# US 2022/0034331 A1 · Composite airfoil with metal strength > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0034331 A1 - Document ID: US20220034331A1 - Status: Published application - Kind: A1 - Application number: 17/502,620 - Filed: 2021-10-15 - Published: 2022-02-03 - Earliest claimed: 2017-05-04 - Assignees: General Electric Company - Applicants: General Electric Company - Inventors: Nitesh Jain; Sujana Chandrasekar; Ramkrishna Maripalli; Nicholas Joseph Kray; Wendy Wenling Lin - Web page: https://patentgrep.com/patent/US20220034331A1 ## CPC - F04D 29/388: {characterised by construction} - B29C 70/02: comprising combinations of reinforcements, {e.g. non-specified reinforcements, fibrous reinforcing inserts} and fillers, {e.g. particulate fillers}, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers {(combinations of fibrous reinforcement only B29C70/04; combinations of fillers only B29C70/58; combinations with non reinforcing inserts, e.g. foam blocks, B29C70/68)} - B29C 70/202: {arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] (B29C70/207 takes precedence)} - B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} - B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other} - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 7/02: Physical, chemical or physicochemical properties - B32B 37/144: {using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding (constructional features for tensioning B32B38/1825)} - F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments} - F02C 3/04: having a turbine driving a compressor (power transmission arrangements F02C7/36; control of working fluid flow F02C9/16) - F02K 3/06: with front fan - F04D 29/023: {especially adapted for elastic fluid pumps} - F04D 29/324: {Blades} - B29L 2031/7504: {Turbines} - B32B 2250/20: All layers being fibrous or filamentary - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/046: Synthetic resin - B32B 2262/103: Metal fibres - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2262/14: Mixture of at least two fibres made of different materials - B32B 2305/076: Prepregs - B32B 2307/546: Flexural strength; Flexion stiffness - B32B 2307/558: Impact strength, toughness - B32B 2457/00: Electrical equipment - B32B 2605/18: Aircraft - F05D 2220/36: specially adapted for the fan of turbofan engines - F05D 2300/171: Steel alloys - F05D 2300/174: Titanium alloys, e.g. TiAl - F05D 2300/177: Ni - Si alloys - F05D 2300/224: Carbon, e.g. graphite - F05D 2300/6032: Metal matrix composites [MMC] - Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft - F04D: NON-POSITIVE-DISPLACEMENT PUMPS (engine fuel-injection pumps F02M; ion pumps H01J41/12; electrodynamic pumps H02K44/02) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - F02C: GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS (construction of turbines F01D; jet-propulsion plants F02K; construction of compressors or fans F04; generating combustion products of high pressure or high velocity F23R; using gas turbines in compression refrigeration plants F25B11/00) - F02K: JET-PROPULSION PLANTS (features of jet-propulsion plants common to gas-turbine plants, air intakes or fuel supply control of air-breathing jet-propulsion plants F02C7/00, F02C9/00) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A laminated composite airfoil assembly includes a first lamina formed of a material including metal fibers, and at least a second lamina formed of a material including at least one of metal fibers intermixed with carbon fibers, only metal fibers, only carbon fibers, a substrate including metal fibers, a substrate including carbon fibers, and combinations thereof. ## Claims ### Claim 1 A laminated composite airfoil assembly comprising: a first lamina formed of a material comprising metal fibers; and at least a second lamina formed of a material comprising at least one of metal fibers intermixed with carbon fibers, only metal fibers, only carbon fibers, a substrate comprising metal fibers, a substrate comprising carbon fibers, and combinations thereof, wherein the airfoil assembly comprises a plurality of laminae formed from materials including the first lamina and the second lamina, and wherein a subset of laminae of the plurality of laminae are formed from material comprising carbon fibers, the airfoil assembly further comprising metal threads extending into the subset of laminae of the plurality of laminae. ### Claim 2 (depends on 1) The airfoil assembly of claim 1, wherein the material of the first lamina is a pre-preg material, and wherein the material of the second lamina is a pre-preg material. ### Claim 3 (depends on 2) The airfoil assembly of claim 2, wherein the pre-preg material of the first lamina comprises the metal fibers oriented in a first direction and the pre-preg material of the second lamina comprises the carbon fibers oriented in a second direction. ### Claim 4 (depends on 1) The airfoil assembly of claim 1, wherein the carbon fibers are unidirectional carbon fibers oriented in a first direction and the metal fibers crisscross the carbon fibers in at least one of the first lamina and the second lamina. ### Claim 5 (depends on 1) The airfoil assembly of claim 1, wherein the metal threads extend into the subset of the plurality of laminae in a 2.5D configuration. ### Claim 6 (depends on 1) The airfoil assembly of claim 1, wherein the metal threads extend into the subset of the plurality of laminae in a 3D configuration. ### Claim 7 (depends on 1) The airfoil assembly of claim 1, wherein the metal fibers comprise at least one of annealed steel, a nickel alloy, a nickel and chromium alloy, titanium, tungsten, and combinations thereof. ### Claim 8 A method of forming a laminated composite airfoil assembly comprising: providing a first lamina formed of a material including metal fibers; positioning a second lamina adjacent the first lamina, the second lamina formed of a material including at least one of metal fibers intermixed with carbon fibers, only metal fibers, only carbon fibers, a substrate including metal fibers, a substrate including carbon fibers, and combinations thereof; and curing at least the first and second laminae to form the laminated composite airfoil assembly, wherein the airfoil assembly comprises a plurality of laminae formed from materials including the first lamina and the second lamina, and wherein a subset of laminae of the plurality of laminae are formed from material comprising carbon fibers, the airfoil assembly further comprising metal threads extending into the subset of the plurality of laminae. ### Claim 9 (depends on 8) The method of claim 8, wherein the material of the first lamina is a pre-preg material, and wherein the material of the second lamina is a pre-preg material. ### Claim 10 (depends on 9) The method of claim 9, wherein the pre-preg material of the first lamina comprises the metal fibers oriented in a first direction and the pre-preg material of the second lamina comprises the carbon fibers oriented in a second direction. ### Claim 11 (depends on 8) The method of claim 8, wherein the carbon fibers are unidirectional carbon fibers oriented in a first direction and the metal fibers crisscross the carbon fibers in at least one of the first lamina and the second lamina. ### Claim 12 (depends on 8) The method of claim 8, wherein threading metal threads into the subset of the plurality of laminae comprises threading the metal threads in a 2.5D configuration. ### Claim 13 (depends on 8) The method of claim 8, wherein threading metal threads into the subset of the plurality of laminae comprises threading the metal threads in a 3D configuration. ### Claim 14 An engine comprising: a core engine; and a fan powered by gas generated in the core engine, wherein the fan comprises at least one laminated composite airfoil assembly, the laminated composite airfoil assembly comprising: a first lamina formed of a material comprising metal fibers; and at least a second lamina formed of a material comprising at least one of metal fibers intermixed with carbon fibers, only metal fibers, only carbon fibers, a substrate comprising metal fibers, a substrate comprising carbon fibers, and combinations thereof, wherein the airfoil assembly comprises a plurality of laminae formed from materials including the first lamina and the second lamina, and wherein a subset of laminae of the plurality of laminae are formed from material comprising carbon fibers, the airfoil assembly further comprising metal threads extending into the subset of the plurality of laminae. ### Claim 15 (depends on 14) The engine of claim 14, wherein the material of the first lamina is a pre-preg material, and wherein the material of the second lamina is a pre-preg material. ### Claim 16 (depends on 15) The engine of claim 15, wherein the pre-preg material of the first lamina comprises the metal fibers oriented in a first direction and the pre-preg material of the second lamina comprises the carbon fibers oriented in a second direction. ### Claim 17 (depends on 14) The engine of claim 14, wherein the carbon fibers are unidirectional carbon fibers oriented in a first direction and the metal fibers crisscross the carbon fibers in at least one of the first lamina and the second lamina. ### Claim 18 (depends on 14) The engine of claim 14, wherein the metal fibers comprise at least one of annealed steel, a nickel alloy, a nickel and chromium alloy, titanium, tungsten, and combinations thereof. ### Claim 19 (depends on 14) The engine of claim 14, wherein the metal threads extend into the subset of the plurality of laminae in a 2.5D configuration. ### Claim 20 (depends on 14) The engine of claim 14, wherein the metal threads extend into the subset of the plurality of laminae in a 3D configuration.