Composite airfoil for turbine engine

Abstract

A composite airfoil for a turbine engine, the composite airfoil having at least one airfoil body element. The at least one airfoil body element includes a core and a composite wrap, wherein the composite wrap covers at least a portion of the core. The core includes a set of composite layouts.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to composite airfoils, and more particularly, to composite airfoils for turbine engines. BACKGROUND

[0002] Turbine engines generally include an engine core having a compressor section, a combustor section, and a turbine section in serial flow arrangement. A fan section can be provided upstream of the compressor section. The compressor section compresses air that is directed to the combustor section where it is mixed with fuel, which is then ignited in the combustor section to generate hot combustion gases. The combustion gases are directed to the turbine section, which extracts energy therefrom for powering the compressor section, as well as for producing useful work to propel an aircraft in flight or to power a load, such as an electrical generator.

[0003] With the advent of composites, composites have been used to make components of turbine engines, particularly in lower temperature regions, such as blades of a fan section. Composites generally include a fiber-reinforced matrix and exhibit a high strength-to-weight ratio. Due to the high strength-to-weight ratio and formability in relatively complex shapes, composites are used in various applications, such as turbine engines or aircraft. For example, composites can be installed on or define a portion of a fuselage, a wing, a rudder, a manifold, an airfoil, or other components of an aircraft or turbine engine. BRIEF DESCRIPTION OF DRAWINGS

[0004] A complete 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, which makes reference to the appended drawings, in which:

[0005] Figure 1 is a schematic cross-sectional view of a turbine engine.

[0006] Figure 2 is a schematic perspective view of an aircraft including a non-ducted or open rotor turbine engine.

[0007] Figure 3 is a schematic perspective view of a composite airfoil and disk assembly suitable for use in a turbine engine according to an example embodiment of the present disclosure. Figure 1 and Figure 2 is a schematic perspective view of a composite airfoil and disk assembly suitable for use in a turbine engine according to an example embodiment of the present disclosure.

[0008] Figure 4 is a schematic cross-sectional view taken along line IV-IV of Figure 3 is a schematic cross-sectional view taken along line IV-IV of

[0009] Figure 5 is a schematic cross-sectional view taken along line IV-IV ofFigure 3 A side view of the composite airfoil, with a portion removed to further illustrate... Figure 4 Airfoil components.

[0010] Figure 6 This is a flowchart illustrating a method for manufacturing an airfoil element having a plywood core in accordance with exemplary embodiments of the present disclosure.

[0011] Figure 7 This is based on exemplary embodiments of the present disclosure. Figure 4 A variation of the schematic cross-sectional view.

[0012] Figure 8 This is based on exemplary embodiments of the present disclosure. Figure 4 Another variation of the schematic cross-sectional view.

[0013] Figure 9 This is based on exemplary embodiments of the present disclosure. Figure 5 A variation of the side view of the composite airfoil shows the sparsity core.

[0014] Figure 10 It is along the exemplary embodiments of this disclosure. Figure 9 The schematic cross-sectional view taken from line XX, wherein the composite airfoil includes a sparsus core.

[0015] Figure 11 This is based on exemplary embodiments of the present disclosure. Figure 10 A variation of the schematic cross-sectional view.

[0016] Figure 12 This is a flowchart illustrating a method for manufacturing a composite airfoil having a sparsity core according to an exemplary embodiment of the present disclosure. Detailed Implementation

[0017] The aspects disclosed herein relate to composite components to be used in engine parts of turbine engines. The composite component is shown as a composite airfoil comprising at least one airfoil element. The airfoil element comprises a plywood core or sparsity core consisting of a set of composite plies and composite wrappings.

[0018] As used herein, the term "ply core" refers to the core defined by the set of composite plies. The ply core includes a pressure surface facing the pressure side of the composite airfoil and a suction surface facing the suction side of the composite airfoil. In this context, the term "facing" means that the first surface may define the second surface, be in contact with the second surface, or be spaced apart from and oriented toward the second surface. For example, when described as a pressure surface facing the pressure side, the pressure surface may define a portion of the pressure side, be in contact with a portion of the pressure side, be spaced apart from and oriented toward the pressure side, or any combination thereof.

[0019] The pressure surface and the suction surface extend between a forward end proximate the leading edge and an aft end proximate the trailing edge. The forward end and the aft end, together with the tip end proximate the tip, define an outer peripheral edge of the core. Optionally, when the composite airfoil includes a mounting mechanism other than a dovetail, the outer peripheral edge can be defined by the root end, the tip end proximate the tip, the forward end, and the aft end.

[0020] As used herein, the term "spar core" is a core having a spar, at least one support in contact with the spar, and a set of composite plies. The set of composite plies is a set of polymer matrix composite plies applied to the spar, the at least one support, or both. As a non-limiting example, the spar of the spar core can include a spar leading edge and a spar trailing edge, with a first support in contact with the spar trailing edge and a second support in contact with the spar leading edge. The set of polymer matrix composite plies can extend over the first support, the spar, the second support, or any combination thereof.

[0021] The composite wrap covers at least a portion of the ply core or the spar core. The composite wrap is in contact with and extends from the pressure surface, over the outer peripheral edge, and to the suction surface. In other words, the composite wrap is in contact with the pressure surface, the outer peripheral edge, and the suction surface while extending or wrapping from the pressure surface, over the outer peripheral edge, and to the suction surface. That is, the composite wrap, shown as a single piece ply, wraps a stack of composite plies, shown as the set of composite plies. A first portion of the composite wrap is in contact with the pressure surface defined at least in part by a first ply of the set of composite plies closest to the pressure side. A second portion of the composite wrap is in contact with the suction surface defined at least in part by a second ply of the set of composite plies closest to the suction side. An end portion of the composite wrap is in contact with the outer peripheral edge of the ply core or the spar core at the tip end, the forward end, the aft end, the root end, or any combination thereof. Alternatively, in different and non-limiting examples, the end portion can be proximate the tip end, the forward end, the aft end, or the root end. As used herein, "proximate" means that the end portion is within 15% or less of the airfoil chord length from the tip end, the forward end, the aft end, or the root end.

[0022] It is contemplated that the composite airfoil having the ply core and the composite wrap can further include a skin that circumscribes the at least one airfoil element to define at least a portion of an outer airfoil surface. The skin can be a laminated skin.

[0023] It is further contemplated that the composite airfoil having the spar core can further include a skin, where the skin can be defined by the set of polymer matrix composite plies and the composite wrap.

[0024] Benefits of the composite airfoil include an increase in strength as the composite wrap wraps and provides strength and structure in at least three dimensions. The increased strength, particularly the increased strength throughout the thickness of the composite airfoil, improves performance during impact events.

[0025] Another benefit is a single ply or composite wrap that encases several sides of the set of composite plies. The encircling feature of the composite wrap improves the laminate of the set of composite plies by encasing the set of composite plies with the composite wrap.

[0026] Additionally, benefits of the composite airfoil include reduced weight due to the use of composite materials.

[0027] It should be appreciated that in non-limiting examples, the present disclosure is applicable to other engine components of a turbine engine, not just airfoils, such as a disk or a combustor liner. Moreover, while described in terms of a core for manufacturing an airfoil, it should be appreciated that the present disclosure can be applicable to any other suitable environment.

[0028] Reference will now be made in detail to the current embodiments of the present disclosure, one or more examples of which are illustrated in the drawings. The detailed description uses numerical and letter designations

[0029] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, unless otherwise indicated, the description herein of any implementation should be considered as an example of one implementation rather than as an exhaustive list of implementations.

[0030] As used herein, the terms "first", "second", or "third" can be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

[0031] The term "at least one of in the context of, for example, "at least one of A, B, and C," is used to mean A alone, B alone, C alone, or any combination of A, B, and C.

[0032] The term "turbomachine" or "turbomachinery" refers to a machine that includes one or more compressors, a heat generating section (e.g., a combustion section), and one or more turbines that together generate a torque output.

[0033] The term "turbine engine" refers to an engine that has a turbomachine as all or a portion of its power source. Example turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, and the like, as well as hybrid-electric versions of one or more of these engines.

[0034] As used herein, the term "upstream" refers to a direction opposite to the direction of fluid flow, while the term "downstream" refers to a direction the same as the direction of fluid flow. The terms "front" or "forward" mean in front of and the terms "rear" or "rearward" mean behind with respect to something. For example, when used in relation to fluid flow, front / forward can mean upstream, while rearward can mean downstream.

[0035] As used herein, the terms "axial" and "axially" refer to a direction and orientation that extends substantially parallel to a centerline of the turbine engine. Further, the terms "radial" and "radially" refer to a direction and orientation that extends substantially perpendicular to the centerline of the turbine engine. For example, in the context of the overall turbine engine, radial refers to a direction along a ray that extends between a central longitudinal axis of the engine and an outer periphery of the engine. Additionally, as used herein, the terms "circumferential" and "circumferentially" refer to a direction and orientation that extends arcuately about the centerline of the turbine engine.

[0036] Unless otherwise defined herein, the terms "coupled," "fixed," "attached" and the like, mean directly coupled, fixed, or attached and also include indirect couplings, fixings or attachments through one or more intermediate components or features unless otherwise stated.

[0037] All directional references (e.g., radial, axial, upper, lower, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, front, forward, rearward, etc.) are for identification purposes only and do not create limitations, particularly as to the position, orientation, or use of the aspects of the disclosure described herein. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and will be

[0038] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Also, as used herein, the term "set" or a "set" of elements can be any number of elements, including only one.

[0039] The term "parallel" means substantially parallel, where a first line and a second line extend such that a third line can be drawn that intersects the first line and the second line, where the third line is within a range of 85 degrees to 95 degrees from both the first line and the second line.

[0040] The term "perpendicular" means substantially perpendicular, where an angle between a first line and a second line is within a range of 85 degrees to 95 degrees.

[0041] The term "tangent" is a straight line or plane that touches a curve or surface at a single point.

[0042] As used herein, the term "composite" means a component having two or more materials. The composite can be a combination of at least two or more metals, non-metals, or a combination of metallic and non-metallic elements or materials. Examples of composites can be, but are not limited to, polymer matrix composites (PMCs), ceramic matrix composites (CMCs), metal matrix composites (MMCs), carbon fibers, polymeric resins, thermoplastics, bismaleimide (BMI) materials, polyimide materials, epoxy resins, glass fibers, silicon matrix materials, silicate glass fibers (e.g., aluminosilicate), carbon fibers, aramid fibers, or combinations thereof. That is, unless explicitly stated, the composite can be, but is not limited to, a PMC, CMC, or MMC.

[0043] 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, can include several layers or several plies of composite material. The stiffness, material, and size of the layers or plies can vary to achieve a desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0044] One or more adhesive layers can be used to form or couple composite components. The adhesive can include a resin and a phenolic resin, where the adhesive can need to be cured at elevated temperatures or other hardening techniques.

[0045] In the present disclosure, when a layer is described as being "on" or "over" another layer or substrate, it is understood that the layers can be in direct contact with one another or have another layer or feature between the layers unless explicitly stated to the contrary. As such, these terms merely describe the relative positioning of the layers with respect to one another and do not necessarily mean "on top of" as the relative position of over or under depends on the orientation of the device relative to the observer.

[0046] As used herein, PMC refers to a class of materials. As an example, PMC materials are defined in part by a prepreg, which is a reinforcing material pre-impregnated with a polymeric matrix material, such as a thermoplastic resin. Non-limiting examples of processes used to produce thermoplastic prepregs include: hot-melt prepregging, in which a fiber reinforcement is pulled through a bath of molten resin; and powder prepregging, in which resin is deposited onto a fiber reinforcement, such as electrostatically onto a fiber reinforcement, which is then adhered to the fiber, such as in an oven or with the aid of heated rollers. The prepregs can be in the form of unidirectional tapes or woven fabrics, which are then stacked on top of one another to form the desired number of stacked plies for a part.

[0047] The multiple layers of prepreg are stacked to the appropriate thickness and orientation of the composite part, and then the resin is cured and solidified to provide a fiber-reinforced composite part. Resins used for PMC matrix materials can generally be classified as either thermoset resins or thermoplastic resins. Thermoplastic resins are generally classified as polymers that can repeatedly soften and flow upon heating and harden upon sufficient cooling due to a physical change rather than a chemical change. Notable example classes of thermoplastic resins include nylons, thermoplastic polyesters, polyaryletherketones, and polycarbonate resins. Specific examples of high-performance thermoplastic resins that have been contemplated for aerospace applications include polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK), and polyphenylene sulfide (PPS). In contrast, thermoset resins do not undergo appreciable softening upon heating, but rather thermally decompose upon sufficient heating, once fully cured into a hard, rigid solid. Notable examples of thermoset resins include epoxy, bismaleimide (BMI), and polyimide resins.

[0048] Instead of using prepreg, in another non-limiting example, by using a thermoplastic polymer, a woven fabric can be utilized. The woven fabric can include, but is not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. A non-prepreg braided architecture can be fabricated in a similar manner. By this method, the fiber volume of the part can be tailored by specifying the relative concentrations of the thermoplastic and reinforcing fibers that have been woven or braided together. Further, different types of reinforcing fibers can be braided or woven together at different concentrations to tailor the properties of the part. For example, glass fibers, carbon fibers, and thermoplastic fibers can all be woven together at different concentrations to tailor the properties of the part. The carbon fibers provide strength to the system, glass fibers can be incorporated to enhance impact properties, which is a design feature of parts located near the engine inlet, and thermoplastic fibers provide bonding for the reinforcing fibers.

[0049] In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of the composite part. Generally, RTM includes applying dry fibers or matrix material to a mold or cavity. The dry fibers or matrix material can include prepreg, braided material, woven material, or any combination thereof.

[0050] Resin can 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. The composite part can require post-cure processing when removed from the mold.

[0051] It is contemplated that the RTM can be a vacuum-assisted process. That is, air in the cavity or mold can be removed and replaced with resin prior to heating or curing. It is further contemplated that the placement of the dry fibers or matrix material can be manual or automated.

[0052] The dry fibers or matrix material can be shaped to shape the composite part or to direct the resin. Optionally, additional layers or reinforcement layers of material different from the dry fibers or matrix material can also be included or added prior to heating or curing.

[0053] The core of the PMC part can be a multi-ply layup or a woven material. In another different and non-limiting example, the core of the PMC part can include one or more of a spar, a foam, or a honeycomb structure with PMC plies applied thereon.

[0054] 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 can 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 (AI2O3), silicon dioxide (SiO2), aluminosilicates (such as mullite), or mixtures thereof), or mixtures thereof.

[0055] Some examples of ceramic matrix materials can 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 (AI2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic components (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) can also be included within the ceramic matrix.

[0056] Typically, specific CMCs can be referred to by 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 / nitride matrix hybrid, and the like. In other examples, CMCs can be composed of a matrix containing oxide-based materials such as aluminum oxide (AI2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof, and reinforcing fibers. The aluminosilicates can include crystalline materials (e.g., mullite (3AI2O3-2SiO2)) as well as glassy aluminosilicates.

[0057] In certain non-limiting examples, the reinforcing fibers can be bundled, coated, or both, prior to being included in the ceramic matrix. For example, the fiber bundles can be formed into reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes can be laid up together to form a preform component. The fiber bundles can be impregnated with a slurry composition prior to forming the preform or after forming the preform. The preform can then be subjected to heat treatment and subsequent chemical treatment, such as silicon melt infiltration, to yield a component formed from a CMC material having a desired chemical composition. For example, the preform can be subjected to cure or burn out to produce a high char residue in the preform and subsequently melt infiltrated with silicon, or subjected to cure or pyrolysis to produce a silicon carbide matrix in the preform and subsequently chemical vapor infiltrated with silicon carbide. Additional steps can be taken to enhance densification of the preform, either before or after chemical vapor infiltration, by infusing the preform with a liquid resin or polymer followed by a heat treatment step to fill the voids with silicon carbide. The CMC materials as used herein can 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.

[0058] The reinforcing fibers can be at least some portion of individual filaments or strands. As used herein, a "ceramic fiber tow," "fiber tow," or simply "tow" refers to a bundle of multiple individual fibers, filaments, or loose strands. The filaments of the tow can be randomly mixed or arranged in a pattern, and the filaments can be continuous or discontinuous. For example, the tow can include broken filaments or filament segments. As another example, the filaments of the tow can be substantially parallel, twisted, or otherwise arranged. The tow can function in substantially the same manner as a single or individual filament. It will also be understood that "individual ceramic filaments" or simply "individual filaments" as used herein refer to a single or non-bundled elongated ceramic member.

[0059] Such materials, along with certain monolithic ceramics (i.e., ceramic materials without reinforcing materials), are particularly suitable for use in higher temperature applications. Further, these ceramic materials are lighter in weight compared to superalloys, yet are able to provide strength and durability to components made therefrom. As such, there is currently consideration for using such materials for many turbine components used in the higher temperature sections of turbine engines, such as airfoils (e.g., turbine blades and vanes), combustors, shrouds, and the like, which would benefit from the lighter weight and higher temperature capability that these materials can provide.

[0060] The term "metal" as used herein means materials that include metals (e.g., but not limited to titanium, iron, aluminum, stainless steel, brass, copper, and nickel alloys). The metallic material or alloy can be a combination of at least two or more elements or materials, at least one of which is a metal.

[0061] Figure 1is a schematic cross-sectional view of a turbine engine 10 for an aircraft. The 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 turbine engine 10 includes a set of circumferentially spaced apart blades or propellers in downstream serial flow relationship including a fan section 18 including a fan 20, a compressor section 22 including a booster or low pressure (LP) compressor 24 and a high pressure (HP) compressor 26, a combustion section 28 including a combustor 30, a turbine section 32 including a HP turbine 34 and a LP turbine 36, and an exhaust section 38. The 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.

[0062] An exterior surface of the turbine engine 10 defined by a casing, such as a nacelle 40, extends from the forward end 14 of the turbine engine 10 toward the aft end 16 of the turbine engine 10. Optionally, the nacelle 40 can cover at least a portion of the compressor section 22, the combustion section 28, the turbine section 32, the exhaust section 38, or a combination thereof.

[0063] The fan section 18 can be positioned at a forward portion of the nacelle 40. The fan section 18 includes a set of fan blades 42 and a set of stationary fan vanes 82 downstream of the set of fan blades 42, both of which are disposed radially about the engine centerline 12. The turbine engine 10 includes any number of sets or groups of rotating blades or propellers disposed upstream of the set of stationary fan vanes 82 (e.g., the set of fan blades 42). As a non-limiting example, the turbine engine 10 can include multiple sets of fan blades 42 or the set of stationary fan vanes 82. The turbine engine 10 is further defined by the position of the fan section 18 relative to the combustion section 28. The fan section 18 can be upstream, downstream, or axially aligned with the axial positioning of the combustion section 28.

[0064] The compressor section 22, the combustion section 28, and the turbine section 32 are collectively referred to as an engine core 44 that generates combustion gases. The engine core 44 is surrounded by an engine casing 46 that is operably coupled with a portion of the nacelle 40 of the turbine engine 10.

[0065] A HP shaft or spool 48 coaxially disposed about the engine centerline 12 of the turbine engine 10 drivingly connects the HP turbine 34 to the HP compressor 26. A LP shaft or spool 50 coaxially disposed about the engine centerline 12 of the 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.

[0066] It should be appreciated that the turbine engine 10 is a direct drive or integrated drive engine that utilizes a reduction gearbox to couple the LP shaft or spool 50 to the fan 20.

[0067] The LP compressor 24 and the HP compressor 26 each include a set of compressor stages 52, 54 in which 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 a 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, with a corresponding static compressor vane 60, 62 positioned upstream and adjacent to the compressor blades 56, 58. Notably, Figure 1 The number of blades, vanes, and compressor stages shown in FIG. 1 is selected for purposes of illustration only, and other numbers are possible.

[0068] The compressor blades 56, 58 for a stage 52, 54 of the compressors 24, 26 are mounted to a disk 61 that is mounted to a corresponding one of the HP spool 48 and the LP spool 50, with each stage 52, 54 having its own disk 61. The static compressor vanes 60, 62 for a stage 52, 54 of the compressors 24, 26 are mounted to the engine case 46 in a circumferential arrangement.

[0069] 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 a fluid flow passing through the stage 64, 66. In a single turbine stage 64, 66, a plurality of turbine blades 68, 70 are arranged in a ring and extend radially outward from a blade platform to a blade tip relative to the engine centerline 12, with a corresponding static turbine vane 72, 74 positioned upstream and adjacent to the turbine blades 68, 70. Notably, Figure 1 The number of blades, vanes, and turbine stages shown in FIG. 1 is selected for purposes of illustration only, and other numbers are possible.

[0070] The turbine blades 68, 70 for a stage of the turbine section 32 are mounted to a disk 71 that is mounted to a corresponding one of the HP spool 48 and the LP spool 50, with each stage 64, 66 having its own disk 71. The static turbine vanes 72, 74 for a stage of the turbine section 32 are mounted to the engine case 46 in a circumferential arrangement.

[0071] The rotating portions of the turbine engine 10, such as the blades 56, 58, 68, 70 in the compressor section 22 and turbine section 32, are also referred to individually or collectively as the rotor 51. Thus, the rotor 51 refers to the combination of rotating elements throughout the turbine engine 10.

[0072] Complementary to the rotor 51, the stationary portions of the turbine engine 10, such as the static vanes 60, 62, 72, 74 in the compressor section 22 and turbine section 32, are also referred to individually or collectively as the stator 63. Thus, the stator 63 refers to the combination of non-rotating elements throughout the turbine engine 10.

[0073] During operation of the turbine engine 10, a portion of the inlet airflow 78 enters the engine core 44 and is described as the working airflow 76, which is used for combustion within the engine core 44.

[0074] More specifically, the working airflow 76 flows into the LP compressor 24, which then pressurizes the working airflow 76, defining a pressurized airflow that is supplied to the HP compressor 26, which further pressurizes the air. The working airflow 76 or pressurized airflow from the HP compressor 26 is mixed with fuel in the combustor 30 and ignited, generating combustion gases. The HP turbine 34 extracts some work from these gases, which drives the HP compressor 26. 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 is ultimately discharged from the turbine engine 10 via the exhaust section 38. The driving 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, combustion section 28, and turbine section 32 of the turbine engine 10.

[0075] The inlet airflow 78 flows through the set of fan blades 42. Subsequently, the inlet airflow 78 flows over at least a portion of the set of stationary fan vanes 82, which directs the inlet airflow 78 so that it is laterally toward the engine centerline 12. The inlet airflow 78 then flows through the set of stationary fan vanes 82 and toward the exhaust section 38. The pylon can mount the turbine engine 10 to an external structure, such as the fuselage, wing, tail, etc. of an aircraft.

[0076] The working airflow 76 and at least some of the inlet airflow 78 converge downstream of the exhaust section 38 of the turbine engine 10. The working airflow 76 and the inlet airflow 78 together form the total thrust of the turbine engine 10.

[0077] A portion of the working airflow 76 is contemplated to be extracted as bleed air 77 (e.g., from the compressor section 22). The bleed air 77 provides an airflow to engine components that require cooling. The temperature of the working airflow 76 exiting the combustor 30 is significantly increased relative to the working airflow 76 within the compressor section 22. Accordingly, the cooling provided by the bleed air 77 can be used to cool engine components in an elevated temperature environment or in a hot portion of the turbine engine 10. In the case of the turbine engine 10, the hot portion of the engine is generally downstream of the combustor 30, particularly the turbine section 32, with the HP turbine 34 being the hottest portion as it is 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 26.

[0078] Figure 2 is a turbine engine 10 suitable for use as Figure 1 is a schematic perspective view of an aircraft 86 including a general non-ducted turbine engine 88 of the turbine engine 10 suitable for use as

[0079] The non-ducted turbine engine 88 includes a circumferentially spaced set of fan blades 100. A circumferentially spaced set of stationary fan vanes 102 is disposed downstream of the circumferentially spaced set of fan blades 100. The fuselage 90 extends between a nose 104 and a tail 106 and includes a fuselage centerline 108 extending therebetween.

[0080] Additionally, while the tail 94 is shown as a T-tail, other tails are contemplated, such as a cruciform tail, an H-tail, a tri-tail, a V-tail, an inverted tail, a Y-tail, a twin tail, a boomerang tail, or a ring tail, all of which are referred to herein as the tail 94.

[0081] Figure 3 is a schematic perspective view of a composite airfoil 110 and disk assembly 112 suitable for use within the turbine engine 10 of Figure 1 or the non-ducted turbine engine 88 of Figure 2 is a schematic perspective view of a composite airfoil 110 and disk assembly 112 suitable for use within the turbine engine 10 of Figure 1 or the non-ducted turbine engine 88 of Figure 1), at least one of the set of compressor blades 56, 58 ( Figure 1 ), the set of turbine vanes 68, 70 ( Figure 1 ), the set of fan blades 42 ( Figure 1 ), or the set of turbine blades 68, 70 ( Figure 1 ). As a non-limiting example, the composite airfoil 110 can be a composite fan blade assembly.

[0082] The disk assembly 112 can be rotating or stationary about a rotational axis 114. The rotational axis 114 can coincide or deviate from an engine centerline (e.g., the engine centerline 12 of the engine 10). Figure 1 The disk assembly 112 includes a plurality of slots 116 extending axially through a radially outer portion of the disk assembly 112 and circumferentially spaced about the disk assembly 112 relative to the rotational axis 114.

[0083] The composite airfoil 110 extends between a leading edge 124 and a trailing edge 126 opposite the leading edge 124 to define a chordwise direction (CHd). The composite airfoil 110 extends between a root 128 and a tip 130 to define a radial direction (Rd). An airfoil outer surface 136 of the composite airfoil 110 is defined by a pressure side 132 and a suction side 134 opposite the pressure side 132. The pressure side 132 and the suction side 134 extend radially in the radial direction (Rd) from the root 128 to the tip 130. The suction side 134 can mirror the pressure side 132 and have the same surface area. However, it is contemplated that the surface area of the suction side 134 can be less than or greater than the surface area of the pressure side 132.

[0084] The leading edge 124 and the trailing edge 126 extend radially in the radial direction (Rd) from the root 128 to the tip 130. A dovetail portion 138 can extend from the root 128 of the composite airfoil 110. Alternatively, a mounting mechanism 129 can replace the dovetail portion 138. The mounting mechanism 129 can extend from the root 128 of the composite airfoil 110 and be used to secure the composite airfoil 110 to the turbine engine 10 or the unducted turbine engine 88. As an example, the mounting mechanism 129 can include a spar or other fastening mechanism. The mounting mechanism 129 can include a composite material, a metallic material, or any combination thereof.

[0085] Optionally, the composite airfoil 110 includes a cladding 120. The cladding 120 can include a metallic material.

[0086] The composite airfoil 110 is coupled to the disk assembly 112 by inserting at least a portion of the dovetail portion 138 into a respective slot of the plurality of slots 116. The composite airfoil 110 is held in place by frictional contact with the slots 116. Additionally or alternatively, the composite airfoil 110 can be coupled to the slots 116 via any suitable coupling method, such as but not limited to welding, adhering, fastening, etc. While only a single composite airfoil 110 is shown, it should be understood that there can be any number of composite airfoils 110 coupled to the disk assembly 112. As a non-limiting example, there can be a number of composite airfoils 110 corresponding to a total number of slots in the plurality of slots 116.

[0087] For ease of reference, a set of relative reference directions and a coordinate system can be applied to the composite airfoil 110. An axial direction (Ad) can extend from front to back and is shown as extending at least partially into the page. The axial direction (Ad) can be arranged parallel to the rotational axis 114. A radial direction (Rd) extends perpendicular to the axial direction (Ad) and can extend perpendicular to the engine centerline 12 Figure 1 ) of the turbine engine 10 Figure 1 ) of the turbine engine 10 Figure 4 ) of the turbine engine 10

[0088] Figure 3 is a schematic cross-sectional view taken along line IV-IV of Figure 3 is a schematic cross-sectional view taken along line IV-IV of

[0089] The first airfoil body element 140 includes a layup core 142 and a composite wrap 144 covering at least a portion of the layup core 142. The layup core 142 can define at least a portion of an airfoil core 143.

[0090] The layup core 142 is defined by a set of composite plies 146. The layup core 142 does not include a foam, a foam-based sheet, or a three-dimensional woven core. Each ply or sheet of the set of composite plies 146 can include a woven pattern, but adjacent plies of the set of composite plies 146 are not woven together. It is contemplated that the layup core 142, the airfoil core 143 is composed of one or more sets of composite plies 146.

[0091] The set of composite plies 146 of the first airfoil element 140 includes a pressure ply 162 nearest the pressure side 132 and a suction ply 166 nearest the suction side 134. The pressure surface 152 of the ply core 142 is defined at least in part by the pressure ply 162 nearest the pressure side 132. The suction surface 154 of the ply core 142 is defined at least in part by the suction ply 166 nearest the suction side 134.

[0092] The pressure surface 152 and the suction surface 154 of the ply core 142 extend between a forward end 156 of the airfoil core 143 proximate the leading edge 124 and an aft end 158 of the airfoil core 143 proximate the trailing edge 126. While shown as being defined by a single ply, the pressure surface 152, the suction surface 154, or both can be defined by any number of plies.

[0093] As an example, the set of composite plies 146 is shown as having five layers, with the distal end of the plies terminating in and in contact with the composite wrap 144 of the first airfoil element 140. However, any number of layers or plies of plies can be envisioned to define the ply core 142.

[0094] A subset of the set of composite plies 146 can extend from the forward end 156 to the aft end 158, however any number of plies, including zero plies, can extend from the forward end 156 to the aft end 158.

[0095] As shown, the thickness of each ply of the set of composite plies 146 can vary in one or more directions, such as a chordwise direction (CHd), as an example. Alternatively, the thickness of each ply or each ply of plies can remain constant.

[0096] It is also envisioned that the number of layers, plies of plies, ply thickness, or combinations thereof can vary in an axial direction (Ad) Figure 3 ), a radial direction (Rd) Figure 7 ), or both.

[0097] The composite wrap 144 of the first airfoil element 140 is in contact with and extends from the pressure surface 152 of the ply core 142, across the aft end 158, and to the suction surface 154. That is, the composite wrap 144 wraps the aft end 158 of the set of composite plies 146.

[0098] The composite wrap 144 can include a first portion 160, a second portion 164, and an end portion 168. The first portion 160 is in contact with the pressure surface 152. The second portion 164 is in contact with the suction surface 154. The end portion 168 of the composite wrap 144 is in contact with the aft end 158 of the ply core 142.

[0099] The first portion 160 of the composite wrap 144 of the first airfoil element 140 extends a first chordal distance 170 in the chordal direction (CHd). The first chordal distance 170 can be measured from an aftward end 172 of the composite wrap 144 to a pressure end 174. The aftward end 172 is a point of the composite wrap 144 closest to or at the trailing edge 126. The pressure end 174 is a point of the composite wrap 144 along the pressure surface 152 in the chordal direction (CHd) furthest from the aftward end 172. The first chordal distance 170 is in a range of 2-100% of an airfoil chordal length 150. The airfoil chordal length 150 is measured from the leading edge 124 to the trailing edge 126 of the composite airfoil 110. For example, the first chordal distance 170 can be in a range of 2-50%, 2-40%, 2-30%, 5-50%, 5-40%, 5-30%, or 10-30% of the airfoil chordal length 150. The first portion 160 of the composite wrap 144 of the first airfoil element 140 having the first chordal distance 170 selected can improve the coupling between the composite wrap 144 and the layup core 142. Further, the first portion 160 of the composite wrap 144 provides strength and shape to the composite airfoil 110 along the pressure surface 152.

[0100] The second portion 164 of the composite wrap 144 extends a second chordal distance 176 in the chordal direction (CHd). The second chordal distance 176 can be measured from the aftward end 172 of the composite wrap 144 to a suction end 180. The suction end 180 is a point of the composite wrap 144 along the suction surface 154 in the chordal direction (CHd) furthest from the aftward end 172. The second chordal distance 176 is in a range of 2-100% of the airfoil chordal length 150. For example, the second chordal distance 176 is in a range of 2-50%, 2-40%, 2-30%, 5-50%, 5-40%, 5-30%, or 10-30% of the airfoil chordal length 150. The second portion 164 of the composite wrap 144 of the first airfoil element 140 having the second chordal distance 176 selected can improve the coupling between the composite wrap 144 and the layup core 142. Further, the second portion 164 of the composite wrap 144 provides strength and shape to the composite airfoil 110 along the suction surface 156.

[0101] When combined, the first chordal distance 170 and the second chordal distance 176 can improve the strength of the composite airfoil 110.

[0102] As shown, as an example, a first chordwise distance 170 of the composite wrap 144 can be greater than a second chordwise distance 176 of the composite wrap 144 of the first airfoil element 140. Alternatively, in different and non-limiting examples, the first chordwise distance 170 can be equal to or less than the second chordwise distance 176.

[0103] As a non-limiting example, the composite wrap 144 includes one or more of glass fibers, silicate glass fibers (e.g., aluminosilicate), carbon fibers, or aramid fibers. Although shown as a single layer, it is contemplated that the composite wrap 144 can include multiple layers. It is contemplated that the multiple layers can have different thicknesses, different surface areas, or both.

[0104] When the first airfoil element 140 is provided structure via a single layup extending from the pressure surface 152, over the trailing end 158, and to the suction surface 154, the composite wrap 144 of the first airfoil element 140 provides strength in at least three planes. That is, the composite wrap 144 of the first airfoil element 140 includes a portion that lies in a plane parallel to a portion of the pressure side 132, another portion that lies in a plane parallel to a portion of the suction side 134, and yet another portion that lies in a plane tangent to the trailing edge 126, which portions add strength to the composite airfoil 110 in each of these planes.

[0105] The second airfoil element 141 includes a layup core 182 and a composite wrap 184 covering at least a portion of the layup core 182. The layup core 182 is defined by a set of composite layups 186.

[0106] The composite wrap 184 is in contact with and extends from the pressure surface 152, over the leading end 156 of the layup core 182, and to the suction surface 154. That is, the composite wrap 184 wraps the leading end 156 of the set of composite layups 186. In other words, a distal end of some or all of the set of composite layups 186 contacts an inner surface of the composite wrap 184 of the second airfoil element 141.

[0107] The pressure surface 152 facing the pressure side 132 and the suction surface 154 facing the suction side 134 are defined by the same pressure layups 162 and suction layups 166 as the pressure layups 162 and suction layups 166 of the first airfoil element 140. However, it is contemplated that one or both of the pressure surface 152 or the suction surface 154 can be defined by different layups at different locations, such as in the chordwise direction (CHd).

[0108] The composite wrap 184 of the second airfoil element 141 can include a first portion 188, a second portion 190, and an end portion 192. The first portion 188 contacts the pressure surface 152, while the second portion 190 contacts the suction surface 154. The end portion 192 of the composite wrap 184 of the second airfoil element 141 contacts the leading end 156.

[0109] The first portion 188 of the composite wrap 184 extends a first chordal distance 196 in the chordal direction (CHd). The first chordal distance 196 can be measured from a forward end 198 of the composite wrap 184 to a pressure end 200. The forward end 198 is positioned at a point of the composite wrap 184 closest to or at the leading edge 124. The pressure end 200 can be a point of the composite wrap 184 extending in the chordal direction (CHd) along the pressure surface 152 furthest from the forward end 198. The first chordal distance 196 is in a range of 2% to 100% of the airfoil chordal length 150. For example, the first chordal distance 196 can be in a range of 2% to 50%, 2% to 40%, 2% to 30%, 5% to 50%, 5% to 40%, 5% to 30%, or 10% to 30% of the airfoil chordal length 150.

[0110] The set of composite plies 186 of the second airfoil element 141 can include one or more of the same plies as the set of composite plies 146 of the first airfoil element 140. It is contemplated that the set of composite plies 186 of the second airfoil element 141 can include anywhere from all the same plies of the set of composite plies 146 of the first airfoil element 140 to none of the same plies. Alternatively, the set of composite plies 186 of the second airfoil element 141 can be similar to the set of composite plies 146 of the first airfoil element 140, where the set of composite plies 186 is where the composite wrap 184 of the second airfoil element 141 wraps the ply core 182. The set of composite plies 146 of the first airfoil element 140 is where the composite wrap 184 of the first airfoil element 140 wraps the ply core 142, where the ply core 142 of the first airfoil element 140 and the ply core 182 of the second airfoil element 141 can define portions of the airfoil core 143 of the composite airfoil 110.

[0111] The total pressure wrap distance is determined by adding the sum of the first chordwise distances together. That is, for example, the total pressure wrap distance of the compound airfoil 110 can be the sum of the first chordwise distance 170 of the first airfoil body element 140 and the first chordwise distance 196 of the second airfoil body element 141. The total pressure wrap distance can be in the range of 2% to 100% of the airfoil chord length 150. For example, the total pressure wrap distance can be in the range of 2% to 50%, 2% to 40%, 2% to 30%, 5% to 50%, 5% to 40%, 5% to 30%, 10% to 50%, 10% to 40%, or 15% to 40% of the airfoil chord length 150.

[0112] The second portion 190 of the compound wrap 184 extends a second chordwise distance 202 in the chordwise direction (CHd). The second chordwise distance 202 can be measured from the forward end 198 of the compound wrap 184 to the suction end 204. The suction end 204 is the point of the compound wrap 184 that extends the farthest in the chordwise direction (CHd) along the suction surface 154 from the forward end 198. The second chordwise distance 202 is in the range of 2% to 100% of the airfoil chord length 150. For example, the second chordwise distance 202 can be in the range of 2% to 50%, 2% to 40%, 2% to 30%, 5% to 50%, 5% to 40%, 5% to 30%, or 10% to 30% of the airfoil chord length 150.

[0113] The total suction wrap distance is determined by adding the sum of the second chordwise distances together. That is, for example, the total suction wrap distance is determined by adding the second chordwise distance 176 of the first airfoil body element 140 and the second chordwise distance 202 of the second airfoil body element 141 together. The total suction wrap distance can be in the range of 2% to 100% of the airfoil chord length 150. For example, the total suction wrap distance can be in the range of 2% to 50%, 2% to 40%, 2% to 30%, 5% to 50%, 5% to 40%, 5% to 30%, 10% to 50%, 10% to 40%, or 15% to 40% of the airfoil chord length 150.

[0114] As shown, by way of example, the first chordwise distance 196 can be greater than the second chordwise distance 202. Alternatively, in different and non-limiting examples, the first chordwise distance 196 of the compound wrap 184 can be equal to or less than the second chordwise distance 202 of the compound wrap 184.

[0115] When the second airfoil element 141 is provided via a unitary layup structure extending from the pressure surface 152, over the leading end 156, and to the suction surface 154, the composite wrap 184 of the second airfoil element 141 provides strength in at least three planes. That is, the composite wrap 184 of the second airfoil element 141 includes a portion lying within a plane parallel to a portion of the pressure side 132, another portion lying within a plane parallel to a portion of the suction side 134, and yet another portion lying within a plane tangent to the leading edge 124, which portions add strength to the composite airfoil 110 within each of these planes.

[0116] Optionally, in various and non-limiting examples and as Figure 5 Further shown, the composite wrap 144 can wrap the trailing end 158 and the leading end 156 by extending the length of the pressure surface 152, or extending the length of the suction surface 154, or both.

[0117] Optionally, the composite airfoil 110 can include a skin 208 that surrounds the first airfoil element 140 and the second airfoil element 141 to define at least a portion of the airfoil outer surface 136. The skin 208 can be a laminated skin. That is, the skin 208 can be formed as a set of laminated layers disposed around or about the first airfoil element 140 and the second airfoil element 141. The skin 208 is distinct from the set of composite plies 146, 186. For example, one or more of the weave, fiber direction, or material can vary between the set of composite plies 146 and the skin 208. That is, the skin 208 can be a fabric that is not a unidirectional fiber like the set of composite plies 146. In non-limiting examples, it is contemplated that the skin can be pre-impregnated, formed by automated fiber placement, formed by manually placed plies or dry fiber laminates. In non-limiting examples, such laminated layers forming the skin 208 can be formed by resin transfer molding (RTM), partial RTM, same qualified resin transfer molding (SQRTM), or out-of-autoclave.

[0118] As shown, by way of example, the skin 208 can include skin plies 212a, 212b extending between the composite wrap 144 of the first airfoil element 140 and the composite wrap 184 of the second airfoil element 141. The skin 208, the skin plies 212a, 212b, or both can be applied to at least a portion of the ply core 142, the set of composite plies 146, 186, or both.

[0119] Each ply or composite wrap 144, 184 in the set of composite plies 146, 186 can be composed of a composite material such as carbon or carbon fiber, glass or glass fiber, nylon, rayon, poly-para-phenylene-terephthalimide fiber or other aramid fiber, while other materials such as nickel, steel, titanium, metal fiber, or ceramic composite and various combinations thereof can also be contemplated in non-limiting examples. It is contemplated that one or more plies in the set of composite plies 146, 186 can be made of a different material than the composite wrap 144, 184. It is also contemplated that one or more plies in the set of composite plies 146, 186, the composite wrap 144, 184, or one or more plies in the set of composite plies 146, 186 and the composite wrap 144, 184 can be made of a different material than the skin 208.

[0120] Figure 4 is a zoomed-in view of the composite airfoil 110 with the skin 208 removed for ease of understanding Figure 3 As an example, at least one airfoil element of the composite airfoil 110 is shown to include a set of airfoil elements including a first airfoil element 140, a second airfoil element 141, and a third airfoil element 214.

[0121] An outer peripheral edge 220 of the composite airfoil 110 is defined by the leading end 156, the trailing end 158, and a tip 222. The tip 222 connects the leading end 156 and the trailing end 158, with the tip 222 being proximate to the sharp 130 Figure 4

[0122] The first airfoil element 140 includes a composite wrap 144 covering at least a portion of the ply core 142, with the composite wrap 144 being in contact with and extending from the pressure surface 152, past the trailing end 158, and to the suction surface 154. However, it is contemplated that the composite wrap 144 can be in contact with and extend from the pressure surface 152, past any one or more portions of the outer peripheral edge 220, and to the suction surface 154. That is, as an example, the composite wrap 144 can be in contact with and extend from the pressure surface 152, past one or more of the leading end 156, the trailing end 158, or the tip 222, and to the suction surface 154.

[0123] The composite wrap 144 can include one or more wraps shown as a first composite wrap 144a and a second composite wrap 144b as non-limiting examples. That is, the composite wrap 144 can be a plurality of composite wraps including at least the first composite wrap 144a and the second composite wrap 144b. However, it is contemplated that the composite wrap 144 can include any number of composite wraps wrapping the set of composite plies 146 Figure 3 )​

[0124] The first composite wrap 144a can extend in the radial direction (Rd) from a tip edge 224 to a root edge 226, where the tip edge 224 is the portion of the first composite wrap 144a closest to the tip 222 and the root edge 226 is the portion of the first composite wrap 144a closest to the root 128.

[0125] The first composite wrap 144a extends in the radial direction (Rd) along the outer perimeter edge 220 a first radial distance 228. The first radial distance 228 is in a range of 2% to 100% of a airfoil radial length 230. For example, the first radial distance 228 is in a range of 5% to 80%, 5% to 60%, 10% to 80%, 10% to 60%, 15% to 80%, 15% to 60%, or 20% to 60% of the airfoil radial length 230. The airfoil radial length 230 can be measured from the root 128 to the tip 222. Alternatively, it is contemplated that the airfoil radial length 230 can be measured from the root 128 to the tip portion 130. Figure 3 Covering the outer perimeter edge 220 by one or more wraps, such as the first composite wrap 144a or the second composite wrap 144b, can improve strength across the entire airfoil thickness while minimally increasing the weight of the composite airfoil 110. The thickness of the composite airfoil 110 can be defined as generally perpendicular to the chordwise direction (CHd).

[0126] The second composite wrap 144b can extend in the radial direction (Rd) from a tip edge 234 to a root edge 236, where the tip edge 234 is the portion of the second composite wrap 144b closest to the tip 222 and the root edge 236 is the portion of the second composite wrap 144b closest to the root 128.

[0127] The second composite wrap 144b extends in the radial direction (Rd) along the outer perimeter edge 220 a second radial distance 238. The second radial distance 238 is in a range of 2% to 100% of the airfoil radial length 230. For example, the second radial distance 238 is in a range of 5% to 80%, 5% to 60%, 10% to 80%, 10% to 60%, 15% to 80%, 15% to 60%, or 20% to 60% of the airfoil radial length 230.

[0128] The total radial coverage distance 240 can be the total length of the trailing end 158 covered by one or more composite wraps, shown by way of example as the first composite wrap 144a and the second composite wrap 144b. That is, for example, the total radial coverage distance 240 can be measured from the tip edge 234 of the second composite wrap 144b to the root edge 226 of the first composite wrap 144a. The total radial coverage distance 240 can be in the range of 2% to 100% of the airfoil radial length 230. For example, the total radial coverage distance 240 can be in the range of 10% to 90%, 10% to 70%, 15% to 90%, 15% to 70%, 20% to 90%, 20% to 70%, 30% to 90%, 30% to 70%, 40% to 90%, 40% to 70%, 50% to 90%, or 50-70% of the airfoil radial length 230.

[0129] As shown, the overlap region 242 can be defined by the radial overlap of the first composite wrap 144a and the second composite wrap 144b, by way of example. In different and non-limiting examples, the first composite wrap 144a and the second composite wrap 144b can be spaced apart. That is, the first composite wrap 144a and the second composite wrap 144b can be discrete or non-overlapping. In yet another different and non-limiting example, the first composite wrap 144a can abut the second composite wrap 144b in the radial direction (Rd).

[0130] The third airfoil element 214 includes a layup core 246. Optionally, the layup core 246 can be another portion of the airfoil core 143( Figure 3 ). The layup core 246 can include a set of layups, where the set of layups can be defined by one or more of the same layups as the layup core 142 of the first airfoil element 140, the layup core 182 of the second airfoil element 141, or both.

[0131] The composite wrap 248 covers at least a portion of the layup core 246 of the third airfoil element 214. The composite wrap 248 extends from and is in contact with the pressure surface 152, wraps over at least a portion of the tip 222 of the outer peripheral edge 220, and extends to and is in contact with the suction surface 154. The radial coverage distance 250 can be measured in the radial direction (Rd) from a tip edge 252 to a root edge 254, where the tip edge 252 is the portion of the composite wrap 248 closest to the tip 222 and the root edge 254 is the portion of the composite wrap 248 closest to the root 128.

[0132] The radial coverage distance 250 of the third airfoil element 214 is in the range of 2% to 100% of the radial length 230 of the airfoil. For example, the radial coverage distance 250 is in the range of 5% to 80%, 5% to 60%, 10% to 80%, 10% to 60%, 15% to 80%, 15% to 60%, or 20% to 60% of the radial length 230 of the airfoil.

[0133] The composite enclosure 248 of the third airfoil element 214 can have a chord length 256 measured along the tip 222 in the chord direction (CHd). The chord length 256 can be within the chord length of the airfoil (150...). Figure 6 The percentage ranges from 2% to 100%.

[0134] As an example, the first airfoil element 140, the second airfoil element 141, and the third airfoil element 214 in this group of airfoil elements are shown spaced apart in the chordal direction (CHd), the radial direction (Rd), or both the chordal direction (CHd) and the radial direction (Rd). Although shown as spaced apart, it is conceivable that adjacent airfoil elements in this group of airfoil elements may be adjacent or partially overlap in the chordal direction (CHd), the radial direction (Rd), or both the chordal direction (CHd) and the radial direction (Rd).

[0135] Figure 1 The manufacture of a turbine engine 10 is shown. Figure 4 Composite airfoil elements (such as composite airfoil 110) Figure 7 Method 300 for airfoil elements 140, 141. The method includes stacking multiple plies at 302 to form the set of composite plies 146, 186. It is conceivable that stacking multiple plies at 302 to form the set of composite plies 146, 186 includes stacking the multiple plies on at least a portion of the first portions 160, 188 of the composite envelopes 144, 184.

[0136] Optionally, at 303, the composite layup 146, 186 can be cured.

[0137] At 304, composite wrappers 144, 184, or the remainder of composite wrappers 144, 184, are applied to the composite ply 146, 186. Composite wrappers 144, 184 cover and contact portions of the pressure surface 152, outer peripheral edge 220, and suction surface 154 of the composite ply 146, 186.

[0138] That is, the composite wrap 144, 184 is wrapped around the set of composite plies 146, 186 such that a first portion 160, 188 of the composite wrap 144, 184 is in contact with the pressure surface 152, a second portion 164, 190 is in contact with the suction surface 154 of the set of composite plies 146, 186, and an end portion 168, 192 is in contact with the outer peripheral edge 220. The set of composite plies 146, 186 defines a set of distal ends at the aft end 172 or the forward end 198, the set of distal ends being in contact with the end portion 168, 192 of the composite wrap 144, 184.

[0139] Optionally, if the set of composite plies 146, 186 is cured at 303, an adhesive can be applied between the composite wrap 144, 184 and the set of composite plies 146, 186 to apply the composite wrap 144, 184 to the set of composite plies 146, 186.

[0140] At 306, the composite wrap 144, 184, the set of composite plies 146, 186, or both the composite wrap 144, 184 and the set of composite plies 146, 186 can be cured. Curing can include additional curing of any of the set of composite plies 146, 186 cured at 303.

[0141] Figure 4 is Figure 4 a variant of the schematic cross-section showing the interior of the composite airfoil 410. The composite airfoil 410 is similar to the composite airfoil 110 Figure 8 ), and thus, similar parts of the composite airfoil 410 will be identified with like numerals increased by 300, it being understood that the description of the similar parts of the composite airfoil 110 apply to the composite airfoil 410 unless otherwise noted.

[0142] The composite airfoil 410 includes at least one airfoil body element, shown by way of example as a set of airfoil body elements including a first airfoil body element 445 and a second airfoil body element 447. As shown, by way of example, the first airfoil body element 445 abuts the second airfoil body element 447 within the thickness of the composite airfoil 410. In different and non-limiting examples, it is contemplated that the second airfoil body element 447 can be spaced apart from the first airfoil body element 445 by any dimension. In yet a different and non-limiting example, it is further contemplated that one or more portions of the second airfoil body element 447 overlap one or more portions of the first airfoil body element 445.

[0143] The first airfoil element 445 includes a set of composite plies 446 defining a ply core 442 and a composite wrap 444. The set of composite plies 446 can include, for example, five plies 449a, 449b, 449c, 449d, 449e. However, any number of layers or plies can be envisioned to define the ply core 442. The five plies 449a, 449b, 449c, 449d, 449e include first distal ends 451a, 451b, 451c, 451d, 451e and second distal ends 453a, 453b, 453c, 453d, 453e. Each ply in the set of composite plies 446 can include fibers having a different fiber direction than an adjacent ply in the set of composite plies 446. It is envisioned that if two plies are in contact with each other, one ply has fibers at a non-zero angle to the fibers of the other ply. It is further envisioned that adjacent plies can have different weave patterns.

[0144] For the five plies 449a, 449b, 449c, 449d, 449e, the pressure ply 449e positioned closest to the pressure side 432 defines or faces the pressure surface 452. The suction ply 449a closest to the suction side 134 defines or faces the suction surface 454. The first distal ends 451a, 451b, 451c, 451d, 451e can be located at an aft end 458 proximate the trailing edge 426 of the composite airfoil 410. The second distal ends 453a, 453b, 453c, 453d, 453e can be located at a forward end 456 proximate the leading edge 424 of the composite airfoil 410.

[0145] A set of ply thicknesses 455 of the set of composite plies 446 is measured from the pressure ply 449e to the suction ply 449a. That is, the set of ply thicknesses 455 is the thickness of the ply core 442. For example, the set of ply thicknesses 455 can be measured generally perpendicular to the chordwise direction (CHd) from the pressure surface 452 to the suction surface 454. The set of ply thicknesses 455 can vary at least in the chordwise direction (CHd). When the set of ply thicknesses 455 is measured proximate the airfoil thickness 457, the set of ply thicknesses 455 is in the range of 1-100% of the airfoil thickness 457 measured from the pressure side 432 to the suction side 434. As used herein, “proximate” the airfoil thickness 457 measuring the set of ply thicknesses 455 means that the set of ply thicknesses 455 and the airfoil thickness 457 are measured within 5% or less of the airfoil chordwise length 450 from each other. It is envisioned that when the set of ply thicknesses 455 is measured proximate the airfoil thickness 457, the set of ply thicknesses 455 is in the range of 10-50% of the airfoil thickness 457.

[0146] As an example, the composite wrap 444 extends from the suction surface 454, over the aft end 458, and to the pressure surface 452. The composite wrap 444 extends the entire length of the pressure surface 452 and over the forward end 456, and again to the suction surface 454. That is, the composite wrap 444 wraps the aft end 458 and the forward end 456 while extending the length of the pressure surface 452.

[0147] While shown in contact with the first distal ends 451a, 451b, 451c, 451d, 451e and the second distal ends 453a, 453b, 453c, 453d, 453e, it is contemplated that the composite wrap 444 can be in contact with a subset of the first distal ends 451a, 451b, 451c, 451d, 451e, a subset of the second distal ends 453a, 453b, 453c, 453d, 453e, or both.

[0148] In other words, the composite wrap 444 can include a first portion 460 in contact with the pressure surface 452, a second portion 464 in contact with the suction surface 454, and an end portion 468 in contact with the outer peripheral edge 421 of the composite airfoil 410, shown as an example as the forward end 456 and the aft end 458.

[0149] The second airfoil element 447 includes a set of composite plies 486 and a composite wrap 484, where the set of composite plies 486 define a ply core 482.

[0150] The pressure plies 462 positioned closest to the pressure side 132 define a pressure surface 463. The suction plies 470 positioned closest to the suction side 134 define a suction surface 471.

[0151] A set of ply thicknesses 465 of the set of composite plies 486 is measured from the pressure plies 462 to the suction plies 470. For example, the set of ply thicknesses 465 can be measured generally normal to the chordwise direction (CHd) from the pressure surface 463 to the suction surface 471. The set of ply thicknesses 465 can vary at least in the chordwise direction (CHd). When the set of ply thicknesses 465 is measured adjacent to the airfoil thickness 457, the set of ply thicknesses 465 within the composite wrap 484 is in a range of 1% to 100% of the airfoil thickness 457. For example, when the set of ply thicknesses 465 is measured adjacent to the airfoil thickness 457, the set of ply thicknesses 465 is in a range of 5% to 60%, 5% to 50%, 5% to 40%, 10% to 60%, 10% to 50%, 10% to 40%, 15% to 60%, 15% to 50%, or 15% to 40% of the airfoil thickness 457.

[0152] As an example, the composite wrap 484 extends from the suction surface 471, over the aft end 473, to the pressure surface 463.

[0153] Optionally, an adhesive 475 can be located between one or more portions of the composite wrap 484 and one or more portions of the set of composite plies 486. The adhesive 475 can couple the composite wrap 484 to the set of composite plies 486.

[0154] Figure 4 is a variant of the schematic cross-section of Figure 4 , showing the interior of the composite airfoil 510. The composite airfoil 510 is similar to the composite airfoil 110 Figure 9 ), and thus, similar parts of the composite airfoil 510 will be identified with like numerals increased by 400, it being understood that the description of similar parts of the composite airfoil 110 apply to the composite airfoil 510, unless otherwise noted.

[0155] As an example, the at least one airfoil element is shown as a set of airfoil elements including a first airfoil element 540 and a second airfoil element 541. As shown, as an example, a portion of the first airfoil element 540 overlaps a portion of the second airfoil element 541, however any configuration can be contemplated.

[0156] The first airfoil element 540 includes a set of composite plies 546 and a composite wrap 544, where the set of composite plies 546 defines a ply core 542. The set of composite plies 546 defines a pressure surface 552 and a suction surface 554.

[0157] As an example, the composite wrap 544 is a set of discrete composite wraps, shown as a first composite wrap 544a and a second composite wrap 544b. The first composite wrap 544a can abut the second composite wrap 544b at inner surfaces 577, 579.

[0158] The second airfoil element 541 includes a set of composite plies 586 and a composite wrap 584, where the set of composite plies 586 defines a ply core 582. The set of composite plies 586 defines a pressure surface 563 to a suction surface 571.

[0159] The composite wrap 584 extends around the leading end 556 from the suction surface 571 to the pressure surface 563. As an example, the composite wrap 584 extends along the pressure surface 563 in the chordwise direction (CHd) toward the trailing end 558 such that a portion of the composite wrap 584 overlaps a portion of the second composite wrap 544b of the first airfoil element 540.

[0160] Figure 5 is a variant of Figure 3 , showing a side view of the composite airfoil 1110, with the overwrap 120 Figure 4 removed for ease of understanding.

[0161] Composite airfoil 1110 is similar to composite airfoil 110 Figure 5 and Figure 3 ), therefore, similar parts of composite airfoil 1110 will be identified with like numerals increased by 1000, and it should be understood that the description of the similar parts of composite airfoil 110 applies to composite airfoil 1110 unless otherwise noted.

[0162] An outer perimeter edge 1220 of composite airfoil 1110 is defined by a leading end 1156, a trailing end 1158, a tip end 1222 proximate to tip 1130, and a root end 1223 proximate to root 1128.

[0163] Composite airfoil 1110 includes a mounting mechanism 129 in place of dovetail portion 138 Figure 5 and Figure 10 ). Mounting mechanism 129 is shown as including a spar 1159. Spar 1159 is shown as having a metallic portion 1193 and a composite portion 1195, for example, however, spar 1159 can be a metallic spar or a composite spar.

[0164] Metallic portion 1193 of spar 1159 is a metallic base that extends through root 1128 into composite airfoil 1110, as a non-limiting example. Metallic portion 1193 can receive composite portion 1195 of spar 1159, where composite portion 1195 extends from metallic portion 1193 in a radial direction (Rd) toward tip 1130. While shown as transitioning within composite airfoil 1110, it is contemplated that the transition from metallic portion 1193 to composite portion 1195 can occur at root 1128 or otherwise outside of composite airfoil 1110.

[0165] Figure 9 is a schematic cross-sectional view taken along line X-X of Figure 9 showing an interior of composite airfoil 1110, where composite airfoil 1110 includes a spar core 1142.

[0166] Composite airfoil 1110 includes an airfoil outer surface 1136 that defines a pressure side 1132 and a suction side 1134 opposite pressure side 1132. Pressure side 1132 and suction side 1134 extend between leading edge 1124 and trailing edge 1126 in a chordal direction (CHd).

[0167] The composite airfoil 1110 includes a spar core 1142 and composite wraps, shown as a first composite wrap 1144a and a second composite wrap 1144b. The spar core 1142 includes a spar 1159, at least one support (shown as a first support 1161a and a second support 1161b), and a set of polymeric matrix composite plies 1146. The set of polymeric matrix composite plies 1146 covers the spar 1159, the first support 1161a, the second support 1161b, or any combination thereof.

[0168] The spar 1159 has a spar leading edge 1167 facing the leading edge 1124 of the composite airfoil 1110 and a spar trailing edge 1169 facing the trailing edge 1126 of the composite airfoil 1110. The first support 1161a is coupled to the spar leading edge 1167, while the second support 1161b is coupled to the spar trailing edge 1169. Optionally, the first support 1161a, the second support 1161b, or both can be coupled to a composite portion 1195 of the spar 1159. Figure 9

[0169] The at least one support, shown as the first support 1161a and the second support 1161b, can include a foam. It is contemplated that the first support 1161a, the second support 1161b, or both can additionally or alternatively include one or more of titanium, aluminum, fiberglass, polyurethane, thermoplastic, or honeycomb structure.

[0170] The spar core 1142 includes a pressure surface 1152 facing the pressure side 1132 of the composite airfoil 1110 and a suction surface 1154 facing the suction side 1134 of the composite airfoil 1110. The pressure surface 1152 and the suction surface 1154 extend between a forward end 1156 proximate the leading edge 1124 of the composite airfoil 1110 and an aft end 1158 proximate the trailing edge 1126. The pressure surface 1152, the suction surface 1154, or both can be defined by one or more plies of the set of polymeric matrix composite plies 1146. It is contemplated that the first support 1161a, the second support 1161b, the spar 1159, or any combination thereof can define a portion of the pressure surface 1152, the suction surface 1154, or both.

[0171] ​The set of polymer matrix composite plies 1146 can include a first ply 1181 facing the pressure surface 1152 and a second ply 1183 facing the suction surface 1154. A first composite wrap 1144a covers the first ply 1181 and extends, for example, over the leading end 1156 to cover the second ply 1183. That is, the first composite wrap 1144a can wrap the leading end 1156 and cover at least a portion of the pressure surface 1152 and at least a portion of the suction surface 1154. In other words, the first composite wrap 1144a can define a portion of the leading edge 1124 of the composite airfoil 1110.

[0172] A second composite wrap 1144b covers the first ply 1181 and extends, for example, over the trailing end 1158 to cover the second ply 1183. That is, the second composite wrap 1144b can wrap the trailing end 1158 and cover at least a portion of the pressure surface 1152 and at least a portion of the suction surface 1154. In other words, the second composite wrap 1144b can define a portion of the trailing edge 1126 of the composite airfoil 1110.

[0173] The first composite wrap 1144a and the second composite wrap 1144b can include end surfaces 1191a, 1191b. The first composite wrap 1144a and the second composite wrap 1144b can abut one another at the end surfaces 1191a, 1191b.

[0174] Additionally or alternatively, the first composite wrap 1144a can have a first end 1187 and the second composite wrap 1144b has a second end 1189. The first end 1187 and the second end 1189 can overlap. While shown with the first end 1187 extending above the second end 1189, it is contemplated that the second end 1189 can extend above the first end 1187.

[0175] While shown with the first composite wrap 1144a wrapping the leading end 1156 and the second composite wrap 1144b wrapping the trailing end 1158, either of the first composite wrap 1144a or the second composite wrap 1144b can wrap both the leading end 1156 and the trailing end 1158, or any one or more portions of the outer peripheral edge 1220 Figure 11 ) of the composite airfoil 1110.

[0176] The first composite wrapper 1144a, the second composite wrapper 1144b, and the set of polymer matrix composite layups 1146 may define a skin 1208. The outer portion of the skin 1208 may define the airfoil outer surface 1136 of the composite airfoil 1110. The skin 1208 may include a polymer resin and one or more of glass fibers, silicate glass fibers (e.g., aluminosilicates), carbon fibers, or aramid fibers. Additionally or alternatively, the first composite wrapper 1144a, the second composite wrapper 1144b, or the set of polymer matrix composite layups 1146 may include a polymer resin and one or more of glass fibers, carbon fibers, or aramid fibers.

[0177] Adhesive 1185 is shown between the skin 1208 and the first support 1161a, the second support 1161b and the spar 1159; however, adhesive 1185 may be located between any two parts of the composite airfoil 1110.

[0178] Figure 10 yes Figure 7 A variant of the schematic cross-sectional view shows the interior of the composite airfoil 1410, which includes a sparsor core 1442. The composite airfoil 1410 is similar to the composite airfoil 410. Figure 9 ) and composite airfoil 1110 ( Figure 10 and Figure 7 Therefore, a similar portion of the composite airfoil 1410 will be used similarly to that of the composite airfoil 410. Figure 9 ) and composite airfoil 1110 ( Figure 10 and Figure 7 ) from composite airfoil 410 ( Figure 9 The addition of a similar number of 1000 for identification should be understood to mean that, unless otherwise stated, the description of the similar parts of composite airfoil 410 and composite airfoil 1110 applies to composite airfoil 1410.

[0179] The composite airfoil 1410 includes an outer surface 1436 that defines a pressure side 1432 and a suction side 1434 opposite to the pressure side 1432. The pressure side 1432 and the suction side 1434 extend in the chord direction (CHd) between a leading edge 1424 and a trailing edge 1426.

[0180] The composite airfoil 1410 includes a sparsity core 1442 and composite cladding, shown as a first composite cladding 1444a and a second composite cladding 1444b. (The text abruptly ends here, so the translation stops as well.) Figure 12Similarly, the spar core 1442 includes a spar 1459, at least one support (shown as a first support 1461a and a second support 1461b), and a set of polymer matrix composite plies 1446. The set of polymer matrix composite plies 1446 can cover the spar 1459, the first support 1461a, the second support 1461b, or any combination thereof. The set of polymer matrix composite plies 1446 can define at least a portion of a pressure surface 1452 facing the pressure side 1432 of the composite airfoil 1410 and / or a suction surface 1454 facing the suction side 1434 of the composite airfoil 1410.

[0181] The set of composite plies 1446 can include, for example, five plies 1449a, 1449b, 1449c, 1449d, 1449e. However, any number of layers or plies can be contemplated. The five plies 1449a, 1449b, 1449c, 1449d, 1449e include distal ends 1451a, 1451b, 1451c, 1451d, 1451e, respectively.

[0182] As an example, the first composite wrap 1444a extends from the first ply 1449a facing the pressure surface 1452, over the first distal end 1451a and the second distal end 1451b of the second ply 1449b, to the second ply 1449b facing the suction surface 1454. That is, the first composite wrap 1444a wraps the first ply 1449a, the second ply 1449b, and is in contact with the first distal end 1451a and the second distal end 1451b.

[0183] The second composite wrap 1444b extends the entire length of the pressure surface 1452 and over the leading end 1456 of the composite airfoil 1410, and again to the suction surface 1454. That is, the composite wrap 1444 wraps the trailing end 1458 and the leading end 1456 of the composite airfoil 1410, while extending the length of the pressure surface 1452. In other words, the second composite wrap 1444b covers the pressure surface 1452, the leading end 1456, the trailing end 1458, and at least a portion of the suction surface 1454.

[0184] The second composite wrap 1444b at least partially covers the first composite wrap 1444a. Although shown as being in contact, the first composite wrap 1444a can be spaced apart from the second composite wrap 1444b, such as by any number of plies.

[0185] Although shown as being in contact with the third distal end 1451c and the fourth distal end 1451d, it is contemplated that the second composite wrap 1444b can be in contact with any number of distal ends.

[0186] Figure 1The manufacture of a turbine engine 10 is shown. Figure 10 Composite airfoils (such as composite airfoils 1110, 1410) Figure 11 , Figure 6 Method 2300 is similar to Method 300. Figures 9-12 Therefore, similar parts of method 2300 will be identified by similarity numbers increasing by 2000. It should be understood that, unless otherwise stated, the description of similar parts of method 300 applies to method 2300.

[0187] refer to Figure 5 Method 2000 includes attaching at least one support to spars 1159, 1459 at 2301. The at least one support is shown as a first support 1161a, 1461a and a second support 1161b, 1461b, wherein the first support 1161a, 1461a is attached to the leading edge 1167 of the spar, and the second support 1161b, 1461b is attached to the trailing edge 1169 of the spar. Furthermore, at 2301, a set of polymer matrix composite layups 1146, 1446 are applied to the exterior portion of the first support 1161a, 1461a, the second support 1161b, spars 1159, 1459, or any combination thereof.

[0188] Optionally, at 2303, the polymer matrix composite layup 1146, 1446 can be cured.

[0189] At position 2304, composite encapsulants 1144a, 1144b, 1444a, and 1444b are applied to the polymer matrix composite layup 1146 and 1446. Composite encapsulants 1144a, 1144b, 1444a, and 1444b may cover the pressure surfaces 1152 and 1452 of the spar cores 1142 and 1442, and the outer peripheral edge 220 (…). Figure 5 The portions of the spar and suction surfaces 1154, 1454. As a non-limiting example, during the formation of the spar core 1442 at 2301, a first composite wrap 1444a may be applied to the set of polymer matrix composite plies 1446. When applied, composite wraps 1144a, 1144b, 1444a, 1444b may contact any number of distal ends of the set of polymer matrix composite plies 1146, 1446. Optionally, an adhesive 1185 may be applied to one or more of the set of polymer matrix composite plies 1146, 1446, the first or second composite wraps 1144a, 1144b, 1444a, 1444b, spars 1159, 1459, the first support 1161a, 1461a, the second support 1161b, 1461b, or any combination thereof.

[0190] At 2306, the composite wrap 1144a, 1144b, 1444a, 1444b, the set of polymer matrix composite plies 1146, 1446, or any combination thereof can be cured. Curing can include additional curing of any of the set of polymer matrix composite plies 1146, 1446 cured at 2303.

[0191] The set of polymer matrix composite plies 1146, 1446 provide a weight benefit of at least 20-30% over traditional metal components. PMC is selected over CMC in certain environments because PMC has higher strength and resistance to mechanical loads. Mechanical loads experienced by PMC components can include, but are not limited to, linear forces (e.g., impact), rotational forces (e.g., torque while rotating during operation), or any combination thereof. CMC plies typically utilize additional material or reinforcement to achieve the fracture toughness of PMC plies. While CMC has superior heat resistance over PMC, in environments where mechanical loads are a higher priority than heat resistance, PMC provides advantages over CMC. Further, PMC components are less expensive and often easier to manufacture than the same components made with CMC or MMC.

[0192] Benefits associated with the composite wrap include increasing strength in at least three planes of the composite airfoil. At least one airfoil element or composite wrap increases strength across the thickness of the set of plies. That is, the strength of the composite airfoil in the thickness direction of the composite airfoil is improved. Improved strength across the thickness is provided by the composite wrap extending partially in the thickness direction. That is, the composite wrap includes portions of the wrap that lie within a plane parallel to the leading edge, the trailing edge, the tip, or any combination thereof.

[0193] Improved strength across the thickness reduces, disperses, or reduces and disperses stress or force, for example, caused by an impact event.

[0194] In ranges not yet described, different features and structures of various embodiments can be used in combination with each other, or substituted for each other, as needed. Not all features of each embodiment are shown in all embodiments, but the features of each embodiment can be mixed and matched as needed. Thus, various features of different embodiments can be mixed and matched to form new embodiments, whether or not the new embodiments are expressly described herein. All combinations or permutations of features described herein are covered by this disclosure.

[0195] This written description uses examples to disclose the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. Sizes and ranges can be interchanged between embodiments. For example, sizes such as, but not limited to Figure 7 or Figure 10 may be applied to Figure 11 or ​ .

[0196] Further aspects are provided by the subject matter of the following clauses:

[0197] A composite airfoil for a turbine engine, the composite airfoil having an airfoil outer surface defining a pressure side and a suction side opposite the pressure side, the pressure side and the suction side extending in a chordwise direction between a leading edge and a trailing edge and in a radial direction from a root to a tip, the composite airfoil comprising at least one airfoil body element, the at least one airfoil body element comprising: a layup core comprising a set of composite layups defining a pressure surface facing the pressure side and a suction surface facing the suction side, wherein the pressure surface and the suction surface extend between a forward end proximate the leading edge and an aft end proximate the trailing edge, wherein at least the forward end, the aft end, and a tip end proximate the tip define an outer peripheral edge of the composite airfoil; and a composite wrap covering at least a portion of the layup core, wherein the composite wrap is in contact with and extends from the pressure surface, over the outer peripheral edge, and to the suction surface.

[0198] A composite airfoil for a turbine engine, the composite airfoil having an airfoil outer surface defining a pressure side and a suction side opposite the pressure side, the pressure side and the suction side extending in a chordwise direction between a leading edge and a trailing edge, and extending in a radial direction from a root to a tip, the composite airfoil comprising at least one airfoil body element comprising: a set of composite plies defining a pressure surface facing the pressure side and a suction surface facing the suction side, wherein the pressure surface and the suction surface extend between a forward end proximate the leading edge and an aft end proximate the trailing edge, wherein the forward end, the aft end, and a tip end proximate the tip define an outer peripheral edge of the composite airfoil; and a composite wrap covering at least a portion of the ply core, wherein the composite wrap is in contact with and extends from the pressure surface, over the outer peripheral edge, and to the suction surface.

[0199] A composite airfoil for a turbine engine, the composite airfoil having an airfoil outer surface defining a pressure side and a suction side opposite the pressure side, the pressure side and the suction side extending in a chordwise direction between a leading edge and a trailing edge, and extending in a radial direction from a root to a tip, the composite airfoil comprising: a spar core having a pressure surface facing the pressure side, a suction surface facing the suction side, wherein the pressure surface and the suction surface extend between a forward end proximate the leading edge and an aft end proximate the trailing edge, wherein at least the forward end, the aft end, and a tip end proximate the tip define an outer peripheral edge of the composite airfoil, the spar core comprising a spar, a support in contact with the spar, and a set of polymer matrix composite plies including a first ply facing the pressure surface and a second ply facing the suction surface, the first ply having a first distal end, the second ply having a second distal end; and a composite wrap covering the first ply, extending over the outer peripheral edge or over the first distal end and the second distal end, and covering the second ply, wherein the composite wrap is a polymer matrix composite wrap.

[0200] The composite airfoil of any preceding clause, wherein the composite wrap comprises a first portion in contact with the pressure surface, a second portion in contact with the suction surface, and an end portion in contact with the outer peripheral edge, wherein the first portion of the composite wrap extends a first chordwise distance in the chordwise direction, and wherein the first chordwise distance is in a range of 2-100% of an airfoil chordwise length measured from the leading edge to the trailing edge.

[0201] The composite airfoil according to any preceding clause, wherein the first chordwise distance is in a range of 10-30% of the airfoil chordwise length measured from the leading edge to the trailing edge.

[0202] The composite airfoil according to any preceding clause, wherein the composite wrap includes a first portion in contact with the pressure surface, a second portion in contact with the suction surface, and an end portion in contact with the outer peripheral edge, wherein the first portion of the composite wrap extends a first chordwise distance in the chordwise direction, and the second portion of the composite wrap extends a second chordwise distance in the chordwise direction, wherein the first chordwise distance is in a range of 2-100% of the second chordwise distance.

[0203] The composite airfoil according to any preceding clause, wherein the composite wrap extends a radial distance in the radial direction along the outer peripheral edge, wherein the radial distance is in a range of 2-100% of an airfoil radial length measured from the root to the tip.

[0204] The composite airfoil according to any preceding clause, wherein the radial distance is in a range of 20-60% of the airfoil radial length.

[0205] The composite airfoil according to any preceding clause, wherein the at least one airfoil body element is a set of airfoil body elements having at least a first airfoil body element and a second airfoil body element.

[0206] The composite airfoil according to any preceding clause, wherein adjacent airfoil body elements of the set of airfoil body elements are partially overlapping, abutting, or spaced apart in the radial direction.

[0207] The composite airfoil according to any preceding clause, wherein adjacent airfoil body elements of the set of airfoil body elements are partially overlapping, abutting, or spaced apart in the chordwise direction.

[0208] The composite airfoil according to any preceding clause, wherein the set of composite plies includes a pressure ply facing the pressure surface and a suction ply facing the suction surface, wherein a set of ply thicknesses is measured from the pressure ply to the suction ply.

[0209] The composite airfoil according to any preceding clause, wherein the set of ply thicknesses is in a range of 1-50% of an airfoil thickness measured from the pressure side to the suction side.

[0210] The composite airfoil of any preceding clause, wherein a total pressure wrap distance is determined by summing the first chordwise distance of the set of composite plies, wherein the total pressure wrap distance can range from 2-100% of the airfoil chordwise length measured from the leading edge to the trailing edge.

[0211] The composite airfoil of any preceding clause, wherein a total suction wrap distance is determined by summing the second chordwise distance of the set of composite plies, wherein the total suction wrap distance can range from 10-40% of the airfoil chordwise length.

[0212] The composite airfoil of any preceding clause, wherein the outer surface is defined by a skin covering at least a portion of the composite wrap.

[0213] The composite airfoil of any preceding clause, wherein each ply of the set of composite plies includes fibers having a different fiber direction than an adjacent ply of the set of composite plies.

[0214] The composite airfoil of any preceding clause, wherein the composite wrap includes one or more of glass fibers, silicate glass fibers (e.g., aluminosilicate), carbon fibers, or aramid fibers.

[0215] The composite airfoil of any preceding clause, further comprising an adhesive coupling the composite wrap to the set of composite plies.

[0216] The composite airfoil of any preceding clause, wherein the composite wrap includes a set of discrete composite wraps abutting at an inner surface.

[0217] The composite airfoil of any preceding clause, wherein the ply core does not include a foam.

[0218] The composite airfoil of any preceding clause, wherein the set of plies includes at least five plies.

[0219] The composite airfoil of any preceding clause, wherein the outer peripheral edge is further defined by a root end proximate the root.

[0220] The composite airfoil of any preceding clause, wherein the ply core is comprised of the set of composite plies.

[0221] The composite airfoil of any preceding clause, wherein the composite wrap and the set of polymer matrix composite plies define a skin.

[0222] The composite airfoil according to any preceding clause, further comprising an adhesive between the skin and at least one of the spar or the support.

[0223] The composite airfoil according to any preceding clause, wherein the skin comprises a polymer resin and one or more of glass fibers, carbon fibers, or aramid fibers.

[0224] The composite airfoil according to any preceding clause, wherein the support comprises a first support coupled to a spar leading edge and a second support coupled to a spar trailing edge.

[0225] The composite airfoil according to any preceding clause, wherein the first support and the second support comprise foam.

[0226] The composite airfoil according to any preceding clause, wherein the composite wrap covers at least a portion of the pressure surface and at least a portion of the suction surface at the trailing end of the spar core.

[0227] The composite airfoil according to any preceding clause, wherein the composite wrap covers at least a portion of the pressure surface and at least a portion of the suction surface at the leading end of the spar core.

[0228] The composite airfoil according to any preceding clause, wherein the composite wrap covers at least a portion of the pressure surface and at least a portion of the suction surface at the tip end of the spar core.

[0229] The composite airfoil according to any preceding clause, wherein the composite wrap covers at least a portion of the pressure surface and at least a portion of the suction surface at a root end proximate the root of the spar core.

[0230] The composite airfoil according to any preceding clause, wherein the composite wrap comprises a plurality of composite wraps having at least a first composite wrap and a second composite wrap.

[0231] The composite airfoil according to any preceding clause, wherein the first composite wrap defines a portion of the leading edge of the composite airfoil and the second composite wrap defines a portion of the trailing edge of the composite airfoil.

[0232] The composite airfoil according to any preceding clause, wherein the first composite wrap has a first end and the second composite wrap has a second end, wherein the first end and the second end overlap.

[0233] The composite airfoil of any preceding clause, wherein the second composite wrap covers the first composite wrap.

[0234] The composite airfoil of any preceding clause, wherein the composite wrap covers at least a portion of the pressure surface, the leading end, the trailing end, and the suction surface.

[0235] The composite airfoil of any preceding clause, wherein the composite wrap comprises one or more of glass fibers, silicate glass fibers, carbon fibers, or aramid fibers.

[0236] The composite airfoil of any preceding clause, wherein the set of polymer matrix composite plies comprises end portions, wherein the end portions are in contact with the composite wrap.

[0237] The composite airfoil of any preceding clause, wherein the turbine engine is a non- ducted turbine engine and the composite airfoil is a blade of a set of circumferentially spaced apart fan blades or a vane of a set of stationary fan vanes.

[0238] The composite airfoil of any preceding clause, wherein the spar contacts the support at a portion of the spar comprising composite material.

[0239] The composite airfoil of any preceding clause, wherein the composite wrap is a thermoset or thermoplastic plastic.

[0240] The composite airfoil of any preceding clause, wherein the first composite wrap and the second composite wrap abut at an end surface.

[0241] The composite airfoil of any preceding clause, wherein the composite wrap covers at least a portion of the pressure surface and at least a portion of the suction surface at two or more of the trailing end, the leading end, the tip, or the root of the spar core.

[0242] The composite airfoil of any preceding clause, wherein the composite wrap covers at least a portion of the pressure surface and at least a portion of the suction surface at two or more of the trailing end, the leading end, the tip, or the root of the spar core.

[0243] The composite airfoil of any preceding clause, wherein the composite wrap covers at least a portion of at least one of the pressure surface at the leading end of the spar core or a portion of the suction surface at the leading end of the spar core.

[0244] The composite airfoil of any preceding clause, wherein the spar comprises a composite material and a metallic material.

[0245] The composite airfoil of any preceding clause, wherein the composite wrap comprises a first portion in contact with the pressure surface, a second portion in contact with the suction surface, and an end portion in contact with the outer peripheral edge, wherein the first portion of the composite wrap extends a first chordwise distance in the chordwise direction, and wherein the first chordwise distance is in a range of 2-100% of an airfoil chordwise length measured from the leading edge to the trailing edge.

[0246] The composite airfoil of any preceding clause, wherein the first chordwise distance is in a range of 10-30% of the airfoil chordwise length measured from the leading edge to the trailing edge.

[0247] The composite airfoil of any preceding clause, wherein the composite wrap comprises a first portion in contact with the pressure surface, a second portion in contact with the suction surface, and an end portion in contact with the outer peripheral edge, wherein the first portion of the composite wrap extends a first chordwise distance in the chordwise direction, the second portion of the composite wrap extends a second chordwise distance in the chordwise direction, wherein the first chordwise distance, the second chordwise distance, or the first chordwise distance and the second chordwise distance is in a range of 2-100% of an airfoil chordwise length measured from the leading edge to the trailing edge.

[0248] The composite airfoil of any preceding clause, wherein the composite wrap extends a radial distance in the radial direction along the outer peripheral edge, wherein the radial distance is in a range of 2-100% of an airfoil radial length measured from the root to the tip.

[0249] The composite airfoil of any preceding clause, wherein the radial distance is in a range of 5-40% of the airfoil radial length.

[0250] The composite airfoil of any preceding clause, comprising a spar core and a ply core.

[0251] A method of manufacturing an airfoil body element for a composite airfoil for a turbine engine, the method comprising: stacking a plurality of plies to form a set of composite plies; applying a composite wrap such that the composite wrap covers and is in contact with portions of a pressure surface, an outer peripheral edge, and a suction surface of the set of composite plies; and curing the composite wrap, the set of composite plies, or both the composite wrap and the set of composite plies.

[0252] A method of manufacturing a polymer matrix composite airfoil for a turbine engine, the method comprising: coupling at least one support to a spar; applying a set of polymer matrix composite plies to one or more portions of the at least one support, the spar, or both to define a spar core having a pressure surface, an outer peripheral edge, and a suction surface; applying a composite wrap extending from the pressure surface, over the outer peripheral edge to the suction surface, or wrapping the distal end of the set of polymer matrix composite plies; and curing the composite wrap, the set of polymer matrix composite plies, or both the composite wrap and the set of polymer matrix composite plies.

[0253] The method of any preceding paragraph, further comprising curing the set of polymer matrix composite plies prior to applying the composite wrap.

[0254] The method of any preceding paragraph, further comprising applying an adhesive to one or more of the set of polymer matrix composite plies, the composite wrap, the spar, a first support, a second support, or any combination thereof prior to curing.

[0255] The method of any preceding paragraph, wherein stacking a plurality of plies comprises stacking a plurality of plies on at least a portion of the first portion of the composite wrap.

[0256] The method of any preceding paragraph, further comprising curing the set of composite plies prior to applying the composite wrap.

[0257] The method of any preceding paragraph, wherein applying the composite wrap comprises applying an adhesive to one or more of the composite wrap or a set of cured composite plies.

[0258] The method of any preceding paragraph, further comprising applying an adhesive to one or more of the composite wrap or a set of cured composite plies.

Claims

1. A composite airfoil for a turbine engine, the composite airfoil having an airfoil outer surface defining a pressure side and a suction side opposite the pressure side, the pressure side and the suction side extending in a chordwise direction between a leading edge and a trailing edge and in a radial direction from a root to a tip, characterized by, The composite airfoil includes: at least one airfoil element, the at least one airfoil element including: a layup core including a set of composite plies, the set of composite plies defining: a pressure surface facing the pressure side; and a suction surface facing the suction side, wherein the pressure surface and the suction surface extend between a leading end proximate the leading edge and a trailing end proximate the trailing edge; wherein at least the leading end, the trailing end, and a tip end proximate the tip define an outer peripheral edge of the composite airfoil; and a composite wrap covering at least a portion of the layup core, wherein the composite wrap is in contact with and extends from the pressure surface, across the outer peripheral edge, and to the suction surface.

2. The composite airfoil of claim 1, wherein wherein, the composite wrap includes a first portion in contact with the pressure surface, a second portion in contact with the suction surface, and an end portion in contact with the outer peripheral edge, wherein the first portion of the composite wrap extends a first chordwise distance in the chordwise direction, and wherein the first chordwise distance is in a range of 2%-100% of an airfoil chordwise length measured from the leading edge to the trailing edge.

3. The composite airfoil of claim 2, wherein, wherein, the first chordwise distance is in a range of 10%-30% of the airfoil chordwise length measured from the leading edge to the trailing edge.

4. The composite airfoil of claim 1, wherein, wherein, the composite wrap includes a first portion in contact with the pressure surface, a second portion in contact with the suction surface, and an end portion in contact with the outer peripheral edge, wherein the first portion of the composite wrap extends a first chordwise distance in the chordwise direction, and the second portion of the composite wrap extends a second chordwise distance in the chordwise direction, wherein the first chordwise distance is in a range of 2%-100% of the second chordwise distance.

5. The composite airfoil of claim 1, wherein, wherein, the composite wrap extends a radial distance in the radial direction along the outer peripheral edge, wherein the radial distance is in a range of 2%-100% of an airfoil radial length measured from the root to the tip.

6. The composite airfoil of claim 5, wherein, wherein, the radial distance is in a range of 20%-60% of the airfoil radial length.

7. The composite airfoil of claim 1, wherein wherein, the at least one airfoil element is a set of airfoil elements having at least a first airfoil element and a second airfoil element.

8. The composite airfoil of claim 7, wherein, wherein, adjacent airfoil elements of the set of airfoil elements partially overlap, abut, or are spaced apart in the radial direction.

9. The composite airfoil of claim 7, wherein, wherein, adjacent airfoil elements of the set of airfoil elements partially overlap, abut, or are spaced apart in the chordwise direction.

10. The composite airfoil of claim 1, wherein wherein, the set of composite plies includes a pressure ply facing the pressure surface and a suction ply facing the suction surface, wherein a set of ply thicknesses is measured from the pressure ply to the suction ply.

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