Composite article including composite to metal interlock and method of fabrication

A composite article comprising:

• composite component extending heightwise from a component base to a component tip and lengthwise between spaced apart component first and second edges, the composite component including a composite material lay-up of a plurality of filament reinforced composite plies, wherein each of the plurality of filament reinforced plies have widthwise spaced apart ply sides and ply edges therebetween;
• and
• a pre-threaded metallic component including a first surface and a second surface, the pre-threaded metallic component including a plurality of openings formed therein and extending from the first surface to the second surface, the pre-threaded metallic component including one or more interlock components, each of the one or more interlock components interwoven through at least two of the plurality of openings in the pre-threaded metallic component,
• wherein the one or more interlock components extend from one of a tab forward edge to a tab aft edge or a tab base to a tab tip of the pre-threaded metallic component and into and at least partially embedded in the composite component to provide an interlock system between the composite component and the pre-threaded metallic component, and
• wherein the composite component and the pre-threaded metallic component are co-cured.

A method of fabricating a composite article comprising:

• laying up a plurality of filament reinforced composite plies formed from a composite material, wherein each of the plurality of filament reinforced composite plies have widthwise spaced apart ply sides and ply edges therebetween;
• inserting a pre-threaded metallic component, into the plurality of filament reinforced composite plies during the laying up of the plurality of filament reinforced composite plies to form a composite to metallic interface;
• and
• co-curing the plurality of filament reinforced composite plies and the pre-threaded metallic component to form a composite article including an interlock system for the composite to metallic interface,
• wherein the pre-threaded metallic component includes a first surface and a second surface and a plurality of openings formed therein and extending from the first surface to the second surface, the pre-threaded metallic component further including one or more interlock components, wherein each of the interlock components is interwoven through at least two of the plurality of openings, and
• wherein the one or more interlock components extend across one of a substantial width or substantial length of the pre-threaded metallic component and into and at least partially embedded in the plurality of filament reinforced composite plies to provide an interlock system between the plurality of filament reinforced composite plies and the pre-threaded metallic component.