Molded Composite Ply Layups and Methods for Molding Composite Ply Layups

摘要

Ply layups (102) and methods for forming composite components (112) are provided. For example, a method for forming a composite component (112) comprises laying up a plurality of composite plies (100) to form a composite ply layup (102); partially processing the composite ply layup (102) to form a green state layup (104); machining the green state layup (104); assembling the green state layup (104) with one or more sub-assemblies (108); and processing the green state layup (104) and the one or more sub-assemblies (104, 108, 114, 116) to form the composite component (112). In an exemplary embodiment, the composite component is a turbine nozzle airfoil (112). Another exemplary method comprises laying up a plurality of composite plies (100) to form a composite ply layup (102); compacting the composite ply layup (102) to form a green state layup (104); machining the green state layup (104); assembling the green state layup (104) with one or more sub-assemblies (108); and processing the green state layup (104) and the one or more sub-assemblies (104, 108, 114, 116) to form the composite component.