may vary to achieve a desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0029] One or more layers of adhesive may be used to form or join the composite parts. The adhesive may include resins and phenolics, where the adhesive may require curing at elevated temperatures or other hardening techniques.

[0030] As used herein, PMC refers to a class of materials. As an example, PMC materials are defined in part by prepregs, which are reinforcing materials pre-impregnated with polymer matrix materials (e.g., thermoplastic resins). Non-limiting examples of processes for producing thermoplastic prepregs include: hot melt prepregs, in which fiber reinforcements are pulled through a molten bath of resin; and powder prepregs, in which resin is deposited on the fiber reinforcements, as a non-limiting example, electrostatically deposited on the fiber reinforcements, and then adhered to the fibers, as a non-limiting example, in an oven or with the help of heated rollers. Prepregs can be in the form of unidirectional tapes or woven fabrics, which are then stacked on top of each other to form the desired number of stacked composite plies for a part.

[0031] Multilayer prepreg is stacked to the appropriate thickness and orientation of composite parts, and then resin is cured and solidified to provide fiber reinforced composite parts. The resin for PMC matrix material can be generally classified as thermosetting resin or thermoplastic resin. Thermoplastic resin is generally classified as a polymer that can be repeatedly softened and flowed when heated and can be hardened due to physical changes rather than chemical changes when fully cooled. The famous example category of thermoplastic resin includes nylon, thermoplastic polyester, polyaryletherketone and polycarbonate resin. The specific example of high-performance thermoplastic resin for aerospace applications has been envisioned to include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK) and polyphenylene sulfide (PPS). On the contrary, once fully cured into a hard rigid solid, thermosetting resin will not experience significant softening when heated, but thermally decomposes when fully heated. The famous example of thermosetting resin includes epoxy resin, bismaleimide (BMI) and polyimide resin.

[0032] Instead of using prepreg, in another non-limiting example, by using thermoplastic polymers, braided fabrics can be utilized. Braided fabrics may include, but are not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg braided architectures can be made in a similar manner. In this way, the fiber volume of a part can be customized by specifying the relative concentrations of thermoplastic fibers and reinforcing fibers that have been woven or braided together. In addition, different types of reinforcing fibers can be braided or braided together at different concentrations to customize the properties of a part. For example, glass fibers, carbon fibers, and thermoplastic fibers can all be woven together at different concentrations to customize the properties of a part. Carbon fibers provide the strength of the system, glass fibers can be incorporated to enhance impact properties, which is a design feature of a part located near the engine inlet, and thermoplastic fibers provide bonding for reinforcing fibers.

[0033] In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of a composite component. Typically, RTM includes applying a dry fiber or matrix material to a mold or cavity. The dry fiber or matrix material may include prepregs, woven materials, braided materials, or any combination thereof.

[0034] The resin may be pumped or otherwise provided to the mold or cavity to impregnate the dry fibers or matrix material. The combination of the impregnated fibers or matrix material and the resin is then cured and removed from the mold. When removed from the mold, the composite part may require a post-curing process.

[0035] It is contemplated that RTM may be a vacuum assisted process. That is, the air in the cavity or mold may be removed and replaced with resin prior to heating or curing. It is further contemplated that placement of dry fiber or matrix material may be manual or automated.

[0036] The dry fiber or matrix material may be shaped to form the composite part or to guide the resin. Optionally, additional layers or reinforcements of a material different from the dry fiber or matrix material may also be included or added prior to heating or curing.

[0037] As used herein, CMC refers to a class of materials having reinforcing fibers in a ceramic matrix. Typically, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of reinforcing fibers may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates (such as mullite), or mixtures thereof), or mixtures thereof.

[0038] Some examples of ceramic matrix materials may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) may also be included in the ceramic matrix.

[0039] In general, specific CMCs can be referred to as their fiber type / matrix type combination. For example, C / SiC is carbon fiber reinforced silicon carbide, SiC / SiC is silicon carbide fiber reinforced silicon carbide, SiC / SiN is silicon carbide fiber reinforced silicon nitride, SiC / SiC-SiN is silicon carbide fiber-reinforced silicon carbide / silicon nitride matrix mixture, etc. In other examples, CMCs can be composed of a matrix and reinforcing fibers comprising oxide-based materials such as aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof. Aluminosilicates can include crystalline materials such as mullite (3Al2O3·2SiO2), as well as glassy aluminosilicates.

[0040] In certain embodiments, the reinforcing fibers may be bundled and / or coated before being included in the matrix. For example, the fiber bundles may be formed into reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes may be stacked together to form a preform component. The fiber bundles may be impregnated with a slurry composition before or after forming the preform. The preform may then be subjected to heat treatment and subsequent chemical treatment to obtain a component formed of a CMC material having a desired chemical composition. For example, the preform may undergo curing or burnout to produce a high coke residue in the preform, and then be melt infiltrated with silicon, or undergo curing or pyrolysis to produce a silicon carbide matrix in the preform, and then be chemically infiltrated with silicon carbide. Additional steps may be taken to improve the densification of the preform, by injecting the preform with a liquid resin or polymer before or after chemical vapor infiltration, and then performing a heat treatment step to fill the voids with silicon carbide. CMC materials as used herein may be formed using any known or later developed method including, but not limited to, melt infiltration, chemical vapor infiltration, polymer infiltration pyrolysis (PIP), or any combination thereof.

[0041] Such materials, along with certain monolithic ceramics (i.e., ceramic materials without reinforcement materials), are particularly useful for higher temperature applications. In addition, these ceramic materials are lightweight compared to superalloys, yet still provide strength and durability to components made therefrom. As a result, such materials are currently being considered for use in many gas turbine components used in the higher temperature sections of gas turbine engines (such as airfoils (e.g., turbines and buckets), combustors, shrouds, and other components) that would benefit from the lighter weight and higher temperature capabilities that these materials can provide.

[0042] The term "metal" as used herein refers to materials including metals such as, but not limited to, titanium, iron, aluminum, stainless steel, and nickel alloys. A metal material or alloy may be a combination of at least two or more elements or materials, at least one of which is a metal.

[0043] Figure 1is a schematic cross-sectional view of a turbine engine, particularly an open rotor or non-ducted turbine engine 10 for an aircraft. The non-ducted turbine engine 10 has a generally longitudinally extending axis or engine centerline 12 extending from a forward end 14 to an aft end 16. The non-ducted turbine engine 10 includes, in downstream serial flow relationship, a set of circumferentially spaced blades or propellers defining: a fan section 18 including a fan 20; a compressor section 22 including a supercharger or low pressure (LP) compressor 24 and a high pressure (HP) compressor 27; a combustion section 28 including a combustor 30; a turbine section 32 including an HP turbine 34 and an LP turbine 36; and an exhaust section 38. The non-ducted turbine engine 10 as described herein is a non-limiting example, and other architectures are possible, such as, but not limited to, a steam turbine engine, a supercritical carbon dioxide turbine engine, or any other suitable turbine engine.

[0044] The outer surface of the non-ducted turbine engine 10 defined by the outer casing or nacelle 40 extends from the front end 14 of the non-ducted turbine engine 10 toward the rear end 16 of the non-ducted turbine engine 10 and covers at least a portion of the compressor section 22, the combustion section 28, the turbine section 32, and the exhaust section 38. The fan section 18 may be positioned at the front of the nacelle 40 and extends radially outward from the nacelle 40 of the non-ducted turbine engine 10. Specifically, the fan section 18 extends radially outward from the nacelle 40. The fan section 18 includes a set of fan blades 42 and a set of stationary fan blades 82 downstream of the set of fan blades 42, both of which are radially arranged from the engine centerline 12 and circumferentially arranged around the engine centerline 12. The non-ducted turbine engine 10 includes any number of one or more sets of rotating blades or propellers (e.g., the set of fan blades 42) disposed upstream of the set of stationary fan blades 82. As a non-limiting example, the non-ducted turbine engine 10 may include multiple sets of fan blades 42 or fan blades 82. Therefore, the non-ducted turbine engine 10 is further defined as a non-ducted single fan turbine engine. The non-ducted turbine engine 10 is further defined by the position of the fan section 18 relative to the combustion section 28. The fan section 18 may be upstream, downstream, or aligned with the axial positioning of the combustion section 28.

[0045] The compressor section 22 , the combustion section 28 , and the turbine section 32 are collectively referred to as an engine core 44 , which generates combustion gases. The engine core 44 is surrounded by an engine casing 46 operably coupled to a portion of a nacelle 40 of the non-ducted turbine engine 10 .

[0046] An HP shaft or spool 48 disposed coaxially about the engine centerline 12 of the non-ducted turbine engine 10 drivingly connects the HP turbine 34 to the HP compressor 27. An LP shaft or spool 50 disposed coaxially about the engine centerline 12 of the non-ducted turbine engine 10 within the larger diameter annular HP spool 48 drivingly connects the LP turbine 36 to the LP compressor 24 and the fan 20. The spools 48, 50 are rotatable about the engine centerline 12 and are coupled to a set of rotatable elements that collectively define a rotor 51.

[0047] It should be appreciated that the non-ducted turbine engine 10 is a direct drive or integral drive engine utilizing a reduction gearbox coupling the LP shaft or spool 50 to the fan 20 .

[0048] The LP compressor 24 and the HP compressor 27 each include a set of compressor stages 52, 54, wherein a set of compressor blades 56, 58 rotate relative to a corresponding set of static compressor vanes 60, 62 (also referred to as nozzles) to compress or pressurize the fluid flow passing through the stage. In a single compressor stage 52, 54, a plurality of compressor blades 56, 58 are arranged in a ring and extend radially outward from a blade platform to a blade tip relative to the engine centerline 12, while the corresponding static compressor vanes 60, 62 are positioned upstream of and adjacent to the compressor blades 56, 58. Notably, Figure 1 The numbers of blades, buckets, and compressor stages shown in FIG. 5 are selected for illustration purposes only, and other numbers are possible.

[0049] Compressor blades 56, 58 for one stage of compressor section 22 are mounted to disks 61 mounted to corresponding ones of HP spool 48 and LP spool 50, with each stage having its own disk 61. Static compressor vanes 60, 62 for one stage of compressor section 22 are mounted to engine case 46 in a circumferential arrangement.

[0050] The HP turbine 34 and the LP turbine 36 each include a set of turbine stages 64, 66 in which a set of turbine blades 68, 70 rotate relative to a corresponding set of static turbine vanes 72, 74 (also referred to as nozzles) to extract energy from the fluid flow passing through the stage. In a single turbine stage 64, 66, a plurality of turbine blades 68, 70 are arranged in a ring and extend radially outward from the blade platform to the blade tip relative to the engine centerline 12, while the corresponding static turbine vanes 72, 74 are positioned upstream of and adjacent to the turbine blades 68, 70. Notably, Figure 1 The number of blades, buckets, and turbine stages shown in FIG. 5 are selected for illustrative purposes only, and other numbers are possible.

[0051] Turbine blades 68, 70 for one stage of turbine section 32 are mounted to disks 71 mounted to a respective one of HP spool 48 and LP spool 50, with each stage having a dedicated disk 71. Static turbine buckets 72, 74 for one stage of turbine section 32 are mounted to engine casing 46 in a circumferential arrangement.

[0052] The rotating portions of the non-ducted turbine engine 10, such as the blades 56, 58, 68, 70 in the compressor section 22 and the turbine section 32, are also individually or collectively referred to as rotors 51. Thus, the rotor 51 refers to the combination of rotating elements throughout the non-ducted turbine engine 10.

[0053] Complementing the rotating parts, the stationary parts of the non-ducted turbine engine 10, such as the static blades 60, 62, 72, 74 in the compressor section 22 and the turbine section 32, are also individually or collectively referred to as stators 63. Therefore, the stator 63 refers to the combination of non-rotating elements throughout the non-ducted turbine engine 10.

[0054] The nacelle 40 is operably coupled to the non-ducted turbine engine 10 and covers at least a portion of the engine core 44, the engine case 46, or the exhaust section 38. At least a portion of the nacelle 40 extends axially forward or upstream of the position shown. For example, the nacelle 40 extends axially forward so that a portion of the nacelle 40 covers or covers a portion of the fan section 18 or the supercharger section (not shown) of the non-ducted turbine engine 10.

[0055] It will be appreciated that the non-ducted turbine engine 10 may be divided into at least two separate portions; a rotor portion and a stator portion. The rotor portion may be defined as any portion of the non-ducted turbine engine 10 that rotates about a respective axis of rotation. The stator portion may be defined by a combination of non-rotating elements disposed within the non-ducted turbine engine 10. As non-limiting examples, the rotor portion may include a plurality of fan blades 42, compressor blades 56, 58, or turbine blades 68, 70. As non-limiting examples, the stator portion may include a plurality of fan blades 82, static compressor blades 60, 62, or static turbine blades 72, 74.

[0056] During operation of non-ducted turbine engine 10, free stream airflow 79 flows against the front of non-ducted turbine engine 10. A portion of free stream airflow 79 enters annular region 25 defined by the outer surface of nacelle 40 and the swept area between the tips of fan blades 42, where the air flow is inlet airflow 78. A portion of inlet airflow 78 enters engine core 44 and is described as working airflow 76, which is used for combustion within engine core 44.

[0057] More specifically, the working airflow 76 flows into the LP compressor 24, which then pressurizes the working airflow 76, thereby defining a pressurized airflow that is supplied to the HP compressor 27, which further pressurizes the air. The working airflow 76 or pressurized airflow from the HP compressor 27 is mixed with the fuel in the combustor 30 and ignited, thereby generating combustion gases. The HP turbine 34 extracts some work from these gases, which drives the HP compressor 27. The combustion gases are discharged into the LP turbine 36, which extracts additional work to drive the LP compressor 24, and the working airflow 76 or exhaust gas is ultimately discharged from the non-ducted turbine engine 10 via the exhaust section 38. The drive of the LP turbine 36 drives the LP spool 50 to rotate the fan 20 and the LP compressor 24. The working airflow 76, including the pressurized airflow and the combustion gases, defines the working airflow that flows through the compressor section 22, the combustion section 28, and the turbine section 32 of the non-ducted turbine engine 10.

[0058] Inlet airflow 78 flows over the set of fan blades 42, past at least a portion of the set of stationary fan blades 82, and nacelle 40 of non-ducted turbine engine 10. Inlet airflow 78 then follows the curvature of nacelle 40 and flows past the set of stationary fan blades 82 toward exhaust section 38. Pylon 84 mounts non-ducted turbine engine 10 to an external structure (e.g., a fuselage, wing, tail, etc. of an aircraft).

[0059] Working airflow 76 and at least some inlet airflow 78 merge downstream of exhaust section 38 of non-ducted turbine engine 10. Working airflow 76 and inlet airflow 78 together create the overall thrust of non-ducted turbine engine 10.

[0060] It is envisioned that a portion of the working airflow 76 is extracted as bleed air 77 (e.g., from the compressor section 22). The bleed air 77 provides airflow to engine components that require cooling. The temperature of the working airflow 76 leaving the combustor 30 is significantly increased relative to the working airflow 76 within the compressor section 22. Therefore, the cooling provided by the bleed air 77 is necessary for the operation of these engine components in an elevated temperature environment or in the hot section of the non-ducted turbine engine 10. In the case of a turbine engine, the hot section of the engine is typically downstream of the combustor 30, particularly the turbine section 32, with the HP turbine 34 being the hottest section because it is located directly downstream of the combustion section 28. Other sources of cooling fluid are, but are not limited to, fluid discharged from the LP compressor 24 or the HP compressor 27.

[0061] Figure 2 Is suitable for Figure 11 is a schematic diagram of an airfoil assembly 100 for use within a non-ducted turbine engine 10. The airfoil assembly 100 may be any suitable airfoil of the non-ducted turbine engine 10. As non-limiting examples, the airfoil assembly 100 may be a blade of the plurality of fan blades 42, or a blade from the compressor blades 56, 58 or the turbine blades 68, 70. In the event that the airfoil assembly 100 is a blade, the airfoil assembly 100 may be disposed within a rotor portion of the non-ducted turbine engine 10. It is contemplated that the airfoil assembly 100 may be a blade, bucket, airfoil, or other component of any suitable turbine engine, such as, but not limited to, a gas turbine engine, a turboprop engine, a turboshaft engine, a ducted turbofan engine, or a non-ducted turbine engine 10.

[0062] The airfoil assembly 100 may be defined by an assembly of parts. As a non-limiting example, the airfoil assembly 100 may include a body 102 and a tip cap 116. The body 102 and the tip cap 116 may together define an outer wall 101. The outer wall 101 may extend between a leading edge 108 and a trailing edge 110 in a chordwise direction (C). The outer wall 101 may extend between a root 104 and a tip 106 in a spanwise direction (S). The tip cap 116 may define at least a portion of the tip 106.

[0063] A cladding 112 may be disposed along at least a portion of the leading edge 108. It is contemplated that at least a portion of the trailing edge 110 may include a corresponding cladding.

[0064] The body 102, the tip cap 116, and the cladding 112 may be any suitable material. It will be appreciated that at least a portion of the airfoil assembly 100 may include a composite material. Thus, the airfoil assembly 100 may be defined as a composite airfoil assembly.

[0065] As a non-limiting example, at least a portion of the body 102 may include a woven composite material, a woven composite material, a 3D or 2D preform composite material, or any combination thereof. As a non-limiting example, the body 102 may include a polymer portion formed by a PMC, the PMC including but not limited to a matrix of thermosetting (epoxy resin, phenolic resin) or thermoplastic (polycarbonate, polyvinyl chloride, nylon, acrylic resin) and embedded glass, carbon, steel or Kevlar fibers. As a non-limiting example, the body 102 may include carbon or carbon fiber, glass or glass fiber, nylon, rayon or aramid fiber, while including other materials such as nickel, titanium, ceramic composite materials or combinations thereof. The body 102 may further include a plurality of components. As a non-limiting example, the body 102 may include a core (not shown) (such as a woven core), and a laminated skin (not shown) disposed on the core. The laminated skin may define an outer wall 101. The laminated skin may be formed as a group of laminated layers disposed around or around the core. In a non-limiting example, the laminate skin can be pre-impregnated, fiber-placed, or formed from a dry fiber laminate. In a non-limiting example, such laminate layers forming the laminate skin can be formed by resin transfer molding (RTM), partial RTM, same qualified resin transfer molding (SQRTM), or autoclave. The core can include a core bulk modulus, and the laminate skin can include a skin bulk modulus. The skin bulk modulus can be different from the core bulk modulus. As a non-limiting example, the skin bulk modulus can be greater than the core bulk modulus.

[0066] As a non-limiting example, the cladding 112 may include a metallic material. As a non-limiting example, the tip cap 116 may include a metallic material. As a non-limiting example, the tip cap 116 may include any suitable material, such as, but not limited to, aluminum, titanium, a steel alloy, or a combination thereof. As a non-limiting example, the body 102 may include a composite material.

[0067] It is contemplated that the tip cap 116 may include a first density and the body 102 may include a second density. The first density may be greater than the second density such that the tip cap 116 may add significant weight to the tip 106 of the airfoil assembly 100 .

[0068] Figure 3 yes Figure 2108. A schematic exploded isometric view of an airfoil assembly 100 of FIG. 100 with the cladding 112 and the tip cap 116 removed from the body 102. The tip cap 116 and the cladding 112 may each fit over a corresponding portion of the body 102. As shown, the tip cap 116 may form an inverted u-shape so that the tip cap 116 can be placed over the body 102. It is contemplated that at least a portion of the tip cap 116 may at least partially surround or cover a portion of the body 102 corresponding to the trailing edge 110 or the leading edge 108. The body 102 may be shaped to receive or otherwise form a seat 114 for at least one of the tip cap 116 or the cladding 112.

[0069] Figure 4 1 is a top-down schematic diagram of the airfoil assembly 100 as viewed along the tip 106. The outer wall 101 defines a suction side 120 and a pressure side 122. A camber line 126 extends through the airfoil assembly 100 between the leading edge 108 and the trailing edge 110. The camber line 126 is equidistant between opposing portions of the outer wall 101 defining the pressure side 122 and the suction side 120.

[0070] Figure 5 is from Figure 2 1 is a schematic cross-sectional view of the airfoil assembly 100 as viewed from section line VV. The illustration is taken along a plane extending along the camber line 126 in the spanwise direction, the plane being at the leading edge 108 ( Figure 2 ) and trailing edge 110( Figure 2 ) with the same percentage as the root 104 ( Figure 2 ) and intersect with tip 106.

[0071] The body 102 may terminate at a distal end 150 prior to the tip 106. The tip cap 116 may cover a portion of the body 102. As a non-limiting example, the tip cap 116 may cover a portion of the body 102 corresponding to the pressure side 122 of the airfoil assembly 100, the suction side 120 of the airfoil assembly 100, and the distal end 150. The tip cap 116 extends axially over respective portions of the body 102 corresponding to the suction side 120 and the pressure side 122 of the airfoil assembly 100 relative to the camber line 126. The tip cap 116 extends radially over respective portions of the body 102 relative to the camber line 126.

[0072] The tip cap 116 may extend across the entire distal end 150. The tip cap 116 may be formed as a unitary body that extends continuously along the tip between the suction side 120 and the pressure side 122. The distal end 150 may extend a first width (W1) between radially opposite sides of the body 102 relative to the camber line 126. The tip cap 116 may extend a second width (W2) radially along the tip 106 relative to the camber line 126. The second width (W2) may be greater than or equal to the first width (W1).

[0073] The tip cap 116 may include a Figure 2 ) is defined as an area of ​​increased thickness defined by a height (H) extending in the span direction (S) of the airfoil assembly 100. The height (H) may be any suitable size. As a non-limiting example, the height (H) may be greater than 0% and less than or equal to 15% of the maximum length of the airfoil assembly 100 in the span direction (S). As a non-limiting example, the height (H) may be greater than or equal to 4% and less than or equal to 15% of the maximum length of the airfoil assembly 100 in the span direction (S). A void defining a hollow interior 128 may be provided within a portion of the tip cap 116. As a non-limiting example, the hollow interior 128 may be provided within an area of ​​increased thickness defined by the height (H). The hollow interior 128 is shown in dotted lines, and therefore, it will be understood that the tip cap 116 may be formed as a solid material without the hollow interior 128. The hollow interior 128 may be used to reduce the weight of the tip cap 116. It is further contemplated that the hollow interior 128 may be used for cooling purposes. As a non-limiting example, cooling fluid may be supplied to the hollow interior 128 to effectively cool the tip cap 116 during operation of the airfoil assembly 100 .

[0074] During operation, external forces may be applied to the airfoil assembly 100. As a non-limiting example, the external force may be, but is not limited to, the working airflow flowing over the airfoil assembly 100. The tip cap 116 may provide structural support for the body 102 and protect at least a portion of the body 102 from the external forces. As a non-limiting example, the tip cap 116 may be configured to provide structural support for the body 102 and protect at least a portion of the body 102 from the external forces. Figure 2 ) and along the thickness between the pressure side 122 and the suction side 120 of the outer wall 101. Specifically, the tip cap 116 defines a solid or other area of ​​the airfoil assembly 100 that has a higher density than the body 102, which in turn makes it difficult to bend the tip cap 116 in the chordwise direction (C), thereby making it difficult to bend the airfoil assembly 100. Furthermore, in some cases, if the tip cap 116 is not included, the external force may be directed in such a way or be large enough to deflect the tip in the direction of the external force. It has been found that the tip cap 116 can reduce and / or eliminate the deflection of the tip.

[0075] Figure 6 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly 200 of airfoil assembly 100. Airfoil assembly 200 is similar to airfoil assembly 100; therefore, like parts will be identified with like numerals incremented into the 200 series, with the understanding that the description of airfoil assembly 100 applies to airfoil assembly 200 unless otherwise noted.

[0076] The airfoil assembly 200 includes an outer wall 201 terminating at a tip 206. The outer wall 201 defines a suction side 220, a pressure side 222, and a camber line 226. The outer wall 201 extends in a spanwise direction (S) and a chordwise direction (C). The airfoil assembly 200 includes a body 202 (e.g., a composite body) and a tip cap 216, both of which at least partially define the outer wall 201. The body 202 terminates at a distal end 250.

[0077] The airfoil assembly 200 is similar to the airfoil assembly 100 ( Figure 2 ), because the tip cap 216 at least partially covers a portion of the body 202 corresponding to the tip 206, the suction side 220, and the pressure side 222. However, the airfoil assembly 200 includes a tip cap 216 having multiple bodies (a first body 234 and a second body 236). At least a portion of the tip cap 216 is discontinuous. As a non-limiting example, the first body 234 can be radially spaced apart from the second body 236 along the tip 206. In other words, a gap (G) can be provided between the first body 234 and the second body 236 along a portion of the tip 206. The multiple bodies can be symmetrical or asymmetrical about the camber line 226. A portion of the body 202 can extend into the gap (G) such that the body 202 at least partially defines the tip 206.

[0078] The tip cap 216 extends axially over respective portions of the body 202 corresponding to the suction side 220 and the pressure side 222 of the airfoil assembly 200 relative to the camber line 226. The tip cap 216 extends radially over respective portions of the body 202 relative to the camber line 226.

[0079] It will be appreciated that the first body 234 can be coupled to the second body 236. As a non-limiting example, a rod (not shown) can extend through the gap (G) between the first body 234 and the second body 236 and effectively couple the first body 234 to the second body 236. In other words, an additional body (e.g., a rod) can extend from the first body 234 to the second body 236 through the gap (G). The additional body can be coupled to each of the first body 234 and the second body 236 such that the additional body couples the first body 234 to the second body 236. Alternatively, the gap (G) can be eliminated at certain portions of the tip cap 216 such that the first body 234 and the second body 236 are integrally formed or coupled to each other at one or more portions of the tip cap 216, but are removed from each other at another portion (e.g., forming the gap (G) therebetween).

[0080] The tip cap 216 may include a set of internal ribs 230. The set of internal ribs 230 may define a portion of the tip cap 216 that extends radially toward the camber line 226. As shown, the set of internal ribs 230 are formed along a portion of the tip cap 216 that extends along the tip 206. The set of internal ribs 230 may have any suitable shape when viewed along a plane that extends along the camber line 226, at the leading edge (e.g., Figure 2 leading edge 108) and trailing edge (e.g., Figure 2 The trailing edge 108) is connected to the root (eg, Figure 2 The root 104) and the tip 206 intersect. As non-limiting examples, the set of internal ribs 230 can include trapezoidal, rectangular, circular, triangular or any combination of cross-sectional areas thereof.

[0081] The set of internal ribs 230 may also include a set of additional internal ribs 232 that extend into the body 202 and are axially displaced from the tip 206. The set of additional internal ribs 232 may extend radially into the body 202. The set of additional internal ribs 232 may be used as a method of coupling the tip cap 216 to the body 202. As a non-limiting example, the set of additional internal ribs 232 may maintain the tip cap 216 in frictional contact with the body 202, or at least a portion of the tip cap 216 may be coupled to the body by any other suitable method, such as, but not limited to, bonding, welding, adhering, fastening, or any combination thereof.

[0082] It is contemplated that the set of internal ribs 230 may also function as a set of stress risers for the body 202. As a non-limiting example, the body 202 may include a series of composite layups stacked radially on top of each other. The set of internal ribs 230 may extend through one or more composite layups, thereby discontinuing at least a portion of the composite layups of the body 202. It is contemplated that such discontinuity in one or more composite layups of the body 202 may, in turn, induce tip brittleness, which may be desirable in some systems.

[0083] It is contemplated that, for manufacturing purposes, the tip cap 216 may be used in place of the tip cap 116. For example, the tip cap 116 may need to be formed as a single body, while the tip cap 216 may be formed as two separate bodies. Nevertheless, it is contemplated that the tip cap 216 may include the set of internal ribs 230 such that increased stiffness of the airfoil assembly 200 in the chord-wise direction (C) is still achieved. The set of internal ribs 230 increases the thickness of the tip cap 216, which in turn increases the resilience of the tip cap 216 to bending.

[0084] Figure 7 yes Figure 6Schematic isometric view of a first body 234 of a tip cap 216 of the tip cap 216. Although described in terms of the first body 234, it should be understood that the aspects described herein can be applied to any of the multiple bodies of the tip cap 216. The tip cap 216 can extend between a front face 260 and a rear face 262. The set of internal ribs 230 can extend across the entire tip cap 216 between the front face 260 and the rear face 262. Alternatively, at least one rib in the set of internal ribs 230 can extend less than the entire distance between the front face 260 and the rear face 262. As a non-limiting example, the additional internal rib 232 can extend less than the entire distance between the front face 260 and the rear face 262.

[0085] The set of internal ribs 230 may include any suitable number of one or more ribs along any suitable portion of the tip cap 216 that faces the body 202 ( Figure 6 ) is provided. At least a portion of the set of internal ribs 230 can be segmented between the front face 260 and the rear face 262. As a non-limiting example, the illustrated internal rib 230 can be divided into two internal ribs such that the tip cap 216 includes two internal ribs spaced apart in the chordwise direction (C) along the tip cap 216.

[0086] Figure 8 Is suitable for use as Figure 3 Schematic cross-sectional view of an exemplary airfoil assembly 300 of airfoil assembly 100. Airfoil assembly 300 is similar to airfoil assemblies 100, 200; therefore, like parts will be identified with like numerals incremented to the 300 series, it being understood that the description of each airfoil assembly 100, 200 applies to airfoil assembly 300 unless otherwise noted.

[0087] The airfoil assembly 300 includes an outer wall 301 terminating at a tip 306. The outer wall 301 defines a suction side 320, a pressure side 322, and a camber line 326. The outer wall 301 extends in a spanwise direction (S) and a chordwise direction (C). The airfoil assembly 300 includes a body 302 (e.g., a composite body) and a tip cap 316, both of which at least partially define the outer wall 301. The body 302 terminates at a distal end 350. The tip cap 316 extends axially relative to the camber line 326 over respective portions of the body 302 corresponding to the suction side 320 and the pressure side 322 of the airfoil assembly 300. The tip cap 316 extends radially over respective portions of the body 302 relative to the camber line 326.

[0088] The airfoil assembly 300 is similar to the airfoil assembly 100 ( Figure 2 )、200( Figure 6 ), because the tip cap 316 at least partially covers a portion of the body 302 corresponding to the tip 306, the suction side 320, and the pressure side 322. Figure 5), the tip cap 316 includes a plurality of bodies; namely, a first body 334 and a second body 336. However, the first body 334 and the second body 336 extend over the entire radial length of the tip 306, rather than forming a gap therebetween (e.g., Figure 5 of gap (G).

[0089] The first body 334 is coupled to the second body 336 along a joint 338. As a non-limiting example, the joint 338 is a butt joint. The joint 338 can be disposed along any suitable portion of the tip cap 316. As a non-limiting example, the joint 338 can be formed along the tip 306. The multiple bodies can be coupled to each other at the joint 338 by any suitable method, such as, but not limited to, bonding, welding, adhering, fastening, or any combination thereof.

[0090] Using a tip cap 316 that includes a connector 338 rather than a tip cap that is formed as a single body (e.g., Figure 2 The tip cap 116 of the tip cap 116) allows to reduce the manufacturing burden. It is conceivable that manufacturing the tip cap as a one-piece body may be more difficult than manufacturing the tip cap 316 as two separate bodies and then connecting them together at the joint 338.

[0091] Fig. 9 Suitable for use as Figure 4 Schematic cross-sectional view of an exemplary airfoil assembly 400 of airfoil assembly 100. Airfoil assembly 400 is similar to airfoil assemblies 100, 200, 300; therefore, like parts will be identified with like numbers incremented to the 400 series, it being understood that the description of each airfoil assembly 100, 200, 300 applies to airfoil assembly 400 unless otherwise noted.

[0092] The airfoil assembly 400 includes an outer wall 401 terminating at a tip 406. The outer wall 401 defines a suction side 420, a pressure side 422, and a camber line 426. The outer wall 401 extends in a spanwise direction (S) and a chordwise direction (C). The airfoil assembly 400 includes a body 402 (e.g., a composite body) and a tip cap 416, both of which at least partially define the outer wall 401. The body 402 terminates at a distal end 450. The tip cap 416 extends axially relative to the camber line 426 over respective portions of the body 402 corresponding to the suction side 420 and the pressure side 422 of the airfoil assembly 400. The tip cap 416 extends radially over respective portions of the body 402 relative to the camber line 426.

[0093] The airfoil assembly 400 is similar to the airfoil assembly 100 ( Figure 2 )、200( Figure 6 )、300( Figure 8), because the tip cap 416 at least partially covers a portion of the body 402 corresponding to the tip 406, the suction side 420, and the pressure side 422. Figure 8 ), the tip cap 416 includes a plurality of bodies, namely a first body 434 and a second body 436 connected at a joint 438. However, the joint 438 is a lap joint, rather than a lap joint like the joint 338 ( Figure 8 )A similar butt joint. It will be appreciated that joint 438 may be any suitable joint.

[0094] Fig.10 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly 500 of airfoil assembly 100. Airfoil assembly 500 is similar to airfoil assemblies 100, 200, 300, 400; therefore, like parts will be identified with like numbers incremented to the 500 series, it being understood that the description of each airfoil assembly 100, 200, 300, 400 applies to airfoil assembly 500 unless otherwise noted.

[0095] The airfoil assembly 500 includes an outer wall 501 terminating at a tip 506. The outer wall 501 defines a suction side 520, a pressure side 522, and a camber line 526. The outer wall 501 extends in a spanwise direction (S) and a chordwise direction (C). The airfoil assembly 500 includes a body 502 (e.g., a composite body) and a tip cap 516, both of which at least partially define the outer wall 501. The body 502 terminates at a distal end 550. The tip cap 516 extends axially relative to the camber line 526 over respective portions of the body 502 corresponding to the suction side 520 and the pressure side 522 of the airfoil assembly 500. The tip cap 516 extends radially relative to the camber line 526 over respective portions of the body 502.

[0096] The airfoil assembly 500 is similar to the airfoil assembly 100 ( Figure 2 )、200( Figure 6 )、300( Figure 8 )、400( Fig. 9), because the tip cap 516 at least partially covers a portion of the body 502 corresponding to the tip 506, the suction side 520, and the pressure side 522. However, the tip cap 516 includes a plurality of bodies. As a non-limiting example, the tip cap 516 includes a first body 534, a second body 536, and a third body 552. The third body 552 can interconnect the first body 534 and the second body 536. The first body 534, the second body 536, and the third body 552 can each define any suitable portion of the outer wall 501. As a non-limiting example, the first body 534 can extend along a portion of the suction side 520, the second body 536 can extend across a portion of the pressure side 522, and the third body 552 can extend across a portion of the tip 506.

[0097] The first body 534 can be coupled to the third body 552 at one end of the third body 552, and the second body 536 can be coupled to the third body 552 at a second end of the third body 552. The tip cap 516 can include a plurality of joints 538 that couple the plurality of bodies. Each of the plurality of joints 538 can be a butt joint. Each of the plurality of joints 538 can be a lap joint. It will be understood that the plurality of joints 538 can be any suitable joints, such as, but not limited to, lap joints, butt joints, or combinations thereof.

[0098] Fig.11 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly 600 of airfoil assembly 100. Airfoil assembly 600 is similar to airfoil assemblies 100, 200, 300, 400, 500; therefore, like parts will be identified with like numbers incremented into the 600 series, it being understood that the description of each airfoil assembly 100, 200, 300, 400, 500 applies to airfoil assembly 600 unless otherwise noted.

[0099] The airfoil assembly 600 includes an outer wall 601 terminating at a tip 606. The outer wall 601 defines a suction side 620, a pressure side 622, and a camber line 626. The outer wall 601 extends in a spanwise direction (S) and a chordwise direction (C). The airfoil assembly 600 includes a body 602 (e.g., a composite body) and a tip cap 616, both of which at least partially define the outer wall 601. The body 602 terminates at a distal end 650. The tip cap 616 extends axially relative to the camber line 626 over respective portions of the body 602 corresponding to the suction side 620 and the pressure side 622 of the airfoil assembly 600. The tip cap 616 extends radially relative to the camber line 626 over respective portions of the body 602.

[0100] The airfoil assembly 600 is similar to the airfoil assembly 100 ( Figure 2 )、200( Figure 6 )、300( Figure 8 )、400( Fig. 9 )、500( Fig.10 ), because the tip cap 616 at least partially covers a portion of the body 602 corresponding to the tip 606, the suction side 620, and the pressure side 622. However, the tip cap 616 also includes a set of external ribs 640 extending along the outer wall 601. The set of external ribs 640 can be formed on either side of the outer wall 601, such as along the suction side 620 or the pressure side 622. As a non-limiting example, the set of external ribs 640 can be formed to at least partially define the tip 606. The set of external ribs 640 may include any number of one or more external ribs 640 formed along the outer wall 601 in the span direction (S). For example, the set of external ribs 640 may include additional external ribs 642 spaced apart from the external ribs 640 shown in the span direction. The set of external ribs 640 may be symmetrical or asymmetrical about the camber line 626.

[0101] The set of external ribs 640 may have any suitable shape when viewed along a plane extending along the camber line 626, at the leading edge (e.g., Figure 2 leading edge 108) and trailing edge (e.g., Figure 2 The trailing edge 108) is connected to the root (eg, Figure 2 The root 104) and the tip 606 intersect. As non-limiting examples, the set of external ribs 640 can include trapezoidal, rectangular, circular, triangular or any combination of cross-sectional areas thereof.

[0102] During operation, the set of external ribs 640 can extend into the working airflow path so that the working airflow flows through the set of external ribs 640. It is contemplated that the set of external ribs 640 can extract work from the working airflow or direct the working airflow in a desired manner. Thus, the set of external ribs 640 can be defined as aerodynamic ribs formed along the tip cap 616.

[0103] Fig.12 yes Fig.11 Schematic isometric view of the tip cap 616 of FIG. The tip cap 616 can extend between a front face 660 and a rear face 662. The set of external ribs 640 can extend across the entire tip cap 616 between the front face 660 and the rear face 662. Alternatively, at least one rib in the set of external ribs 640 can extend less than the entire distance between the front face 660 and the rear face 662. As a non-limiting example, the additional external rib 642 can extend less than the entire distance between the front face 660 and the rear face 662.

[0104] The set of external ribs 640 can include any suitable number of one or more ribs disposed along any suitable portion of the tip cap 616 disposed along the outer wall 601. At least a portion of the set of external ribs 640 can be segmented between a front face 660 and a rear face 662. As a non-limiting example, the illustrated external rib 640 can be segmented into two internal ribs such that the tip cap 616 includes two internal ribs spaced apart in a chordwise direction (C) along the tip cap 616.

[0105] Fig.13 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly 700 of airfoil assembly 100. Airfoil assembly 700 is similar to airfoil assemblies 100, 200, 300, 400, 500, 600; therefore, like parts will be identified with like numbers incremented to the 700 series, it being understood that the description of each airfoil assembly 100, 200, 300, 400, 500, 600 applies to airfoil assembly 700 unless otherwise noted.

[0106] The airfoil assembly 700 includes an outer wall 701 terminating at a tip 706. The outer wall 701 defines a suction side 720, a pressure side 722, and a camber line 726. The outer wall 701 extends in a spanwise direction (S) and a chordwise direction (C). The airfoil assembly 700 includes a body 702 (e.g., a composite body) and a tip cap 716, both of which at least partially define the outer wall 701. The body 702 terminates at a distal end 750. The tip cap 716 extends axially relative to the camber line 726 over respective portions of the body 702 corresponding to the suction side 720 and the pressure side 722 of the airfoil assembly 700. The tip cap 716 extends radially relative to the camber line 726 over respective portions of the body 702.

[0107] The airfoil assembly 700 and the airfoil assembly 100 ( Figure 2 )、200( Figure 6 )、300( Figure 8 )、400( Fig. 9 )、500( Fig.10 )、600( Fig.11 ) in that the tip cap 716 at least partially covers a portion of the body 702 corresponding to the tip 706, the suction side 720, and the pressure side 722. Fig. 9 ), the tip cap 716 includes a set of external ribs 740. However, the difference is that the set of external ribs 740 includes radially opposed external ribs 740, so that the set of external ribs 740 is formed on both the suction side 720 and the pressure side 722. As shown, the set of external ribs 740 is symmetrical about the camber line 726, but it will be understood that the set of external ribs 740 can be asymmetrical about the camber line 726.

[0108] Fig.14 Suitable for use as Figure 2 Schematic cross-sectional view of an exemplary airfoil assembly 800 of airfoil assembly 100. Airfoil assembly 800 is similar to airfoil assemblies 100, 200, 300, 400, 500, 600, 700; therefore, like parts will be identified with like numbers incremented to the 800 series, it being understood that the description of each airfoil assembly 100, 200, 300, 400, 500, 600, 700 applies to airfoil assembly 800 unless otherwise noted.

[0109] The airfoil assembly 800 includes an outer wall 801 terminating at a tip 806. The outer wall 801 defines a suction side 820, a pressure side 822, and a camber line 826. The outer wall 801 extends in a spanwise direction (S) and a chordwise direction (C). The airfoil assembly 800 includes a body 802 (e.g., a composite body) and a tip cap 816, both of which at least partially define the outer wall 801. The body 802 terminates at a distal end 850. The tip cap 816 extends axially relative to the camber line 826 over respective portions of the body 802 corresponding to the suction side 820 and the pressure side 822 of the airfoil assembly 800. The tip cap 816 extends radially relative to the camber line 826 over respective portions of the body 802.

[0110] The airfoil assembly 800 is similar to the airfoil assembly 100 ( Figure 2 )、200( Figure 6 )、300( Figure 8 )、400( Fig. 9 )、500( Fig.10 )、600( Fig.11 )、700( Fig.13 ), because the tip cap 816 at least partially covers a portion of the body 802 corresponding to the tip 806, the suction side 820, and the pressure side 822. Fig. 9 )、716( Fig.10 ), the tip cap 816 includes a set of external ribs 840. However, the difference is that the set of external ribs 840 includes a semi-circular cross-sectional area when viewed along a plane extending along the camber line 826, at the leading edge (e.g., Figure 2 leading edge 108) and trailing edge (e.g., Figure 2 The trailing edge 108) is connected to the root (eg, Figure 2 The tip cap 816 is asymmetrical about the camber line 826, however, it will be understood that the tip cap 816 can be symmetrical about the camber line 826.

[0111] Fig.15 Suitable for use as Figure 2Schematic cross-sectional view of an exemplary airfoil assembly 900 of airfoil assembly 100. Airfoil assembly 900 is similar to airfoil assemblies 100, 200, 300, 400, 500, 600, 700, 800; therefore, like parts will be identified with like numbers incremented to the 900 series, it being understood that the description of each airfoil assembly 100, 200, 300, 400, 500, 600, 700, 800 applies to airfoil assembly 900 unless otherwise noted.

[0112] The airfoil assembly 900 includes an outer wall 901 terminating at a tip 906. The outer wall 901 defines a suction side 920, a pressure side 922, and a camber line 926. The outer wall 901 extends in a spanwise direction (S) and a chordwise direction (C). The airfoil assembly 900 includes a body 902 (e.g., a composite body) and a tip cap 916, both of which at least partially define the outer wall 901. The body 902 terminates at a distal end 950. The tip cap 916 extends axially relative to the camber line 926 over respective portions of the body 902 corresponding to the suction side 920 and the pressure side 922 of the airfoil assembly 900.

[0113] The airfoil assembly 900 is similar to the airfoil assembly 100 ( Figure 2 )、200( Figure 6 )、300( Figure 8 )、400( Fig. 9 )、500( Fig.10 )、600( Fig.11 )、700( Fig.13 )、800( Fig.14 ), because the tip cap 916 at least partially covers a portion of the body 902 corresponding to the suction side 920 and the pressure side 922. Figure 5 ), the tip cap 916 includes a plurality of bodies; a first body 934 and a second body 936. However, the tip cap 916 does not extend along the distal end 950. Instead, the body 902 extends to the tip 906 and defines a corresponding portion of the tip 906.

[0114] The body 902 may include a flared section 954. The tip cap 916 may follow the contour of the body 902. As such, the tip cap 916 may flare outwardly with the body 902. A set of external ribs 940 may be formed by the flaring of the tip cap 916. Thus, it will be appreciated that the body 902 and the tip cap 916 may together form the set of external ribs 940. The tip cap 916, the body 902, and the set of external ribs 940 may be symmetrical or asymmetrical about the camber line 926.

[0115] Fig.16 Is suitable for use as Figure 2Schematic cross-sectional view of an exemplary airfoil assembly 100 of airfoil assembly 100. Airfoil assembly 1000 is similar to airfoil assemblies 100, 200, 300, 400, 500, 600, 700, 800, 900; therefore, like parts will be identified with like numbers increased to the 1000 series, it being understood that the description of each airfoil assembly 100, 200, 300, 400, 500, 600, 700, 800, 900 applies to airfoil assembly 1000 unless otherwise indicated.

[0116] The airfoil assembly 1000 may include an outer wall 1001 extending in a chordwise direction (C) between a leading edge 1008 and a trailing edge 1010, and in a spanwise direction (S) between a root 1004 and a tip 1006. A tip cap 1016 and a body 1002 (e.g., a composite body) may each form a respective portion of the outer wall 1001. A cladding 1012 may optionally be provided along a portion of the leading edge 1008.

[0117] The airfoil assembly 1000 is similar to the airfoil assembly 100 ( Figure 2 )、200( Figure 6 )、300( Figure 8 )、400( Fig. 9 )、500( Fig.10 )、600( Fig.11 )、700( Fig.13 )、800( Fig.14 )、900( Fig.15 ), because the tip cap 1016 at least partially covers a portion of the body 1002. The tip cap 1016 is similar to the tip cap 616 ( Fig. 9 )、716( Fig.10 )、816( Fig.11 )、916( Fig.12 ), because the tip cap 1016 includes a set of external ribs 1040. The set of external ribs 1040 can be spaced apart relative to each other in the spanwise direction (S) or the chordwise direction (C).

[0118] Each rib in the set of external ribs 1040 may extend in the chord-wise direction (C) by a respective length that is greater than or equal to 10% and less than or equal to 100% of the length of the outer wall 1001 in the chord-wise direction (C) between the leading edge 1008 and the trailing edge 1010 in which the respective external rib is disposed. In other words, each rib in the set of external ribs 1040 may extend in the chord-wise direction (C) by a length that is greater than or equal to 10% and less than or equal to 100% of the chord-wise length of the outer wall 1001. Each rib in the set of external ribs 1040 may extend between the leading edge 1008 and the trailing edge 1010 by the same distance or by different distances relative to each other.

[0119] Each rib in the set of external ribs 1040 can extend along a line (e.g., along the linear line shown, as shown). The line, and therefore the rib, can be positioned at an angle (θ) relative to a straight line 1044 extending in the chord direction (C). The straight line 1044 can intersect the leading edge 1008 and the trailing edge 1010 at the same percentage between the root 1004 and the tip 1006. The angle (θ) can be any suitable angle. As a non-limiting example, the angle (θ) can have an absolute value greater than or equal to 0 degrees and less than or equal to 180 degrees. As a non-limiting example, the angle (θ) can be + / - 30 degrees with the straight line 1044. As a non-limiting example, the angle (θ) can be non-zero.

[0120] The set of external ribs 1040 may include any number of one or more external ribs. The set of external ribs 1040 may be disposed along any suitable portion of the tip cap 1016. As a non-limiting example, the set of external ribs 1040 may be disposed between the leading edge 1008 and the trailing edge 1010 in the chordwise direction (C), or may correspond to at least a portion of at least one of the leading edge 1008 or the trailing edge 1010. Although shown as extending linearly, it will be understood that the set of external ribs 1040 may sweep or otherwise extend nonlinearly in the chordwise direction (C).

[0121] It is contemplated that the set of external ribs 1040 may be used for aerodynamic or acoustic purposes of the airfoil assembly 100. As a non-limiting example, the angle (θ) may be selected so as to adjust aerodynamic or acoustic properties associated with including the set of external ribs 1040. As a non-limiting example, at least one of the set of external ribs 1040 may be angled or otherwise positioned so that the external rib extracts work from the working airflow flowing around the airfoil assembly 100. In other words, the external ribs may be used for aerodynamic purposes to increase aerodynamic efficiency or otherwise increase the work extracted from the working airfoil by the airfoil assembly 100. As a non-limiting example, at least one of the set of external ribs 1040 may reduce vibrations of the airfoil assembly 100 due to the working airflow flowing around the airfoil assembly 1000. In other words, at least one external rib may be included to reduce acoustics associated with the use of the airfoil assembly 100.

[0122] Benefits associated with the present disclosure include a composite airfoil assembly having increased resilience compared to conventional composite airfoil assemblies. For example, a conventional composite airfoil assembly may include a composite body having a metal sheath disposed on an exterior of the composite body. The metal sheath is bonded to or directly coupled to the composite body and does not extend over a portion of the composite body corresponding to a tip. Conventional composite airfoil assemblies may require a metal sheath to protect the composite body from external forces during operation of the conventional composite airfoil assembly. However, a composite airfoil assembly as described herein includes a tip cap that replaces the conventional metal sheath. The tip cap extends over a portion of the tip corresponding to the body and thus adds additional stiffness and resilience to the composite airfoil assembly compared to conventional composite airfoil assemblies.

[0123] In addition, the composite airfoil assembly described herein can reduce deflection (e.g., movement) of the tip when external forces are applied to the composite airfoil assembly, as compared to conventional composite airfoil assemblies. For example, while conventional composite airfoil assemblies can help shield external forces, it has been found that some forces still cause the tip to deflect undesirably, ultimately resulting in a shortened life of the conventional composite airfoil assembly. However, the composite airfoil assembly as described herein includes a tip cap extending over a portion of the tip corresponding to the body. It has been found that such additional extension of the tip cap can, in some cases, significantly reduce the amount by which the tip can deflect, as compared to conventional composite airfoil assemblies.

[0124] To the extent not yet described, the different features and structures of the various embodiments may be used in combination, or may be replaced with each other as desired. A feature not shown in all embodiments is not meant to be interpreted as not being able to be so shown, but rather is done so for the sake of brevity of description. Therefore, the various features of the different embodiments may be mixed and matched as desired to form new embodiments, whether or not the new embodiments are explicitly described. All combinations or permutations of the features described herein are covered by the present disclosure.

[0125] This written description uses examples to describe the disclosed aspects described herein, including the best mode, and also to enable any person skilled in the art to practice aspects of the disclosure, including making and using any device or system and performing any combined methods. The patentable scope of aspects of the disclosure is defined by the claims, and may include other examples that occur to one skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0126] Further aspects are provided by the subject matter of the following clauses:

[0127] A turbine engine comprises a fan section, a compressor section, a combustion section and a turbine section in a serial flow arrangement, and a composite airfoil assembly, the composite airfoil assembly comprising: an outer wall extending between a leading edge and a trailing edge in a chordwise direction and between a root and a tip in a spanwise direction, the outer wall defining a pressure side and a suction side and defining a camber line extending equidistantly between the pressure side and the suction side; a composite body at least partially defining the outer wall and terminating at a distal end; and a tip cap defining at least a portion of the outer wall and extending axially over at least a portion of the composite body corresponding to the pressure side and the suction side and extending radially over at least a portion of the composite body.

[0128] A composite airfoil assembly comprises: an outer wall extending in a chordwise direction between a leading edge and a trailing edge and in a spanwise direction between a root and a tip, the outer wall defining a pressure side, a suction side, and a camber line extending through the composite airfoil assembly and equidistant between the pressure side and the suction side; a composite body at least partially defining the outer wall and terminating at a distal end; and a metal tip cap defining at least a portion of the outer wall and extending axially over at least a portion of the composite body corresponding to the pressure side and the suction side and extending radially over at least a portion of the composite body.

[0129] A turbine engine comprises a fan section, a compressor section, a combustion section and a turbine section in a serial flow arrangement, and an airfoil assembly, the airfoil assembly comprising: an outer wall extending between a leading edge and a trailing edge in a chordwise direction and between a root and a tip in a spanwise direction, the outer wall defining a pressure side and a suction side and defining a camber line extending equidistantly between the pressure side and the suction side; a body at least partially defining the outer wall and terminating at a distal end; and a tip cap defining at least a portion of the outer wall and extending axially over at least a portion of the composite body corresponding to the pressure side and the suction side and extending radially over at least a portion of the composite body.

[0130] An airfoil assembly, the airfoil assembly comprising: an outer wall, the outer wall extending in the chordwise direction between a leading edge and a trailing edge, and extending in the spanwise direction between a root and a tip, the outer wall defining a pressure side, a suction side, and a camber line, the camber line extending through the airfoil assembly and equidistant between the pressure side and the suction side; a body, the body at least partially defining the outer wall and terminating at a distal end; and a tip cap defining at least a portion of the outer wall and extending axially over at least a portion of the composite body corresponding to the pressure side and the suction side, and extending radially over at least a portion of the composite body.

[0131] A turbine engine as claimed in any preceding clause, wherein the tip cap is formed as a unitary body extending continuously along the tip between the suction side and the pressure side.

[0132] A turbine engine as in any preceding clause, wherein the tip cap comprises a plurality of bodies, adjacent ones of the plurality of bodies being coupled to one another along at least one joint.

[0133] A turbine engine according to any preceding clause, wherein said at least one joint is a butt joint or a lap joint.

[0134] A turbine engine as claimed in any preceding clause, wherein said at least one joint is formed along a portion of said tip cap corresponding to said tip.

[0135] A turbine engine as claimed in any preceding clause, wherein the at least one joint is formed along a portion of the tip cap corresponding to at least one of the suction side or the pressure side.

[0136] A turbine engine according to any preceding clause, wherein the at least one joint includes a first joint disposed on the pressure side and a second joint disposed on the suction side, and the plurality of bodies includes a first body, a second body, and a third body interconnecting the first body and the second body.

[0137] A turbine engine as claimed in any preceding clause, wherein the tip cap is symmetrical or asymmetrical about the camber line.

[0138] A turbine engine as described in any preceding clause, wherein the tip cap includes a hollow interior.

[0139] A turbine engine as described in any preceding clause, wherein the tip cap includes at least one internal rib extending inwardly into the composite body.

[0140] A turbine engine according to any preceding clause, wherein said at least one internal rib is formed at said tip.

[0141] A turbine engine as claimed in any preceding clause, wherein the tip cap comprises at least one external rib disposed along the outer wall.

[0142] A turbine engine as claimed in any preceding clause, wherein said at least one external rib extends along said tip cap in said chordwise direction and defines a line along which said at least one external rib extends.

[0143] A turbine engine as claimed in any preceding clause, wherein the line forms a non-zero angle with respect to a straight line extending in the chordwise direction.

[0144] A turbine engine as claimed in any preceding clause, wherein said at least one external rib comprises a plurality of external ribs spaced apart in said spanwise direction.

[0145] A turbine engine according to any preceding clause, wherein said at least one external rib comprises a trapezoidal or semicircular cross-section when viewed along a plane extending along said camber line between said root and said tip and equidistant between said leading edge and said trailing edge.

[0146] A turbine engine according to any preceding clause, wherein said at least one external rib is symmetrical or asymmetrical about said camber line.

[0147] A turbine engine as claimed in any preceding clause, wherein the tip cap and the composite body together define at least one external rib disposed along the outer wall.

[0148] A turbine engine as claimed in any preceding clause, wherein at least a portion of said distal end is disposed along said tip.

[0149] A turbine engine as described in any preceding clause, wherein the body comprises a composite material and the tip cap comprises a metallic material.

[0150] A turbine engine as in any preceding clause, wherein the body has a first width extending between opposite sides of the outer wall of the body along the distal end, and the tip cap has a second width extending between the suction side and the pressure side at the tip.

[0151] A turbine engine as claimed in any preceding clause, wherein the first width is less than the second width.

[0152] A turbine engine as claimed in any preceding clause, wherein said tip cap extends across the entire first width.

[0153] A turbine engine as claimed in any preceding clause, wherein said tip cap extends across the entirety of said second width.

[0154] A turbine engine as described in any preceding clause, wherein the tip cap extends outwardly from the distal end in the spanwise direction to define an increasing thickness having a height in the spanwise direction.

[0155] A turbine engine as described in any preceding clause, wherein the airfoil assembly extends a maximum length in the spanwise direction between the root and the tip, and the height of the tip cap is greater than 0% and less than or equal to 15% of the maximum length.

[0156] A turbine engine according to any preceding clause, wherein the airfoil assembly extends a maximum length between the root and the tip in the spanwise direction, and the height of the tip cap is greater than or equal to 4% and less than or equal to 15% of the maximum length.

[0157] A composite airfoil assembly as described in any preceding clause, wherein the tip cap is formed as a unitary body extending continuously along the tip between the suction side and the pressure side.

[0158] A composite airfoil assembly as described in any preceding clause, wherein the tip cap comprises a plurality of bodies, adjacent ones of the plurality of bodies being coupled to one another along at least one joint.

[0159] A composite airfoil assembly according to any preceding clause, wherein the at least one joint is a butt joint or a lap joint.

[0160] A composite airfoil assembly as described in any preceding clause, wherein the at least one joint is formed along a portion of the tip cap corresponding to the tip.

[0161] A composite airfoil assembly as described in any preceding clause, wherein the at least one joint is formed along a portion of the tip cap corresponding to at least one of the suction side or the pressure side.

[0162] A composite airfoil assembly according to any preceding clause, wherein the at least one joint comprises a first joint disposed on the pressure side and a second joint disposed on the suction side, and the plurality of bodies comprises a first body, a second body, and a third body interconnecting the first body and the second body.

[0163] A composite airfoil assembly as described in any preceding clause, wherein the tip cap is symmetrical or asymmetrical about the camber line.

[0164] A composite airfoil assembly as described in any preceding clause, wherein the tip cap includes a hollow interior.

[0165] A composite airfoil assembly as described in any preceding clause, wherein the tip cap includes at least one internal rib extending inwardly into the composite body.

[0166] A composite airfoil assembly as described in any preceding clause, wherein said at least one internal rib is formed at said tip.

[0167] A composite airfoil assembly as described in any preceding clause, wherein the tip cap includes at least one external rib disposed along the outer wall.

[0168] A composite airfoil assembly according to any preceding clause, wherein the at least one external rib extends along the tip cap in the chord-wise direction and defines a line along which the at least one external rib extends.

[0169] A composite airfoil assembly as described in any preceding clause, wherein the line forms a non-zero angle with respect to a straight line extending in the chord-wise direction.

[0170] A composite airfoil assembly as described in any preceding clause, wherein said at least one external rib comprises a plurality of external ribs spaced apart in said spanwise direction.

[0171] A composite airfoil assembly according to any preceding clause, wherein said at least one external rib comprises a trapezoidal or semi-circular cross-section when viewed along a plane extending along said camber line between said root and said tip and equidistant between said leading edge and said trailing edge.

[0172] A composite airfoil assembly as described in any preceding clause, wherein said at least one external rib is symmetrical or asymmetrical about said camber line.

[0173] A composite airfoil assembly as described in any preceding clause, wherein the tip cap and the composite body together define at least one external rib disposed along the outer wall.

[0174] A composite airfoil assembly as described in any preceding clause, wherein at least a portion of the distal end is disposed along the tip.

[0175] A composite airfoil assembly as described in any preceding clause, wherein the body comprises a composite material and the tip cap comprises a metallic material.

[0176] A composite airfoil assembly as in any preceding clause, wherein the body has a first width extending between opposite sides of the outer wall of the body along the distal end, and the tip cap has a second width extending between the suction side and the pressure side at the tip.

[0177] A composite airfoil assembly as described in any preceding clause, wherein the first width is less than the second width.

[0178] A composite airfoil assembly as described in any preceding clause, wherein said tip cap extends across the entire first width.

[0179] A composite airfoil assembly as described in any preceding clause, wherein said tip cap extends across the entirety of said second width.

[0180] A composite airfoil assembly as described in any preceding clause, wherein the tip cap extends outwardly from the distal end in the spanwise direction to define an increasing thickness having a height in the spanwise direction.

[0181] A composite airfoil assembly as described in any preceding clause, wherein the airfoil assembly extends a maximum length in the spanwise direction between the root and the tip, and wherein the height of the tip cap is greater than 0% and less than or equal to 15% of the maximum length.

[0182] A composite airfoil assembly according to any preceding clause, wherein the airfoil assembly extends a maximum length in the spanwise direction between the root and the tip, and wherein the height of the tip cap is greater than or equal to 4% and less than or equal to 15% of the maximum length.

[0183] An airfoil assembly as claimed in any preceding clause, wherein the tip cap is formed as a unitary body extending continuously along the tip between the suction side and the pressure side.

[0184] An airfoil assembly as recited in any preceding clause, wherein the tip cap comprises a plurality of bodies, adjacent ones of the plurality of bodies being coupled to one another along at least one joint.

[0185] An airfoil assembly as claimed in any preceding clause, wherein the at least one joint is a butt joint or a lap joint.

[0186] An airfoil assembly as claimed in any preceding clause, wherein the at least one joint is formed along a portion of the tip cap corresponding to the tip.

[0187] An airfoil assembly as recited in any preceding clause, wherein the at least one joint is formed along a portion of the tip cap corresponding to at least one of the suction side or the pressure side.

[0188] An airfoil assembly according to any preceding clause, wherein the at least one joint comprises a first joint disposed on the pressure side and a second joint disposed on the suction side, and the plurality of bodies comprises a first body, a second body, and a third body interconnecting the first body and the second body.

[0189] An airfoil assembly as claimed in any preceding clause, wherein the tip cap is symmetrical or asymmetrical about the camber line.

[0190] An airfoil assembly as described in any preceding clause, wherein the tip cap comprises a hollow interior.

[0191] An airfoil assembly as recited in any preceding clause, wherein the tip cap includes at least one internal rib extending inwardly into the composite body.

[0192] An airfoil assembly as claimed in any preceding clause, wherein said at least one internal rib is formed at said tip.

[0193] An airfoil assembly as claimed in any preceding clause, wherein the tip cap comprises at least one external rib disposed along the outer wall.

[0194] An airfoil assembly as claimed in any preceding clause, wherein said at least one external rib extends along said tip cap in said chord-wise direction and defines a line along which said at least one external rib extends.

[0195] An airfoil assembly as claimed in any preceding clause, wherein the line forms a non-zero angle with respect to a straight line extending in the chord-wise direction.

[0196] An airfoil assembly as claimed in any preceding clause, wherein said at least one external rib comprises a plurality of external ribs spaced apart in said spanwise direction.

[0197] An airfoil assembly according to any preceding clause, wherein said at least one external rib comprises a trapezoidal or semi-circular cross-section when viewed along a plane extending along said camber line between said root and said tip and equidistant between said leading edge and said trailing edge.

[0198] An airfoil assembly as claimed in any preceding clause, wherein said at least one external rib is symmetrical or asymmetrical about said camber line.

[0199] An airfoil assembly as claimed in any preceding clause, wherein the tip cap and the composite body together define at least one external rib disposed along the outer wall.

[0200] An airfoil assembly as claimed in any preceding clause, wherein at least a portion of the distal end is disposed along the tip.

[0201] An airfoil assembly as described in any preceding clause, wherein the body comprises a composite material and the tip cap comprises a metallic material.

[0202] An airfoil assembly as in any preceding clause, wherein the body has a first width extending between opposite sides of the outer wall of the body along the distal end, and the tip cap has a second width extending between the suction side and the pressure side at the tip.

[0203] An airfoil assembly as recited in any preceding clause, wherein the first width is less than the second width.

[0204] An airfoil assembly as described in any preceding clause, wherein said tip cap extends across the entire first width.

[0205] An airfoil assembly as described in any preceding clause, wherein said tip cap extends across the entire second width.

[0206] An airfoil assembly as recited in any preceding clause, wherein the tip cap extends outwardly from the distal end in the spanwise direction to define an increasing thickness having a height in the spanwise direction.

[0207] An airfoil assembly as in any preceding clause, wherein the airfoil assembly extends a maximum length in the spanwise direction between the root and the tip, and the height of the tip cap is greater than 0% and less than or equal to 15% of the maximum length.

[0208] An airfoil assembly as described in any preceding clause, wherein the airfoil assembly extends a maximum length in the spanwise direction between the root and the tip, and the height of the tip cap is greater than or equal to 4% and less than or equal to 15% of the maximum length.

[0209] A turbine engine according to any preceding clause, wherein the turbine engine is a non-ducted turbine engine.

[0210] The non-ducted turbine engine of any preceding clause, further comprising a nacelle, and wherein the fan section comprises fan blades extending outwardly from the nacelle.

[0211] A non-ducted turbine engine as described in any preceding clause, wherein said composite airfoil assembly comprises said fan blade.

[0212] A turbine engine as described in any preceding clause, wherein the body comprises a composite material and the tip cap comprises a metallic material.

[0213] A composite airfoil assembly as described in any preceding clause, wherein the body comprises a composite material and the tip cap comprises a metallic material.

[0214] An airfoil assembly as described in any preceding clause, wherein the body comprises a composite material and the tip cap comprises a metallic material.

[0215] A non-ducted turbine engine as described in any preceding clause, wherein the body comprises a composite material and the tip cap comprises a metallic material.

Claims

1. A turbine engine, characterized in that: include: a fan section, a compressor section, a combustion section, and a turbine section in a series flow arrangement; as well as A composite airfoil assembly, the composite airfoil assembly comprising: an outer wall extending in a chordwise direction between a leading edge and a trailing edge and in a spanwise direction between a root and a tip, the outer wall defining a pressure side and a suction side and defining a camber line extending equidistantly between the pressure side and the suction side; a composite body at least partially defining the outer wall and terminating at a distal end; and A tip cap defines at least a portion of the outer wall and extends axially over at least a portion of the composite body corresponding to the pressure side and the suction side and extends radially over at least a portion of the composite body.

2. The turbine engine according to claim 1, characterized in that in, The tip cap is formed as a unitary body extending continuously along the tip between the suction side and the pressure side.

3. The turbine engine according to claim 1, characterized in that: in, The tip cap includes a plurality of bodies, adjacent bodies of the plurality of bodies being coupled to each other along at least one joint.

4. The turbine engine according to claim 3, characterized in that in, The at least one joint is a butt joint or a lap joint.

5. The turbine engine according to claim 3, characterized in that: in, The at least one joint is formed along a portion of the tip cap corresponding to the tip.

6. The turbine engine according to claim 3, characterized in that in, The at least one joint is formed along a portion of the tip cap corresponding to at least one of the suction side or the pressure side.

7. The turbine engine according to claim 6, characterized in that in, The at least one joint includes a first joint disposed on the pressure side and a second joint disposed on the suction side, and the plurality of bodies includes a first body, a second body, and a third body interconnecting the first body and the second body.

8. The turbine engine according to claim 1, characterized in that in, The tip cap is symmetrical or asymmetrical about the curvature line.

9. The turbine engine according to claim 1, characterized in that in, The tip cap includes a hollow interior.

10. The turbine engine according to claim 1, characterized in that in, The tip cap includes at least one internal rib extending inwardly toward the camber line, and the at least one internal rib is formed at the tip.

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