Fabrication and quality assurance processes for superhybrid composite fan blades

The feasibility of fabricating full-scale fan blades from superhybrid composites (SHC) for use large, commercial gas turbine engines was evaluated. The type of blade construction selected was a metal-spar/SHC-shell configuration, in which the outer shell was adhesively bonded to a short, internal, titanium spar. Various aspects of blade fabrication, inspection, and quality assurance procedures developed in the investigation are described. It is concluded that the SHC concept is feasible for the fabrication of prototype, full-scale, metal-spar/SHC-shell fan blades that have good structural properties and meet dimensional requirements.