Method for manufacturing a composite guide vane having a metallic leading edge

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 body 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 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.

4. The method as defined in claim 3 , 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.

5. The method as defined in claim 4 , wherein the body end portion includes an anchoring feature engaged with the head or foot.

6. The method as defined in claim 1 , wherein the sheath end portion includes an anchoring feature engaged with the head or foot.

7. 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.

8. 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;

overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath; and

receiving overmolding material into a hole formed in the vane body during the overmolding.

9. The method as defined in claim 8 , 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.

10. 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; and

wherein the body end portion includes a hole and overmolding material of the head or foot extends into the hole.

11. The guide vane as defined in claim 10 , 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.

12. The guide vane as defined in claim 11 , wherein the body includes a joggle accommodating the metallic sheath.

13. The guide vane as defined in claim 10 , wherein the sheath end portion includes an anchoring feature engaged with the head or foot.

14. The guide vane as defined in claim 10 , wherein the body end portion includes an anchoring feature engaged with the head or foot.

15. The guide vane as defined in claim 10 , 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.