Composite assembly

Abstract

The present invention is concerned with a method of forming a composite assembly. The method comprises forming a 3D woven fabric comprising a plurality of fibre yarns; forming a metallic region comprising a plurality of metal filaments; forming a transition region between the 3D woven fabric and the metallic region by interweaving the plurality of metal filaments at an edge of the metallic region with the plurality of fibre yarns at an edge of in the 3D woven fabric; and welding the metallic region to a metallic part.

Description

COMPOSITE ASSEMBLYFIELD AND BACKGROUND

[0001] The present invention relates particularly, but not exclusively, to a method of forming a composite assembly, for example in aircraft components such as outlet guide vanes (OGVs).

[0002] Currently, composite OGVs are manufactured with several manufacturing steps and materials involved. The current generation of OGVs are expected to have impact resistance functions as well as systems in place for lightning strike protection. These solutions often comprise metallic leading edges to provide impact protection for the outlet guide vane against debris. These metallic leading edges have to be adhesively bonded to the composite vane by co-bonding or co-curing. Furthermore, lightning strike protection is often included by introducing a metallic strip separately to interface the composite to the metallic fittings on either ends of the guide vane to act as an electric current flow path. This method of manufacturing articles is time consuming and complicated.

[0003] Additionally, the manufacturing of composite OGVs involves either co-bonding of the composites to metallic end fittings with suitable adhesives during the infusion and curing process or by secondary bonding after curing with suitable adhesives. Both of these methods are complex and time consuming in terms of manufacturing processes, requiring tight tolerances and careful control of process parameters. This can lead to sub-optimal bond line strengths (in case of co-bonding) or complex assembly costs (in case of secondary bonding). Furthermore, the use of adhesives to bond dissimilar materials has its drawbacks if not performed correctly leading to insufficient load transfer capabilities. Additionally, if adhesives are used, the location of the component is limited to cooler parts of the engine. It is also known in aerospace applications to use bolts or other additional fastening members to connect composite materials and metals. Bolts are undesirable as they add additional weight to the aerospace component.

[0004] There is therefore a desire to provide a method of quickly and simply joining metals and composites without the use of adhesives or additional fastening members.

[0005] The inventors have discovered a new and counterintuitive way of interfacing metals and composites without having to use complicated manufacturing processes or time consuming secondary process, and also without the use of adhesives or additional fastening members. The new method developed by the inventors can advantageously be used in the manufacture of aircraft components or other non-aircraft related components.SUMMARY

[0006] Particular aspects and embodiments are set out in the appended claims.

[0007] Viewed from a first aspect, there is provided a method of forming a composite assembly. The method comprises forming a 3D woven fabric comprising a plurality of fibre yarns; forming a metallic region comprising a plurality of metal filaments; forming a transition region between the 3D woven fabric and the metallic region by interweaving the plurality of metal filaments at an edge of the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; and welding the metallic region to a metallic part.

[0008] The term '3D woven fabric' is intended to mean a 3D composite made using fibre yarns formed into three-dimensional structures (otherwise called preforms). The fibres may be any reinforcement fibre like carbon, glass, kevlar and so on. The wording 'at an edge of the 3D woven fabric' does not restrict the metallic region to being formed at one edge of the 3D woven fabric. In some examples, the metallic region is formed at more than one edge. The term 'transition region' is intended to mean a region in which the fibre yarns are interwoven with the metallic filaments. The width of the transition region is chosen such that a strong and permanent connection is provided between the 3D woven fabric and the metallic region which can withstand extreme temperatures. The size of the transition region or the number of overlapping fibres in the transition region may be determined based on the size of the parts formed of the 3D woven fabric and the metallic region in order to ensure the connection between these has sufficient strength. The term 'metallic region' is intended to mean a region that comprises metal filaments. The metallic region may be formed of a mix of metal alloys that may enhance or enable better welding to the metallic part. Both the metallic region and the transition region are smaller in size than the 3D composite. This is to minimise the weight of the component.

[0009] Thus, according to the first aspect of the invention, a composite fabric can be reliably joined to a metallic part without the use of adhesives or additional fastening members. Since no adhesives are used, the interface between the metal filaments and metallic part is very strong. Furthermore, since no adhesives are used, the composite assembly formed according to the invention may be used in high temperature applications. For example, the assembly may be used throughout an aircraft engine rather than solely in cooler parts of the engine. The metallic region may be formed in the 3D woven fabric during the manufacturing process of the 3D composite. The composite assembly formed according to the first aspect of the invention also has a lower weight than one which uses additional fastening members to join the composite material and metal.

[0010] The method may further comprise infusing the composite assembly with resin. This improves the strength of the part. A number of different resins may be used. For example, thermosetting resins like epoxy, bismaleimide, polyimide, vinylesters may be used. Additionally, other types of thermosetting resins may be used. In other examples, different types of resin may be used. For example, thermoplastic resins may be used.

[0011] Infusing the composite assembly with resin may comprise performing resin transfer molding on the combined 3D woven fabric and metallic part. Specifically, the composite assembly may be placed in a resin transfer molding mold and resin infused to create the final part that has composites and metallic components already interfaced. This is advantageous because no adhesives are required and since the metallic filaments are interwoven into the 3D composite architecture, the interface is very robust and strong. Furthermore, resin transfer molding enables geometrically accurate parts to be formed. In other examples, the part may be infused with resin using vacuum infusion. This provides a simpler manufacturing process.

[0012] The metallic part may be a load carrying part or a non-load carrying part. Specifically, the load carrying part may be a bearing interface which carries a load or forms a load path. The nonload carrying part may be an interface part such as a bushing.

[0013] The composite assembly may be an outlet guide vane for an aircraft engine. By using the method according to a first aspect, the metallic part may be incorporated into the outlet guide vane. For example, the metallic part may be a metallic leading edge component and / or a metallic trailing edge component of the outlet guide vane. When incorporated as a metallic leading edge component, the metallic part provides protection against debris for the outlet guide vane. Furthermore, the metallic part provides lightning strike protection for the outlet guide vane. Therefore, the metallic part has a dual purpose; a protective leading edge component and a component providing lightning strike protection. This avoids the need for further lightning strike components to be attached to the outlet guide vane which unnecessarily increase the weight and complexity of the part. When incorporated as a metallic trailing edge component, the metallic part provides lightning strike protection. Additionally, the metallic parts can be directly welded on to the hybrid laminate by appropriate techniques. This ensures a better contact interface between the composite assembly (i.e. the guide vanes) and the metallic fittings and hence a stronger load transfer path for structural outlet guide vanes.

[0014] The metallic leading edge component and / or the metallic trailing edge component may extend along the outlet guide vane from a first radial end of the outlet guide vane to a secondradial end of the outlet guide vane. In some examples, the metallic leading edge component and / or the metallic trailing edge component interfaces with metallic end fittings attached to a first and second radial end of the outlet guide vane. The term 'interfaces' is intended to mean that the metallic leading edge component and / or the metallic trailing edge component is in abutment with the metallic end fittings at both ends. This provides an electric current flow path along the length of the vane and therefore enables the metallic part combined with the metallic end fittings to be used for lightning strike protection.

[0015] The metallic region may be formed at first and second radial ends of the outlet guide vane. This may be in addition to the metallic region formed at the leading and / or trailing edge or instead of this. The method may further comprise welding the metallic part to metallic end fittings. In this way, the metallic fittings can be directly welded on to the hybrid laminate by appropriate techniques. This ensures a better contact interface between the composite laminate and the metallic fittings and hence a stronger load transfer path for structural OGVs. Alternatively, the metallic end fittings may be welded directly to the metallic region.

[0016] The metallic end fittings may be formed of Titanium. In other examples, the metallic end fittings may be formed of aluminium, steel or another metal. The metal used may depend on the application. For example, where there is no significant load bearing necessary, metals such as aluminium or steel may be used.

[0017] The metal filaments may be formed of steel. In other examples, the metal filaments may be formed of titanium. In some examples, the metal filaments are formed of the same metal as the metallic part they are welded on to. This improves the strength of the weld line between the metallic part and the metallic region due to the consistent thermal expansion of the metal in both regions.

[0018] The welding may be performed by resistance welding. In other examples, other types of welding may be used. For example, Tungsten Inert Gas welding, electron beam welding or laser spot welding may be used. Any suitable form of welding can be used that will enable good connection between the metallic region of the 3D woven preform (formed by metallic filaments) and the solid metal.

[0019] According to a second aspect of the invention, there is provided an outlet guide vane comprising the composite assembly formed by the method of the first aspect. When incorporated as a metallic leading edge component, the metallic part provides protection against debris for the outlet guide vane. Furthermore, if the metallic part extends the entirety of the length of the bladeand interfaces with metallic end fittings at either end of the vane, the metallic part provides lightning strike protection for the outlet guide vane. Therefore, the metallic part may have a dual purpose; a protective leading edge component and a component providing lightning strike protection. This avoids the need for further lightning strike components to be attached to the outlet guide vane which unnecessarily increase the weight and complexity of the part. When incorporated as a metallic trailing edge component, the metallic part provides lightning strike protection.

[0020] According to a third aspect of the invention, there is provided a method of joining a composite vane to a metallic end fitting. The method comprises forming the composite vane from a 3D woven fabric comprising a plurality of fibre yarns; forming a metallic region comprising a plurality of metal filaments; forming a transition region between the 3D woven fabric and the metallic region by interweaving the plurality of metal filaments at an edge of the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; welding the metallic region to a metallic end fitting.

[0021] In some examples, the metallic region is first welded to a metallic part and the metallic part is welded to the metallic end fitting. The benefit of this configuration is that the resin infusion and curing may be carried out on the 3D woven fabric, the metallic region and the metallic part without the metallic end fitting. This makes the assembly easier to cure due to the size and shape of the end fitting. On the other hand, if the metallic end fitting is welded directly to the metallic region, the weight of the part may be reduced. The composite vane may further comprise 2D woven fabric. For example, the 2D and 3D portions may be interfaced for example using a 3D insert into the 2D structure.

[0022] According to a fourth aspect of the invention, there is provided a method of joining a composite vane to a metallic leading edge component and / or a metallic trailing edge component. The method comprises forming the composite vane from a 3D woven fabric comprising a plurality of fibre yarns; forming a metallic region comprising a plurality of metal filaments; forming a transition region between the 3D woven fabric and the metallic region by interweaving the plurality of metal filaments at an edge of the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; and welding the metallic region to the metallic leading edge component and / or the metallic trailing edge component.

[0023] According to a fifth aspect of the invention, there is provided a composite guide vane comprising: a body formed of a 3D woven fabric comprising a plurality of fibre yarns; a metallic region comprising a plurality of metal filaments interwoven in a transition region between the 3Dwoven fabric and the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; and a metallic part welded to the metallic region.

[0024] The metallic part may be a load carrying part or a non-load carrying part. Specifically, the load carrying part may be a bearing interface which carries a load or forms a load path. The nonload carrying part may be an interface part such as a bushing.

[0025] The metallic part may be a metallic leading edge component and / or a metallic trailing edge component.

[0026] The composite guide vane may further comprise metallic end fittings, wherein the metallic end fittings may be welded to the metallic part.

[0027] The composite guide vane may be infused with resin.

[0028] According to a sixth aspect of the invention, there is provided a metallic flange for a composite frame. The frame assembly comprises a body formed of a 3D woven fabric comprising a plurality of fibre yarns; a metallic region comprising a plurality of metal filaments interwoven in a transition region between the 3D woven fabric and the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; and a metallic flange part welded to the metallic region.

[0029] The metallic region may first be welded to a metallic part and the metallic part may then be welded to the flange. In this way, the assembly including the 3D woven fabric, the metallic region and the metallic part can be cured before being welded to the flange. This improves the ease of curing due to the size and shape of the flange.

[0030] Other aspects will also become apparent upon review of the present disclosure, in particular upon review of the Brief Description of the Drawings, Detailed Description and Claims sections.BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Examples of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0032] Figure 1 shows a composite preform assembly according to the claimed invention;

[0033] Figure 2 shows the composite preform assembly welded to a metallic part;

[0034] Figures 3A and 3B show the metallic part incorporated in an outlet guide vane in a first application;

[0035] Figures 4A and 4B show the metallic part incorporated in an outlet guide vane in a second application;

[0036] Figures 5A and 5B show the metallic part incorporated in an outlet guide vane in the second application;

[0037] Figure 6 shows a composite frame body comprising positive and negative flanges;

[0038] Figures 7A to 7C show the connection between the positive flanges and the composite frame body; and

[0039] Figures 8A to 8C show the connection between the negative flanges and the composite frame body.

[0040] While the disclosure is susceptible to various modifications and alternative forms, specific example approaches are shown by way of example in the drawings and are herein described in detail. It should be understood however that the drawings and detailed description attached hereto are not intended to limit the disclosure to the particular form disclosed but rather the disclosure is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claimed invention.

[0041] As used in this specification, the words "comprises", "comprising", and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean "including, but not limited to".

[0042] It will be recognised that the features of the above-described examples of the disclosure can conveniently and interchangeably be used in any suitable combination. It will also be recognised that the invention covers not only individual embodiments but also combinations of the embodiments that have been discussed herein.DETAILED DESCRIPTION

[0043] The present teaching relates particularly, but not exclusively, to a method of forming a composite assembly. It will be recognised from the disclosure herein that the composite assembly could be used in a number of applications including but not limited to an outlet guide vane, a flange or any other aircraft engine component.

[0044] Figure 1A shows a composite assembly 1 comprising a 3D woven fabric 2 comprising a plurality of layers. The 3D woven fabric 2 may be formed of tows or yarns 5 of a fibre made of a material such as carbon. The composite assembly 1 further comprises a metallic region 3. The metallic region 3 comprises a plurality of metal filaments 6. The metallic region 3 connects with the 3D woven fabric 2 in a transition region 4. The zoomed in portion in figure IB shows a portion of the transition region 4 between the 3D woven fabric 2 and the metallic region 3. In the transition region 4, metal filaments of the metallic region are interwoven with the plurality of yarns of the 3D woven fabric 2 in order to form the connection between the 3D woven fabric 2 and the metallic region 3. The metallic filaments 6 may be formed of steel. In other examples, the metallic filaments 6 may be formed of titanium or another metal.

[0045] Figure 2 show the composite assembly additionally comprising a metallic part 8. The metallic part may be manufactured by conventional manufacturing methods such as casting or with additively manufactured processes such as powder bed or wire deposition. The metallic region 3 of the 3D composite is welded to the metallic part 8 along weld line 7. In some examples, the metallic part 8 and the metallic filaments 6 are formed of the same material.

[0046] The invention generally relates to a method of forming the composite assembly as shown in figure 2.

[0047] The method comprises first forming the 3D woven fabric 2. This may be done by any of the typical or atypical 3D weaving methods such as (and not limited to) orthogonal, layer-to-layer or angle interlocking. The metallic region 3 is formed at an edge of the 3D woven fabric 2 by interweaving the metal filaments 6 with the fibre yarns of the 3D woven fabric 2 using the same or similar weaving method as the 3D woven fabric 2. The metallic filaments are also interwoven in such a way that the metallic filaments are interwoven between the fibers 5 through the thickness of the preform, as shown in figure IB. Next, the metallic region 3 is welded to the metallic part 8 along weld line 7. The welding may be carried out by resistance welding. In other examples, tungsten inert gas welding, laser spot welding or any other suitable form of welding may be used that will enable good connection between the metallic filaments 6 and the metallic part 8.

[0048] Once the welding step has been carried out, the composite assembly 1 is infused with a resin such as a thermosetting or thermoplastic resin. This may be done by resin transfer molding or vacuum infusion. Other methods may be used to infuse the assembly with resin. Next, the composite assembly 1 is cured.

[0049] Figure 3 shows an application of the method of the present application. Specifically, figure 3 shows an outlet guide vane 9. Figure 3A shows a side view of the outlet guide vane 9 and figure 3B shows a cross sectional view of the outlet guide vane 9 shown in the direction indicated as B-B.

[0050] As can be seen from this figure, the outlet guide vane comprises the 3D woven fabric 2. The 3D woven fabric comprises the metallic region 3 comprising metal filaments. As shown in figure 1, the metal filaments (not shown in this figure) are interwoven in the edge of 3D woven fabric 2 in transition region 4. In this way, the metallic region 3 is formed at an edge of the outlet guide vane 9. As is also shown in this figure, a metallic leading edge component 8 is attached to the metallic region 3 by welding along a weld line 7.

[0051] The outlet guide vane comprises metallic end fittings 10 at a first radial end and second radial end of the outlet guide vane 9. These are discussed further later. The metallic leading edge component 8 extends from the first radial end to the second radial end of the outlet guide vane 9. As can be seen from figure 3A, there is a gap between the metallic leading edge component 8 and the metallic end fittings 10. In some examples, the metallic leading edge component 8 extends along the entire length of the outlet guide vane and is in abutment with the first and second end of the outlet guide vane 9. This enables the metallic leading edge component 8 to provide lightning strike protection as it enables a metallic connection along the length of the guide vane.

[0052] In some examples, a metallic region may be formed at a trailing edge of the composite guide vane 9. A metallic trailing edge component may then be welded to the metallic region. This configuration is not shown in the figures. This may be in addition to or instead of the metallic leading edge component.

[0053] Figures 4 and 5 show a further application of the method of the present application. Specifically, figures 4 and 5 shows an outlet guide vane 9. Figure 4A shows a side view of the outlet guide vane 9 and figure 4B shows a cross sectional view of the outlet guide vane 9 shown in the direction indicated as B-B.

[0054] Figure 4A shows the outlet guide vane 9 with the metallic leading edge component 8. As can be seen from figure 4B, the body of the outlet guide vane 9 comprises a portion made of the3D woven fabric 2. Each end of this portion comprises a metallic region 3 comprising metallic filaments (not shown in this figure). The metallic filaments are interwoven in the 3D woven fabric 2 in transition region 4. Attached to the metallic regions 3 at either end of the portion are metallic portions 8 via a weld line 7. This enables the attachment of metallic end fittings 10 (not shown in this figure) to the outlet guide vane. This configuration may be used in combination with that shown in figure 3B. Specifically, the metallic leading edge component 8 may also be welded to a metallic region 3 comprising metallic filaments (not shown in this figure) interwoven in the 3D woven fabric 2. The outlet guide vane 9 shown in figures 4A and 4B is infused with resin and cured.

[0055] Turning to figures 5A and 5B, these correspond to figures 4A and 4B but additionally show the metallic end fittings 10 attached to the composite guide vane. This is typically done after the assembly shown in figures 4A and 4B is infused with resin and cured. The metallic end fittings 10 may be formed of Titanium. The metallic end fittings 10 are joined to the metallic portions 8 via a weld line 11. In some examples, the metallic portions 8 are not included. In this way, the metallic end fittings 10 are welded directly to the metallic region 3. This results in a weight reduction however requires the curing to occur with the end fitting attached.

[0056] Figures 6 to 8 show a further application of the method of the present application. Specifically, figure 6 shows a composite frame body 12. The composite frame body 12 comprises negative flanges 13 and positive flanges 14. The method of the present invention enables the joining of the composite frame with metallic flanges. This is discussed further with respect to figures 7 and 8.

[0057] Figure 7 shows the positive flange arrangement in more detail. Figure 7A shows the composite frame body 12 as shown in figure 6. As is shown in figure 7B, the composite frame body 12 comprises a 3D composite 2 and a metallic region 3 comprising metal filaments (not shown). As shown in figure 1, the metal filaments (not shown in this figure) are interwoven in the 3D woven fabric 2 in transition region 4. The metallic region 3 of the 3D composite is welded to a metallic part 8 along weld line 7. Figure 7C shows the metallic part welded to a positive flange 14 along weld line 15. In other examples, the metallic region 3 may be welded directly to flange 14.

[0058] Figure 8 shows the negative flange arrangement in more detail. Figure 8A shows the composite frame body 12 as shown in figure 6. As is shown in figure 8B, the composite frame body 12 comprises a 3D composite 2 and a metallic region 3 comprising metal filaments (not shown). As shown in figure 1, the metal filaments (not shown in this figure) are interwoven in the 3D woven fabric 2 in transition region 4. The metallic region 3 of the 3D composite is welded to a metallic part8 along weld line 7. Figure 8C shows the metallic part welded to a negative flange 13 along weld line 15. In other examples, the metallic region 3 may be welded directly to flange 13.

[0059] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the spirit and scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

CLAIMS:

1. A method of forming a composite assembly comprising:forming a 3D woven fabric comprising a plurality of fibre yarns;forming a metallic region comprising a plurality of metal filaments;forming a transition region between the 3D woven fabric and the metallic region by interweaving the plurality of metal filaments at an edge of the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; andwelding the metallic region to a metallic part.

2. The method of claim 1, further comprising infusing the composite assembly with resin.

3. The method of claim 1, wherein infusing the composite assembly with resin comprises performing resin transfer molding on the combined 3D woven fabric and metallic part.

4. The method of any of claims 1 to 3, wherein the metallic part is a load carrying part or a nonload carrying part.

5. The method of any of claims 1 to 3, wherein the composite assembly is an outlet guide vane.

6. The method of claim 5, wherein the metallic part is a metallic leading edge component and / or a metallic trailing edge component of the outlet guide vane.

7. The method of claim 6, wherein the metallic leading edge component and / or the metallic trailing edge component extends along the outlet guide vane from a first radial end of the outlet guide vane to a second radial end of the outlet guide vane.

8. The method of claim 6 or 7 , wherein the metallic leading edge component and / or the metallic trailing edge component interfaces with metallic end fittings attached to a first and second radial end of the outlet guide vane.

9. The method of claim 5, wherein the metallic region is formed at first and second radial ends of the outlet guide vane, and wherein the method further comprises welding the metallic part to metallic end fittings.

10. The method of claim 8 or 9, wherein the metallic end fittings are formed of Titanium.

11. The method of any preceding claim, wherein the metal filaments are formed of steel.

12. The method of any preceding claim, wherein the welding is performed by resistance welding.

13. An outlet guide vane comprising the composite assembly formed by the method of any of claims 1 to 12.

14. A method of joining a composite vane to a metallic end fitting, the method comprising: forming the composite vane from a 3D woven fabric comprising a plurality of fibre yarns; forming a metallic region comprising a plurality of metal filaments;forming a transition region between the 3D woven fabric and the metallic region by interweaving the plurality of metal filaments at an edge of the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; andwelding the metallic region to a metallic end fitting.

15. The method of claim 14, wherein the metallic region is first welded to a metallic part and the metallic part is welded to the metallic end fitting.

16. A method of joining a composite vane to a metallic leading edge component and / or a metallic trailing edge component, the method comprising:forming the composite vane from a 3D woven fabric comprising a plurality of fibre yarns; forming a metallic region comprising a plurality of metal filaments;forming a transition region between the 3D woven fabric and the metallic region by interweaving the plurality of metal filaments at an edge of the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; andwelding the metallic region to the metallic leading edge component and / or the metallic trailing edge component.

17. A composite guide vane comprising:a body formed of a 3D woven fabric comprising a plurality of fibre yarns;a metallic region comprising a plurality of metal filaments interwoven in a transition region between the 3D woven fabric and the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; anda metallic part welded to the metallic region.

18. The composite guide vane of claim 17, wherein the metallic part is a load carrying part or a non-load carrying part.

19. The composite guide vane of claim 17, wherein the metallic part is a metallic leading edge component and / or a metallic trailing edge component.

20. The composite guide vane of claim 17 or 19, further comprising metallic end fittings, wherein the metallic end fittings are welded to the metallic part.

21. The composite guide vane of any of claims 17 to 20, wherein the composite guide vane is infused with resin.

22. A flange assembly for a composite frame, the flange assembly comprising:a body formed of a 3D woven fabric comprising a plurality of fibre yarns;a metallic region comprising a plurality of metal filaments interwoven in a transition region between the 3D woven fabric and the metallic region with the plurality of fibre yarns at an edge of the 3D woven fabric; anda flange welded to the metallic region.

23. The flange assembly of claim 22, wherein the metallic region is first welded to a metallic part and the metallic part is welded to the flange.

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