Three-dimensionally woven composite blade with spanwise weft yarns

1. A method of forming a composite blade, the method comprising:

forming a three-dimensional woven core, the step of forming the three-dimensional woven core comprising:

extending warp yarns in a chordwise direction of the woven core;

pulling the warp yarns apart to form a shed extending in a spanwise direction;

passing a weft yarn in the spanwise direction through the shed formed by the warp yarns; and

moving the warp yarns after weft yarn is passed through the shed to interlock the weft yarn and the warp yarns; and

curing the three-dimensional woven core to form the composite blade.

2. The method of claim 1 and further comprising:

varying the yarn size as measured by filament count of the warp yarns in the spanwise direction.

3. The method of claim 2 , wherein the step of varying the yarn size of the warp yarns comprises decreasing the yarn size of the warp yarns with decreasing distance to a tip of the woven core.

4. The method of claim 1 and further comprising:

stacking a plurality of plies on a suction side of the three-dimensional woven core prior to the step of curing the three-dimensional woven core.

5. The method of claim 1 wherein the step of passing the weft yarns through the shed formed by the warp yarns comprises:

passing the weft yarns through the shed formed by the warp yarns to form a layer-to-layer angle interlock weave pattern.

6. The method of claim 1 wherein the step of passing the weft yarns through the shed formed by the warp yarns comprises:

passing the weft yarns through the shed formed by the warp yarns to form a through-thickness angle interlock weave pattern.

7. The method of claim 1 wherein the step of passing the weft yarns through the shed formed by the warp yarns comprises:

passing the weft yarns through the shed formed by the warp yarns to form an orthogonal interlock weave pattern.