Method for manufacturing a composite guide vane having a metallic leading edge
A method of manufacturing a composite guide vane with a metallic leading edge includes receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a resin. A vane body is formed from the layup of sheets. The vane body includes a body mid portion for interacting with a fluid and a body end portion. The method includes applying a metallic sheath on part of the vane body. The metallic sheath defines a leading edge of the guide vane. The method includes overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath.
1. A method of manufacturing a composite guide vane of a gas turbine engine, the method comprising:
receiving a body made of a fiber-reinforced composite material, the body including a body mid portion for interacting with a fluid and a body end portion;
applying a metallic sheath on part of the body, the metallic sheath including:
a sheath mid portion applied to the body mid portion to define a leading edge of the guide vane; and
a sheath end portion applied to the body end portion;
forming a hole in the sheath end portion;
overmolding a head or a foot of the guide vane onto the body end portion and onto the sheath end portion; and
receiving overmolding material into the hole during the overmolding.
2. The method as defined in claim 1 , wherein:
the body end portion is a first body end portion;
the body includes a second body end portion opposite the first body end portion;
the sheath end portion is a first sheath end portion;
the metallic sheath includes a second sheath end portion applied to the second body end portion;
the method includes:
overmolding the head onto the first body end portion and onto the first sheath end portion; and
overmolding the foot onto the second body end portion and onto the second sheath end portion.
3. The method as defined in claim 1 , wherein:
the hole in the sheath end portion is a sheath hole;
the method comprises:
forming a body hole in the body end portion; and
receiving overmolding material into the body hole during the overmolding.
4. The method as defined in claim 3 ,
wherein the body hole is at least partially aligned with the sheath hole.
5. The method as defined in claim 1 , wherein:
the body end portion is a first body end portion;
the body includes a second body end portion opposite the first body end portion;
the body mid portion is disposed between the first body end portion and the second body end portion;
a core of the body includes substantially parallel fibers embedded in a matrix material; and
at least some of the substantially parallel fibers extend continuously from the first body end portion to the second body end portion.
6. The method as defined in claim 5 , wherein:
a skin of the body includes randomly oriented fibers embedded in another matrix material; and
the randomly oriented fibers are shorter than the substantially parallel fibers.
7. The method as defined in claim 6 , wherein the body end portion includes an anchoring feature engaged with the head or foot.
8. The method as defined in claim 1 , wherein the sheath end portion includes an anchoring feature engaged with the head or foot.
9. The method as defined in claim 1 , wherein applying the metallic sheath on part of the body includes nickel plating the metallic sheath on part of the body.
10. A method of manufacturing a composite guide vane of a gas turbine engine, the method comprising:
receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a thermoplastic resin;
forming a vane body from the layup of sheets, the vane body including a body mid portion for interacting with a fluid and a body end portion;
applying a metallic sheath on part of the vane body, the metallic sheath defining a leading edge of the guide vane; and
overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath,
wherein forming the vane body includes:
stamping the layup of sheets into a preform of a core of the vane body; and then
overmolding a skin on the preform.
11. A guide vane for a gas turbine engine, the guide vane comprising:
a body made of a fiber-reinforced composite material, the body including a body mid portion for interacting with a fluid and a body end portion;
a metallic sheath applied to part of the body, the metallic sheath including:
a sheath mid portion applied to the body mid portion and defining a leading edge of the guide vane; and
a sheath end portion applied to the body end portion; and
a head or foot overmolded onto the body end portion and onto the sheath end portion,
wherein the sheath end portion includes a hole and overmolding material of the head or foot extends into the hole.
12. The guide vane as defined in claim 11 , comprising both the head and the foot, wherein:
the body end portion is a first body end portion;
the body includes a second body end portion opposite the first body end portion;
the sheath end portion is a first sheath end portion;
the metallic sheath includes a second sheath end portion applied to the second body end portion;
the head is overmolded onto the first body end portion and onto the first sheath end portion; and
the foot is overmolded onto the second body end portion and onto the second sheath end portion.
13. The guide vane as defined in claim 12 , wherein the body includes a joggle accommodating the metallic sheath.
14. The guide vane as defined in claim 11 , wherein the sheath end portion includes an anchoring feature engaged with the head or foot.
15. The guide vane as defined in claim 11 , wherein the body end portion includes an anchoring feature engaged with the head or foot.
16. The guide vane as defined in claim 11 , wherein:
the hole is a through sheath hole;
the body end portion includes a body hole at least partially aligned with the sheath hole; and
overmolding material of the head or foot extends into the sheath hole and into the body hole.
17. The guide vane as defined in claim 11 , wherein:
the body end portion is a first body end portion;
the body includes a second body end portion opposite the first body end portion;
the body mid portion is disposed between the first body end portion and the second body end portion;
a core of the body includes long fibers embedded in a matrix material; and
a skin of the body includes randomly oriented short fibers embedded in another matrix material.
18. A guide vane for a gas turbine engine, the guide vane comprising:
a body made of a fiber-reinforced composite material, the body including a body mid portion for interacting with a fluid and a body end portion;
a metallic sheath applied to part of the body, the metallic sheath including:
a sheath mid portion applied to the body mid portion and defining a leading edge of the guide vane; and
a sheath end portion applied to the body end portion; and
a head or foot overmolded onto the body end portion and onto the sheath end portion,
wherein:
the body end portion is a first body end portion;
the body includes a second body end portion opposite the first body end portion;
the body mid portion is disposed between the first body end portion and the second body end portion;
a core of the body includes long fibers embedded in a matrix material; and
a skin of the body includes randomly oriented short fibers embedded in another matrix material.