DE102022206242A1 - Method for producing an engine component from at least one fiber-reinforced plastic - Google Patents

Abstract

The proposed solution relates in particular to a method for producing an engine component (2) from at least one fiber-reinforced plastic, comprising at least the following steps: - producing a fiber-containing base structure (B1a) for the engine component (2) using a first processing method (101a, 1201a ),- attaching at least one local reinforcement (202, 203, 205; B1b) containing fibers to the base structure (B1a) using a second processing method (101b, 1202b) that is different from the first processing method (101a, 1201a) and - consolidating the with the basic structure provided with at least one local reinforcement for producing a consolidated component structure (B2) with which the engine component (2) is completed, wherein a) fiber-reinforced plastic is used at least for producing the basic structure (B1a) or b) for producing the basic structure (B1a ) Fiber material is used and plastic is supplied during the consolidation of the basic structure formed from fiber material.

Description

The proposed solution relates in particular to a method for producing an engine component from at least one fiber-reinforced plastic.

Particularly with a view to achievable weight advantages, there is often an effort in various areas, particularly in automobile construction, to produce components that were previously conventionally made from metallic materials using fiber-reinforced plastics. This makes it possible to achieve significant weight advantages and, if necessary, also simplifications in construction. In the aircraft engine sector, the use of fiber-reinforced plastics has so far been limited due to the high demands on the material used, in particular due to the temperatures and mechanical loads prevailing in certain areas of the engine. Fiber-reinforced plastics are currently rarely used, particularly in the area of the core engine of an aircraft engine. Due to the high temperatures caused by the waste heat from the core engine, conventional fiber composite materials cannot be used. This includes in particular the housing of the core engine, which has typically been made of titanium in order to withstand the temperatures and mechanical stresses that occur during operation.

Against this background, there is a need for the use of engine components that are improved in this regard and an improved method for producing an engine component made of at least one fiber-reinforced plastic, so that such an engine component can be used in areas of a core engine.

In the course of the proposed solution, a two-stage approach is chosen in the production of the engine component, in which a fiber-containing basic structure for the engine component is first produced using a first processing method, before then at least one local reinforcement containing fibers (e.g. formed with at least one reinforcing element and /or to form reinforcing structures) is attached to the base structure using a second processing method that is different from the first processing method. The basic structure provided with the at least one local reinforcement is subsequently consolidated during production in order to provide a consolidated component structure. The engine component is completed from this consolidated component structure. It is provided here that the consolidation takes place under the influence of heat and, if necessary, under increased pressure in order to consolidate at least one fiber-reinforced plastic material used to produce the basic structure (and possibly also the local reinforcement). Alternatively, fiber material can be used to produce the basic structure and plastic can be supplied during the consolidation of the basic structure formed from fiber material, so that the consolidation is accompanied by hardening of the basic structure provided with the at least one local reinforcement.

By using two different processing methods, the different thermal and mechanical loads on an engine component can be taken into account more specifically. For example, using a first processing method, a flat basic structure that already contains fibers can be produced. Using a second processing method that is different from this, reinforcements appropriate to the load path are then specifically attached to the basic structure before consolidation takes place afterwards. By using a second processing method for attaching at least one local reinforcement to the basic structure that has already been produced, mechanical parameters can be specifically adjusted even in the smallest areas and thus the high requirements existing in the engine area are sufficiently taken into account. The approach of the proposed solution enables in particular an effective use of high-temperature-resistant high-performance plastics or polymer systems for the fiber-reinforced plastic. This then means, for example, plastics whose glass transition temperature and/or permanent operating temperature is above 120 °C, in particular above 220 °C. The proposed approach allows in particular the effective production of complex shaped housing or shell structures, in particular at least simply curved housing and shell structures.

In principle, the fibers used can be aramid, glass, basalt, or carbon fibers, and possibly also at least some natural fibers. In an embodiment variant of the proposed manufacturing method, the engine component that creates it is therefore made from at least one fiber-reinforced, for example carbon fiber-reinforced, plastic.

In one embodiment variant, a functional element of the engine component is attached to the basic structure provided with the at least one local reinforcement in a tool in which the consolidation also takes place. This then includes, for example, that a corresponding functional element, for example at least one reinforcement profile or at least one Reinforcing rib is attached in a tool, for example molded or pressed, in which the basic structure is arranged and consolidated with the local reinforcement already attached thereto.

Alternatively, the at least one functional element of the engine component can be attached to the already consolidated component structure - possibly also in a different tool and/or using a different machine. If necessary, the functional element can also be attached using a further processing method that is different from the first and second processing methods.

In principle, the at least one functional element can, for example, be molded on, glued, thermally attached (in particular welded or directly thermally attached) and/or mechanically attached.

The basic structure produced using the first processing method and thus in a first process step can be designed in multiple layers. The basic structure is therefore designed to consist of several material layers or material layers. In particular, a layer structure of the basic structure can be constructed symmetrically, quasi-isotropically or individually. In one embodiment variant, the basic structure is formed with a total layer thickness in the range from 0.5 to 4 mm, in particular from 0.5 to 3 mm and 1 to 2 mm.

In one embodiment variant, producing the basic structure from several sheets of fiber-reinforced plastic has proven to be advantageous in view of the special requirements of the engine sector. Here, one of several (at least two) material layers of the multi-layer basic structure is formed from a large number of sheets of fiber-reinforced plastic. This is understood in particular to mean that a material layer is formed from a large number of identically aligned sheets of fiber-reinforced plastic. A web of fiber-reinforced plastic can correspond to a section of a strip of fiber-reinforced plastic that is provided prefabricated for the first processing method. For example, the basic structure is made from so-called tapes, in particular thermoplastic tapes, in particular tapes made of carbon fiber-reinforced PEEK, such as: Tenax®-E TPUD PEEK-6-34-IMS65 P12 24K-UD-146" from Teijin Carbon Europe GmbH. One A large number of webs placed side by side then each form a material layer of the basic structure. Several material layers placed one above the other, for example at least 3, 4, 8, 10, 12 or 16 material layers then form the basic structure, on which in a subsequent process step and using a different processing method at least one local reinforcement is applied.

With a view to a quasi-isotropic structure of the basic structure, it is advisable to lay the sheets of fiber-reinforced plastic in different material layers with different orientations of the fibers. For example, the webs of fiber-reinforced plastic of one material layer can be aligned at an angle of 45°, 60° or 70° to the webs of fiber-reinforced plastic of another material layer. In particular, a symmetrical quasi-isotropic material layer structure such as [45/0/-45/90]s or [45/0/-45/90] _2S can be provided. The material layers or paths of these material layers, each aligned at an angle of 45° to one another, allow the creation of a basic structure with a balanced property profile, in particular with regard to the torsional rigidity of the engine component produced.

When applying the webs in the first processing method, for example on a manufacturing platform, at least some of the webs can be unwound from a tape of fiber-reinforced plastic, e.g. B. from a role. The Tenax® tape already mentioned above, for example, is made available in appropriate rolls. In particular, this fiber-reinforced plastic material is then also suitable for producing the basic structure using an automated tape placement, ATP process.

In contrast, in one embodiment variant, a printing process is used to attach the at least one local reinforcement. This includes, for example, a 3D printing process for producing the at least one local reinforcement, for example a 3D printing process using a meltable yarn, in particular using a hybrid yarn, or a 3D printing process using a tape and therefore a 3D tape printing process.

Fiber-reinforced plastic is then printed onto the already manufactured basic structure using a print head. A 3D tape printing process that can be used for this is, for example Bourne, A.; Vogel, C.; Behnisch, T.; Geske, V.; Gude, M.; Modler, N. “Additive Manufacturing-Based In Situ Consolidation of Continuous Carbon Fiber-Reinforced Polycarbonate,” Materials 2021, 14, 2450 . (https://doi.org/10.3390/ma14092450).

Regardless of the use of a 3D tape printing process, one embodiment variant provides that for attaching the at least a local reinforcement of at least one web of fiber-reinforced plastic is provided on a designated area of the base structure. This particularly includes that the same or a different fiber-reinforced plastic is deposited on a designated area of the base structure as part of the second processing method in order to form the at least one local reinforcement, which is also processed in the first processing method to form the base structure. For example, the aforementioned Tenax® tape can also be used in the second processing method. By using the same fiber-reinforced plastic material, the subsequent consolidation is simplified. To form the at least one local reinforcement on the basic structure in accordance with the load path, the other second processing method is used, for example in one embodiment variant the 3D tape printing method mentioned above.

In the course of the other second processing method, it can also be provided that a web of a material layer for forming the basic structure has a width that corresponds to at least twice the width of a web for the at least one local reinforcement. In one embodiment variant, for example, a web is provided for forming a material layer of the basic structure with a width of at least 6 mm, for example 1/4 inch (corresponds to 6.35 mm) and optionally up to a width of 12 inches (corresponds to 304.8 mm). In contrast, the width of a strip for the at least one local reinforcement does not exceed a maximum width of 3.5 mm. For example, a maximum width here is 1/8 inch (corresponds to 3.175 mm). This additionally supports the possibility of designing courses for the at least one local reinforcement with comparatively small or narrow radii. This refers to radii of less than 5 mm, in particular less than 3 mm.

In principle, in the course of an embodiment variant of the proposed solution, thermoplastic materials can be provided which have a comparatively low thermal stability, for example polyamide, in particular PA6 or PA66, or polybutylene terephthalate (PBT) or polycarbonate (PC). With a view to achieving higher temperature resistance, the use of high-temperature-resistant thermoplastics, such as polyether ether ketone (PEEK), polyether ketone ketones (PEKK), polyaryl ether ketones (PAEK), polyphenylene sulfide (PPS) or polyetherimide (PEI), is particularly considered advantageous.

Instead of producing a material layer of the basic structure from several sheets of fiber-reinforced plastic, for example by means of an automated tape placement process, it can also be provided that dry or pre-impregnated fiber layers or textile semi-finished products are layered on top of one another in order to form the multi-layer basic structure in the first processing method. Here, for example, dry fabric or pre-impregnated fabric (so-called “prepreg”) can be used instead of tape to form the basic structure in a first process step. Such a procedure is particularly suitable when using a duromer as a plastic. In particular, the first processing method can include automated (i.e. rotor-controlled) preforming.

If dry or pre-impregnated fibers, in particular as dry or pre-impregnated textile semi-finished products, are used in the first processing method to form the basic structure, the application of the at least one local reinforcement in the other, second processing method can include sewing fiber material to the basic structure. For example, the second processing method can then include a tailored fiber placement, TFP, method.

If the use of fiber layers is intended in the first and second processing steps, the consolidation can include hardening of the plastic, which is only supplied in the consolidation step. For example, an infiltration tool is then used for this purpose, into which the basic structure provided with the at least one local reinforcement is inserted.

Regardless of whether fiber-reinforced plastic is already used to form the basic structure and the at least one local reinforcement or the plastic is only added later in the consolidation step, an embodiment variant can provide that at least one locally reinforced material is already applied to the basic structure using the first processing method Area is formed, namely a) by at least one layer of fiber-reinforced plastic, in particular a band or several bands of fiber-reinforced plastic or b) by a fiber layer, i.e. in particular by a dry or pre-impregnated fiber layer. Accordingly, with the formation of the basic structure via a band or several bands of fiber-reinforced plastic and/or one or more fiber layers, a local thickening and thus a reinforced area is formed on the basic structure.

In one embodiment variant, for example, the basic structure becomes more different as a result of the first processing method with bands of fiber-reinforced plastic that (only) overlap in a defined overlap area Alignment trained. For example, such an overlap area is formed on a circumferential edge of the flat basic structure, for example, and using strips of fiber-reinforced plastic deposited using the ATP process. Such a variant includes that with an ATP process in a first process step, the basic structure is already produced with a base area and reinforced areas with comparatively larger radii, before then precisely in a subsequent process step, for example using 3D printing processes, in particular 3D tape printing processes Local reinforcements with narrow radii that are appropriate for the load path must be installed.

In principle, the engine component to be manufactured can be a component of a core engine. In particular, it can be at least one curved part of a housing of a core engine, for example a housing segment.

The proposed solution also relates to an engine component made of at least one fiber-reinforced plastic, which has a basic structure formed from several material layers of fiber-reinforced plastic and at least one local reinforcement also formed with fiber-reinforced plastic, the latter being attached to the basic structure, for example by 3D tape printing processes or tailored fiber placement , is attached and has been consolidated with the basic structure.

A proposed engine component can in particular have been produced by an embodiment variant of a proposed manufacturing method. Features and advantages explained above and below for embodiment variants of a proposed manufacturing method therefore also apply to embodiment variants of a proposed engine component.

The attached figures illustrate exemplary possible embodiment variants of the proposed solution.

• 1 schematisch einen Gesamtfertigungsprozess für eine Ausführungsvariante eines vorgeschlagenen Herstellungsverfahrens, bei dem eine Herstellung eines Triebwerksbauteils auf Basis eines kohlenstofffaserverstärkten Thermoplasten erfolgt;
• 2A-2D eine mit dem Verfahren der 1 herzustellendes Triebwerksbauteil in Form eines Gehäusesegments in verschiedenen Phasen während der Herstellung;
• 3 das Gehäusesegment in mit den 2A bis 2D übereinstimmender Seitenansicht und unter Darstellung unterschiedlicher beispielhaft gewählter Materiallagen an einer Grundfläche;
• 4 einen vergrößerten Ausschnitt der Basisfläche der 3 unter Darstellung verschiedener Materiallagen;
• 5A-5C in vergrößertem Maßstab unterschiedliche Varianten eines randseitigen Überlappungsbereich des Gehäusesegments;
• 6 in vergrößertem Maßstab nachträglich in einem zweiten Verarbeitungsverfahren hergestellte lokale Verstärkungen im Bereich von randnahen Bohrungen des Gehäusesegments;
• 7 schematisch ein Druckkopf für das Aufbringen der lokalen Verstärkung der 6 im Wege eines 3D Tape Druckverfahrens;
• 8 einzelne Darstellung unterschiedlicher beispielhafter gedruckter lokaler Verstärkungen;
• 9 in Seitenansicht das Gehäusesegment nach einem Funktionalisierungsschritt, während dem Funktionselemente in Form von Quer- und Längsrippen an der Basisfläche fixiert werden;
• 10 ein vergrößerter Ausschnitt der Grundfläche der 9;
• 11 ein Diagramm zu einem exemplarischen Temperatur-, Druck- und Zeitverlauf für eine Konsolidierung einer im Rahmen des Herstellungsverfahrens des Gehäusesegments hergestellten Grundstruktur mit hieran angebrachten lokalen Verstärkungen;
• 12 schematisch ein Gesamtfertigungsprozess für eine weitere Ausführungsvariante eines vorgeschlagenen Herstellungsverfahrens, bei dem ein kohlenstofffaserverstärktes Duromer zum Einsatz kommt;
• 13 in geschnittener Seitenansicht ein Triebwerk, in dem ein gemäß der vorgeschlagenen Lösung hergestelltes Triebwerksbauteil zum Einsatz kommt.

Show here:

• 1 schematically an overall manufacturing process for an embodiment variant of a proposed manufacturing method, in which an engine component is manufactured based on a carbon fiber-reinforced thermoplastic;
• 2A-2D one with the procedure of 1 Engine component to be manufactured in the form of a housing segment in various phases during production;
• 3 the housing segment in with the 2A until 2D matching side view and showing different exemplary material layers on a base surface;
• 4 an enlarged section of the base area of the 3 showing different material layers;
• 5A-5C on an enlarged scale, different variants of an edge overlap area of the housing segment;
• 6 Local reinforcements subsequently produced on an enlarged scale in a second processing method in the area of holes near the edge of the housing segment;
• 7 schematically a print head for applying the local reinforcement 6 using a 3D tape printing process;
• 8th individual representation of different exemplary printed local reinforcements;
• 9 in side view the housing segment after a functionalization step, during which functional elements in the form of transverse and longitudinal ribs are fixed to the base surface;
• 10 an enlarged section of the base area of the 9 ;
• 11 a diagram of an exemplary temperature, pressure and time curve for a consolidation of a basic structure produced as part of the manufacturing process of the housing segment with local reinforcements attached thereto;
• 12 schematically an overall manufacturing process for a further embodiment variant of a proposed manufacturing method in which a carbon fiber-reinforced thermoset is used;
• 13 in a sectional side view of an engine in which an engine component manufactured according to the proposed solution is used.

The 13 illustrates schematically and in a sectional view a (turbofan) engine T, in which the individual engine components are arranged one behind the other along a rotation axis or central axis R and the engine T is designed as a turbofan engine. At an inlet or intake E of the engine T, air is sucked in along an inlet direction by means of a fan F. This fan F, which is arranged in a fan housing FC, is driven via a rotor shaft S, which is rotated by a turbine TT of the engine T. The turbine TT is connected to a compressor V, which has, for example, a low-pressure compressor 111 and a high-pressure compressor 112, and possibly also a medium pressure compressor. On the one hand, the fan F supplies air to the compressor V in a primary air flow F1 and, on the other hand, to generate the thrust, in a secondary air flow F2, a secondary flow channel or bypass channel B. The bypass channel B runs around a core engine comprising the compressor V and the turbine TT, which comprises a primary flow duct for the air supplied to the core engine by the fan F.

The air conveyed into the primary flow channel via the compressor V reaches a combustion chamber assembly BK of the core engine, in which the drive energy for driving the turbine TT is generated. The compressor V can in principle be designed as an axial compressor or as a radial compressor or centrifugal compressor, in which case it is assumed that it is designed as an axial compressor.

To generate the drive energy, the turbine TT also has a high-pressure turbine 113, an (optional) medium-pressure turbine 114 and a low-pressure turbine 115. The turbine TT uses the energy released during combustion to drive the rotor shaft S and thus the fan F in order to generate the required thrust via the air conveyed into the bypass channel B. Both the air from the bypass duct B and the exhaust gases from the primary flow duct of the core engine flow out via an outlet A at the end of the engine T. The outlet A usually has a thrust nozzle with a centrally arranged outlet cone C.

Particularly in the area of the core engine, the (aircraft) engine T prevails 13 high temperatures and pressures as well as mechanical loads during operation. A housing structure for the core engine must therefore meet specific thermal and mechanical requirements. Typically, corresponding housing structures of the core engine are made of titanium. If production could be achieved using a fiber-plastic composite construction, this would result in significant weight savings. Until now, the operating temperatures of more than 120 °C have posed a particular challenge in this context. At the same time, a manufactured engine component that is intended to be part of a housing structure for the core engine must also be able to withstand high mechanical loads, especially in specifically specified areas. This could not be achieved with conventional manufacturing processes and conventional technical plastics or standard plastics. In the proposed solution, different processing methods, for example using high-performance plastics, are combined with one another before a consolidation step in order to form basic structures containing fibers with local reinforcements for the engine component to be produced.

However, the proposed method can of course also be used for other engine components that are not used in the area of a core engine. With one of the 1 As can be seen from the overall manufacturing process 100, for example, a housing segment 2 for the core engine as the final engine component/end product B4 to be produced is to be understood only as an example.

In the overall manufacturing process 100, using a processing material W1, a housing structure B1a is first produced by means of a first processing method 101a - here by Automated Tape Placement, ATP. With the help of various machines or devices M1 and M2, here in the form of a robot and a tape laying head, webs of carbon fiber-reinforced plastic with a width of more than 6 mm unwound from a roll are used to form different material layers. A housing segment 2 to be produced (compare in particular 2A until 2D and 3 ) is part of a housing of the core engine. Such a housing (a so-called “core fairing”) consists, for example, of four such housing segments 2 with an approximate length in the range of 450 mm to 600 mm and a width in the range of 600 mm to 700 mm, although of course the size depends on the type of the engine T can vary.

The basic structure B1a is created via the ATP 2A manufactured. This multi-layer basic structure B1a has, for example, a symmetrical, quasi-isotropic material layer structure with 8 or 16 layers and a total layer thickness in the range of 0.5 to 4 mm, for example 0.5 to 3 mm or 1-2 mm. For example, a layer structure [45/0/-45/90]s or [45/0/-45/90] _2S is selected. A tape is used for the band-shaped starting material, for example Tenax®-E TPUD PEEK-6-34-IMS65 P12 24K-UD-146" from Teijin Carbon Europe GmbH. The thermoplastic tapes can be laid down fully automatically via ATP and this is already the case form individual reinforced areas on the basic structure B1a. According to the illustration 2A This includes, for example, a circumferential frame reinforcement 201, which is also formed by appropriately oriented strips/tapes. On the surrounding edge frame of the basic structure B1a is in accordance with that in the 2A Housing segment 2 shown also has a large number of holes 21 for further fixing of the housing sea segments 2 are provided. In the present case, the frame reinforcement 201 completely surrounds a base area 20 of the housing segment 2 on the circumference, in which a larger through hole 200 is also provided. The through hole 200 (as well as a bore 21) can have been subsequently produced on the basic structure B1a, for example by milling or drilling.

Using ATP, for example, in the area of the through hole 200 or the bores 21, local reinforcements cannot ultimately be formed easily and possibly not with the desired narrow courses. Therefore, the overall manufacturing process sees 100 of the 1 Before a consolidation step 102, the attachment of local reinforcements by means of a second processing method 101b, here using 3D tape printing methods. A robot and a tape laying head or, alternatively, at least one print head can also be used here. The tape used for attaching local reinforcements B1b and thus the strips deposited on the base structure B1a are significantly narrower than the strips for producing the base structure B1a. For example, the sheets/tapes of local reinforcement have a maximum width in the range of 3 mm or 3.5 mm. The aforementioned Tenax® material or a similar carbon fiber-reinforced plastic material can also be used in the 3D tape printing process. Using the 3D tape printing process, load path-appropriate local reinforcements B1b are attached to the manufactured base structure B1a, in particular for the through hole 200 and the bores 21 (explained in more detail below using the other figures).

In particular, the application of local reinforcements provided by 3D tape printing can also take into account any later distortion of the engine component when cooling during the manufacturing process. For this purpose, for example, the local reinforcements B1b are in a plane of symmetry of the engine component 2, i.e. H. for example, in the middle of a base laminate formed using the ATP process, positioned electronically and therefore automatically. This can lead to an even load distribution in the finished housing segment 2 in the assembled state.

The 2A , 2 B and 2C show in matching views different phases during the overall manufacturing process 100 or a manufactured basic structure B1 b for the housing segment 2 with reinforced areas already provided thereon in the form of the frame reinforcement 201 or an additional transverse reinforcement 204 (compare 2C ). In addition, a hole reinforcement 202 around the through hole 200 and several narrow hole reinforcements 203 around the holes 21 are already attached here in the 3D tape printing process.

If the basic structure B1a is completed with additional local reinforcements B1b designed to suit the load path, this takes place as part of the further overall manufacturing process 100 1 a consolidation step 102, for example in an autoclave M3. The basic structure B1a with local reinforcements B1b, which is made from carbon fiber-reinforced thermoplastic tapes using a combination of two different processing methods, is heated and subjected to increased pressure in order to consolidate the material. The result is a consolidated component structure B2. The consolidation step can in principle also be combined with functionalization in that functional elements, such as the bore reinforcements 203, are already produced in this phase.

(Further) functional elements can be added to this consolidated component structure B2 in a subsequent functionalization step 103, for example using an injection molding machine 4. For example, this is according to the 2D an injection molding (alternatively, for example, welding or pressing) of a reinforcing profile 3 in the area of the transverse reinforcement 204 is provided. An intermediate product B3 thus completed is further processed in a subsequent processing step 104. For example, the housing segment 2 suitable for assembly is finalized using an M5 milling machine.

The manufacturing process described allows additional functional elements to be integrated into the consolidated component structure B2 in a variety of ways, which contributes to making the manufacturing process significantly more flexible and expanding the design options.

It should also be emphasized at this point that one in the 2A shown housing segment 2 with already formed frame reinforcement 201 and hole reinforcement 202 around the through hole 200 can of course - after consolidation - also represent the end product, which is manufactured using a proposed manufacturing method. Based on this, additional functionalization is therefore not mandatory.

In the lower area of the 1 Possible alternatives to the individual processing methods/process steps are also shown. For example, coal can be used before consolidation instead of automated depositing of the railways Fabric fiber-reinforced tapes can also be provided with manual production 101c or automated preforming 101d. As part of the consolidation 102, an injection molding process 102a, a pressing process 102b or an oven process 102c can also be provided instead of using an autoclave M3. Here, for example, for an injection molding process 102a, both functionalization and consolidation can take place in an injection molding machine. For the attachment of additional functional elements in the (if necessary additionally carried out) functionalization step 103, a thermal direct joining 103a, a mechanical joining 103b, a welding 103c or a bonding 103d can alternatively or additionally be provided.

The consolidated component structure B2 for the housing segment 2 is in the 3 shown again in more detail in a partially sectioned view. In particular, in the 3 different material layers 20A to 20D can be seen, the individual strips of carbon fiber reinforced tapes are aligned identically for each material layer 20A to 20D. However, sheets of two material layers are aligned at an angle of 45° or 90° to one another in order to provide a quasi-isotropic basic structure B1a, in particular in the area of the base surface 20. The corresponding material layer structure can be, for example, [45/0/-45/90] _S or [45/0/-45/90] _2S . In the enlarged view of the 4 A 45/-45/45/-45 setup is shown.

During the ATP process for the formation of the basic structure B1a, the frame reinforcement 201 is also formed via individual plastic sheets 2011, 2012, here fiber-reinforced tapes. The 5A , 5B and 5C show an example of three plastic sheets 2011 or 2012 running parallel to one another, each of which runs along an edge section 201a or 201b of the basic structure B1a of the housing segment 2 and overlaps in a targeted manner in an overlap area L (for example at a corner of the housing segment 2). For example, all plastic sheets 2011 or 2012 of an edge section 201a or 201b can completely overlap the ends of the plastic sheets 2012 or 2011 of the other edge section 201b or 201a ( 5A and 5B) . Alternatively, a stepped or staggered overlap or an abutting arrangement is also possible (compare 5C ). The overlap area L can thus be designed flexibly and in particular while avoiding an increase in thickness.

Using the chosen two-stage approach and the combination of different processing methods 101 a, 101 b, the local reinforcements can be made on the basic structure B1 b - in the present case using the 3D tape printing process - with load path-appropriate and straight courses, ie with courses and a radius of less than 5 mm, in particular less than 3 mm. In the 6 This is illustrated, for example, on an enlarged scale using narrow-band paths deposited in a helical manner for the formation of a respective bore reinforcement 203.

In the 7 A print head 4 is shown schematically with a print nozzle 40 provided for dispensing the carbon fiber-reinforced tape to be deposited. Using a corresponding print head 4 for the 3D tape printing process, the plastic sheets 2011, 2012 for the frame reinforcement 201 can then be formed, for example. In one embodiment, the 3D tape printing process is primarily used for smaller local reinforcements. The shows examples 8th For this purpose, the hole reinforcement 202 and a hole reinforcement 203. In addition, an additional - here oval - hole reinforcement 205 is shown, which is also formed from several printed plastic sheets running parallel to one another.

The 9 shows a consolidated component structure for the housing segment 2, to the base surface 20 of which a rib structure 31 with several overlapping longitudinal and transverse ribs 311, 312 is added during functionalization. This rib structure 31 is in the 10 with an enlarged section of the frame reinforcement 201 and some borehole reinforcements 203 shown in detail on an enlarged scale.

The diagram 1100 of the 11 exemplarily illustrates possible pressure, temperature and time curves for consolidation when using a carbon fiber-reinforced thermoplastic for the ATP process and 3D tape printing. Here, for example, starting from an initial temperature T ₁ , for example ambient temperature, an increase - in this case a linear increase - to a target temperature T ₂ is provided at an initial time to. This temperature T ₂ is maintained for a defined consolidation period of t ₃ -t ₁ before cooling takes place. At a time t ₂ > t ₁ (with t ₂ <t ₃ ), there is also a significant increase in pressure from an initial pressure p ₁ to a target pressure p ₂ as part of the consolidation. For example, T ₂ is in the range of 400 °C, in particular around 390 °C ± 10 °C. The pressure p ₂ is, for example, in the range of 20 bar ± 10 bar. For example, 20 minutes ± 10 minutes are provided for the consolidation time t ₃ -t ₁ .

The 12 shows an overall manufacturing process 1200 for an alternative embodiment of a proposed manufacturing process, in which instead of a fiber-reinforced thermoplastic a fiber-reinforced, for example carbon fiber-reinforced, duromer is used. The starting material here is therefore not a fiber-reinforced tape W1, but a textile semi-finished product W2, e.g. fabric and/or scrim. Accordingly, the first processing method for the formation of the multi-layer basic structure B1a of the housing segment 2 is an automated placement of dry or pre-impregnated fiber layers or their layering on top of one another using a robot M21 with a laying head M22. Automated preforming is therefore used here. Local reinforcements B1b, such as a hole reinforcement 202 or a hole reinforcement 203, are applied here via Tailored Fiber Placement, TFP, as a second processing method 1201B. Here, fiber material is locally sewn to the already produced basic structure B1a in specific areas. A corresponding M23 sewing head can be provided for sewing.

It should also be mentioned that instead of automated preforming, manual or semi-automated preforming can of course also be provided, in accordance with the specifications in the 12 steps 1201c and 1201d shown.

The basic structure B1a provided with the local reinforcements B1b is then fed to a consolidation step 202. For example, the basic structure B1a provided with the reinforcements is inserted into an infiltration tool M24. If dry fabric layers were previously used, infiltration with the duromer also takes place here. Alternatively, consolidation process steps 1202a, 1202b and 1202c with autoclaves, oven processes or VARI processes (VARI for “Vacuum Assisted Resin Infusion”) can be used.

The consolidated component structure B2 created with the consolidation step 1202 can be analogous to the overall manufacturing process 100 1 be further functionalized. In a corresponding functionalization step 1203, which takes place, for example, in the same or a different (infiltration) tool M25 as the consolidation, functional elements can, for example, be infiltrated or molded on. Alternatively or additionally, functionalization can include mechanical joining 1203a or bonding 1203c. However, due to the thermoset plastic material used, welding is typically not an option here.

From the then functionalized intermediate product B3, the ready-to-assemble housing segment 2 is made available as the end product B4 as part of a post-processing step 1204, for example carried out using a milling machine M26.

With the proposed manufacturing method, in particular housing segments for a housing structure of a core engine made of fiber-reinforced plastic, in particular using fiber-reinforced high-performance plastics, can be effectively provided, which are significantly lighter than metal housing structures previously used in practice. The engine components produced, such as housing segment 2, have excellent damping behavior. In addition, due to the chosen approach, component costs can be significantly reduced and various process steps can be easily integrated into an overall manufacturing process 100 or 120 so that at the end of the manufacturing process a high-temperature-resistant engine component that is specifically adapted to the operating conditions that arise is available.

Reference symbol list

100

Overall thermoplastic manufacturing process

101a - 101d

Processing method

102 - 104

Process step

1100

Diagram showing temperature, pressure and time progression

111

Low pressure compressor

112

High pressure compressor

113

High pressure turbine

114

Medium pressure turbine

115

Low pressure turbine

1200

Thermoset overall manufacturing process

1201 a-1201 d

Processing method

1202 - 1204

Process step

2

Housing segment (engine component)

20

Floor space

200

through hole

201

Frame reinforcement (reinforced area)

2011, 2012

Plastic track

201a, 201b

Frame section

202

Hole reinforcement

203

Bore reinforcement

204

Transverse reinforcement (reinforced area)

205

Hole reinforcement

20A - 20D

material location

21

drilling

3

Reinforcement profile (functional element)

31

Rib structure

311

Longitudinal rib (functional element)

312

Transverse rib (functional element)

4

Printhead

40

pressure nozzle

A

outlet

b

Bypass channel

B1a

Basic structure

B1b

Local reinforcement

B2, B3

Component structure / intermediate product

B4

Final component structure / final product

BK

Combustion chamber assembly

C

outlet cone

E

Inlet / Intake

F

fan

F1, F2

Fluid flow

FC

Fan housing

G

Core engine casing

L

Overlap area

M1 - M5

Machine/device

M6 - M21

Machine/device

R

Central axis / rotation axis

S

Rotor shaft

T

(Turbofan) engine

TT

turbine

v

(Axial) compressor

W1

Thermoplastic processing material

W2

Thermoset processing material

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Non-patent literature cited

• Bourne, A.; Vogel, C.; Behnisch, T.; Geske, V.; Gude, M.; Modler, N. “Additive Manufacturing-Based In Situ Consolidation of Continuous Carbon Fiber-Reinforced Polycarbonate”, Materials 2021, 14, 2450 [0015]

Claims (26)

Method for producing an engine component (2) from at least one fiber-reinforced plastic, comprising at least the following steps: - Producing the basic structure (B1a) for the engine component (2) using a first processing method (101a, 1201a), - Attaching at least one local reinforcement (202, 203, 205; B1b) containing fibers to the base structure (B1a) using a second processing method (101b, 1202b) that is different from the first processing method (101a, 1201a) and - Consolidating the basic structure provided with the at least one local reinforcement to produce a consolidated component structure (B2) with which the engine component (2) is completed, wherein a) fiber-reinforced plastic is used at least for producing the basic structure (B1a) or b) for production the basic structure (B1a) fiber material is used and plastic is supplied during the consolidation of the basic structure formed from fiber material. Procedure according to Claim 1 , characterized in that a functional element (3, 311, 312) of the engine component (2) is attached to the basic structure provided with the at least one local reinforcement in a tool in which the consolidation also takes place or to the consolidated component structure (B2) at least one functional element (3, 311, 312) of the engine component (2) is attached. Procedure according to Claim 2 , characterized in that the at least one functional element (3, 311, 312) is molded on, glued, thermally attached, in particular welded or directly thermally attached and/or mechanically attached. Procedure according to Claim 2 or 3 , characterized in that the functional element comprises a reinforcing profile (3) or a reinforcing rib (311, 312). Method according to one of the preceding claims, characterized in that the basic structure (B1a) is formed in multiple layers. Procedure according to Claim 5 , characterized in that the basic structure (B1a) is made from several sheets of fiber-reinforced plastic, one of several material layers (20A-20D) of the multi-layer basic structure (B1a) being formed from a plurality of sheets. Procedure according to Claim 6 , characterized in that the sheets of fiber-reinforced plastic of different material layers (20A-20D) are laid with different orientations to one another. Procedure according to Claim 7 , characterized in that the fiber-reinforced plastic webs of one material layer (20A-20D) are aligned at an angle of 45°, 60° or 70° to the fiber-reinforced plastic webs of another material layer (20D-20A). Procedure according to one of the Claims 6 until 8th , characterized in that at least part of the webs is formed with a band of fiber-reinforced plastic, which is unwound from a winding body, in particular a roll, in the first processing method. Procedure according to Claim 9 , characterized in that an automated tape placement, ATP, method (101a) is used to produce the basic structure (B1a). Procedure according to one of the Claims 6 until 10 , characterized in that a printing process (101b) is used to attach the at least one local reinforcement (202, 203, 205; B1b). Procedure according to one of the Claims 6 until 11 , characterized in that for attaching the at least one local reinforcement (202, 203, 205; B1b), at least one sheet of fiber-reinforced plastic is provided on a designated area of the base structure (B1a). Procedure according to Claim 12 , characterized in that the path for the at least one local reinforcement (202, 203, 205; B1b) is formed by a section of a band of fiber-reinforced plastic. Procedure according to Claim 12 or 13 , characterized in that a web of a material layer (20A-20D) for forming the basic structure (B1a) has a width which corresponds to at least twice a width of a web for the at least one local reinforcement (202, 203, 205; B1b). . Procedure according to Claim 11 and one of the Claims 12 until 14 , characterized in that a 3D tape printing process (101b) is used to produce the at least one local reinforcement (202, 203, 205; B1b). Procedure according to one of the Claims 6 until 15 , characterized in that as a fiber server Reinforced plastic is a fiber-reinforced thermoplastic, in particular PEEK, PEKK, PAEK, PPS or PEI. Procedure according to one of the Claims 6 until 16 , characterized in that the same fiber-reinforced plastic is used for the production of the basic structure (B1a) and the at least one reinforcement (202, 203, 205; B1b) or fiber-reinforced plastics of the same type are used. Procedure according to Claim 5 , characterized in that to form the multi-layer base structure (B1a) in the first processing method (1201a, 1201c, 1201d), dry or pre-impregnated fiber layers are stacked on top of each other. Procedure according to Claim 18 , characterized in that the first processing method includes automated or semi-automated preforming (1201a, 1201d). Procedure according to Claim 18 or 19 , characterized in that for attaching the at least one local reinforcement (202, 203, 205; B1b) fiber material is sewn to the base structure (B1a). Procedure according to Claim 20 , characterized in that the second processing method comprises a Tailored Fiber Placement, TFP, method. Procedure according to one of the Claims 18 until 21 , characterized in that the plastic used is a duromer. Procedure according to Claim 22 , characterized in that consolidating includes hardening of the plastic. Method according to one of the preceding claims, characterized in that using the first processing method (101a, 1201a) at least one locally reinforced area (201, 204) is already provided on the basic structure (B1a) by at least one layer of fiber-reinforced plastic or a fiber layer. Method according to one of the preceding claims, characterized in that the engine component (2) to be produced is a component of a core engine, in particular forms at least a curved part of a housing of the core engine. Engine component (2) made of at least one fiber-reinforced plastic, in particular produced in a method according to one of the preceding claims, comprising: - a basic structure (B1a) formed from several material layers (20A-20B) of fiber-reinforced plastic and - at least one local reinforcement (202, 203, 205; B1b), also formed with fiber-reinforced plastic, which is attached to the basic structure (B1a) and has been consolidated with the basic structure (B1a).

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