Method and apparatus for fabricating large scale integrated airfoils

1. A method of fabricating an airfoil, comprising:

making a pair of cured composite skins;

making at least one spar, including assembling uncured spar chords and at least one cured composite spar web;

assembling the cured skins to the spar; and

curing the spar chords.

2. The method of claim 1 , further comprising:

compacting the spar chords against the cured skins.

3. The method of claim 1 , wherein assembling the skins and the spar includes:

holding the spar web and the spar chords in a tool, and

mounting the skins on the tool with an inner mold line of each of the skins in proximity to the spar chords.

4. The method of claim 3 , wherein holding the spar web and the spar chords in the tool includes:

adhering the spar chords to the spar web, and

clamping the spar web in the tool.

5. The method of claim 3 , wherein assembling the cured skins and the spar includes:

forming holes in each of the skins, and

removably mounting the skins on the tool by inserting pins through the holes into the tool.

6. The method of claim 4 , wherein assembling the cured skins and the spar includes indexing the spar relative to the cured skins by mounting the tool on indexing rods.

7. The method of claim 2 , wherein:

assembling the skins and the spar includes holding the spar web and the spar chords in a tool, and mounting the skins on the tool with an inner mold line of each of the skins in proximity to the spar chords, and

compacting the spar chords against the skins is performed by installing vacuum bags on the tool respectively covering the spar chords, and evacuating the vacuum bags.

8. The method of claim 1 , wherein assembling the cured skins and the spar includes:

placing a tool on an assembly fixture,

assembling the cured spar web and the uncured spar chords on the tool, and

transferring the tool having the assembled spar web and spar chords to a cure fixture.

9. The method of claim 1 , wherein assembling the uncured spar chords and at the least one cured composite spar web includes pre-compacting the spar chords against the at least one uncured spar web.

10. The method of claim 9 , wherein the pre-compacting includes:

placing chord compaction tools respectively against the spar chords, and

compacting of the chord compaction tools respectively against the spar chords.

11. The method of claim 10 , wherein:

assembling the skins and the spar includes transferring the spar and the spar compaction tools to an internal tool, and mounting the skins on the internal tool with an inner mold line of each of the skins in proximity to the spar chords, and

curing the spar chords includes using the spar compaction tools to compact the spar chords against the skin and the at least one spar web.

12. A method of fabricating an airfoil box, comprising:

providing a pair of cured composite skins each having a span;

assembling at least one composite spar, including attaching uncured composite spar chords to a cured composite spar web;

holding the spar and the cured skins in an assembled, indexed relationship to each other along the span; and

bonding the spar to the cured composite skins by curing the uncured composite spar chords.

13. The method of claim 12 , further comprising:

generating a compaction force compacting the spar chords against the spar web and the skins as the spar chords are being cured.

14. The method of claim 13 , wherein compacting the spar chords includes:

installing vacuum bags respectively over the spar chords, and

evacuating each of the vacuum bags.

15. The method of claim 13 , wherein the skins and the spar webs are used to react the compaction force.

16. The method of claim 12 , wherein assembling the spar includes:

laying up and curing the composite spar web,

laying up and forming the composite spar chords,

applying an adhesive to one of the spar web and the spar chords,

assembling the spar web and the spar chords together, and

compacting the spar web and the spar chords together.

17. The method of claim 12 , further comprising:

assembling the spar and the skins, including placing the assembled spar in a tool, attaching the skins to the tool, and transferring the assembled skins and spar to a cure fixture.

18. The method of claim 17 , wherein the curing is performed by:

placing the cure fixture in an autoclave, and

subjecting substantially only the spar chords to autoclave pressure.