Method of manufacturing woven fabric for composite component of turbine engine

Abstract

A method of manufacturing a woven fabric for a composite component of a turbine engine. The method includes weaving a plurality of reinforcing fiber bundles to form a woven fabric having a surface. The reinforcing fiber bundles include a plurality of first fiber bundles and a plurality of second fiber bundles oriented transverse to the plurality of first fiber bundles. The woven fabric is a three-dimensional woven fabric. The method further includes forming a cavity extending in a first direction during weaving of the plurality of reinforcing fiber bundles. Forming the cavity includes positioning the plurality of first fiber bundles to create the cavity, and weaving the plurality of second fiber bundles around the cavity. The method further includes forming a slit connecting the cavity to the surface during weaving of the plurality of reinforcing fiber bundles.

Description

[0001] Government interests

[0002] This invention was completed with the support of the U.S. government. The U.S. government may enjoy certain rights to this invention. Technical Field

[0003] This disclosure relates to three-dimensional woven fabrics and methods for forming woven fabrics (particularly woven fabrics used in composite components of aircraft engines). Background Technology

[0004] Turbine engines used in aircraft typically consist of a fan and a turbo-engine section arranged in fluid communication with each other. A combustor is located in the turbo-engine to generate combustion gases that drive a turbine in the turbo-engine, and the turbine can be used to drive the fan. A portion of the air flowing into the fan flows through the turbo-engine as core air, while another portion flows around the core section as bypass air through the turbine. The turbo-engine section may include one or more compressors to compress the core air before it flows into the combustor. Composite materials can be used to manufacture various components of turbine engines, especially when the turbine engine is intended for use in aircraft. Attached Figure Description

[0005] Features and advantages of this disclosure will become apparent from the following description of various exemplary embodiments, as illustrated in the accompanying drawings, wherein similar reference numerals generally denote identical, functionally similar, and / or structurally similar elements.

[0006] Figure 1 This is a schematic cross-sectional view of a turbine engine used in aircraft.

[0007] Figure 2A This is a schematic diagram of a three-dimensional fiber weaving pattern.

[0008] Figure 2B It is along Figure 2A The line 2B-2B is intercepted. Figure 2A A schematic cross-sectional view of the fiber weave pattern shown.

[0009] Figure 2C It is shown as with Figure 2A The schematic cross-sectional view of the fiber weave patterns shown are similar but have different interlocking fiber patterns.

[0010] Figure 2D It is shown as with Figure 2A The schematic cross-sectional view of a fiber weave pattern that is similar to, but has a different interlocking fiber pattern, is shown.

[0011] Figure 3 It is used to manufacture... Figure 1 A flowchart illustrating the general processing of composite components used in turbine engines.

[0012] Figure 4 It is along Figure 1 The line 4-4 in the middle can be cut off. Figure 1 The diagram shows a schematic cross-sectional view of the airfoil used in the turbine engine.

[0013] Figure 5 It can be used to form Figure 4 A schematic diagram of the woven fabric of the airfoil shown.

[0014] Figure 6A and Figure 6B It shows the use Figure 5 The diagram shows the steps involved in manufacturing preforms from woven fabrics. Figure 6A It is the first step, and Figure 6B yes Figure 6A The second step following the steps shown.

[0015] Figure 7 From and Figure 4 Similar perspectives can be observed Figure 1 The diagram shows a schematic cross-sectional view of the airfoil used in the turbine engine.

[0016] Figure 8 It can be used to form Figure 7 A schematic diagram of another woven fabric for the airfoil shown. Detailed Implementation

[0017] The features, advantages, and embodiments of this disclosure will be set forth or apparent from consideration of the following detailed description, accompanying drawings, and claims. Furthermore, the following detailed description is exemplary and intended to provide further explanation, without limiting the scope of the claimed disclosure.

[0018] Various embodiments are discussed in detail below. Although specific embodiments are discussed, this is for illustrative purposes only. Those skilled in the art will recognize that other components and constructions can be used without departing from this disclosure.

[0019] As used herein, the terms “first,” “second,” “third,” etc., are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the components.

[0020] Unless otherwise stated herein, the terms “connection,” “fixation,” “attachment,” “linkage,” etc., refer to both direct connection, fixation, attachment, or linking, and indirect connection, fixation, attachment, or linking through one or more intermediate components or features.

[0021] As used herein, the terms "axial" and "axially" refer to a direction and orientation that extends substantially parallel to the centerline of the turbine engine. Furthermore, the terms "radial" and "radially" refer to a direction and orientation that extends substantially perpendicular to the centerline of the turbine engine. Additionally, as used herein, the terms "circumferential" and "circumferentially" refer to a direction and orientation that extends in an arc around the centerline of the turbine engine.

[0022] Unless the context clearly indicates otherwise, the singular forms “a,” “a,” and “the” include plural references.

[0023] Scope limitations are combined and interchanged herein and throughout the specification and claims. Unless the context or language otherwise indicates, such scopes are identified and include all subscopes contained herein. For example, all scopes disclosed herein include endpoints, and endpoints may be combined independently of each other.

[0024] As used herein, the term "composite" refers to a material having two or more constituent materials. A composite material can be a combination of at least two or more metals, nonmetals, or metal and nonmetal elements or materials. Examples of composite materials can be, but are not limited to, polymer matrix composites (PMCs), ceramic matrix composites (CMCs), and metal matrix composites (MMCs). Composite materials can be formed from a matrix material and reinforcing elements, such as fibers (referred to herein as reinforcing fibers).

[0025] As used herein, "reinforcing fiber" may include, for example, glass fiber, carbon fiber, steel fiber, or para-aramid fiber, such as those available from DuPont of Wilmington, Delaware. Reinforcing fibers can be in the form of fiber bundles, which include multiple fibers forming a bundle.

[0026] As used in this article, a “preform” is a three-dimensional woven fabric formed by multiple reinforcing fibers, including warp and weft fiber bundles.

[0027] As used herein, a “composite component” refers to a structure or component comprising any suitable composite material. A composite component (e.g., a composite airfoil) may comprise several layers or plies of composite material. The stiffness, material, and dimensions of the layers or plies may vary to achieve a desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0028] One or more layers of adhesive can be used to form or join composite components. The adhesive may require curing at elevated temperatures or other hardening techniques.

[0029] As used herein, PMC refers to a class of materials. PMC materials can be prepregs. A prepreg is a reinforcing material (e.g., reinforcing fibers) pre-impregnated with a polymer matrix material. Non-limiting examples of processes for producing polymer prepregs include: hot melt prepreg, in which molten resin is deposited onto the fiber reinforcing material; and powder prepreg, in which resin is deposited onto the fiber reinforcing material, as a non-limiting example, electrostatically deposited onto the fiber reinforcing material, and then adhered to the fibers, as a non-limiting example, in an oven or with the aid of heated rollers.

[0030] Resins used as matrix materials for PMCs are generally classified as thermosetting or thermoplastic resins. Thermoplastic resins are typically categorized as polymers that repeatedly soften and flow upon heating, and harden upon sufficient cooling due to physical rather than chemical changes. Well-known examples of thermoplastic resins include nylon, thermoplastic polyesters, polyaryletherketones (PAEs), and polycarbonate resins. Specific examples of high-performance thermoplastic resins envisioned for aerospace applications include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK), and polyphenylene sulfide (PPS). Conversely, thermosetting resins do not undergo significant softening upon heating once fully cured into a rigid solid, but rather thermally decompose upon sufficient heating. Well-known examples of thermosetting resins include epoxy resins, bismaleimide (BMI), and polyimide resins.

[0031] Instead of using prepregs with thermoplastic polymers, another non-limiting example utilizes woven fabrics. Woven fabrics may include, but are not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg woven structures can be fabricated in a similar manner. With this method, the fiber volume of the part can be customized by specifying the relative concentrations of the woven or braided thermoplastic fibers and reinforcing fibers. Furthermore, different types of reinforcing fibers can be woven or braided together at different concentrations to customize the properties of the part. For example, glass fibers, carbon fibers, and thermoplastic fibers can all be woven together at different concentrations to customize the properties of the part. Carbon fibers provide the strength of the system, can be incorporated into glass fibers to enhance impact characteristics—a design feature of parts located near the engine inlet—and thermoplastic fibers provide bonding for the reinforcing fibers.

[0032] In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of a composite part. Typically, RTM involves applying dry fibers to a mold or cavity. The dry fibers can include prepreg, braided material, woven material, or any combination thereof. Resin can be pumped into or otherwise supplied to the mold or cavity to impregnate the dry fibers. The impregnated fibers combined with the resin are then cured and removed from the mold. The composite part may require post-curing treatment upon removal from the mold. RTM can be a vacuum-assisted process. That is, air in the cavity or mold can be removed and replaced with resin before heating or curing. The placement of the dry fibers can also be manual or automatic. The dry fibers can be shaped to form the composite part or guide the resin. Optionally, additional layers or reinforcing layers of materials different from the dry fibers can be included or added before heating or curing.

[0033] As used herein, CMC refers to a class of materials having reinforcing fibers within 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, alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates (such as mullite), or mixtures thereof), or mixtures thereof.

[0034] 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, alumina (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 within the ceramic matrix.

[0035] Typically, a specific CMC can be referred to by a combination of its fiber type / matrix type. 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, and SiC / SiC-SiN is a mixture of silicon carbide fiber-reinforced silicon carbide / silicon nitride matrix, etc. In other examples, a CMC can consist of a matrix comprising an oxide-based material (such as alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates, and mixtures thereof) and reinforcing fibers. Aluminosilicates can include crystalline materials (e.g., mullite (3Al₂O₃·2SiO₂)) as well as glassy aluminosilicates.

[0036] In some non-limiting examples, the reinforcing fibers may be bundled (e.g., forming fiber bundles) and / or coated before being incorporated into the matrix. The fiber bundles may be impregnated with a slurry composition before or after the formation of the preform. The preform may then undergo heat treatment and subsequent chemical treatment to obtain a component formed from a CMC material having a desired chemical composition. For example, the preform may undergo curing or burn-out to produce a high coke residue in the preform and subsequently melt infiltration with silicon, or undergo curing or pyrolysis to produce a silicon carbide matrix in the preform and subsequently chemical vapor infiltration with silicon carbide. Additional steps may be taken to enhance the densification of the preform, either before or after chemical vapor infiltration, by injecting the preform with a liquid resin or polymer followed by a heat treatment step to fill the voids with silicon carbide. The CMC material used herein may be formed using any known or later developed method (including, but not limited to, melt infiltration, chemical vapor infiltration, polymer impregnation pyrolysis (PIP), or any combination thereof).

[0037] As used herein, the term "metal" refers to materials that include metals (such as, but not limited to, titanium, iron, aluminum, stainless steel, and nickel alloys). Metallic materials or metal alloys can be combinations of at least two or more elements or materials (at least one of which is a metal).

[0038] As mentioned above, certain components of gas turbine engines (particularly those used in aircraft) can be made of composite materials. Such components include, for example, various airfoils, including static airfoils such as blades (e.g., outlet guide blades in bypass airflow paths) or nozzles (e.g., compressor nozzles). These airfoils are located in the airflow path of the gas turbine engine, and components of the gas turbine engine positioned radially inward of the flow path may need to be connected to components and systems positioned radially outward of the flow path. Therefore, these static airfoils can include service tubes disposed within them to allow fluid, electrical, and other connections to pass through the static airfoil and thus through the airflow path. Service tubes can be provided by machining cavities in the airfoil, inserting the tubes into the cavities, and then using springs to support the tubes to secure them within the cavities. When the airfoil is formed from a composite material, the cavities can be machined, but machining can be difficult and requires additional processing. Alternatively, tools (such as mandrels) can be placed in the preform during its formation and prior to infiltration and curing, but this also requires additional processing. Furthermore, the cavity needs to have sufficient clearance to insert the tube, and then, due to the increased clearance, a spring is used to hold the tube in place. The clearance and spring increase the thickness of the airfoil. The embodiments discussed herein disclose a method for forming three-dimensional (3D) woven fabrics, wherein the tubes can be co-molded, resulting in thinner supports and better manufacturability.

[0039] The composite materials discussed in this article may be particularly suitable for use in aircraft turbine engines. Figure 1 This is a schematic cross-sectional view of a turbine engine 100 that can be used on an aircraft. The turbine engine 100 has an axial direction A (extending parallel to the longitudinal centerline axis 101, where the longitudinal centerline axis 101 is located at...) Figure 1 (Shown for reference) the radial direction R and the circumferential direction C. The circumferential direction C extends in the direction of rotation about the longitudinal centerline axis 101 (axial direction A). Figure 1 In the depicted embodiment, the turbine engine 100 is a high-bypass turbofan engine, including a fan section 102 and a turbocharger engine 104 disposed downstream of the fan section 102.

[0040] Figure 1 The turbocharged engine 104 depicted includes a compressor section 110, a combustion section 120, and a turbine section 130 in a series flow relationship. The turbocharged engine 104 is substantially enclosed within a housing 106, which is substantially tubular and defines a core inlet 141. In this embodiment, the core inlet 141 is annular. Figure 1 As schematically shown, compressor section 110 includes a turbocharger or low-pressure (LP) compressor 112, followed downstream by a high-pressure (HP) compressor 114. Combustion section 120 is downstream of compressor section 110. Turbine section 130 is downstream of combustion section 120 and includes a high-pressure (HP) turbine 132, followed downstream by a low-pressure (LP) turbine 134. Turbocharged engine 104 also includes a core air exhaust nozzle 143 (also referred to as an injection exhaust nozzle) downstream of turbine section 130. Compressor section 110, combustion section 120, and turbine section 130 together at least partially define a core airflow path 140 extending from core inlet 141 to core air exhaust nozzle 143, through which core air 145 flows. As will be discussed in more detail below, turbocharged engine 104 includes a high-pressure (HP) shaft 108 or HP spool and a low-pressure (LP) shaft 109. HP shaft 108 drives HP turbine 132 to HP compressor 114. HP turbine 132 and HP compressor 114 rotate synchronously via HP shaft 108. LP shaft 109 drives LP turbine 134 to LP compressor 112. LP turbine 134 and LP compressor 112 rotate synchronously via LP shaft 109.

[0041] Each of the LP compressor 112 and HP compressor 114 may include multiple compressor stages. In each stage, multiple compressor blades 116 rotate relative to corresponding multiple static compressor impellers 118 (also referred to as nozzles) to compress or pressurize the core air 145 passing through that stage. In a single compressor stage, the multiple compressor blades 116 may be arranged in a ring extending radially outward from the blade platform relative to the longitudinal centerline axis 101 to the blade tip (e.g., extending in the radial direction R). The compressor blades 116 may be part of a compressor rotor including a disk, and the multiple compressor blades 116 extend radially from the disk. Other configurations of the compressor rotor may be used, including, for example, impeller disks, where the disk and compressor blades 116 are integrally formed as a single piece. The corresponding static compressor impellers 118 are positioned upstream of and adjacent to the rotating compressor blades 116. The compressor impellers 118 of a stage of the compressor may be mounted circumferentially to the core housing 107. The core housing 107 may at least partially define the core airflow path 140. Each compressor stage can be used to sequentially compress core air 145 flowing through the core airflow path 140, thereby generating compressed air 147. Any suitable number of compressor blades 116, compressor impellers 118, and compressor stages can be used.

[0042] Each of the HP turbine 132 and LP turbine 134 may further include multiple turbine stages. In each stage, multiple turbine blades 136 rotate relative to corresponding multiple static turbine blades 138 (also referred to as nozzles) to extract energy from combustion gas 149 passing through the stage. The turbine blades 136 may be part of a turbine rotor. Any suitable configuration of the turbine rotor may be used, including, for example, a disk from which the multiple turbine blades 136 extend. The corresponding static turbine blades 138 are positioned upstream of and adjacent to the rotating turbine blades 136. The turbine blades 138 of the first stage of the turbine may be mounted to the core housing 107 in a circumferential arrangement.

[0043] In combustion section 120, fuel received from the fuel system (not shown) is injected into combustion chamber 124 of combustor 122 via fuel nozzle 126. The fuel is mixed with compressed air 147 from compressor section 110 to form a fuel-air mixture, which is then combusted to produce combustion products (i.e., combustion gases 149). As will be discussed further below, adjusting the fuel metering unit (not shown) of the fuel system alters the amount of fuel supplied to combustion chamber 124, and thus changes the amount of propulsive thrust generated by turbine engine 100. Combustion gases 149 are discharged from combustion chamber 124. These combustion gases can be directed to turbine blades 136 of HP turbine 132, and then to turbine blades 136 of LP turbine 134, and the combustion gases 149 drive (rotate) the turbine blades 136 of HP turbine 132 and LP turbine 134. Any suitable number of turbine blades 136, turbine wheel blades 138, and turbine stages can be used. After flowing through the turbine section 130, the combustion gases 149 are discharged from the turbine engine 100 through the core air exhaust nozzle 143 to provide propulsive thrust.

[0044] The turbocharged engine 100, and more specifically, the turbocharged engine 104, also includes one or more drive shafts. As described above, the turbocharged engine 104 includes a high-pressure (HP) shaft 108 drivingly connecting an HP turbine 132 to an HP compressor 114, and a low-pressure (LP) shaft 109 drivingly connecting an LP turbine 134 to an LP compressor 112. More specifically, the turbine rotor of the HP turbine 132 is connected to the HP shaft 108, and the compressor rotor of the HP compressor 114 is connected to the HP shaft 108. Combustion gas 149 is directed into and expands through the HP turbine 132, wherein a portion of the thermal or kinetic energy from the combustion gas 149 is extracted via one or more stages of turbine blades 136 and turbine wheel blades 138 of the HP turbine 132. This causes the HP shaft 108 to rotate, which supports the operation of the HP compressor 114 (self-sustaining cycle) and rotates the compressor rotor via the HP shaft 108, thereby rotating the compressor blades 116 of the HP compressor 114. In this manner, the combustion gas 149 performs work on the HP turbine 132. The combustion gas 149 is then directed into the LP turbine 134 and expands through it. Here, a second portion of thermal or kinetic energy is extracted from the combustion gas 149 via one or more stages of turbine blades 136 and turbine wheel blades 138 of the LP turbine 134. This causes the LP shaft 109 to rotate, which supports the operation of the LP compressor 112 (self-sustaining cycle) and rotates the compressor rotor via the LP shaft 109, thereby rotating the compressor blades 116 of the LP compressor 112. In this manner, the combustion gas 149 performs work on the LP turbine 134. The HP shaft 108 and the LP shaft 109 are coaxially arranged about a longitudinal centerline axis 101. The diameter of the HP shaft 108 is larger than the diameter of the LP shaft 109, and the HP shaft 108 is located radially outside the LP shaft 109. HP shaft 108 and LP shaft 109 are rotatable about longitudinal centerline axis 101 and are coupled to rotatable elements, such as compressor rotors and turbine rotors, as discussed above.

[0045] Figure 1 The fan section 102 shown includes a fan 150, which has multiple fan blades 152 connected to a disk 154. The fan blades 152 and the disk 154 can rotate together via an LP shaft 109 about a longitudinal centerline (axis) 101. The LP compressor 112 can also be directly driven by the LP shaft 109, as... Figure 1As depicted, the disk 154 is covered by a fan hub 156, which is aerodynamically shaped to facilitate airflow through a plurality of fan blades 152. Furthermore, a nacelle 160 circumferentially surrounds the fan 150, and in the depicted embodiment, circumferentially surrounds at least a portion of the turbocharged engine 104. The nacelle 160 may also be referred to as an annular fan housing or an outer nacelle. The nacelle 160 is supported relative to the turbocharged engine 104, and more specifically, relative to the outer casing 106, by a plurality of outlet guide vanes 158 circumferentially spaced around the nacelle 160 and the turbocharged engine 104. A downstream section 162 of the nacelle 160 extends over the outer portion of the turbocharged engine 104, and more specifically, over the outer casing 106, to define a bypass airflow passage 164 between them.

[0046] During operation of the turbine engine 100, a certain amount of air 166 enters the turbine engine 100 through the inlet (referred to herein as engine inlet 159) of the nacelle 160 and / or fan section 102. As the certain amount of air 166 passes through the fan blades 152, a first portion of the air (bypass air 168) is directed or directed into the bypass airflow passage 164, and a second portion of the air (core air 145) is directed or directed into the upstream section of the core airflow path 140, or more specifically, into the core inlet 141. The ratio between the bypass air 168 and the core air 145 is commonly referred to as the bypass ratio. Simultaneously, as the core air 145 flows through the core airflow path 140 (as discussed above), the bypass air 168, directed through the bypass airflow passage 164 before being discharged from the bypass air exhaust nozzle 169 of the turbine engine 100, also provides propulsive thrust. The bypass air exhaust nozzle 169 and the core air exhaust nozzle 143 are the exhaust nozzles of the turbine engine 100.

[0047] Figure 1The turbine engine 100 (turbofan engine) shown and discussed herein is provided by way of example only. In other embodiments, any other suitable engine may be used with aspects of this disclosure. For example, in other embodiments, the engine may be any other suitable gas turbine engine, such as a turboshaft engine, a turboprop engine, a turbojet engine, a non-ducted single-fan engine, etc. In this way, in other embodiments, the gas turbine engine may have other suitable configurations, such as other suitable numbers or arrangements of shafts, compressors, turbines, fans, etc. Furthermore, although turbine engine 100 is shown as a direct-drive fixed-pitch turbofan engine, in other embodiments, turbine engine 100 may be a geared turbine engine (e.g., including a gearbox between fan 150 and a shaft (such as LP shaft 109) driving the fan), a variable-pitch turbine engine (i.e., including a fan 150 having a plurality of fan blades 152 rotatable about their respective pitch axes), etc. Furthermore, in alternative embodiments, aspects of this disclosure may be incorporated into or otherwise used with any other type of engine (such as a reciprocating engine).

[0048] The turbine engine 100 discussed herein is suitable for use on aircraft. Suitable aircraft include, for example, airplanes, helicopters, and unmanned aerial vehicles (UAVs). In other embodiments, the turbine engine can be any other turbine engine, such as an industrial turbine engine incorporated into a power generation system, or a marine turbine engine on a ship or other vessel.

[0049] Various components of the turbine engine 100 can be formed from composite materials. These components are referred to herein as composite components. For example, fan blades 152, outlet guide vanes 158, compressor blades 116, and compressor wheel blades 118 can be made of PMC materials. Other composite materials (such as CMC materials) can be used for other components, including, for example, turbine blades 136, turbine wheel blades 138, and components of the combustion section 120 (such as the combustor liner for forming the combustion chamber 124). Furthermore, although the embodiments are described with respect to turbine engine 100, composite components and manufacturing methods can be used to form composite components for use in applications other than turbine engines.

[0050] Figure 2A and Figure 2B This is a schematic diagram showing a three-dimensional fiber weaving pattern that can be used to form the woven fabric 200. Figure 2B It is along Figure 2AThe image shows a cross-sectional view taken from line BB. In the embodiments discussed herein, the composite component may be formed of a plurality of reinforcing fibers, and more specifically, of a plurality of reinforcing fiber bundles 202. The plurality of reinforcing fiber bundles 202 are woven together to form a woven fabric 200. The plurality of reinforcing fiber bundles 202 include a plurality of first fiber bundles, which in this embodiment are a plurality of warp fiber bundles 210. The plurality of reinforcing fiber bundles 202 also include a plurality of second fiber bundles, which in this embodiment are a plurality of weft fiber bundles 220. The weft fiber bundles 220 are oriented transversely to the warp fiber bundles 210, and in the depicted embodiment, the warp fiber bundles 210 and the weft fiber bundles 220 are oriented substantially orthogonally to each other. Thus, the woven fabric 200 includes a warp direction Wp (also referred to as a first direction) and a weft direction Wf (also referred to as a second direction). The warp fiber bundles 210 extend in the warp direction Wp, and the weft fiber bundles 220 extend in the weft direction Wf.

[0051] In the depicted embodiment, the woven fabric 200 is a three-dimensional woven fabric, and the woven fabric 200 also includes a thickness direction t. The thickness direction may also be referred to as the z-direction. Warp fiber bundles 210 may be arranged relative to each other to form a plurality of warp fiber layers 212 in the thickness direction t and a plurality of warp fiber rows 214 in the weft direction Wf. Figure 2A and Figure 2B The image depicts three warp fiber layers 212, but the woven fabric 200 may include any other number of warp fiber layers 212, including more than three warp fiber layers 212.

[0052] During the weaving process, the warp fiber bundle 210 can be kept taut in the warp direction Wp, and one of the weft fiber bundles 220 is passed through or pulled through it. A shuttle (not shown) can be used to pull one of the weft fiber bundles 220 through the warp fiber bundle 210. The shuttle can pass through the warp fiber bundle 210 in a first direction and then in the opposite direction at different heights in the thickness direction, thereby forming a plurality of weft fiber layers 222 in the thickness direction t. One of the weft fiber bundles 220 can continuously pass through at least a portion of the thickness of the woven fabric 200, and one of the weft fiber bundles 220 may include a portion extending in the thickness direction t, which may be referred to as a turning portion in some embodiments. Thus, this portion of the weft fiber bundle may be referred to herein as a turning portion 224. The warp fiber bundles 210 can be moved relative to each other to make room for one of the weft fiber bundles 220 to pass through the space. The warp fiber bundles 210 can be moved relative to each other in different ways to produce different patterns. In this manner, weaving the woven fabric 200 includes positioning warp fiber bundles 210 (e.g., such that the warp fiber bundles 210 remain stationary under tension), then laying weft fiber bundles 220 (e.g., such that the weft fiber bundles 220 are pulled through and inserted above and below the corresponding warp fibers 210), and repeating this process until the woven fabric 200 is formed. The weft fiber bundles 220 may be arranged relative to each other to form a plurality of weft fiber layers 222 in the thickness direction t and a plurality of weft fiber rows 226 in the warp direction Wp.

[0053] The woven fabric 200 also includes multiple interlocking fiber bundles 230 (also referred to as Z-woven fiber bundles). The interlocking fiber bundles 230 are additional warp fiber bundles that are guided through the thickness of the woven fabric 200 during weaving to stitch the reinforcing fiber bundles 202 together. The interlocking fiber bundles 230 are woven to extend between two or more weft fiber layers 222. Different fiber patterns can be used for the interlocking fiber bundles 230. Figure 2A and Figure 2B The first interlocking fiber pattern shown is a positive interlocking pattern, and the interlocking fiber bundle 230 is referred to herein as positive interlocking fiber bundle 232. In this pattern, the positive interlocking fiber bundle 232 extends substantially in a direction orthogonal to the warp direction Wp, which in the depicted embodiment is the thickness direction t. Like the weft fiber bundle 220, the interlocking fiber bundle 230 (e.g., positive interlocking fiber bundle 232) may include a turning portion 234. In the depicted embodiment, the turning portion 234 of the positive interlocking fiber bundle 232 is positioned to form an alternating pattern between each warp fiber column 214. In the depicted embodiment, the positive interlocking fiber bundle 232 extends through the thickness of the woven fabric 200 and may be referred to as a full-thickness interlocking fiber bundle, but other thicknesses may be used.

[0054] Figure 2C The second interlocking fiber pattern shown is an angle interlocking pattern, and more specifically, an interlayer angle interlocking pattern. Figure 2C From and Figure 2B A cross-sectional view of the woven fabric taken from a similar perspective. The interlocking fiber bundle 230 is referred to in this embodiment as an angled interlocking fiber bundle 236. The angled interlocking fiber bundle 236 does not extend orthogonally through the woven fabric 200, but rather forms an angle relative to the warp direction Wp. In the depicted embodiment, the angled interlocking fiber bundle 236 extends through adjacent weft fiber layers 222 in an alternating or sinusoidal pattern to interlock these adjacent layers with each other, wherein an angle is formed between adjacent turning portions 234 of the angled interlocking fiber bundle 236. The turning portions 234 of the angled interlocking fiber bundle 236 are located on every other weft fiber column 226, but in other embodiments, two or more weft fiber columns 226 may be between adjacent turning portions 234 of the angled interlocking fiber bundle 236. In other embodiments, the angled interlocking fiber bundle 236 may extend through more than two adjacent weft fiber layers 222. For example, as Figure 2D As shown, the interlocking fiber bundle 230 is a full-thickness interlocking fiber bundle, which is referred to herein as the full-thickness angled interlocking fiber bundle 238. Figure 2D From and Figure 2B A cross-sectional view of the woven fabric taken from a similar perspective. For clarity, Figure 2C and Figure 2D The meridional fiber bundle 210 is omitted in the text.

[0055] Figure 3 It is manufactured in Figure 1 A flowchart of a general process for composite components used in turbine engines. The method includes, for example, weaving a woven fabric 200 on a loom in step S10. In step S20, the method includes forming an initial preform using one or more woven fabrics 200. This step may include, for example, laying out multiple woven fabrics 200 or otherwise positioning multiple woven fabrics 200 relative to each other to form the initial preform. In step S30, the initial preform is shaped to form a shaped preform. Shaping the initial preform may include, for example, shaping the initial preform using a die tool. Suitable forming processes may include vacuum forming or other forming processes to impart shape to the initial preform. The shaped preform may form a final preform, but optionally, additional machining and manufacturing processes (such as adding inserts) may be performed on the shaped preform to form the final preform.

[0056] After the preform is completed (i.e., the final preform), a matrix material can be injected into the preform in step S40 to generate an infiltrated (or impregnated) preform. When the composite part is a polymer matrix composite, the polymer and / or resin can be pumped, injected, or otherwise provided to a mold or cavity in this step to infiltrate or impregnate the dry fibers. For example, this step can be performed in conjunction with step S30 when using resin transfer molding (RTM). Other infiltration treatments may be used in this step depending on the matrix material. As mentioned above, the preform can be formed using prepreg fiber bundles introduced into the matrix material, and in such embodiments, this step (step S40) can be omitted.

[0057] The method continues in step S50 to cure the infiltrated preform to bond the composite material, and more specifically, the matrix, together to form a composite component. The curing process depends on the material and may include coagulating or otherwise hardening the matrix material surrounding the fiber bundles within the preform. For example, when the matrix material is a polymer, curing may include coagulating and chemically crosslinking the polymer chains. Curing the infiltrated preform may include several treatments. For example, the infiltrated preform can be thinned and cured by exposing it to elevated temperatures and pressures in an autoclave. The infiltrated preform may also undergo one or more further treatments, such as burn-off cycles and densification treatments. Curing step S50 may be combined with step S40, such as when the matrix material is injected into the final preform in a molten state and the curing step includes cooling the matrix material.

[0058] Furthermore, composite components can be precision-machined as needed. Precision machining can define the final shape or profile of the composite component. For example, when the composite component is a fan blade 152 ( Figure 1 When machining the fan blades 152, the edges can be machined to define the final shape or profile of the airfoil. Additionally, the composite component can be coated with one or more suitable coatings, such as an environmental barrier coating (EBC) or a polyurethane surface coating.

[0059] Figure 4 It is possible Figure 1 A schematic cross-sectional view of the composite components used in the turbine engine 100. As mentioned above, various components of the turbine engine 100 can be composite components formed of composite materials, and in particular of one or more woven fabrics 200. Figure 2A Precast components formed by ) such as Figure 4 The composite component depicted is airfoil 300. More specifically, Figure 4 The airfoil 300 shown is the exit guide vane 158, and Figure 4 It is along Figure 1The image shows a three-dimensional cross-sectional view of the outlet guide vane 158, taken by line 4-4. However, the description of airfoil 300 applies to other airfoils of the turbine engine 100, including, for example, compressor vane 118. Figure 1 The airfoil 300 and its forming method are applicable to components that can be PMC components. However, the airfoil 300 and method discussed herein are also applicable to CMC components, including, for example, turbine blades 138. Figure 1 These processes do not require machining cavities to insert the service tube, because they do not require machining cavities. These static airfoils 300 can also be referred to as struts, and the methods discussed herein can be used for other composite struts located outside the airflow path.

[0060] Airfoil 300 includes a leading edge 312, a trailing edge 314, and an inner end portion 316. Figure 1 ) and outer end portion 318 ( Figure 1 The inner end portion 316 and the outer end portion 318 can each be connected to a housing that defines the airflow passage within the airfoil 300. (As shown) Figure 1 As shown, in this example, when the airfoil 300 is the exit guide vane 158, the airfoil 300 is connected to the housing 106 on the inner end portion 316 and to the nacelle 160 on the outer end portion 318. The airfoil 300 extends radially from the inner end portion 316 outward to the outer end portion 318. This direction may also be referred to as the wingspan direction S. Return to Reference Figure 4 The airfoil 300 includes surfaces formed on each side of the airfoil between the leading edge 312 and the trailing edge 314. These surfaces are a first surface 322 and a second surface 324 located on opposite sides of the airfoil 300. (As can be seen in...) Figure 4 As seen in the image, airfoil 300 is a symmetrical airfoil. However, airfoil 300 can have any suitable shape, including, for example, a concave surface, and airfoil 300 can be an arcuate airfoil, wherein the first surface 322 is a suction surface with a convex curvature, and the second surface 324 is a generally flat pressure surface. Airfoil 300 also includes a chordal direction Ch, which is perpendicular to the span direction S and extends from the leading edge 312 to the trailing edge 314. The thickness direction T of airfoil 300 is also perpendicular to each of the span direction S and the chordal direction Ch.

[0061] Airfoil 300 is composed of reinforcing fiber bundle 202 ( Figure 2A A composite component composed of a matrix material formed therefrom. The composite material can be, for example, a polymer matrix composite (PMC). However, as mentioned above, the methods discussed herein can be used with other materials, and therefore the airfoil 300 can be formed from these other materials, and the airfoil 300 can be a ceramic matrix composite (CMC). For clarity, Figure 4The reinforcing fiber bundle 202 is omitted in the text.

[0062] The airfoil 300 also includes a tube 330 extending through the airfoil 300 in the spanwise direction S. When the airfoil 300 is PMC, the tube 330 can be formed of metal; however, when the airfoil 300 is formed of other materials and used in different environments, the tube 330 can be formed of other materials suitable for use in those environments. As will be discussed in more detail below, weaving ( Figure 3 Step S10) Weaving fabric 400 ( Figure 5 ), and then in step S20 ( Figure 3 In this process, tube 330 is molded and cured in woven fabric 400 (preform). Figure 3 The tube 330 is inserted into the woven fabric 400 before steps S30 to S50. Therefore, the tube 330 is co-molded with the woven fabric 400. After curing, the matrix material contacts the tube 330, and more specifically, the matrix material surrounds the tube 330, as shown in the image. Figure 4 The tube 330 is an example of an insert that can be inserted into and co-molded with the woven fabric 400. Other inserts may be used, including foam inserts for forming, for example, composite pillars with a foam core.

[0063] Figure 5 It can be used to form Figure 4 A schematic diagram of the woven fabric 400 of the airfoil 300 shown. Figure 5 The woven fabric 400 shown can be similar to the one referenced above. Figures 2A to 2D The woven fabric 200 discussed is formed, and this discussion applies here. For clarity, Figures 5 to 6B Interlocking fiber bundle 230 is omitted in the text. Figures 2A to 2D The woven fabric 400 also includes one or more surfaces 402 formed by the external reinforcing fiber bundles 202 of the woven fabric 400.

[0064] When the initial prefabricated components are formed (as discussed above) Figure 3 In step S20), the warp direction Wp of the woven fabric 400 is... Figure 2A ) can be used in airfoil 300 ( Figure 4 ) wingspan direction S( Figure 4 Therefore, step S20 may include weaving and arranging the woven fabric 400 and reinforcing fiber bundles 202 in such a way that the warp fiber bundles 210 can extend in the spanwise direction S and can be oriented in the spanwise direction S. Therefore, the weft direction Wf of the woven fabric 400 can be approximately aligned with the chord direction Ch of the airfoil 300. Figure 4The weft fiber bundle 220 extends approximately in the tangential direction Ch and can be oriented approximately in the tangential direction Ch. The thickness direction t of the woven fabric 400 can also approximately correspond to the thickness direction T of the airfoil 300.

[0065] The meridional fiber bundle 210 is positioned to form in the meridional direction ( Figure 2A The cavity 410 extends upwards. When the interlocking fiber bundle 230 ( Figure 2B In the meridional direction Wp( Figure 2B When oriented upwards, the interlocking fiber bundle 230 can be positioned similarly to the warp fiber bundle 210 to form the cavity 410. When the weft fiber bundle 220 is woven into the warp fiber bundle 210, the weft fiber bundle 220 is woven around the cavity 410, and the weft fiber bundle 220 does not extend through the cavity 410. Figure 5 As depicted herein, the woven fabric 400 includes a region in the weft direction Wf that includes a cavity 410. This region is referred to herein as cavity region 420. The woven fabric 400 also includes a front region 422 and a back region 424. These regions are truncated relative to the cavity 410 and cavity region 420. Both the front region 422 and the back region 424 include more weft fiber layers 222 than the portion of the woven fabric 400 in cavity region 420. One or more of the weft fiber bundles 220 may be woven to have a portion of the weft fiber bundles 220 extending beyond the surface 402 of the woven fabric 400 in cavity region 420 (referred to as extension portion 228). The extension portion 228 of one or more weft fiber bundles 220 extending beyond surface 402 may be trimmed as part of forming the woven fabric 400 or as part of a subsequent operation prior to molding.

[0066] Cavity 410 is tube 330 ( Figure 4 The cavity 410 provides space. However, the cavity 410 is surrounded by the reinforcing fiber bundle 202 and is an internal cavity of the woven fabric 400. To allow the tube 330 to be positioned within the cavity 410, the woven fabric 400 also includes a slit 412. The slit 412 connects the cavity 410 to the surface 402 of the woven fabric 400 and extends from the cavity 410 to the surface 402, and as... Figure 5 As depicted, slit 412 extends to become airfoil 300 ( Figure 4 The trailing edge 314 ( Figure 4 The position of ). Slits 412 are formed while multiple reinforcing fiber bundles 202 are woven. For example Figure 5 As depicted, slit 412 is formed between two adjacent meridional fiber layers 212. Figure 2BBetween the first and second portions, a first portion and a second portion are formed. In the depicted embodiment, the first and second portions are located in the rear region 424 and will be referred to as the first rear portion 432 and the second rear portion 434 in the following discussion. For example, the slit 412 may be formed in other locations in the woven fabric 400, such as in the front region 422. The second rear portion 434 is opposite to the first rear portion 432, with the slit 412 located between them. These two adjacent warp fiber layers 212 are referred to herein as bifurcation layers, and more specifically, as the first bifurcation layer 436 in the first rear portion 432 and the second bifurcation layer 438 in the second rear portion 434. The slit 412 is in Figure 5 It is depicted as being formed between two meridional fiber layers 212.

[0067] The first rear portion 432 and the second rear portion 434 are not interconnected across the slit 412 by a plurality of interlocking fiber bundles 230. More specifically, the first branch layer 436 and the second branch layer 438 are not connected to each other by interlocking fiber bundles 230 across the slit 412. Similarly, when the weft fiber bundles 220 are woven into the woven fabric 400, the first rear portion 432 and the second rear portion 434 are not interconnected across the slit 412 by the weft fiber bundles 220. More specifically, the first branch layer 436 and the second branch layer 438 are not connected to each other by the weft fiber bundles 220 across the slit 412. During the weaving process, a minimum amount of temporary interlocking fiber bundles can be used to stabilize the first branch layer 436 and the second branch layer 438 during the process, and the slit 412 can be formed by cutting or otherwise removing these temporary interlocking fiber bundles before formation.

[0068] Various fiber patterns can be used for weft fiber bundles 220. For example... Figure 5 As depicted, the latitudinal fiber bundle 220 begins in one of the first rear portion 432 or the second rear portion 434 and ends in the other of the first rear portion 432 and the second rear portion 434. For example, a latitudinal fiber bundle 220 may begin in the first rear portion 432 and extend around the cavity 410 and through the front region 422 before extending back around the cavity 410 again and entering the second rear portion 434.

[0069] Figure 6A and Figure 6B It shows the use of Figure 5 The woven fabric 400 shown manufactures preform 440 ( Figure 6B The steps are as discussed above, specifically step S20. Figure 3As part of the initial preform, tube 330 is inserted through slit 412 (as indicated by arrow A) and then positioned in cavity 410. To allow tube 330 to pass through slit 412 and between the first rear portion 432 and the second rear portion 434, the first rear portion 432 and the second rear portion 434 can be pulled apart, thereby separating the first bifurcation layer 436 and the second bifurcation layer 438 from each other to widen slit 412. Thus, slit 412 is opened to a size that allows tube 330 to slide into cavity 410, such as... Figure 6A As shown in the image.

[0070] The tube 330 includes, for example, an opening 332 or channel through which a fluid or electrical connection can pass. Figure 6B As shown, tube 330 is positioned such that opening 332 is in the spanwise direction S( Figure 4 Extending upwards, and as Figure 6B As depicted, tube 330, and more specifically, opening 332 in the meridional direction Wp ( Figure 2A Extending on the tube 330. After the tube 330 is positioned in the cavity 410, the first rear portion 432 and the second rear portion 434 move back together to bring the first bifurcation layer 436 and the second bifurcation layer 438 close to each other. Thus, with the tube 330 inserted, the slit 412 is closed, forming the preform 440. The first bifurcation layer 436 and the second bifurcation layer 438 are positioned close enough to each other that in subsequent molding steps (e.g., Figure 3 During steps S30-S50, the matrix material flows between the first bifurcation layer 436 and the second bifurcation layer 438 to bind the reinforcing fiber bundles 202 together, and more specifically, to bind the warp fiber bundles 210 and weft fiber bundles 220 together in the first bifurcation layer 436 and the second bifurcation layer 438. In this way, the woven fabric 400 is cured. Figure 3 In step S50), the first bifurcation layer 436 and the second bifurcation layer 438 are combined, and the slit 412 is removed. The woven fabric 400 can be a near-net-shape woven fabric 400, allowing for the preparation of preforms with minimal post-processing after weaving. For example... Figure 6B As depicted, the woven fabric 400 has the shape of the airfoil 300 (e.g., a symmetrical teardrop shape), and the slit 412 is formed on the chordal axis of the airfoil 300.

[0071] Figure 7 It is possible Figure 1 A schematic cross-sectional view of the composite components used in the turbine engine 100. (See diagram.) Figure 7 The composite component depicted is airfoil 500. More specifically, Figure 7 The airfoil 500 shown is the outlet guide vane 158, and Figure 7 From and Figure 4A similar perspective is shown in the three-dimensional cross-sectional view of the outlet guide vane 158. However, the description of airfoil 500 applies to other airfoils of the turbine engine 100, including, for example, compressor vane 118. Figure 1 ). Figure 7 The airfoil 500 depicted in the image is similar to Figure 4 The airfoil 300 is depicted, but includes multiple inserts, such as multiple tubes. More specifically, the airfoil 500 includes a first tube 532 and a second tube 534. Figure 7 In this configuration, the first tube 532 and the second tube 534 are aligned or arranged in the chordal direction Ch, but the first tube 532 and the second tube 534 may have other arrangements within the airfoil 500. The airfoil 500 is otherwise similar to... Figure 4 The airfoil 300 is depicted in the diagram, and the discussion above applies here. The first tube 532 and the second tube 534 are similar to the tube 330 discussed above, and the discussion above regarding the tube 330 applies to the first tube 532 and the second tube 534.

[0072] Figure 7 It can be used to form Figure 5 A schematic diagram of another woven fabric 600 of the airfoil 500 shown. The woven fabric 600 is similar to... Figure 5 The woven fabric 400 shown is formed Figure 7 The method of weaving fabric 600 shown is similar to the method of forming woven fabric 400 discussed above. The above discussion also applies here, however, instead of a single cavity 410 ( Figure 5 The reinforcing fiber bundle 202 is woven to form a plurality of cavities in the cavity region 420, including a first cavity 612 and a second cavity 614. The first cavity 612 and the second cavity 614 are formed similarly to the cavity 410 discussed above and are connected to the surface via one or more slits. In the depicted embodiment, the second cavity 614 is connected to the surface 402 via slit 412, and an intermediate slit 616 connects the first cavity 612 to the second cavity 614. Other arrangements may be used, including slits that individually connect each of the first cavity 612 and the second cavity 614 to the surface 402. The intermediate slit 616 is formed similarly to the slit 412 discussed above, and inserts (such as the first tube 532 and the second tube 534) may be as referenced above. Figure 6A and Figure 6B The discussion covers insertion and co-modulation.

[0073] The woven fabrics 400 and 600 discussed herein, the methods for forming the woven fabrics 400 and 600, and the methods for forming composite components (e.g., struts or airfoils 300 and 500) using the woven fabrics 400 and 600 allow tubes 330, 532, 534 (or other inserts) to be co-molded with reinforcing fiber bundles 202, thereby allowing the composite components to be thinner and have better manufacturability than a process of inserting service tubes after molding.

[0074] Further aspects of this disclosure are provided by the subject matter of the following clauses.

[0075] A method of manufacturing a woven fabric for a composite component of a turbine engine includes: weaving a plurality of reinforcing fiber bundles to form a woven fabric having a surface, the reinforcing fiber bundles including a plurality of first fiber bundles and a plurality of second fiber bundles oriented transversely to the plurality of first fiber bundles, the woven fabric being a three-dimensional woven fabric having a first direction, a second direction orthogonal to the first direction, and a thickness direction orthogonal to each of the first and second directions, the plurality of first fiber bundles being arranged in the thickness direction to form a plurality of first fiber layers, and the plurality of second fiber bundles being arranged in the thickness direction to form a plurality of second fiber layers; during weaving the plurality of reinforcing fiber bundles, forming a cavity extending in the first direction by positioning the plurality of first fiber bundles to create the cavity and weaving the plurality of second fiber bundles around the cavity; and during weaving the plurality of reinforcing fiber bundles, forming slits connecting the cavity to the surface.

[0076] According to the method described in the foregoing clause, the plurality of first fiber bundles are a plurality of warp fiber bundles, and the plurality of second fiber bundles are a plurality of weft fiber bundles.

[0077] According to any of the foregoing provisions, the first direction is a meridional direction and the second direction is a latitudinal direction.

[0078] According to any of the foregoing provisions of the method, the woven fabric includes a first portion and a second portion opposite to the first portion, wherein the slit is between the first portion and the second portion, and the plurality of second fiber bundles are woven to extend from the first portion around the cavity to the second portion.

[0079] According to any of the foregoing provisions of the method, wherein the first portion and the second portion are not interconnected across the slit via the plurality of second fiber bundles.

[0080] The method according to any of the foregoing clauses, wherein the reinforcing fiber bundle comprises a plurality of interlocking fiber bundles.

[0081] According to any of the foregoing descriptions of the method, the woven fabric includes a first portion and a second portion opposite to the first portion, wherein the slit is between the first portion and the second portion, and the first portion and the second portion are not interconnected across the slit by the plurality of interlocking fiber bundles.

[0082] According to the method described in the foregoing clause, the interlocking fiber bundle is woven with a positive interlocking pattern.

[0083] According to the method described in the foregoing clause, the positive interlocking pattern extends through the thickness of the woven fabric.

[0084] According to any of the foregoing provisions, the interlocking fiber bundles are woven in an angled interlocking pattern.

[0085] According to the method described in the preceding clause, the angle interlocking pattern extends through adjacent fiber layers in an alternating or sinusoidal pattern to interlock these adjacent layers with each other.

[0086] According to any of the foregoing clauses, the method wherein the angle interlocking pattern extends through more than two adjacent fiber layers.

[0087] According to the method described in the foregoing clause, the angle interlocking pattern extends through the thickness of the woven fabric.

[0088] According to the method described in any of the foregoing clauses, during the weaving of the plurality of reinforcing fiber bundles, a portion of one or more of the plurality of second fiber bundles extends beyond the surface in the region of the cavity.

[0089] The method according to any of the foregoing clauses further includes trimming the portion of the one or more second fiber bundles that extends beyond the surface.

[0090] According to any of the foregoing provisions of the method, the cavity is one of a plurality of cavities formed during the weaving of the plurality of reinforcing fiber bundles.

[0091] According to the method described in the foregoing clause, the slit is one of a plurality of slits that connect each of the plurality of cavities to the surface.

[0092] A method for manufacturing a preform of a composite component for a turbine engine, the method comprising: preparing a woven fabric using the method according to any of the foregoing clauses; inserting an insert through the slit; and positioning the insert in the cavity.

[0093] According to the method described in the foregoing clause, the insert is a tube, and the tube has an opening extending in the first direction.

[0094] A method for forming a composite component, the method comprising: preparing a preform using the method according to any of the preceding clauses, the plurality of reinforcing fiber bundles comprising prepreg fiber bundles to introduce a matrix material; and curing the preform comprising the matrix material to generate the composite component.

[0095] According to any of the foregoing clauses, the composite component is an airfoil including a wingspan direction, and the method further includes positioning the woven fabric such that the first direction extends in the wingspan direction.

[0096] The method according to any of the foregoing clauses further includes curing the preform to remove the slit.

[0097] According to any of the foregoing clauses, the tube comes into contact with the matrix material after the preform has been cured.

[0098] According to any of the foregoing provisions of the method, wherein the matrix material surrounds the tube.

[0099] A method for forming a composite component, the method comprising: preparing a preform using the method according to any of the preceding clauses; injecting a matrix material into the preform to generate a permeable preform; and curing the permeable preform to generate the composite component.

[0100] According to any of the foregoing clauses, the composite component is an airfoil including a wingspan direction, and the method further includes positioning the woven fabric such that the first direction extends in the wingspan direction.

[0101] According to any of the foregoing clauses, the method involves curing the permeation preform to remove the slit.

[0102] According to any of the foregoing clauses, the tube comes into contact with the matrix material after the preform has been cured.

[0103] According to any of the foregoing provisions of the method, wherein the matrix material surrounds the tube.

[0104] While the foregoing description is directed to certain embodiments, other variations and modifications will be apparent to those skilled in the art and can be made without departing from this disclosure. Furthermore, features described in connection with one embodiment may be used in conjunction with other embodiments, even if not explicitly stated above.

Claims

1. A method for manufacturing a woven fabric for a composite component of a turbine engine, characterized in that, The method includes: Multiple reinforcing fiber bundles are woven to form a woven fabric with a surface, the reinforcing fiber bundles comprising multiple first fiber bundles and multiple second fiber bundles oriented transversely to the multiple first fiber bundles, the woven fabric being a three-dimensional woven fabric having a first direction, a second direction orthogonal to the first direction, and a thickness direction orthogonal to each of the first and second directions, the multiple first fiber bundles being arranged in the thickness direction to form multiple first fiber layers, and the multiple second fiber bundles being arranged in the thickness direction to form multiple second fiber layers; During the weaving of the plurality of reinforcing fiber bundles, a cavity extending in the first direction is formed in the following manner: Positioning the plurality of first fiber bundles to create the cavity; and The plurality of second fiber bundles are woven around the cavity; and During the weaving of the plurality of reinforcing fiber bundles, slits are formed to connect the cavity to the surface.

2. The method according to claim 1, characterized in that, in, The plurality of first fiber bundles are plurality of warp fiber bundles, and the plurality of second fiber bundles are plurality of weft fiber bundles.

3. The method according to claim 2, characterized in that, in, The first direction is the longitudinal direction, and the second direction is the latitudinal direction.

4. The method according to claim 1, characterized in that, in, The woven fabric includes a first portion and a second portion opposite to the first portion, wherein the slit is between the first portion and the second portion, and the plurality of second fiber bundles are woven from the first portion to extend around the cavity to the second portion.

5. The method according to claim 4, characterized in that, in, The first portion and the second portion are not interconnected across the slit via the plurality of second fiber bundles.

6. The method according to claim 1, characterized in that, in, The reinforcing fiber bundle includes multiple interlocking fiber bundles.

7. The method according to claim 6, characterized in that, in, The woven fabric includes a first portion and a second portion opposite to the first portion, wherein the slit is between the first portion and the second portion, and the first portion and the second portion are not interconnected across the slit by the plurality of interlocking fiber bundles.

8. The method according to claim 1, characterized in that, in, During the weaving of the plurality of reinforcing fiber bundles, a portion of one or more of the plurality of second fiber bundles extends beyond the surface in the region of the cavity.

9. The method according to claim 8, characterized in that, This further includes trimming the portion of the one or more second fiber bundles that extends beyond the surface.

10. A method for manufacturing a preform of a composite component for a turbine engine, characterized in that, The method includes: The woven fabric is prepared using the method according to claim 1; Insert the tube through the slit; and The tube is positioned in the cavity, the tube having an opening extending in the first direction.

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