CN114072273A - 由复合材料制成的具有改进抗分层性能的旋转部件 - Google Patents

由复合材料制成的具有改进抗分层性能的旋转部件 Download PDF

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CN114072273A
CN114072273A CN202080047176.6A CN202080047176A CN114072273A CN 114072273 A CN114072273 A CN 114072273A CN 202080047176 A CN202080047176 A CN 202080047176A CN 114072273 A CN114072273 A CN 114072273A
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carbon nanotubes
fibrous
texture
fiber
mandrel
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迪迪埃·弗罗蒙泰尔
劳伦特·让·巴普蒂斯特·巴罗姆斯
赫维·格雷林
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Safran Aircraft Engines SAS
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Safran Aircraft Engines SAS
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Abstract

一种制造圆柱形复合部件的方法，包括：通过三维或多层编织产生条状纤维织构(140)，将所述纤维织构(140)缠绕在心轴上的多个叠加匝(141、142、143、144)上，所述心轴的轮廓与待制造部件的轮廓相对应，以形成纤维预制件(300)，用基质使所述纤维预制件(300)致密化。当所述纤维织构(140)缠绕在所述心轴上时，在所述纤维织构的相邻匝(141、142、143、144)之间插入包括填充有碳纳米管的临时性材料的幅材(150)。

Description

由复合材料制成的具有改进抗分层性能的旋转部件
技术领域
本发明涉及制造诸如燃气涡轮外壳等圆柱形部件的一般领域。
背景技术
在航空领域，目标是减轻发动机部件的重量，同时保持其较高的机械性能。例如，在航空涡轮发动机中，限定发动机进气管道轮廓，并且其中容纳支撑风扇叶片的转子的风扇外壳现在由复合材料制成。
复合风扇外壳的制造首先是将纤维增强材料缠绕在心轴上，心轴的轮廓与要生产的外壳的轮廓相匹配。例如，如专利US8322971所述，可通过三维(3D)或多层编织来制造纤维增强件。该纤维增强件构成管状纤维预制件，该预制件形成具有与外壳的凸缘相对应的凸缘的单件。制造方法继续用聚合物基质对纤维预制件进行致密化，这包括用树脂浸渍预制件并将后者聚合以获得最终部件。
三维或多层编织使得生产具有非常好的机械性能，特别是抗分层性能的纤维增强件成为可能。另一方面，在通过缠绕3D或多层编织幅材获得的纤维增强件的情况下，纤维增强件在相邻绕组匝之间的界面处表现出弱点，因为该区域没有Z方向的结合。因此，需要提高圆柱形复合部件的抗分层性能。
发明内容
为此，根据本发明，提出了一种用于制造圆柱形复合材料部件的方法，包括：
通过三维或多层编织产生条状纤维织构，
将纤维织构缠绕在心轴上的多个叠加匝上，所述心轴的轮廓与待制造部件的轮廓相对应，以形成纤维预制件，
用基质使所述纤维预制件致密化，
其特征在于，当所述纤维织构缠绕在所述心轴上时，在所述纤维织构的相邻匝之间插入包括填充有碳纳米管的临时性(fugitive)材料的幅材。
通过在纤维织构的相邻匝之间插入填充有碳纳米管的临时性材料幅材，例如，可以在不借助缝纫或针刺的情况下加强相邻匝之间的结合。事实上，在制造复合部件后，碳纳米管出现在部件的纤维增强件的相邻匝之间的界面上，这增加了这些区域中增强件的抗分层性能。
根据本发明方法的一个特征，使纤维预制件致密化包括用树脂浸渍预制件并通过热处理将树脂转化为基质，包含填充有碳纳米管的临时性材料的幅材是填充有碳纳米管的易熔材料层，易熔材料的熔化温度低于树脂的处理温度。因此，易熔材料可在树脂基质处理的升温过程中去除，从而释放出碳纳米管，该碳纳米管将与存在于相邻纤维织构匝之间的界面处的树脂混合。易熔材料可以是熔融温度低于150℃的热塑性塑料。
根据本发明方法的另一个特征，碳纳米管是基本上具有10nm直径和2μm长度的多壁碳纳米管和/或基本上具有2nm直径和5μm长度的单壁碳纳米管。
本发明还涉及一种圆柱形复合材料部件，该部件包括纤维增强件，该纤维增强件包括多个叠加的纤维织构匝，所述纤维织构的形式为具有三维编织的条带，所述纤维增强件由基质致密化，其特征在于，包含碳纳米管的层插入相邻的纤维织构匝之间。
根据本发明部件的一个特征，碳纳米管是基本上具有10nm直径和2μm长度的多壁碳纳米管和/或基本上具有2nm直径和5μm长度的单壁碳纳米管。
本发明还涉及一种具有根据本发明的复合部件的航空燃气涡轮发动机。
本发明还涉及一种包括一个或多个根据本发明的发动机的航空器。
附图说明
图1是配备有根据本发明实施方式的复合风扇外壳的航空发动机的透视图和局部剖视图，
图2是沿图1的外壳的平面II-II的剖视图，
图3是织机的示意性透视图，显示了用于形成图1和2所示外壳的纤维增强件的纤维织构的编织，
图4是透视图，显示了纤维织构和填充有碳纳米管的热塑性塑料幅材的成形，以形成图1和图2风扇外壳的增强件，
图5是示意图，显式了图4所示纤维织构和填充有碳纳米管的热塑性塑料幅材的同时缠绕，
图6是剖视图，显示了在缠绕图4和5所示纤维之后和填充有碳纳米管的热塑性塑料幅材之后获得的纤维预制件的轮廓，
图7是示意图，显示了用基质致密化图6所示纤维预制件的工具。
具体实施方式
本发明通常适用于任何圆柱形复合部件，其增强件由缠绕数匝的3D编织带形成。
下面将在其应用于航空燃气涡轮发动机风扇外壳的上下文中描述本发明。
如图1中非常示意性地示出的这样的发动机，从上游到下游沿气流方向包括布置在发动机入口处的风扇1、压缩机2、燃烧室3、高压涡轮机4和低压涡轮机5。
发动机容纳在外壳内，该外壳包括对应于发动机的不同元件的若干部分。因此，风扇1被风扇外壳100包围。
图2显示了复合风扇外壳100的轮廓，它可以通过根据本发明的方法获得。外壳的内表面101限定了进气道。它可以设置有与风扇叶片尖端的路径一致的一层耐磨涂层102，以非常示意性的方式部分地示出了叶片13。耐磨涂层因此仅沿着外壳的长度(在轴向方向上)的一部分设置。声学处理涂层(未示出)可以进一步设置在内表面101上，特别是耐磨涂层102的上游。
外壳100可以在其上游端和下游端处设置有外部凸缘104、105，以允许其安装并连接到其他部件。
外壳100由复合材料制成，其中纤维增强件被基质致密化。增强件由纤维制成，例如碳、玻璃、芳族聚酰胺或陶瓷，基质由聚合物制成，例如环氧树脂、双马来酰亚胺或聚酰亚胺、碳或陶瓷。
纤维增强件是通过将通过三维编织制成的纤维织构缠绕在心轴上而形成的，并且具有渐进的厚度(evolving thickness)，心轴具有与要生产的外壳的轮廓相对应的轮廓。有利地，纤维增强件构成外壳100的完整管状纤维预制件，形成具有对应于凸缘104、105的增强部分的单件。
根据本发明，外壳100的纤维增强件由纤维织构140的多个叠加匝141至144组成，所述纤维织构140为具有三维或多层编织的条带形式(在图2中，匝141到144被基质增密化)。此外，在纤维织构的两个相邻匝之间的界面处存在碳纳米管层160。在此处描述的示例中，碳纳米管160存在于纤维织构140的匝141至144之间的界面处。
因此，碳纳米管的存在加强了两个相邻匝之间界面处的结合。
现在解释制造风扇外壳100的方法。
如图3所示，纤维织构140是以已知的方式通过使用提花型织机10进行织造而产生的，在该织机上，一束经线或股线20被排列成多层，经线由纬线或股线30结合。纤维织构是由三维编织而成的。这里所说的“三维编织”或“3D编织”指的是一种编织方式，其中至少部分纬线将经线结合到多层经线，反之亦然。三维编织的一个例子是所谓的“互锁”编织。这里所说的“互锁”编织是指每层经线与几层纬线互连的编织，同一经线列中的所有线在编织平面中具有相同运动。
如图3和4所示，纤维织构140具有条带形状，在与经线或股线20的行进方向相对应的方向X上纵向延伸，并且在与纬线或股线30的方向相对应的方向Y上宽度方向或横向延伸。
纤维织构可由碳纤维纱线、陶瓷如碳化硅、玻璃或芳族聚酰胺编织而成。
如图4所示，纤维预制件通过将由三维编织制成的纤维织构140缠绕到沿方向SR旋转驱动的心轴200上而形成，心轴具有与要生产的外壳的轮廓相对应的轮廓。
根据本发明，包括碳纳米管160的幅材150缠绕有纤维织构140，幅材150位于缠绕在心轴200上的织构140的第一匝141上方，以便将一匝幅材150插入在纤维织构140的两个相邻匝之间。在本文描述的示例中，幅材150的宽度1150等于纤维织构140的宽度1140。根据替代方案，幅材150的宽度可小于纤维织构140的宽度，幅材150放置在纤维织构的相邻匝之间，位置根据匝之间界面处的增强件需要确定。
有利地，纤维预制件构成外壳100的完整管状纤维增强件，形成具有对应于外壳的保持区的加厚部分的单件。
为此，心轴200具有外表面201，该外表面的轮廓对应于待生产的外壳的内表面。当它缠绕在心轴200上时，纤维织构140与其轮廓相符。心轴200还包括两个凸缘220和230，用于形成与外壳100的凸缘104和105相对应的纤维预制件的部分。
在通过缠绕在心轴200上而形成纤维预制件的过程中，纤维织构140和填充有碳纳米管160的幅材150分别从滚筒60和70中被调出，它们如图5所示被存储在滚筒上。
图6示出了在将纤维织构140和幅材150缠绕在心轴200上几圈之后获得的纤维预制件300的剖视图。匝数或卷数取决于所需的厚度和纤维织构的厚度。其优选至少等于2。在这里描述的示例中，预制件300包括纤维织构140的4匝141至144以及分别插入相邻匝141和142、142和143以及143和144之间的幅材150的3匝151至153。
纤维预制件300通过在纤维织构140的重叠层141至144之间插入填充有碳纳米管160的幅材150的匝151至153而形成的界面获得。
幅材150对应于填充有碳纳米管160的临时材料层，即可以在制造过程中去除的材料。在所描述的示例中，临时材料对应于易熔材料，幅材150对应于热塑性塑料幅材，其熔化温度低于旨在形成如下所述的基质的树脂的聚合温度。例如，热塑性塑料可以是熔化温度为106℃的PA6/PA66共聚酰胺。熔化温度通常在85℃和148℃之间的其他热塑性塑料也可用于形成幅材。
对应于特定类型的热塑性纤维无纺布的幅材可以通过已知的熔喷技术生产，幅材另外填充有碳纳米管。
如此生产的幅材呈直径为30至70μm的互锁热塑性纤维层的形式。这种类型的幅材的优点是没有化学粘合剂，因为纤维是热粘合在一起的。无纺布的克重介于15g/m2和100g/m2之间。
这里使用的碳纳米管可以是单壁碳纳米管(SWNTs或SWCNTs)和/或多壁碳纳米管(MWNTs或MWCNTs)。多壁碳纳米管通常具有约10nm的直径和约2μm的长度。单壁碳纳米管通常具有约2nm的直径和约5μm的长度。
幅材中碳纳米管的填充水平可以是例如约3.5重量％。
幅材可以例如由其中存在碳纳米管的颗粒(母料)制成。这些颗粒将通过在模具出口处相互连接的长丝的挤出形成幅材。
然后用基质使纤维预制件300致密化。
纤维预制件的致密化在于用构成基质的材料填充预制件的全部或部分体积的孔隙。
基质可以通过液体工艺以本身已知的方式获得。
液体工艺包括用包含基质材料的有机前体的液体组合物浸渍预制件。有机前体通常为聚合物形式，例如树脂，任选地在溶剂中稀释。将纤维预制件放置在可密封模具中，该模具的壳体具有最终模制部件的形状。如图7所示，将纤维预制件300放置在形成反模的多个区段240和形成支撑件的心轴200之间，这些元件分别具有要制造的外壳的外部和内部形状。接着，将液体基质前体，例如树脂，注入整个外壳中以浸渍预制件的整个纤维部分。
将前体转化为有机基质，即对前体进行聚合，是通过热处理进行的，通常是通过加热模具，在除去任选的溶剂并进行聚合物交联之后，预制件仍然保持在模具中，其形状与待制造部件的形状相对应。有机基质尤其可以从环氧树脂中获得，例如，出售的高性能环氧树脂。
根据本发明的一个方面，纤维预制件的致密化可以通过众所周知的树脂转移模塑(RTM)方法进行。根据RTM工艺，将纤维预制件放置在具有要生产的外壳形状的模具中。将热固性树脂注入心轴200和反模240之间限定的内部空间。通常在注入树脂的位置和树脂排出孔之间的内部空间中建立压力梯度，以控制和优化树脂对预制件的浸渍。
所使用的树脂可以是例如环氧树脂。适用于RTM工艺的树脂是众所周知的。它们优选具有低粘度以促进其注入纤维中。树脂的温度等级和/或化学性质的选择取决于部件必须承受的热机械应力。将树脂注入整个增强件后，即可根据RTM工艺通过热处理进行聚合。
当为树脂-基质热处理而加热时，层150中的易熔材料熔化。然后，碳纳米管160与树脂接触，并在纤维织构相邻匝之间的界面处形成增强键(图2)。
树脂注入并转化为基质后，部件脱模。最后，修整部件以去除多余的树脂，加工倒角以获得图1和图2所示的外壳100。
包括缠绕有纤维织构的碳纳米管的层的临时性材料可以是不同于易熔材料的材料。例如，该层可以由能够在诸如水的溶剂存在下溶解的材料制成。与复合部件的纤维和基质在化学上相容并且可以在预制件的致密化之前或期间被去除的任何其他材料都可以用于承载碳纳米管。

Claims (10)

1.一种制造圆柱形复合部件的方法，包括：
通过三维或多层编织产生条状纤维织构(140)，
将所述纤维织构(140)缠绕在心轴(200)上的多个叠加匝(141、142、143、144)上，所述心轴(200)的轮廓与待制造部件的轮廓相对应，以形成纤维预制件(300)，
用基质使所述纤维预制件(300)致密化，
其特征在于，当所述纤维织构(140)缠绕在所述心轴(200)上时，在所述纤维织构的相邻匝(141、142、143、144)之间插入包括填充有碳纳米管的临时性材料的幅材(150)。
2.根据权利要求1所述的方法，其中，使所述纤维预制件(300)致密化包括用树脂浸渍所述预制件并通过热处理将树脂转化为基质，并且其中，包含填充有碳纳米管(160)的临时性材料的幅材(150)是填充有碳纳米管的易熔材料层，所述易熔材料的熔化温度低于树脂的处理温度。
3.根据权利要求2所述的方法，其中，所述易熔材料为熔融温度低于150℃的热塑性塑料。
4.根据权利要求2或3所述的方法，其中，所述碳纳米管为直径为10nm、长度为2μm的多壁碳纳米管。
5.根据权利要求2或3所述的方法，其中，所述碳纳米管为直径基本为2nm、长度基本为5μm的单壁碳纳米管。
6.一种由复合材料制成的圆柱形部件，其具有纤维增强件，所述纤维增强件包括多个纤维织构(140)的叠加匝(141、142、143、144)，所述纤维织构(140)为具有三维编织的条带形式，所述纤维增强件由基质致密化，
其特征在于，包含碳纳米管(160)的层(150)插在所述纤维织构的相邻匝(141、142、143、144)之间。
7.根据权利要求6所述的部件，其中，所述碳纳米管为直径为10nm、长度为2μm的多壁碳纳米管。
8.根据权利要求6所述的部件，其中，所述碳纳米管为直径为2nm、长度为5μm的单壁碳纳米管。
9.一种航空燃气轮机发动机，其具有根据权利要求6至8中任一项所述的复合部件(10)。
10.一种航空器，其包括一个或多个根据权利要求9所述的发动机。
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