COMPOSITE BLADE MANUFACTURE

摘要

A method of manufacturing a lightweight composite propulsor blade of spar and shell construction comprises forming a composite spar (30) having an elongated foam body (20) bonded to a short metal retention tulip (10) and overlayed with a dry braided wrap of angular structural fibers and substantially unidirectional spanwisely aligned structural fiber plies disposed between the braided layers; adding a leading edge foam body (42) and a trailing edge foam body (44) to the spar assembly to form a blade subassembly (50); providing a dry braided fabric wrap over the blade assembly; disposing the fabric covered blade subassembly into a shell molding die and simultaneously impregnating the dry spar fabric wrap and the dry shell fabric wrap with a curable resin material; and curing the impregnated blade subassembly.