Patent Description:
A gas turbine engine typically includes, in axial series, a compressor, combustion equipment, and a turbine that drives the compressor. During operation, air is compressed by the compressor, the compressed air is mixed with fuel and combusted by the combustion equipment, and the resulting combustion products are expelled through the turbine.

The compressor may include a bladed disk or rotor including a disk and a plurality of blades mounted on the disk. It may be advantageous to manufacture the disk from composite materials as opposed to metals, for example, to reduce the weight of the bladed disk or rotor. However, conventional manufacturing techniques may require complex tooling and moulding processes for manufacturing the disk from composite materials as well as complicated assembly processes for mounting the plurality of blades on the disk. Therefore, conventional manufacturing techniques may be complicated and uneconomical.

United States patent <CIT> discloses a blade assembly adapted for use in a fluid flow machine. The blade assembly has a fibre-reinforced rotatable support member with a plurality of axially spaced circumferentially continuous portions separated by gaps. The support member has circumferentially extending fibres at least in the portions for resisting hoop stresses at the rim of the rotatable support member. The blade assembly also has a plurality of angularly spaced apart fibre-reinforced blades. Each of the blades has a root portion defined by a plurality of tangs having slots therebetween. Each of the blades has fibres therein which extend into said tangs. Each of the blades are mounted on the support member with each of the tangs in its root being in one of said gaps and shear bonded to adjacent circumferentially continuous portions of said support member. Centrifugal loads to which the blades are subjected are transmitted by fibres in the tangs of the blades to the circumferentially extending fibres in the portions of the rotatable support members.

United States patent <CIT> discloses a turbomachinery rotor that has a multi-stranded network of fibres that have high tensile strength contained in and bonded by a matrix. The fibres and the matrix consist of the same material respectively and are selected from carbon, quartz and alumina. The rotor has: (a) a disc portion wherein the fibres extend in substantially radial, axial, and circumferential directions, the axial and circumferential fibres being present substantially throughout the disc portion; and (b) a plurality of blade portions that extend radially from the outer periphery of the disc portion, substantially all of the radial fibres of the disc portion extending beyond the outer periphery into the blade portions.

According to a first aspect there is provided a method for manufacturing a composite bladed disk or rotor for a gas turbine engine as set out in claim <NUM>.

The method of the present invention may facilitate mounting of the plurality of blades to the moulded component (which may correspond to a rotor disk). Specifically, mounting of the plurality of blades to the moulded component may be facilitated by providing the plurality of slots, positioning the plurality of blades partially within the plurality of slots, and joining the each pair of adjacent segments to each other. Each of the plurality of blades may consequently be permanently trapped or retained within a corresponding slot from the plurality of slots.

Further, the complementary finger joint profiles may allow providing a reliable structural joint between the each pair of adjacent segments, which may be capable of withstanding loads during operation of the gas turbine engine. Moreover, the method may allow tailoring the complementary finger joint profiles to suit the duty/load case of the structural joint. That is, the design and size of the complementary finger joint profiles may be modified according to the performance requirements. This may ensure that segmenting the moulded component into the plurality of segments and joining the plurality of segments may not negatively affect the load bearing capacity of the moulded component.

The method may further allow the use of blades made from composite materials as well as metals and having different retention features (such as dovetail features and fir-tree features). The method may also allow the use of various different composite materials as well as hybrid assemblies containing mixed classes of materials to manufacture the composite bladed disk or rotor, based on desired application requirements.

The method may therefore be simple, economical, allow flexibility in material choice as per application requirements, and may be carried out without the need to use complex tooling and moulding processes.

In some embodiments, forming the moulded component includes depositing the at least one composite material on a mandrel.

In some embodiments, the method further includes removing the mandrel from the moulded component prior to segmenting the moulded component.

The moulded component may therefore be economically formed using, for example, filament winding.

In some embodiments, the moulded component forms a plurality of stages of the composite bladed disk or rotor. The plurality of blades of the each pair of adjacent segments includes a corresponding stage from the plurality of stages.

In some embodiments, the at least one composite material includes a plurality of composite materials that differ from each other. Each of the plurality of segments includes a corresponding composite material from the plurality of composite materials.

Advantageously, the method may allow forming the plurality of segments with composite materials having different properties (for example, thermal capabilities). Therefore, it may be possible to select composite materials based on the operational thermal environment of a segment. For example, an axially downstream segment may be made from a composite material that has a greater thermal capacity than that of an axially upstream segment.

In some embodiments, each of the complementary finger joint profiles includes a plurality of circumferential fingers concentrically spaced apart from each other with respect to the component axis.

In some embodiments, each of the complementary finger joint profiles comprises a plurality of fingers extending perpendicularly to the component axis.

Thus, the method may allow flexibility in designing the complementary finger joint profiles based on the desired application requirements.

In some embodiments, each adjacent segment of the each pair of adjacent segments has a section thickness defined perpendicularly to the component axis. Each of the complementary finger joint profiles includes a plurality of fingers. Each of the plurality of fingers has a length defined along the component axis. The length is from <NUM> times to <NUM> times of the section thickness.

The aforementioned length of the plurality of fingers may ensure that a reliable structural joint can be formed between the each pair of adjacent segments when the each pair of adjacent segments are joined.

In some embodiments, each of the plurality of slots is a dovetail slot.

The dovetail slot of each of the plurality of slots may receive a blade having a dovetail retention feature.

In some embodiments, the method further includes applying a joint adhesive layer on at least one of the complementary finger joint profiles prior to mating the complementary finger joint profiles of the each pair of adjacent segments.

The joint adhesive layer may improve joining of the each pair of adjacent segments and may improve the robustness of the joint formed between the each pair of adjacent segments.

In some embodiments, joining the each pair of adjacent segments includes curing the joint adhesive layer.

The joint adhesive layer may include an adhesive that can be cured to provide a strong, permanent, and robust bond between the each pair of adjacent segments. An example of such adhesive includes an epoxy adhesive.

In some embodiments, the method further includes applying a slot adhesive layer in each of the plurality of slots prior to positioning the plurality of blades partially within the plurality of slots, such that each of the plurality of blades is bonded to at least one of the each pair of adjacent segments.

The slot adhesive layer may ensure retention of the plurality of blades with the plurality of slots.

In some embodiments, the method further includes providing an alignment feature on the each pair of adjacent segments. The method further includes aligning the each pair of adjacent segments with each other based on the alignment feature prior to mating the complementary finger joint profiles of the each pair of adjacent segments.

The alignment feature may facilitate aligning of the each pair of adjacent segments with each other, and as a result may improve the robustness of the joint formed between the each pair of adjacent segments.

In some embodiments, the method further includes coupling the moulded component to a drive shaft of the gas turbine engine.

The drive shaft of the gas turbine engine may drive the composite bladed disk or rotor.

The following table lists the reference numerals used in the drawings with the features to which they refer:.

The engine core <NUM> comprises, in axial flow series, a low pressure compressor <NUM>, a high pressure compressor <NUM>, combustion equipment <NUM>, a high pressure turbine <NUM>, a low pressure turbine <NUM>, and a core exhaust nozzle <NUM>.

The resultant hot combustion products then expand through, and thereby drive, the high pressure and low pressure turbines <NUM>, <NUM> before being exhausted through the core exhaust nozzle <NUM> to provide some propulsive thrust.

Note that the terms "low pressure turbine" and "low pressure compressor" as used herein may be taken to mean the lowest pressure turbine stages and lowest pressure compressor stages (i.e., not including the fan <NUM>) respectively and/or the turbine and compressor stages that are connected together by the interconnecting shaft <NUM> with the lowest rotational speed in the engine (i.e., not including the gearbox output shaft that drives the fan <NUM>).

Other gas turbine engines to which the present disclosure may be applied may have alternative configurations. For example, such engines may have an alternative number of compressors and/or turbines and/or an alternative number of interconnecting shafts. By way of further example, the gas turbine engine <NUM> shown in <FIG> has a split flow nozzle <NUM>, <NUM> meaning that the flow through the bypass duct <NUM> has its own nozzle <NUM> that is separate to and radially outside the core exhaust nozzle <NUM>. However, this is not limiting, and any aspect of the present disclosure may also apply to engines in which the flow through the bypass duct <NUM> and the flow through the core <NUM> are mixed, or combined, before (or upstream of) a single nozzle, which may be referred to as a mixed flow nozzle. One or both nozzles (whether mixed or split flow) may have a fixed or variable area. Whilst the described example relates to a turbofan engine, the disclosure may apply, for example, to any type of gas turbine engine, such as an open rotor (in which the fan stage is not surrounded by a nacelle) or turboprop engine, for example. In some arrangements, the gas turbine engine <NUM> may not comprise a gearbox <NUM>.

The axial, radial, and circumferential directions are mutually perpendicular.

As used in the present disclosure, the terms "first" and "second" are used as identifiers. Therefore, such terms should not be construed as limiting of this disclosure. The terms "first" and "second" when used in conjunction with a feature or an element can be interchanged throughout the embodiments of this disclosure.

As used herein, "at least one of A and B" should be understood to mean "only A, only B, or both A and B".

<FIG> shows a flowchart depicting various steps of a method <NUM> for manufacturing a composite bladed disk or rotor for a gas turbine engine, such as the gas turbine engine <NUM> of <FIG>, in accordance with an embodiment of the present disclosure. The composite bladed disk or rotor may be included in, for example, the low pressure compressor <NUM> or the high pressure compressor <NUM> of <FIG>. The method <NUM> will be described with further reference to <FIG>, which schematically depict the various steps of the method <NUM>.

At step <NUM>, the method <NUM> includes forming a moulded component from at least one composite material. As used in the present disclosure, the term "composite material" refers to a material including an additive material and a matrix material that supports the additive material. The additive material may be embedded in the matrix material. The matrix material may be, for example, organic/polymeric and/or ceramic. In other words, composite materials may include organic/polymer matrix composites and/or ceramic matrix composites. The matrix material may be thermosetting or thermoplastic. The additive material may be a reinforcing material. The additive material may include, but is not limited to, carbon, glass, graphite, aramid, and organic fibre of any length, size, and orientation.

Furthermore, the moulded component is axisymmetric about a component axis. The moulded component may therefore be a rotationally symmetric component. The moulded component may correspond to a rotor disk (also referred to as "rotor drum" and "rotor hub").

Referring to <FIG>, for example, the method <NUM> may include forming a moulded component <NUM> from at least one composite material. The moulded component <NUM> may be axisymmetric about a component axis <NUM>.

The moulded component <NUM> may be formed using any suitable method, and the disclosure is not limited thereto. For example, the moulded component <NUM> may be formed using automated fibre placement (AFP), filament winding, hand layup, pick and place automation, and the like.

In some embodiments, forming the moulded component may include depositing the at least one composite material on a mandrel. Referring to <FIG>, for example, forming the moulded component <NUM> may include depositing the at least one composite material on a mandrel <NUM>. The mandrel <NUM> is hatched in <FIG> for clarity purposes. The at least one composite material may be deposited on the mandrel <NUM> from a prepreg tape. The prepreg tape may be a thermoplastic or a thermosetting composite prepreg tape. The moulded component <NUM>, once formed, may be removed from the mandrel <NUM>, as shown in <FIG>.

In some examples, the mandrel <NUM> may be a filament winding mandrel that defines an inner surface of the moulded component <NUM>, and the moulded component <NUM> may be formed using a filament winding process. In some examples, the moulded component <NUM> may be formed by employing a wet filament winding process using dry carbon fibre and a liquid matrix resin.

At step <NUM>, the method <NUM> further includes segmenting the moulded component into a plurality of segments disposed adjacent to each other. Each pair of adjacent segments from the plurality of segments includes a pair of surfaces that is formed during segmentation of the moulded component.

Referring to <FIG>, for example, the method <NUM> may include segmenting the moulded component <NUM> into a plurality of segments <NUM> disposed adjacent to each other. For example, in <FIG>, the moulded component <NUM> is segmented into a first segment 210A, a second segment 210B, and a third segment 210C. In other words, the plurality of segments <NUM> includes the first segment 210A, the second segment 210B, and the third segment 210C.

Each pair of adjacent segments <NUM> from the plurality of segments <NUM> includes a pair of surfaces <NUM> that is formed during segmentation of the moulded component <NUM>. In the present disclosure, the reference character "<NUM>" is used to generally indicate each pair of adjacent segments from the plurality of segments <NUM>. For example, in <FIG>, the plurality of segments <NUM> includes a pair of adjacent segments <NUM> that includes the first segment 210A and the second segment 210B, and another pair of adjacent segments <NUM> that includes the second segment 210B and the third segment 210C. Furthermore, the each pair of adjacent segments <NUM> includes the pair of surfaces <NUM> that is formed during segmentation of the moulded component <NUM>.

In some embodiments, the at least one composite material may include a plurality of composite materials that differ from each other. Each of the plurality of segments may include a corresponding composite material from the plurality of composite materials. Referring to <FIG>, for example, the first segment 210A may include a first composite material, the second segment 210B may include a second composite material, and the third segment 210C may include a third composite material. In other words, the first segment 210A may be formed from the first composite material, the second segment 210B may be formed from the second composite material, and the third segment 210C may be formed from the third composite material. The first, second, and third composite materials may differ from each other. For example, the first, second, and third composite materials may have different thermal capabilities.

In some embodiments, the method <NUM> may further include removing the mandrel from the moulded component prior to segmenting the moulded component. Referring to <FIG>, for example, the method <NUM> may include removing the mandrel <NUM> (shown in <FIG>) from the moulded component <NUM> prior to segmenting the moulded component <NUM>. <FIG> shows the moulded component <NUM> with the mandrel <NUM> removed therefrom.

In some embodiments, the method <NUM> may further include providing an alignment feature on the each pair of adjacent segments. Referring to <FIG>, for example, the method <NUM> may include providing an alignment feature <NUM> on the each pair of adjacent segments <NUM>. The alignment feature <NUM> may include indicia, markings, and the like to facilitate aligning the each pair of adjacent segments <NUM>. The alignment feature <NUM> may be provided on the moulded component <NUM> prior to segmenting the moulded component <NUM> into the plurality of segments <NUM>. The alignment feature <NUM> may extend at least partially along the component axis <NUM>. The alignment feature <NUM> may be aligned with the component axis <NUM>.

At step <NUM>, the method <NUM> further includes providing, via computerised numerical control (CNC) machining, complementary finger joint profiles on the pair of surfaces of the each pair of adjacent segments.

Referring to <FIG>, for example, the method <NUM> may include providing, via CNC machining, complementary finger joint profiles <NUM> on the pair of surfaces <NUM> of the each pair of adjacent segments <NUM>. The complementary finger joint profiles <NUM> may be machined by a cutting tool <NUM> that is part of a CNC machine. The complementary finger joint profiles <NUM> may be machined by, for example, turning, milling, and/or grinding.

Each of the complementary finger joint profiles may include a plurality of fingers. Referring to <FIG>, for example, each of the complementary finger joint profiles <NUM> may include a plurality of fingers <NUM>.

<FIG> shows a perspective view of portions of the first segment 210A and the second segment 210B and exemplary complementary finger joint profiles <NUM> including the plurality of fingers <NUM>.

In some embodiments, each adjacent segment of the each pair of adjacent segments may have a section thickness defined perpendicularly to the component axis. Further, each of the plurality of fingers may have a length defined along the component axis. The length may be from <NUM> times to <NUM> times of the section thickness.

Referring to <FIG>, for example, each adjacent segment <NUM> of the each pair of adjacent segments <NUM> may have a section thickness 213T defined perpendicularly to the component axis <NUM>. In <FIG>, each of the first segment 210A and the second segment 210B has the section thickness 213T (only indicated on the first segment 210A for illustrative purposes). Further, each of the plurality of fingers <NUM> may have a length <NUM> (only indicated on the first segment 210A for illustrative purposes) defined along the component axis <NUM>. The length <NUM> may be from <NUM> times to <NUM> times of the section thickness 213T. Preferably, the length <NUM> may be equal to the section thickness 213T. The length <NUM> being from <NUM> times to <NUM> times of the section thickness 213T may increase the robustness of a joint formed by mating and joining the complementary finger joint profiles <NUM>.

In some embodiments, each of the complementary finger joint profiles may include a plurality of circumferential fingers concentrically spaced apart from each other with respect to the component axis. Referring to <FIG>, for example, each of the complementary finger joint profiles <NUM> may include a plurality of circumferential fingers 216A concentrically spaced apart from each other with respect to the component axis <NUM>. In other words, in some embodiments, the plurality of fingers <NUM> may be circumferential and concentrically spaced apart from each other with respect to the component axis <NUM>.

In some embodiments, each of the complementary finger joint profiles may include a plurality of fingers extending perpendicularly to the component axis. Referring to <FIG>, for example, each of the complementary finger joint profiles <NUM> may include a plurality of fingers 216B extending perpendicularly to the component axis <NUM>. In other words, the plurality of fingers <NUM> may extend perpendicularly to the component axis <NUM>. The plurality of fingers 216B may be linear or curved.

At step <NUM>, the method <NUM> further includes providing a plurality of slots on at least one of the pair of surfaces of the each pair of adjacent segments. Each of the plurality of slots at least partially extends along the component axis and perpendicularly to the component axis.

Referring to <FIG>, for example, the method <NUM> may include providing a plurality of slots <NUM> on at least one of the pair of surfaces <NUM> of the each pair of adjacent segments <NUM>. That is, the plurality of slots <NUM> may be provided on one of the pair of surfaces <NUM>, or alternatively, the plurality of slots <NUM> may be provided on each of the pair of surfaces <NUM>. In <FIG>, the plurality of slots <NUM> are provided on each of the pair of surfaces <NUM>.

The each pair of adjacent segments <NUM> may be indexed and provided with the plurality of slots <NUM> by, for example, by a cutting tool <NUM> (shown schematically in <FIG>).

Referring to <FIG>, each of the plurality of slots <NUM> may extend perpendicularly to the component axis <NUM>. Each of the plurality of slots <NUM> may further partially extend along the component axis <NUM>.

In some embodiments, each of the plurality of slots may be a dovetail slot. For example, each of the plurality of slots <NUM> may be a dovetail slot. Alternatively, in some embodiments, each of the plurality of slots <NUM> may be a fir tree slot. It may be noted that the plurality of slots <NUM> may have any suitable configuration to receive a plurality of aerofoils or blades therein.

At step <NUM>, the method <NUM> further includes positioning a plurality of blades partially within the plurality of slots. Referring to <FIG>, for example, the method <NUM> may include positioning a plurality of blades <NUM> partially within the plurality of slots <NUM>.

The plurality of blades <NUM> may be made from composite materials or metallic materials. For example, composite blades may be manufactured by laminating composite materials and autoclave and press moulding the laminated composite materials. Composite blades may also be 3D woven and resin transfer moulded. Composite blades may also be compression moulded from short fibre reinforced composites or a combination of 'continuous' and short fibre composites. Composite blades may be injection moulded using short fibre composites or a combination of 'continuous' and short fibre composites. Metallic blades they may be cast, forged, machined from solid, additive layer manufactured, metal injection moulded and hot iso-statically pressed, or sintered.

Each of the plurality of slots <NUM> may partially receive a corresponding blade <NUM> from the plurality of blades <NUM>. Each of the plurality of blades <NUM> may include a retention feature (not shown) disposed adjacent to its root. The retention feature of the plurality of blades <NUM> may be at least partially positioned within the plurality of slots <NUM>.

In some embodiments, the method <NUM> may further include applying a slot adhesive layer in each of the plurality of slots prior to positioning the plurality of blades partially within the plurality of slots, such that each of the plurality of blades is bonded to at least one of the each pair of adjacent segments. Referring to <FIG>, for example, the method <NUM> may include applying a slot adhesive layer <NUM> (hatched with dots in <FIG>) in each of the plurality of slots <NUM> prior to positioning the plurality of blades <NUM> partially within the plurality of slots <NUM>. The slot adhesive layer <NUM> is only shown in one slot <NUM> in <FIG> for illustrative purposes. The slot adhesive layer <NUM> may be continuous or patterned. The slot adhesive layer <NUM> may include, for example, an epoxy adhesive. The slot adhesive layer <NUM> may include any suitable adhesive capable of bonding the plurality of blades <NUM> to at least one of the each pair of adjacent segments <NUM>.

It may be noted that applying the slot adhesive layer <NUM> in each of the plurality of slots <NUM> is optional and may be omitted. In some examples, where applying the slot adhesive layer <NUM> is omitted, the method <NUM> may include providing an anti-friction coating or an anti-friction liner on each of the plurality of blades <NUM> or in each of the plurality of slots <NUM>. Moreover, in some examples, the method <NUM> may also include providing a biasing member (not shown), such as a spring element, to maintain contact of the plurality of blades <NUM> against the respective plurality of slots <NUM>.

At step <NUM>, the method <NUM> further includes mating the complementary finger joint profiles provided on the pair of surfaces of the each pair of adjacent segments. Referring to <FIG>, for example, the method <NUM> may include mating the complementary finger joint profiles <NUM> provided on the pair of surfaces <NUM> of the pair of adjacent segments <NUM>. A press or similar tools may be employed to move the each pair of adjacent segments <NUM> in order to mate the complementary finger joint profiles <NUM>.

In some embodiments, the method <NUM> may further include aligning the each pair of adjacent segments with each other based on the alignment feature prior to mating the complementary finger joint profiles of the each pair of adjacent segments. For example, the method <NUM> may further include aligning the each pair of adjacent segments <NUM> with each other based on the alignment feature <NUM> (shown in <FIG>) prior to mating the complementary finger joint profiles <NUM> of the each pair of adjacent segments <NUM>.

In some embodiments, the method <NUM> may further include applying a joint adhesive layer on at least one of the complementary finger joint profiles prior to mating the complementary finger joint profiles of the each pair of adjacent segments. Referring to <FIG>, for example, the method <NUM> may further include applying a joint adhesive layer <NUM> (hatched with dots in <FIG>) on at least one of the complementary finger joint profiles <NUM> prior to mating the complementary finger joint profiles <NUM> of the each pair of adjacent segments <NUM>. In <FIG>, the joint adhesive layer <NUM> is applied on one of the complementary finger joint profiles <NUM> (specifically, the finger joint profile <NUM> of the second segment 110B). The joint adhesive layer <NUM> may be continuous or patterned. The joint adhesive layer <NUM> may be applied at least partially between adjacent fingers <NUM> from the plurality of fingers <NUM>. The joint adhesive layer <NUM> may include, for example, an epoxy adhesive. The joint adhesive layer <NUM> may include any suitable adhesive capable of bonding the each pair of adjacent segments <NUM>. The complementary finger joint profiles <NUM> may facilitate bonding of the each pair of adjacent segments <NUM>.

At step <NUM>, the method <NUM> further includes joining the each pair of adjacent segments to each other, such that the plurality of blades is retained within the plurality of slots. Referring to <FIG>, for example, the method <NUM> may include joining the each pair of adjacent segments <NUM> to each other, such that the plurality of blades <NUM> is retained within the plurality of slots <NUM>.

In some embodiments, the each pair of adjacent segments <NUM> may be joined by heating the moulded component <NUM>. Heat may be applied to the moulded component <NUM>, for example, by placing the moulded component <NUM> in an oven.

In some embodiments, joining the each pair of adjacent segments may include curing the joint adhesive layer. For example, joining the each pair of adjacent segments <NUM> may include curing the joint adhesive layer <NUM> (shown in <FIG>). In some examples, the joint adhesive layer <NUM> may be cured by application of heat.

<FIG> shows a bladed disk or rotor <NUM> manufactured by the method <NUM> of <FIG>.

In some embodiments, the moulded component may form a plurality of stages of the composite bladed disk or rotor. The plurality of blades of the each pair of adjacent segments may include a corresponding stage from the plurality of stages. Referring to <FIG>, for example, the moulded component <NUM> may form a plurality of stages <NUM>, <NUM> of the composite bladed disk or rotor <NUM>. In <FIG>, the composite bladed disk or rotor <NUM> may be a two-stage axial compressor (having a first stage <NUM> and a second stage <NUM>). The plurality of blades <NUM> of the each pair of adjacent segments <NUM> includes a corresponding stage <NUM>, <NUM> from the plurality of stages <NUM>, <NUM>.

As discussed above, each of the plurality of segments 210A, 210B, 210C may include a corresponding composite material from the plurality of composite materials that differ from each other. During use, the thermal environment may change along the axial length (i.e., along the component axis <NUM>) of the composite bladed disk or rotor <NUM>. Advantageously, the method <NUM> may allow forming the different segments 210A, 210B, 210C with composite materials having different thermal capability based on the thermal environment. For example, the third segment 210C may be made from a composite material that has a greater thermal capacity than that of the first segment 210A.

Referring to <FIG> and <FIG>, in one aspect, the gas turbine engine <NUM> includes the bladed disk or rotor <NUM>. Specifically, the low pressure compressor <NUM> and/or the high pressure compressor <NUM> may include the bladed disk or rotor <NUM>.

In some embodiments, the method <NUM> may further include coupling the moulded component <NUM> to a drive shaft (e.g., the interconnecting shaft <NUM>) of the gas turbine engine <NUM>. Referring to <FIG> and <FIG>, for example, the moulded component <NUM> may be machined to accept an insert <NUM>. The insert <NUM> may be interference press-fitted to the moulded component <NUM>. The insert <NUM> may be configured to accept a splined shaft (e.g., the interconnecting shaft <NUM>) of the gas turbine engine <NUM>, thereby allowing coupling of the moulded component <NUM> to the drive shaft of the gas turbine engine <NUM>. The drive shaft may connect the composite bladed disk or rotor <NUM> to the turbine of the gas turbine engine <NUM>.

The method <NUM> may facilitate mounting of the plurality of blades <NUM> to the moulded component <NUM>. Specifically, mounting of the plurality of blades <NUM> to the moulded component <NUM> may be facilitated by providing the plurality of slots <NUM>, positioning the plurality of blades <NUM> partially within the plurality of slots <NUM>, and joining the each pair of adjacent segments <NUM> to each other. Each of the plurality of blades <NUM> may consequently be permanently trapped or retained within a corresponding slot <NUM> from the plurality of slots <NUM>.

Further, the complementary finger joint profiles <NUM> may allow providing a reliable structural joint between the each pair of adjacent segments <NUM>, which may be capable of withstanding loads during operation of the gas turbine engine <NUM>. Moreover, the method <NUM> may allow tailoring the complementary finger joint profiles <NUM> to suit the duty/load case of the structural joint. That is, the design and size of the complementary finger joint profiles <NUM> may be modified according to the performance requirements. This may ensure that segmenting the moulded component <NUM> into the plurality of segments <NUM> and joining the plurality of segments <NUM> may not negatively affect the load bearing capacity of the moulded component <NUM>.

The method <NUM> may further allow the use of blades <NUM> made from composite materials as well as metals and having different retention features (such as dovetail features and fir-tree features). The method <NUM> may also allow the use of various different composite materials as well as hybrid assemblies containing mixed classes of materials to manufacture the composite bladed disk or rotor <NUM>, based on desired application requirements.

Claim 1:
A method (<NUM>) for manufacturing a composite bladed disk or rotor (<NUM>) for a gas turbine engine (<NUM>), the method (<NUM>) comprising the steps of:
forming a moulded component (<NUM>) from at least one composite material, wherein the moulded component (<NUM>) is axisymmetric about a component axis (<NUM>);
segmenting the moulded component (<NUM>) into a plurality of segments (<NUM>) disposed adjacent to each other, wherein each pair of adjacent segments (<NUM>) from the plurality of segments (<NUM>) comprises a pair of surfaces (<NUM>) that is formed during segmentation of the moulded component (<NUM>);
providing, via computerised numerical control (CNC) machining, complementary finger joint profiles (<NUM>) on the pair of surfaces (<NUM>) of the each pair of adjacent segments (<NUM>);
providing a plurality of slots (<NUM>) on at least one of the pair of surfaces (<NUM>) of the each pair of adjacent segments (<NUM>), wherein each of the plurality of slots (<NUM>) at least partially extends along the component axis (<NUM>) and perpendicularly to the component axis (<NUM>);
positioning a plurality of blades (<NUM>) partially within the plurality of slots (<NUM>);
mating the complementary finger joint profiles (<NUM>) provided on the pair of surfaces (<NUM>) of the each pair of adjacent segments (<NUM>); and
joining the each pair of adjacent segments (<NUM>) to each other, such that the plurality of blades (<NUM>) is retained within the plurality of slots (<NUM>).