CN114761214A - 用于制造飞行器发动机的复合材料叶片的工艺 - Google Patents

用于制造飞行器发动机的复合材料叶片的工艺 Download PDF

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CN114761214A
CN114761214A CN202080080742.3A CN202080080742A CN114761214A CN 114761214 A CN114761214 A CN 114761214A CN 202080080742 A CN202080080742 A CN 202080080742A CN 114761214 A CN114761214 A CN 114761214A
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adhesive
resin
preform
shroud
blade
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阿德里安·图兹
马加利·梅兰妮·库劳德
尼古拉斯·皮埃尔·朗方
马蒂厄·斯塔克勒
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Safran SA
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Abstract

本公开是一种用于制造涡轮机，特别是飞行器涡轮发动机的由复合材料制成的叶片(10)的方法，所述叶片包括翼型件(12)，该翼型件具有从翼型件的前缘(12a)延伸到后缘(12b)的压力侧(14)和吸力侧(16)，该叶片还包括沿着翼型件的前缘延伸的金属护罩(22)，该方法包括以下步骤：a)将由三维编织纤维制成的预制件布置在模具中，可聚合的粘合剂(24)插入在护罩和预制件的边缘之间；b)将可聚合的树脂注射到模具中以浸渍预制件，以在固化之后形成翼型件，其特征在于，在步骤b)中，在如下的时间间隔内注射树脂，在该时间间隔期间，所述粘合剂达到凝固点。

Description

用于制造飞行器发动机的复合材料叶片的工艺
技术领域
本发明涉及一种用于制造飞行器涡轮机的由复合材料制成的叶片的方法。
背景技术
现有技术特别地包括文献FR-A1-2 956 057、FR-A1-3 029 134和FR-A1-3 051386。
复合材料的使用在航空工业中是有利的，特别是因为这些材料具有相对低质量的有益的机械性能。
本领域技术人员所熟知的用于制造航空工业的复合材料部件的方法是RTM方法，缩写RTM是指树脂转移模塑(Resin Transfer Moulding)。
这是用于生产由基于树脂浸渍纤维的复合材料制成的部件的方法。这种方法例如用于制造风扇叶片，并且包括多个连续的阶段。
首先，将纤维编织以获得三维预制件坯料，然后将该坯料切割以获得大致具有要获得的叶片形状的预制件。然后，将该预制件布置在注射模具中，该注射模具是关闭的。然后，通过保持注射树脂上的压力以液体状态注射树脂，同时通过加热使该部件聚合。
所使用的树脂是非常流体的树脂，即使在减小的压力下注射非常流体的树脂时，该树脂也能够穿透预制件的纤维。在聚合方法的过程中，在热的作用下，注射的树脂依次从液态变为凝胶态，最后变为固态。
为了制造例如用于涡轮机风扇的叶片，预制件通过编织而制成，然后用树脂浸渍，以形成轮叶。该轮叶包括从轮叶的前缘延伸到后缘的压力侧和吸力侧。
复合材料的轮叶相对脆弱，并且特别是对冲击敏感，并且已知通过附接和固定到轮叶的前缘的金属护罩来保护该复合材料的轮叶。
护罩可以通过两种方式附接到轮叶上。第一种方式是在树脂聚合之后，将护罩胶粘到轮叶上。然后，胶水呈糊状物的形式。
另一种方式是通过将护罩与纤维预制件共模塑来固定护罩。将预制件布置在模具中，并且将护罩定位在预制件的用于形成轮叶的前缘的边缘上。注射的树脂浸渍预制件并且与护罩发生接触，以确保在聚合和固化之后将护罩固定到轮叶上。
本发明涉及对该第二技术的改进，其中护罩和预制件进行共模塑。
申请人寻求通过结合两种现有技术并因此除了将护罩与轮叶共模塑之外还使用粘合剂来优化护罩的附接。粘合剂插入在护罩和轮叶的前缘之间。
在这种情况下，树脂和粘合剂是可聚合的。粘合剂具有不同于树脂的流变特性。粘合剂通常在比树脂更低的温度下开始固化。当模具加热到注射树脂的高温时，就会达到该温度。在树脂注射时聚合过快的粘合剂不能使得树脂和粘合剂之间具有有效的共粘合，并降低护罩在轮叶上的机械强度。
本发明提供了一种简单、有效且经济的解决方案，以确保护罩在轮叶上的正确定位和最佳机械强度。
发明内容
本发明提出了一种用于制造涡轮机，特别是飞行器涡轮机的由复合材料制成的叶片的方法，该叶片包括轮叶，该轮叶包括从轮叶的前缘延伸到后缘的压力侧和吸力侧，该叶片还包括沿着轮叶的前缘延伸的金属护罩，该方法包括以下步骤：
a)将由三维编织纤维制成的预制件布置在模具中，护罩定位在预制件的用于形成轮叶的前缘的边缘上，并且可聚合的粘合剂插入在护罩和预制件的边缘之间，
b)将可聚合的树脂注射到模具中以浸渍预制件，以在固化之后形成轮叶，
其特征在于，在步骤b)中，在如下的时间间隔内注射树脂，在所述时间间隔期间，所述粘合剂达到凝胶点。
因此，本发明提出通过共模塑和通过粘合膜将护罩固定到轮叶上。粘合膜插入在护罩和预制件的边缘之间，旨在改善和保持护罩在预制件的边缘上的位置，并且还旨在改善护罩相对于轮叶的固定和抗撕裂性。因此，可以理解，在将树脂注射到轮叶的制造模具中期间，该树脂将浸渍预制件，并且还将与膜或甚至护罩发生接触，因此确保将护罩最佳附接到叶片。
本发明还提出了一种适于粘合剂存在的树脂注射周期。目的是在粘合剂的粘度使得能够获得满意的共粘合的时间间隔内注射树脂。在粘合剂变得太粘之前注射树脂，粘合剂变得太粘将阻止产品之间的良好的共粘合。这通过在粘合剂达到凝胶点的时间间隔内注射树脂来实现。
凝胶由两种介质彼此分散形成：第一种介质称为“固体”或“凝胶”，并且由通过交联点彼此连接的长分子构成，以形成三维(3D)网络。相反的，第二种介质是称为“溶剂”或“溶胶”的液体介质，并且由独立的分子组成。
体系从单相溶胶到溶胶-凝胶双相的状态变化称为溶胶-凝胶转变。通常，凝胶化方法的状态由其推进程度p来表征，其中，p在聚合方法的开始和结束之间介于零至一之间变化。在凝胶点或“凝胶点”处，推进程度的值为pc。“凝胶点”是介质的粘度突变的瞬间。因此，对于0<p<pc，反应浴是粘度η增加到pc的液体。对于1≥p>pc，反应浴是剪切模量μ增长的弹性体。在点pc处，凝胶形成。然而，聚合继续进行，并且粘度增加。在本发明的上下文中，凝胶点的概念是最重要的，以及事实是一旦已经发生凝胶化(固态)就不能再注射，也不能再致密。凝胶点是从多个3D大分子到单个3D大分子的通道，溶剂的存在对粘度没有任何影响(分子独立于3D网络)。
因此，本发明提出根据粘合剂的聚合的进展状态，并且特别是粘合剂的粘度的变化来调整树脂的注射的时间和持续时间。将树脂注射一段时间(包括达到粘合剂的凝胶点的时间)特别是确保树脂和粘合剂之间的良好的共粘合。
根据本发明的方法可包括以下特征中的一个或多个特征，一个或多个特征单独采用或彼此组合采用：
-粘合剂是粘合膜，特别是双面粘合膜的形式；
-在步骤b)中，在如下的时间间隔内注射树脂，在所述时间间隔的中间，所述粘合剂达到凝胶点；
-时间间隔在粘合剂达到凝胶点之前开始至少5分钟，并且优选地10分钟，在粘合剂达到凝胶点之后结束至少5分钟，优选地10分钟；
-当粘合剂达到凝胶点时开始注射树脂；
-调节模具的温度，使该模具的温度在时间间隔内保持恒定；
-模具的温度在时间间隔内保持在至少160℃；
-树脂是环氧树脂；
-粘合剂是环氧粘合剂；
-粘合剂是由索尔维(Solvay)公司以编号
Figure BDA0003651596750000041
309-1销售的粘合剂。
附图说明
在以下详细说明中，为了理解该说明对附图进行参照，本发明的其它特征和优点将显现，在附图中：
[图1]图1是复合材料飞行器涡轮机叶片的示意性透视图，
[图2]图2是示出根据本发明的用于制造如图1所示的叶片的方法的步骤的框图，
[图3]图3是模具的示意性透视图，预制件和护罩旨在布置在模具中，并且树脂旨在注射在模具中，以及
[图4]图4是表示在制造方法期间，树脂和粘合剂的粘度随时间变化以及温度随时间变化的曲线图。
具体实施方式
首先参照图1，图1示出了用于涡轮机的复合材料叶片10，所述叶片10例如是风扇叶片。
叶片10包括轮叶12，该轮叶通过支撑件14连接到根部16，该根部例如具有燕尾形状，并且成形为接合在转子盘的互补形状的凹部中，以便将叶片保持在该盘上。
轮叶12包括用于使气体流入涡轮机的前缘12a和后缘12b。轮叶12具有弯曲或甚至扭曲的空气动力学轮廓，并包括在前缘12a和后缘12b之间延伸的压力侧18和吸力侧20。
轮叶12由纤维预制件制成，该纤维预制件通过将纤维(例如碳)三维编织而获得。
轮叶的前缘12a由附接到该前缘12a的金属护罩22来加强和保护。护罩22例如由镍和钴基合金制成。
在本发明中，这种附接一方面通过将预制件与护罩22共模塑来实现，另一方面通过借助于至少一种粘合剂24(优选地呈膜形式)粘合护罩22来实现。
图2是示出用于制造如图1所示的复合材料叶片10的方法中的步骤的流程图。
该方法可以包括多个步骤，这些步骤中的一些步骤是可选的。
该方法的第一步骤a)包括多个子步骤或操作。在上述讨论的第一操作a1)中，纤维预制件通过将纤维编织而制成。所得到的预制件是未经加工的，并且可以进行例如切割或压缩等操作。
在该方法的进一步操作a2)中，制备一个或多个粘合膜24。在将树脂注射到如图3所示的用于制造叶片的模具30中之前，该粘合膜24旨在插入在护罩22和预制件之间。
该粘合膜24例如是双面膜，即，两面是粘性的膜。因此，该膜的两面涂有或浸有胶水，例如环氧树脂类型的胶水。例如，这是由索尔维公司以编号
Figure BDA0003651596750000051
309-1销售的粘合剂。
该粘合膜24例如具有介于0.1mm至0.2mm之间的厚度。该膜24可以呈条状的形式。因此，该粘合膜可以具有细长形状，该细长形状的尺寸随着护罩22的尺寸而变化。
护罩22通常具有二面体形状并且限定了V形凹槽，预制件的边缘插入到该V形凹槽中。
粘合膜24优选地在凹槽内粘附到护罩22上。
然后，该方法的另一个操作(a3))包括将配备有膜24的预制件和护罩22定位在模具30(图3)中，然后例如用反模具将模具30关闭。
连续的操作a1)到a3)表示制造方法的第一步骤a)。
在该方法的第二步骤b)中，将树脂注射到模具30中，并且将树脂旨在浸渍预制件并与膜24和护罩22发生接触。在树脂的聚合和固化之后，护罩22通过粘合膜24和树脂附接到轮叶。
在树脂的聚合之后，由此获得的叶片10的优点在于该叶片的护罩22完美地定位并保持在轮叶12上。
图4示出了本发明与树脂注射到模具中的时间有关的特征。
图4是包括三条曲线C1、C2和C3的曲线图。
曲线C1表示树脂的粘度随时间的变化。曲线C2表示粘合剂的粘度随时间的变化，曲线C3表示模具30的温度随时间的变化。
在实践中，曲线C1取决于所使用的树脂。树脂在时间T0处注射，并经历粘度的降低。然后，树脂的粘度由于聚合而增加，并在T1处达到凝胶点G1。例如，树脂在介于5巴至15巴之间的压力下注射，并且持续大约120分钟。
模具30的温度(曲线C3)随着树脂的变化来调节，以优化树脂的聚合。温度从时间T2开始逐渐增加，直到在温度大于或等于160℃的T3处达到阈值，该温度对应于树脂的聚合温度。该阈值一直保持到T4，然后温度从T4增加到T5，直到在温度大于或等于180℃时有新的阈值。
T3出现早于T0，即在将树脂注射到模具中之前，在160℃时达到阈值。此外，T4和T5出现在T1之前。因此，树脂的凝胶点G1出现在第二温度阈值期间。
曲线C2取决于所使用的粘合剂。粘合剂的粘度从T2开始降低，即从模具的加热开始降低。然后，粘度从T6开始增加，并在T7处通过凝胶点G2继续上升。T7介于T3至T4之间。粘合剂的玻璃化V1在T8处达到。T8在此晚于T5，并早于T1。
根据本发明，在粘合剂的凝胶点G2周围的时间间隔ΔT内将树脂注射到模具中。该时间间隔ΔT在图4中用由双线界定的矩形表示。因此，可以理解，有利地，在粘合剂的粘度不太高的这段时间推移期间，将树脂注射到模具中。这确保了粘合剂和树脂之间的最佳的共粘合。
在所示的示例中，时间T0和T7重合，即树脂注射发生或开始于粘合剂的凝胶点G2。

Claims (10)

1.一种用于制造涡轮机，特别是飞行器涡轮机的由复合材料制成的叶片(10)的方法，所述叶片包括轮叶(12)，所述轮叶包括从所述轮叶的前缘(12a)延伸到后缘(12b)的压力侧(14)和吸力侧(16)，所述叶片还包括沿着所述轮叶的所述前缘延伸的金属护罩(22)，所述方法包括以下步骤：
a)将由三维编织纤维制成的预制件布置在模具(30)中，所述护罩定位在所述预制件的用于形成所述轮叶的所述前缘的边缘上，并且可聚合的粘合剂(24)插入在所述护罩和所述预制件的所述边缘之间，
b)将可聚合的树脂注射到所述模具中以浸渍所述预制件，以在固化之后形成所述轮叶，
其特征在于，在步骤b)中，在如下的时间间隔(ΔT)内注射所述树脂，在所述时间间隔期间，所述粘合剂达到凝胶点。
2.根据权利要求1所述的方法，其中，所述粘合剂(24)是粘合膜，特别是双面粘合膜的形式。
3.根据权利要求1或2所述的方法，其中，在步骤b)中，在如下的时间间隔内注射所述树脂，在所述时间间隔的中间，所述粘合剂达到所述凝胶点。
4.根据前一项权利要求所述的方法，其中，所述时间间隔在所述粘合剂达到所述凝胶点之前开始至少5分钟，并且优选地10分钟，在所述粘合剂达到所述凝胶点之后结束至少5分钟，优选地10分钟。
5.根据权利要求1或2所述的方法，其中，当所述粘合剂达到所述凝胶点时开始注射所述树脂。
6.根据前述权利要求中任一项所述的方法，其中，调节所述模具的温度，使所述模具的所述温度在所述时间间隔内保持恒定。
7.根据前述权利要求中任一项所述的方法，其中，所述模具的所述温度在所述时间间隔内保持在至少160℃。
8.根据前述权利要求中任一项所述的方法，其中，所述树脂是环氧树脂。
9.根据前述权利要求中任一项所述的方法，其中，所述粘合剂是环氧粘合剂。
10.根据前一项权利要求所述的方法，其中，所述粘合剂是由索尔维公司以编号
Figure FDA0003651596740000021
309-1销售的粘合剂。
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