Patent Publication Number: US-2023158758-A1

Title: Compression tool and method of forming gas turbine engine components

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. application Ser. No. 16/856,460 filed on Apr. 23, 2020. 
    
    
     BACKGROUND 
     This disclosure relates to a gas turbine engine, and more particularly to forming gas turbine engine components. 
     Gas turbine engines can include a fan for propulsion air and to cool components. The fan also delivers air into a core engine where it is compressed. The compressed air is then delivered into a combustion section, where it is mixed with fuel and ignited. The combustion gas expands downstream over and drives turbine blades. Static vanes are positioned adjacent to the turbine blades to control the flow of the products of combustion. 
     The engine typically includes one or more ducts that convey airflow through a gas path of the engine. Some ducts may be made of a composite material. 
     SUMMARY 
     An assembly for forming a gas turbine engine according to an example of the present disclosure includes a layup tool including a main body extending along a longitudinal axis and a flange extending radially from the main body, the flange defining an edge face slopes towards the main body to an axial face. At least one compression tool has a tool body having a first tool section and a second tool section extending transversely from the first tool section. The first tool section is translatable along a retention member in a first direction substantially perpendicular to the edge face such that relative movement causes the second tool section to apply a first compressive force on a composite article trapped between the axial face of the flange and the second tool section. The first compressive force has a major component in an axial direction relative to the longitudinal axis. 
     In a further embodiment of any of the foregoing embodiments, the retention member is a bolt extending along a bolt axis. The bolt has threading that mates with threading along a bore defined in the edge face. 
     In a further embodiment of any of the foregoing embodiments, the layup tool includes a plurality of guide pins extending outwardly from the edge face such that the guide pins are substantially parallel to the bolt axis. The first tool section has a plurality of apertures dimensioned to slidably receive respective ones of the guide pins, and the guide pins are radially and circumferentially offset from the bolt axis. 
     A further embodiment of any of the foregoing embodiments includes a spring member that urges the bolt along the bolt axis in a second direction away from the first tool portion in an installed position. 
     In a further embodiment of any of the foregoing embodiments, the second tool section is cantilevered from the first tool section. 
     In a further embodiment of any of the foregoing embodiments, the relative movement in the first direction causes the second tool section to apply a second compressive force on the composite article. The second compressive force has a major component in a radial direction relative to the longitudinal axis. 
     In a further embodiment of any of the foregoing embodiments, at least one compression tool includes a plurality of compression tools circumferentially distributed in an array along the flange of the layup tool. 
     A further embodiment of any of the foregoing embodiments includes at least one bridging tool spanning a respective intersegment gap established between mate faces of an adjacent pair of the compression tools such that the at least one bridging tool distributes at least one of the first and second compressive forces between the compression tools and the composite article. 
     In a further embodiment of any of the foregoing embodiments, the bridging tool has a generally hook-shaped geometry dimensioned to follow a contour of the adjacent pair of the compression tools. 
     In a further embodiment of any of the foregoing embodiments, the composite article is a composite layup that forms a composite duct. The composite duct is dimensioned to bound a gas path of a gas turbine engine. 
     In a further embodiment of any of the foregoing embodiments, the composite article is a composite layup that forms a composite gas turbine component. 
     A method of forming a gas turbine engine according to an example of the present disclosure includes forming a composite layup along a main body and a flange of a layup tool. The main body extends along a longitudinal axis, and the flange extends in a radial direction from the main body. At least one compression tool mounts to an edge face of the flange at a retention member. The at least one compression tool has a tool body having a first tool section and a second tool section extending transversely from the first tool section. The first tool section moves along the retention member in a first direction towards the edge face of the flange to apply a first compressive force on a portion of the composite layup trapped between an axial face of the flange and the second tool section. The first direction is transverse to the longitudinal axis and substantially perpendicular to the edge face, and the first compressive force has a major component in an axial direction relative to the longitudinal axis. 
     A further embodiment of any of the foregoing embodiments includes curing the composite layup during the applying of the first compressive force to form a gas turbine engine component. 
     In a further embodiment of any of the foregoing embodiments, the step of moving the first tool section along the retention member in the first direction causes the second tool section to apply a second compressive force on the composite layup. The second compressive force has a major component in the radial direction. 
     In a further embodiment of any of the foregoing embodiments, the second tool section is cantilevered from the first tool section during the moving step. 
     In a further embodiment of any of the foregoing embodiments, the retention member is a bolt extending along a bolt axis intersecting the edge face of the flange. The edge face slopes in a second direction towards the main body. The layup tool includes a plurality of guide pins extending outwardly from the edge face such that the guide pins are substantially parallel to the bolt axis. The first tool section has a plurality of apertures dimensioned to slidably receive respective ones of the guide pins, and the guide pins are radially and circumferentially offset from the bolt axis. 
     In a further embodiment of any of the foregoing embodiments, the at least one compression tool includes a plurality of compression tools circumferentially distributed in an array along the flange of the layup tool. 
     A further embodiment of any of the foregoing embodiments includes positioning at least one bridging tool between the composite layup and the second tool section of adjacent pairs of the compression tools such that the at least one bridging tool spans a respective intersegment gap established between mate faces of the adjacent pair of the compression tools. The moving step occurs such that the at least one bridging tool distributes the first and second compressive forces between the compression tools and the composite layup. 
     A further embodiment of any of the foregoing embodiments includes curing the composite layup during the applying of the first and second compressive forces to form a gas turbine engine component. 
     In a further embodiment of any of the foregoing embodiments, the gas turbine engine component is a composite duct including a duct body and an arcuate flange following a perimeter of the duct body. The duct body is dimensioned to bound a gas path of a gas turbine engine, and the arcuate flange is formed between the second tool section and the flange of the layup tool. 
     The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    illustrates an example gas turbine engine. 
         FIG.  2    illustrates another example gas turbine engine. 
         FIG.  3    illustrates a perspective view of an article positioned relative to an assembly. 
         FIG.  4    illustrates a side view of the assembly taken along line  4 - 4  of  FIG.  3   . 
         FIG.  5    illustrates a sectional view of the assembly taken along line  5 - 5  of  FIG.  3   . 
         FIG.  6    illustrates an axial view of the assembly of  FIG.  5   . 
         FIG.  7    is an example method in a flow chart of forming an article. 
         FIG.  8    illustrates the assembly of  FIG.  5    in an environment. 
         FIG.  9    illustrates a sectional view of a composite article. 
         FIG.  10    illustrates a sectional view of another composite article. 
         FIG.  11    illustrates a sectional view of another assembly. 
         FIG.  12    illustrates a sectional view of yet another assembly. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG.  1   , a gas turbine engine  10  includes a fan section  11 , a compressor section  12 , a combustor section  13 , and a turbine section  14 . Air entering into the fan section  11  is initially compressed and fed to the compressor section  12 . In the compressor section  12 , the incoming air from the fan section  11  is further compressed and communicated to the combustor section  13 . In the combustor section  13 , the compressed air is mixed with gas and ignited to generate a hot exhaust stream E. The hot exhaust stream E is expanded through the turbine section  14  to drive the fan section  11  and the compressor section  12 . The exhaust gasses E flow from the turbine section  14  through an exhaust liner assembly  18 . 
     The engine  10  includes one or more ducts  19  arranged about an engine central longitudinal axis A. The ducts  19  are dimensioned to bound a gas path of the engine  10 , such as through the fan, compressor, and turbine sections  11 ,  12 ,  14  and the exhaust liner assembly  18 . In the illustrative example of  FIG.  1   , the engine  10  includes a first duct  19 - 1  that bounds a portion of the gas path through the fan section  11 . The duct  19 - 1  includes a pair of duct halves (indicated at  19 - 1 A,  19 - 1 B) that establish a “split” duct arranged about the longitudinal axis A. 
       FIG.  2    schematically illustrates a gas turbine engine  20  according to another example. The gas turbine engine  20  is disclosed herein as a two-spool turbofan that generally incorporates a fan section  22 , a compressor section  24 , a combustor section  26  and a turbine section  28 . The fan section  22  drives air along a bypass flow path B in a bypass duct defined within a housing  15  such as a fan case or nacelle, and also drives air along a core flow path C for compression and communication into the combustor section  26  then expansion through the turbine section  28 . Although depicted as a two-spool turbofan gas turbine engine in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to use with two-spool turbofans as the teachings may be applied to other types of turbine engines including three-spool architectures. 
     The exemplary engine  20  generally includes a low speed spool  30  and a high speed spool  32  mounted for rotation about an engine central longitudinal axis A relative to an engine static structure  36  via several bearing systems  38 . It should be understood that various bearing systems  38  at various locations may alternatively or additionally be provided, and the location of bearing systems  38  may be varied as appropriate to the application. 
     The low speed spool  30  generally includes an inner shaft  40  that interconnects, a first (or low) pressure compressor  44  and a first (or low) pressure turbine  46 . The inner shaft  40  is connected to the fan  42  through a speed change mechanism, which in exemplary gas turbine engine  20  is illustrated as a geared architecture  48  to drive a fan  42  at a lower speed than the low speed spool  30 . The high speed spool  32  includes an outer shaft  50  that interconnects a second (or high) pressure compressor  52  and a second (or high) pressure turbine  54 . A combustor  56  is arranged in exemplary gas turbine  20  between the high pressure compressor  52  and the high pressure turbine  54 . A mid-turbine frame  57  of the engine static structure  36  may be arranged generally between the high pressure turbine  54  and the low pressure turbine  46 . The mid-turbine frame  57  further supports bearing systems  38  in the turbine section  28 . The inner shaft  40  and the outer shaft  50  are concentric and rotate via bearing systems  38  about the engine central longitudinal axis A which is collinear with their longitudinal axes. 
     The core airflow is compressed by the low pressure compressor  44  then the high pressure compressor  52 , mixed and burned with fuel in the combustor  56 , then expanded over the high pressure turbine  54  and low pressure turbine  46 . The mid-turbine frame  57  includes airfoils  59  which are in the core airflow path C. The turbines  46 ,  54  rotationally drive the respective low speed spool  30  and high speed spool  32  in response to the expansion. It will be appreciated that each of the positions of the fan section  22 , compressor section  24 , combustor section  26 , turbine section  28 , and fan drive gear system  48  may be varied. For example, gear system  48  may be located aft of the low pressure compressor, or aft of the combustor section  26  or even aft of turbine section  28 , and fan  42  may be positioned forward or aft of the location of gear system  48 . 
     The engine  20  in one example is a high-bypass geared aircraft engine. In a further example, the engine  20  bypass ratio is greater than about six (6), with an example embodiment being greater than about ten (10), the geared architecture  48  is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3 and the low pressure turbine  46  has a pressure ratio that is greater than about five. In one disclosed embodiment, the engine  20  bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor  44 , and the low pressure turbine  46  has a pressure ratio that is greater than about five 5:1. Low pressure turbine  46  pressure ratio is pressure measured prior to inlet of low pressure turbine  46  as related to the pressure at the outlet of the low pressure turbine  46  prior to an exhaust nozzle. The geared architecture  48  may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3:1 and less than about 5:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present invention is applicable to other gas turbine engines including direct drive turbofans. 
     A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section  22  of the engine  20  is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet (10,668 meters). The flight condition of 0.8 Mach and 35,000 ft (10,668 meters), with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (‘TSFC’)”—is the industry standard parameter of lbm of fuel being burned divided by lbf of thrust the engine produces at that minimum point. “Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.45. “Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tram ° R)/(518.7° R)] 0.5 . The “Low corrected fan tip speed” as disclosed herein according to one non-limiting embodiment is less than about 1150 ft/second (350.5 meters/second). 
     The engine  20  includes one or more ducts  23  arranged about the engine central longitudinal axis A. The ducts  23  are dimensioned to bound a gas path of the engine  20 , such as the bypass flow path B through the fan section  22  and the core flow path C through the compressor and turbine sections  24 ,  28 . Each duct  23  can include one or more flanges  23 F dimensioned to mount the duct  23  to another component, such as another one of the ducts  23 , or a nacelle or cowling. In the illustrative example of  FIG.  2   , a first duct  23 - 1  establishes at least a portion of the housing  15 . The first duct  23 - 1  bounds a flow path through the fan section  22 , such as the bypass flow path B. The duct  23 - 1  includes a pair of duct halves (indicated at  23 - 1 A,  23 - 1 B) arranged about the longitudinal axis A. Another one of the ducts  23 - 2  can be incorporated in a turbine exhaust case (TEC) of the turbine section  28 , for example. 
       FIGS.  3 - 6    illustrate an exemplary assembly  60  for forming a composite article or component CC. The component CC can be a composite gas turbine engine component such as composite duct incorporated into one of the ducts  19 ,  23  of the engines  10 ,  20 , for example. In the illustrative example of  FIG.  3 - 4   , the component CC is a composite duct including a main (or duct) body MB and an arcuate flange (or flanged portion) FP following a perimeter of the main body MB. The main body MB of the composite duct is dimensioned to bound a gas path of a gas turbine engine such as the engines  10 ,  20 . Although the disclosed examples primarily refer to ducts, other gas turbine engine components and other systems can benefit from teachings disclosed herein, including composite casings and other structures having a flanged interface and systems lacking a fan for propulsion. 
     Referring to  FIGS.  3 - 4   , the assembly  60  includes a layup tool  62  and at least one compression tool  64  mechanically attached or otherwise secured to the layup tool  62 . The layup tool  62  and the compression tool  64  cooperate to apply one or more compressive forces on the composite article during formation of the component CC. The composite article forming the component CC includes a plurality of ply layers PL in stacked relationship to establish a composite layup CL ( FIG.  5   ). The composite layup LL can be utilized to form the component CC. 
     Various materials can be utilized to form the composite layup CL including the ply layers PL. For examples, the composite layup CL can be constructed from continuous and/or discontinuous fibers arranged in various orientations and in one or more ply layers PL based on structural requirements. Example fiber materials include carbon fiber, fiberglass, an aramid such as Kevlar®, a ceramic such as Nextel™, a polyethylene such as Spectra®. The ply layers PL can be constructed from uni-tape plies having a plurality of fibers oriented in the same direction or can be constructed from a two-dimensional and/or three-dimensional network of fibers, which can be woven or interlaced. Other example fiber constructions include a network of stitched or non-crimped fabrics. The network of fibers can be formed from a dry fiber preform, or can be formed from a pre-impregnated (“prepreg”) fabric or tape having fibers pre-impregnated with resin in a matrix, for example. In other examples, the fibers are infused with resin in a matrix subsequent to laying up the ply layers PL on the layup tool  62 . In examples, the composite layup CL is made of an organic matrix composite, including silicon (Si) or silicon carbide (SiC) such as a SiC/SiC matrix composite, in an epoxy or resin matrix. The ply layers PL can be constructed from a carbon fiber prepreg in a polyimide matrix material. One or more coating can also be applied to surfaces of the composite layup CL. 
     The layup tool  62  includes a main body  66  extending along a longitudinal axis X. The layup tool  62  can be dimensioned such that the longitudinal axis X corresponds to the longitudinal axis A of the engines  10 ,  20 . The main body  66  can have a generally arcuate cross-sectional geometry that extends about the longitudinal axis X. In the illustrated example of  FIG.  3   , the main body  66  is dimensioned to extend circumferentially approximately 180 degrees about the longitudinal axis X. It should be appreciated that the main body  66  can be dimensioned to extend circumferentially less or greater than 180 degrees relative to the longitudinal axis X, such as 360 degrees to establish a full hoop. 
     The layup tool  62  includes at least one flange  68  extending radially from the main body  66 . In the illustrative embodiment of  FIGS.  3 - 4   , the layup tool  62  includes a pair of flanges  68  extending from opposed end portions of the main body  66  and includes a plurality of compression tools  64  circumferentially distributed in an array  65  of arc segments along each respective flange  68  with respect to the longitudinal axis X. 
     Referring to  FIG.  5   , with continuing reference to  FIGS.  3 - 4   , the flange  68  defines an edge face  68 E sloping in a direction towards the main body  66  to an axial face  68 A. The edge face  68 E is joined to the axial face  68 A. The axial face  68 A extends radially between the main body  66  and edge face  68 E. The main body  66  and axial face  68 A are joined at an interface  69  having a generally J-shaped cross-sectional geometry including one or more arcuate or radiused segments that establish a substantially smooth transition between surfaces of the main body  66  and axial face  68 A. Other geometries of the interface  69  can be utilized, such as perpendicular and chamfered geometries including planar or conical faces. 
     Each compression tool  64  includes a tool body  70  having a first tool section  72  and a second tool section  74  that extends transversally from the first tool section  72 . In illustrated example of  FIGS.  5 - 6   , the second tool section  74  is cantilevered from the first tool section  72 , and a free end  74 E of the second tool section  74  faces radially towards the longitudinal axis X in an installed position. 
     The first tool section  72  is dimensioned to extend along a first reference plane REF 1 , the second tool section  74  is dimensioned to extend along a second reference plane REF 2  transverse to the first reference plane REF 1 . The first reference plane REF 1  is transverse to the longitudinal axis X, and the second reference plane REF 2  is substantially perpendicular to the longitudinal axis X in an installed position. The reference planes REF 1 , REF 2  of the tool section  72 ,  74  are dimensioned to establish an angle α. In the illustrative example of  FIG.  5   , the angle α is an obtuse angle, such as between approximately 120 degrees and approximately 150 degrees (e.g., approximately 135 degrees). For the purposes of this disclosure, the terms “approximately” and “substantially” mean±3% of the stated value unless otherwise stated. 
     Various techniques can be utilized to mount each compression tool  64  to the layup tool  62 . The assembly  60  includes at least one retention member  76  that mounts a respective one of the compression tools  64 . Example retention members  76  include pins, fasteners, and rails. In the illustrated example of  FIGS.  5 - 6   , the retention member  76  is a bolt or fastener that releasably secures the compression tool  64  to the flange  68  of the layup tool  62 . The bolt  76  extends along a bolt axis BA dimensioned to intersect the edge face  68 E of the flange  68  in an installed position ( FIG.  5   ). The bolt  76  includes threading  76 T that mates with threading along a bore  68 B defined in the edge face  68 E. The bore  68 B is dimensioned such that the bolt axis BA is substantially perpendicular or normal to the edge face  68 E and is transverse to the longitudinal axis X in the installed position. A head of the bolt  76  can be dimensioned to receive tooling for applying or regulating torque. In other examples, a nob extends from a head of the bolt  76  which can be manually rotated to apply or regulate torque. 
     The first tool section  72  is translatable along the bolt axis BA of the bolt  76  in a first direction D 1  substantially perpendicular to the edge face  68 E of the flange  68  such that relative movement causes the second tool section  74  to apply a first (e.g., axial) compressive force C 1  and/or second (e.g., downward) compressive force C 2  on a composite article such as the composite layup CL trapped between the axial face  68 A of the flange  68  and the second tool section  74  of the compression tool  64 , as illustrated in  FIG.  8   . The sloping or inclined plane of the edge face  68 E serves to allow for translation of the composite layup CL both horizontally and vertically relative to the longitudinal axis X. 
     The assembly  60  can include one or more guide pins  71  dimensioned to orient the respective compression tool  64  relative to the flange  68 . In the illustrative example of  FIGS.  5 - 6   , one or more guide pins  71  extend outwardly from the edge face  68 E of the layup tool  62 . Each guide pin  71  extends along a respective pin axis GA that is substantially parallel to the bolt axis BA, as illustrated in  FIG.  5   . The guide pins  71  and bore  68 B can be dimensioned such that the pin axes GA of the guide pins  71  are radially and/or circumferentially offset or staggered from the bolt axis BA of the respective bolt  76 , as illustrated by  FIGS.  5 - 6   . 
     The first tool section  72  includes one or more apertures  72 A extending through a thickness of the first tool section  72 . Each aperture  72 A is dimensioned to slidably receive a respective one of the guide pins  71  to orient the compression tool  64  relative to the flange  68  and reduce a likelihood of tilting. The apertures  72 A can be defined adjacent to respective corners of the first tool section  72 , which can increase a wheel base of the compression tool  64 . More than two guide pins  71  can be utilized to engage each compression tool  64 , such as three guide pins  71  and apertures  72 A at respective corners of the first tool section  72  at various orientations and may be the same or differ from an orientation of fibers in one or more of the ply layers PL. 
     At step  90 B, at least one compression tool  64  is mounted to the edge face  68 E of the flange  68  at the retention member  76 . Step  90 B can include mounting a plurality of compression tools  64  circumferentially distributed in an array  65  along the flange  68  of the layup tool  62 , as illustrated by  FIG.  3   . In other examples, the compression tool  64  is dimensioned to extend circumferentially between opposed sides of the flange  68 . Intersegment gaps GG can be established between the mate faces  64 M of adjacent compression tools  64 , as illustrated by  FIG.  6   . Step  90 B can include at step  90 C positioning one or more bridging tools  80  between the composite layup CL and the second tool section  74  of adjacent pairs of the compression tools  64  such that each of the bridging tools  80  spans a respective intersegment gap GG and distributes at least one of the first and second compressive forces C 1 , C 2  between the compression tools  64  and the composite layup CL, as illustrated by  FIGS.  6  and  8   . In other examples, the bridging tools  80  are omitted, and the second tool section  74  directly contacts surfaces of the composite layup CL adjacent to the flange  68 . 
     At step  90 D, the first tool section  72  of the compression tool  64  is moved along the retention member  76  in a first direction D 1  along the bolt axis BA towards the edge face  68 E of the flange  68  such that the relative movement causes the second tool section  74  to apply the first compressive force C 1  on the arcuate flanged portion FP of the composite layup CL trapped or seated between the axial face  68 A of the flange  68  and the second tool section  74 . Step  90 D can occur such that the bridging tool  80  is trapped between the axial face  68 A of the flange  68  and the second tool section  74 . In the illustrative example of  FIG.  8   , the first direction D 1  is transverse to the longitudinal axis X and is substantially perpendicular or normal to the edge face  68 E. The first compressive force C 1  has a major component in an axial direction AD relative to the longitudinal axis X. In examples, step  90 D includes moving the first tool section  72  along the retention member  76  in the first direction D 1  such that the relative movement causes the second tool section  74  to apply a second compressive force C 2  on the flanged portion FP of the composite layup CL. The second compressive force C 2  is substantially perpendicular to the first compressive force C 1  and has a major component in the radial direction RD relative to the longitudinal axis X. In the illustrative example of  FIG.  8   , the bolt axis BA is oriented relative to the edge face  68 E of the flange  68  such that the first compressive force C 1  is substantially parallel to the longitudinal axis X and such that the second compressive force C 2  is substantially perpendicular or normal to the longitudinal axis X. 
     The compression tools  64  and/or bridging tools  80  may be formed to have a relatively surface low friction, which may prevent or otherwise reduce a likelihood of radially slippage or shearing of the ply layers PL during tightening the bolts  76  or otherwise moving the compression tools  64  towards the flange  68 . Various techniques can be utilized to establish a relatively low friction interface, such as by incorporation of low friction materials and/or depositing a lubricant or coating on surfaces of the compression tools  64  and/or bridging tools  80 . 
     The second tool section  74  is cantilevered from the first tool section  72  during the moving step  90 D such that the cantilevered portion of the second tool section  74  radially aligned with the flanged portion FP applies the first compressive force C 1  on the composite layup CL, and the free end  74 E of the second tool portion  74  applies the second compressive force C 2  on the main body MB of the composite layup CL. Cantilevering the second tool section  74  can more evenly distribute the compressive forces C 1 , C 2  adjacent the flanged portion FP of the composite layup CL. Step  90 D occurs such that the bridging tools  80  distribute or spread the first and/or second compressive forces C 1 , C 2  between the compression tools  64  and the composite layup CL, which may improve uniformity in the finished article. 
     At step  90 E, the composite layup CL is cured to form the composite component CC. The flanged portion FP of the composite layup CL is formed between the second tool section  74  and the flange  68  of the layup tool  62 . Various techniques can be utilized to perform step  90 E, including an autoclave process or a closed-molding process such as a resin transfer molding (RTM) process or a resin pressure molding (RPM) process to form the composite component CC. 
     An autoclave or vacuum bagging process is generally known for manufacturing composite articles and typically includes arranging or laying up one or more prepreg sheets or plies on a mold surface to establish a layup, arranging the layup in a vacuum bagging arrangement, and positioning the layup into an autoclave. The layup can be cured in one or more autoclave cycles. The vacuum bag can be removed after cooling, and the cured article can be taken out of the autoclave. 
     Resin transfer molding (RTM) is generally known for manufacturing composite articles. RTM is a closed-molding process that typically includes fabricating a fiber preform by laying up plies of fiber sheets in a stack, placing the fiber preform in a closed mold, and then saturating the fiber preform with a liquid thermoset resin. The resin is typically mixed with a catalyst or hardener prior to being injected into the closed mold, or can be previously mixed together in a one-part resin system. One-part resin systems already have the catalyst mixed with the resin. The article is heated in the mold to a desired temperature to cure the article. The mold can be heated using a liquid heating system, for example. In some examples, the mold is heated by direct contact with heated platens such as in a compression press or free-standing in an oven. A variation of RTM is vacuum-assisted resin transfer molding (VARTM). In a VARTM process, a vacuum is used to draw the resin into the mold. The RTM process generally results in a part with a slightly lower volume percentage of fiber compared to a part made from prepreg and processed in an autoclave. 
     Resin pressure molding (RPM) is generally known for manufacturing composite articles. RPM can be considered a variation of an RTM process. RPM is a closed-molding process which includes delivering a liquid resin into a closed mold in which some, or all, of the fiber reinforcement has been pre-impregnated with a resin. Thereafter and similar to RTM, a combination of elevated heat and hydrostatic resin pressure are applied to the mold to cure the article. 
     Curing the composite layup CL at step  90 E occurs during the applying and maintaining of the first and/or second compressive forces C 1 , C 2  to form the component CC. A predefined amount of torque can be applied to the bolt  76  to set an amount of the first and/or second compressive forces C 1 , C 2  for reducing porosity and ply waviness or wrinkling in the flanged portion FP of the component CC. The predefined amount of torque can be set at ambient conditions or room temperature, for example. A likelihood of excessive compression that may otherwise reduce resin content can also be reduced. The torque can be maintained and/or adjusted during step  90 E. In examples, step  90 E includes heating and/or pressurizing surfaces of the composite layup CL in an environment ENV (shown in dashed lines in  FIG.  8    for illustrative purposes). The environment ENV can include any of the examples disclosed herein, such as an autoclave or vacuum bag. In examples, step  90 E includes forming the composite layup CL from a carbon fiber prepreg with a polymide matrix and curing the composite layup CL in one or more autoclave cycles. Step  90 E can include delivering a quantity of resin into the environment ENV and applying pressure in the environment ENV to inject or infuse resin in the fibers while holding the composite layup CL between the flange  68  and second tool section  74  of the compression tool  64 , and heating the composite layup CL to cure the resin. Resin materials can include a thermoset epoxy, for example. The spring member  78  can be utilized to substantially maintain a load on the first tool section  72  in response to relaxation or softening of the composite layup CL during step  90 E, which can serve to consolidate the adjacent material of the composite layup CL. 
     One or more finishing operations can be performed at step  90 F. Step  90 F can include one or more machine operations on surfaces of the composite component CC. For example, surfaces along the interface  69  to mate with a mounting block BB (shown in dashed lines in  FIG.  10    for illustrative purposes). The mounting block BB can be made of a metallic material and can serve to provide structural support to the flanged portion FP of the component CC in an assembled position. The composite component CC can be removed from the assembly  60  prior or subsequent to step  90 F. 
     Utilizing the techniques disclosed herein, compressive forces along the flanged region of the composite articles can be regulated during formation such that the flange region plies PL more closely follow a contour of the layup tool  62 .  FIG.  9    illustrates a composite article CC 1  formed without the benefit of the teachings disclosed herein.  FIG.  10    illustrates a composite article CC 2  formed with the assembly  60  and/or method  90 . As illustrated by  FIGS.  9  and  10   , the composite article CC 2  is relatively more robust and exhibits relatively lesser porosity, ply waviness and thickness variation that the composite article CC 1 , which can reduce scrap rates, corrective measures including secondary machining operations due to out-of-tolerance conditions along the interface  69  which may otherwise reduce ply integrity, and cost associated with forming the composite articles. 
     It should be understood that relative positional terms such as “forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like are with reference to the normal operational attitude of the vehicle and should not be considered otherwise limiting. 
     Although the different examples have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples. 
     Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present disclosure. 
     The foregoing description is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be understood that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For that reason the appended claims should be studied to determine true scope and content.