3D Woven Composite Applications for the Next Generation of Aircraft Engines

Abstract

The use 3D woven composites is on the rise, especially in aircraft engine components. OEMs are recognizing the many performance and economic advantages offered by the 3D weaving process, especially in aircraft engine applications that require high damage tolerance. Near net shape preforms with high fiber volume can be produced using the 3D weaving process. 3D weaving also offers the designer with the choice of virtually unlimited fiber architectures and design possibilities. However, a good, reliable and computationally efficient design tool for 3D woven composites is a basic necessity in order to enable the designer to fully exploit the advantages offered by the 3D weaving process. A simple analytical tool like TEXCAD can provide reliable and quick estimates and parametric studies of the 3D stiffnesses and strengths over the full range of fiber architectures that are possible with 3D weaving. Challenges in the use 3D woven composites relate to the lack of structural progressive damage modeling capability, the lack of standards and methods for the quality control, inspection and process control of 3D weaving processes and a lack of a good understanding of the effects of defects and fiber architecture variability on mechanical properties.