Hybrid composite components

Abstract

Hybrid composite components, such as gas turbine engine containment assemblies, and methods of forming such components are provided. For example, a hybrid composite component comprises an annular composite shell and an annular metallic shell joined with the composite shell. At least one segment of the metallic shell interlocks with the composite shell or another segment of the metallic shell along an axial length. An exemplary containment assembly comprises a containment case extending along an axial direction about a longitudinal centerline of the gas turbine engine. The containment case has an inner surface and an outer surface spaced apart along a radial direction and includes an annular composite shell joined with an annular metallic shell. The metallic shell defines a first portion of the inner surface and the composite shell defines a second portion of the inner surface.

What is claimed is: 
     
         1 . A containment assembly of a gas turbine engine, comprising:
 a containment case extending along an axial direction about a longitudinal centerline of the gas turbine engine, the containment case having an inner surface and an outer surface spaced apart along a radial direction, the containment case including an annular composite shell joined with an annular metallic shell,   wherein the metallic shell defines a first portion of the inner surface and the composite shell defines a second portion of the inner surface.   
     
     
         2 . The containment assembly of  claim 1 , wherein the metallic shell interlocks with the composite shell along a circumferential direction. 
     
     
         3 . The containment assembly of  claim 2 , wherein the composite shell is a first composite shell and the containment case further includes a second composite shell, wherein the metallic shell comprises a forward edge and an aft edge, and wherein the first composite shell interlocks with the metallic shell along the forward edge and the second composite shell interlocks with the metallic shell along the aft edge. 
     
     
         4 . The containment assembly of  claim 1 , wherein an edge of the metallic shell is embedded within the composite shell. 
     
     
         5 . The containment assembly of  claim 1 , wherein the metallic shell defines at least a portion of the outer surface of the containment case. 
     
     
         6 . The containment assembly of  claim 1 , wherein the metallic shell comprises a plurality of metallic panels, each metallic panel comprising a first end circumferentially spaced apart from a second end, and wherein the plurality of metallic panels interlock along their respective first and second ends to form the annular metallic shell. 
     
     
         7 . The containment assembly of  claim 6 , wherein each of the first end and the second end of each metallic panel of the plurality of metallic panels defines a groove extending along the axial direction and the circumferential direction such that adjacent metallic panels of the plurality of metallic panels contact one another along their grooves to interlock along their first and second ends. 
     
     
         8 . The containment assembly of  claim 6 , wherein the containment case further includes a plurality of attachment mechanisms, each attachment mechanism disposed between the composite shell and the metallic shell to join the composite shell and the metallic shell. 
     
     
         9 . The containment assembly of  claim 8 , wherein each metallic panel of the plurality of metallic panels comprises an attachment zone, the respective attachment mechanism of the plurality of attachment mechanisms disposed within the attachment zone, and wherein the attachment zone is defined longitudinally inward with respect to each of the first end and the second end of the respective metallic panel. 
     
     
         10 . The containment assembly of  claim 8 , wherein the plurality of attachment mechanisms comprises a plurality of bolts. 
     
     
         11 . The containment assembly of  claim 8 , wherein at least one of the composite shell and the plurality of metallic panels defines a plurality of slots, each slot corresponding to a respective attachment mechanism of the plurality of attachment mechanisms. 
     
     
         12 . The containment assembly of  claim 1 , wherein the metallic shell is recessed within the composite shell such that the composite shell defines the outer surface of the containment case. 
     
     
         13 . The containment assembly of  claim 1 , wherein the containment assembly surrounds a plurality of fan blades attached to a disk, each fan blade of the plurality of fan blades extending along a radial direction, and wherein the disk is rotatable about the longitudinal centerline. 
     
     
         14 . The containment assembly of  claim 13 , wherein the metallic shell is disposed radially adjacent the plurality of fan blades. 
     
     
         15 . The containment assembly of  claim 13 , further comprising:
 a trench filler joined to the containment case, the trench filler disposed radially inward of the containment case such that the trench filler is disposed along the radial direction between the containment case and the plurality of fan blades.   
     
     
         16 . A hybrid composite component of a gas turbine engine, comprising:
 an annular composite shell; and   an annular metallic shell joined with the composite shell,   wherein at least one segment of the metallic shell interlocks with the composite shell or another segment of the metallic shell along an axial length.   
     
     
         17 . The hybrid composite component of  claim 16 , wherein the at least one segment of the metallic shell interlocks with the composite shell along the axial length, wherein the hybrid composite component comprises an inner surface spaced apart from an outer surface along a radial direction, and wherein the metallic shell defines a portion of the inner surface and a portion of the outer surface. 
     
     
         18 . The hybrid composite component of  claim 16 , wherein the metallic shell comprises a plurality of interlocking metallic panels, wherein the at least one segment of the metallic shell is a respective panel of the plurality of interlocking metallic panels which interlocks with an adjacent metallic panel along the axial length, and wherein the metallic shell is disposed in a recess defined by the composite shell. 
     
     
         19 . The hybrid composite component of  claim 16 , wherein the hybrid composite component is a fan containment case assembly surrounding a plurality of fan blades attached to a disk, each fan blade of the plurality of fan blades extending along a radial direction, the disk is rotatable about a longitudinal centerline of the gas turbine engine, and wherein the metallic shell defines an inner surface of the hybrid composite component disposed radially adjacent the plurality of fan blades. 
     
     
         20 . A method for forming a hybrid composite component of a gas turbine engine, comprising:
 forming a metallic segment;   laying up layers of a composite material to form a composite segment;   joining the metallic segment and the composite segment to form the hybrid composite component; and   processing the hybrid composite component.