Method for making a composite airfoil

Abstract

A method of manufacturing a composite airfoil includes the step of providing a core made of a metal or ceramic material. A plastic airfoil portion is molded to envelope at least a portion of the core.

1 . A method of manufacturing a composite airfoil, the method comprising the steps of:
 providing a core made of a metal or ceramic material; and   molding a plastic airfoil portion to envelope at least a portion of the core.   
   
   
       2 . The method of  claim 1  further including the step of providing at least one opening in the core and the molding step includes filling the at least one opening with the plastic material of the airfoil portion to retain the airfoil portion in a position relative to the core. 
   
   
       3 . The method of  claim 1  wherein the core is provided with a leading edge and the molding step comprises injection molding the airfoil portion to envelope the leading edge of the core. 
   
   
       4 . The method of  claim 1  wherein the molding step comprises injection molding the airfoil portion to completely envelope the core. 
   
   
       5 . The method of  claim 4  wherein the injection molding step includes the step of providing a final shape and finish to the airfoil portion. 
   
   
       6 . The method of  claim 1  wherein the providing step comprises providing a metal core by a process selected from die casting, investment casting and forging. 
   
   
       7 . A method of manufacturing a composite airfoil, the method comprising the steps of:
 providing a core made of a metal or ceramic material, the core provided with a leading edge; and   molding a plastic airfoil portion to envelope at least the leading edge of the core.   
   
   
       8 . The method of  claim 7  further including the step of providing at least one opening in the core and the molding step includes filling the at least one opening with the plastic material of the airfoil portion to retain the airfoil portion in a position relative to the core. 
   
   
       9 . The method of  claim 7  wherein the molding step comprises injection molding the airfoil portion. 
   
   
       10 . The method of  claim 7  wherein the molding step comprises injection molding the airfoil portion to completely envelope the core. 
   
   
       11 . The method of  claim 10  wherein the injection molding step includes the step of providing a final shape and finish to the airfoil portion. 
   
   
       12 . The method of  claim 7  wherein the providing step comprises providing a metal core by a process selected from die casting, investment casting and forging. 
   
   
       13 . A method of manufacturing a composite airfoil, the method comprising the steps of:
 forming a metal core by die casting, investment casting or forging; and   injection molding a plastic airfoil portion to envelope at least a portion of the core.   
   
   
       14 . The method of  claim 13  further including the step of forming at least one opening in the core and the injection molding step includes filling the at least one opening with the plastic material of the airfoil portion to retain the airfoil portion in a position relative to the core. 
   
   
       15 . The method of  claim 13  wherein the core is provided with a leading edge and the injection molding step comprises enveloping the leading edge of the core with plastic material. 
   
   
       16 . The method of  claim 13  wherein the injection molding step comprises completely enveloping the core. 
   
   
       17 . The method of  claim 13  wherein the injection molding step includes the step of providing a final shape and finish to the airfoil portion.