Contour weaves for interwoven vanes
A method of forming a ceramic matrix composite (CMC) vane comprises drawing a continuous fiber sheet over at least one contoured surface to form a single-folded sheet. The single-folded sheet comprises an airfoil portion, a first platform at a first end of the airfoil portion, and an integral transition region between the airfoil portion and the first platform. The method further comprises mounting the airfoil portion on a mandrel, attaching a second platform to a second, opposing end of the airfoil portion to form a vane preform, and densifying the vane preform.
1. A method of forming a ceramic matrix composite (CMC) vane, the method comprising:
drawing a continuous fiber sheet over at least one contoured surface to form a single-folded sheet, the single-folded sheet comprising:
an airfoil portion;
a first platform at a first end of the airfoil portion; and
an integral transition region between the airfoil portion and the first platform;
attaching a second platform to a second, opposing end of the airfoil portion to form a vane preform; and
densifying the vane preform,
wherein the step of attaching the second platform to the second end of the airfoil portion comprises:
abutting the second platform to a shear tube layer of the airfoil portion; and
overwrapping the shear tube layer and the second platform with at least one additional fiber sheet to form a shear tube transition region.
2. The method of claim 1 , wherein the at least one contoured surface comprises at least one of a concave roller and a convex roller.
3. The method of claim 1 , wherein densifying the vane preform comprises at least one of chemical vapor infiltration, slurry infiltration, melt infiltration, and polymer infiltration and pyrolysis.
4. The method of claim 1 , wherein the single-folded sheet and the second platform are formed from ceramic fibers.
5. A method of forming a ceramic matrix composite (CMC) vane, the method comprising:
drawing a first continuous fiber sheet over at least one contoured surface to form a first single-folded sheet, the first single-folded sheet comprising:
a first airfoil portion;
a first platform at a first end of the first airfoil portion; and
a first integral transition region between the airfoil portion and the first platform;
drawing a second continuous fiber sheet over the at least one contoured surface to form a second single-folded sheet, the second single-folded sheet comprising:
a second airfoil portion;
a second platform at a first end of the second airfoil portion; and
a second integral transition region between the second airfoil portion and the second platform;
attaching the second platform to a second, opposing end of the first airfoil portion;
attaching the first platform to a second, opposing end of the second airfoil portion to form a vane preform; and
densifying the vane preform.
6. The method of claim 5 , wherein the at least one contoured surface comprises at least one of a concave roller and a convex roller.
7. The method of claim 5 , wherein the step of attaching the second platform to the second end of the first airfoil portion comprises:
abutting the second platform to a shear tube layer of the second airfoil portion; and
overwrapping the shear tube layer and the second platform with at least one additional fiber sheet to form a shear tube transition region.
8. The method of claim 7 , wherein the vane preform is doublet.
9. A method of forming a ceramic matrix composite (CMC) vane, the method comprising:
drawing a first continuous fiber sheet over at least one contoured surface to form a first single-folded sheet, the first single-folded sheet comprising:
a first airfoil portion;
a first platform at a first end of the first airfoil portion; and
a first integral transition region between the airfoil portion and the first platform;
attaching a second platform to a second, opposing end of the first airfoil portion to form a vane preform;
drawing a second continuous fiber sheet over the at least one contoured surface to form a second single-folded sheet, the second single-folded sheet comprising:
a second airfoil portion;
the second platform at a first end of the second airfoil portion; and
a second integral transition region between the second airfoil portion and the second platform; and
densifying the vane preform.
10. The method of claim 9 , and further comprising: splicing the first single-folded sheet to the second single-folded sheet at a first splice location to form a first layer.
11. The method of claim 10 and further comprising: splicing a third single-folded sheet to a fourth single-folded sheet at a second splice location to form a second layer.
12. The method of claim 11 , wherein the first splice location and the second splice location are on the airfoil portion.
13. The method of claim 12 , wherein the first splice location and the second splice location are offset from one another.