EP0657554A1 - Process for preparing a circular fiberreinforced metallic workpiece - Google Patents

Process for preparing a circular fiberreinforced metallic workpiece Download PDF

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Publication number
EP0657554A1
EP0657554A1 EP94402806A EP94402806A EP0657554A1 EP 0657554 A1 EP0657554 A1 EP 0657554A1 EP 94402806 A EP94402806 A EP 94402806A EP 94402806 A EP94402806 A EP 94402806A EP 0657554 A1 EP0657554 A1 EP 0657554A1
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EP
European Patent Office
Prior art keywords
preforms
fiber
obtaining
fibers
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP94402806A
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German (de)
French (fr)
Other versions
EP0657554B1 (en
Inventor
Jean-Claude Berthelemy
Daniel Georges Girault
Gilles Jean-Michel Bessenay
Ludovic Edmond Camille Molliex
Gérard Philippe Gauthier
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Aircraft Engines SAS
Original Assignee
Societe Nationale dEtude et de Construction de Moteurs dAviation SNECMA
SNECMA SAS
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Publication of EP0657554A1 publication Critical patent/EP0657554A1/en
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Publication of EP0657554B1 publication Critical patent/EP0657554B1/en
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/17Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F17/00Jacketing or reinforcing articles with wire
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21KMAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00Making machine elements
    • B21K1/28Making machine elements wheels; discs
    • B21K1/36Making machine elements wheels; discs with blades
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21KMAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00Making machine elements
    • B21K1/76Making machine elements elements not mentioned in one of the preceding groups
    • B21K1/761Making machine elements elements not mentioned in one of the preceding groups rings
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C47/00Making alloys containing metallic or non-metallic fibres or filaments
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C47/00Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/02Pretreatment of the fibres or filaments
    • C22C47/06Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
    • C22C47/062Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element from wires or filaments only
    • C22C47/064Winding wires
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C47/00Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/02Pretreatment of the fibres or filaments
    • C22C47/06Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
    • C22C47/062Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element from wires or filaments only
    • C22C47/068Aligning wires
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C47/00Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/20Making alloys containing metallic or non-metallic fibres or filaments by subjecting to pressure and heat an assembly comprising at least one metal layer or sheet and one layer of fibres or filaments
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05BINDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2250/00Geometry
    • F05B2250/10Geometry two-dimensional
    • F05B2250/14Geometry two-dimensional elliptical
    • F05B2250/141Geometry two-dimensional elliptical circular
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S72/00Metal deforming
    • Y10S72/70Deforming specified alloys or uncommon metal or bimetallic work

Definitions

  • the invention relates to a method comprising isothermal forging and making it possible to obtain circular metal parts internally reinforced with fibers on one or more selected parts of their section.
  • the invention also relates to obtaining the preforms of reinforcing fibers used in this process. These circular parts thus obtained are used in particular as blanks for the production of rotors with a high resistance / mass ratio such as the turbomachine rotors used in aeronautics.
  • Turbomachinery rotors have a general shape of revolution around a rotational axis and they comprise, at their periphery or laterally, a plurality of blades acting as compressor or turbine. These rotors generally rotate at high speed and are subjected to significant stresses mainly coming from centrifugal force, but also from machine vibrations and accidental ingestion of foreign bodies.
  • Reinforcement rings are known for a rotor having a fibrous structure and more particularly fibers made of silicon carbide, boron carbide or other high-resistance material, these fibers being embedded in a matrix metallic.
  • the patent FR 2 607 071 gives an exemplary embodiment thereof.
  • silicon carbide fibers (Sic) are assembled into a helical ribbon or preform, between the turns of which another ribbon produced in the matrix material is interposed. The assembly is pressed at high temperature, the pressure forces diffuse the matrix material between the fibers, which ensures the cohesion of the assembly.
  • the preforms each consist of a single fiber wound in a flat spiral. This process allows a remarkable regularity of the radius of curvature of the fiber, for a better resistance of the ring.
  • the fiber can be held in position before pressing by bands or radiating threads passing alternately below and above the fibers to be held, like the threads of a fabric.
  • This solution which is difficult to implement, also has the drawback of causing the fibers to wave and thus reduce their ability to withstand a tensile force.
  • patent EP 0 490 629 proposes to engrave a spiral groove in a strip of matrix material, to deposit the fiber in the groove and to maintain this fiber in position by projection of an organic binder or by plasma projection of matrix metal, which constitutes a preform containing both fiber and metal of the matrix.
  • This solution no longer has the disadvantage of waving the fibers as previously, but it is costly and difficult to implement, because the grooves into which the fiber must be introduced have only a very small width.
  • the ring is then produced by hot compression, with a temperature and a pressure sufficient for the metal to penetrate between the fibers and weld around them. If an organic binder is used it is destroyed by pyrolysis during the rise in temperature, this binder being chosen to leave only a minimum of carbonaceous residues after pyrolysis.
  • the rings can also be hooped on the rotors. This solution ensures excellent cohesion between the ring and the rotor, but has the drawback of putting the ring in prestress, which reduces its ability to hold the rotor. In addition, the geometry of the rotor must be arranged to receive the ring.
  • the reinforcement rings can also be slid over the periphery of the rotors or introduced into grooves machined in these rotors, then brazed or welded by any means to the rotor.
  • This solution ensures excellent cohesion of the reinforcing ring with the rest of the rotor, but has the drawback of imposing on the fibers two thermal cycles, which increases their degradation.
  • the silicon carbide SiC often used to make reinforcing fibers can react at high temperature with the metal of the matrix. To reduce this phenomenon, the fibers can be covered with a layer of carbon, but this layer diffuses itself in the metal of the matrix and modifies its metallurgical structure. The reaction of the fiber material with the matrix is therefore only delayed.
  • the preforms comprise both fiber and filler metal, this filler metal having an isothermal forging temperature close to or slightly lower than that of the metal of the part and being weldable with the metal of the piece.
  • This spaces left between the preforms and the walls of the grooves will advantageously be filled with powdered filler metal.
  • this cover makes it possible to start the isothermal forging by the compression of the preforms.
  • This cover will preferably in a material having an isothermal forging temperature close to or slightly higher than that of the material of the part, said material also being weldable to said material of the part.
  • the preforms will advantageously be a stack of fiber washers wound in monolayer spirals and of matrix metal strips.
  • Isothermal forging in an axial direction will advantageously be combined with radial isothermal forging in order to obtain a substantially isostatic compression, that is to say homogeneous in all directions, said isostatic compression improving the homogeneity of the welding of the fibrous zone with the rest of the room.
  • Radial forging can be obtained by centrifugal pressure exerted from inside the part.
  • the isothermal forging die is annular with an L-shaped section, the opening of which is turned towards the outside.
  • This matrix is surrounded by a belt made of a material with a low coefficient of thermal expansion and an expansion mandrel is arranged in its central part.
  • An annular piston penetrates between the vertical wall of the L-shaped die and the belt, to allow the forging of the part.
  • the hardening of the coating is just sufficient to prevent it from being crushed during winding. So the turns contiguous ones stick to each other during the winding under the effect of the tension of the fiber, which ensures the cohesion of the preform after its exit from the winding mandrel.
  • the fiber preforms can be economically produced using a device comprising in particular a fiber supply reel, a tank of binder solution, a device for drying the coated fiber such as a tube heated by an electrical resistance, as well as a mandrel comprising two planar and parallel flanges whose listening is equal to or slightly greater than the diameter of the coated fiber.
  • This process which is the subject of the present invention should not be confused with the processes for obtaining reinforcement rings such as that which is described in patent FR 2 607 071 already cited.
  • This process which is the subject of the invention consists in fact in including fibrous reinforcing structures in parts while reserving material to ensure the functions of the part, and then in compressing these fibrous structures inside the part during forging said piece.
  • Patent FR 2 607 071 is, on the contrary, limited to obtaining entirely fibrous parts which must then be added to the parts to be reinforced.
  • the process which is the subject of the present invention thus has the advantage of achieving in a single thermal cycle the compression of the preforms and the intimate connection. , similar to welding, of the area reinforced by the fibers with the rest of the material of the part. The elimination of a thermal cycle protects the reinforcing fibers and allows more economical production of the parts.
  • the process also offers great latitude in the choice of areas to be reinforced. We can indeed have these areas different places in the section of the part, such as the center, the periphery or the sides.
  • the material of the part will be distributed according to the functions to be performed. For example, in the case of a turbomachine rotor with axial circulation of the fluid, material will be provided at the periphery for machining the blades and on the flanks for machining the flanges connecting to the other stages of the machine , and also for example for the machining of sealing labyrinths or grooves for fixing balancing masses.
  • the process is also economical because it avoids a thermal cycle as well as precise machining of the reinforcing ring and the housing intended to receive it on the part.
  • the production of the preforms is also particularly simple.
  • Figure 1 shows a sectional view of the rotor blank and the preforms, all arranged in the isothermal forging die.
  • Figure 2 shows schematically the steps of coating the fiber and winding the preforms.
  • FIG. 3 represents a partial section of the mandrel for winding the preforms.
  • the rotor is machined in the ring 1 which has a general shape of revolution around the geometric axis 2.
  • the ring 1 is obtained by operations 1 to 7 below, and the rotor machined in operation 8.
  • a single annular groove 8 is produced in a sidewall 4.
  • the groove 8 has a U-shaped section open on the sidewall 4 in a direction parallel to the axis 2.
  • the groove 8 has a circular bottom 9, planar and radial to the axis 2, said bottom 9 being adjacent to an interior wall 10 and an outer wall 11 cylindrical around the axis 2 and extending to the side 4 to form the opening of the groove 8. It is understood that the groove 8 defines inside the ring 1 the space annular in which will be arranged the reinforcing fibers. The groove 8 also provides access to this space for depositing the fibers and the filler metal therein.
  • this groove would then take the form of an L open radially and axially.
  • the preforms 12 are a sufficiently rigid shaping of the fiber and of the filler metal so that these two materials can be transported to the place of forging and placed in the grooves 8.
  • preforms 12 containing both fiber and filler metal. It is also known to produce preforms 2 of two different categories, either preforms 12A containing the fiber and separate preforms 12B containing the filler metal.
  • the preforms 12A and 12B have the shape of a flat washer with the dimensions of the groove 8.
  • the plug 14 has a bottom 15 coming by gravity in contact with the preforms 12.
  • the plug 14 emerges from the groove 8 in order to start the isothermal forging operation of the ring by a phase of compression of the fiber and filler metal preforms 12.
  • the plug 14 has the shape of a ring of axis 2 with a circular bottom 15, plane and radial to axis 2.
  • the bottom 15 is adjacent to an inner cylindrical wall 16 whose diameter is slightly greater than that of the wall 10 of the groove 8, and also adjacent to an outer cylindrical wall 17 whose diameter is a little less than that of the wall 11 of the groove 8, the plug 14 thus being able to penetrate the groove 8 with sufficient play.
  • the plug 14 is also axially delimited by a surface 18 opposite the bottom 15.
  • the surface 18 can be circular, planar and radial to the axis 2, but it can also be given a different shape depending on the profile of the ring 1 and the desired deformation of the metal during forging.
  • the part of the plug 14 external to the groove 8 has a protrusion 19 extending radially the plug 14.
  • the protrusion 19 is delimited axially by the surface 18 of the plug 14 opposite the bottom 15, and by the surface 20 opposite the side 4 of the blank 3 and of shape complementary to said side 4, and surrounding the plug 14.
  • the protuberance 19 is also delimited radially to the axis 2 by an internal cylindrical surface 21 in the extension of the surface 6 of the blank 3, and by an external cylindrical surface 22 in the extension of the surface 7.
  • This surface 18 will constitute after forging the second side of the ring 1 and opposite to the side 5.
  • the surface 13 of the projection also has a circular depression 23 extending to the surface 22. It will allow a radial creep of the metal during forging.
  • the blank 3 is placed on its side 5 in a machine 31 itself arranged on the lower plate 32 of a hydraulic press.
  • a piston 33 penetrates into the matrix and transmits on the surface 18 of the plug 14 the pressure 34 exerted parallel to the axis 2 by the upper plate of the press not shown in FIG. 1.
  • the bottom 15 of the plug 14 presses under the effect of the pressure 34 the preforms 12, causing the creep and the agglomeration of the filler metal between the fibers.
  • the total height of the preforms 12 decreases and the plug 14 enters the groove until the surface 20 of the protrusion 19 comes into contact with the sidewall 4 of the blank 3.
  • the pressure 34 is then exerted axially on all the material of the ring 1 which gradually takes the shape imposed by the matrix 31 and the piston 33. In practice, the deformation of the cover 14 begins before the preforms 12 are fully compressed.
  • the metal of the blank 3 Under the effect of the pressure 34, the metal of the blank 3, the filler metal powder introduced into the spaces 13 and the filler metal of the preforms 12 completely fill the space between the fibers, arrive in mutual contact and weld together, thereby achieving compression of the fibers and metal during isothermal forging of the ring.
  • a filler metal will be chosen having isothermal forging temperatures close to or slightly lower than that of the blank metal, so that the solder and the filler metal have greater plasticity which facilitates the penetration of the metal. between the fibers.
  • This filler metal must obviously be weldable with that of the part.
  • the metals of the part, the preforms and the powder may be identical, but this is not a necessity.
  • the metal of the plug 14 will preferably have an isothermal forging temperature close to or higher than the forging temperature of the metal of the blank 3 and the filler metal of the preforms 12, so that it is a little less plastic. than them in order to improve the pressing of the preforms 12 at the bottom of the groove 8, and in particular to start the compression of the preforms 12 before the isothermal forging proper of the ring 1.
  • the metals of the blank 3 and of the plug 14, as well as the filler metal of the preforms 12 and of the powder are identical, which improves the homogeneity and the resistance of the ring 1 .
  • the piston 33 is supported on the plug 14 by its surface 37.
  • This surface 37 includes an additional thickness 38 having the same shape as the depression 23, but the height of the additional thickness 38 is less than the depth of the depression 23. From this fact, there remains a space 39 between said excess thickness 38 and said depression 23, and this space 39 will be filled during isothermal forging by the displacement in a radial direction of the material of the plug 14 near the surface 18 in contact with the piston 33. This displacement of material gives the metal grains an elongated shape called fiberizing which increases their resistance.
  • the isothermal forging device of the ring 1 comprises a matrix 31 placed on the lower plate 32 of a press, a piston 33 on which the upper plate (not shown) of the press exerts an axial pressure 34, said piston 33 penetrating in said matrix 31, and a means 35 exerting a centrifugal pressure 36 on the matrix 31.
  • the matrix 31 has an annular shape around the axis 2 with an L-shaped section, the opening of which faces upwards and outwards.
  • the horizontal branch 41 of the L is at the bottom and forms by its upper surface the bottom 42 of the matrix 31.
  • the vertical branch 43 of the L faces the geometric axis 2 and constitutes the vertical wall 44 of the matrix 31.
  • the matrix 31 is delimited radially towards the axis 2 by a concave cylindrical surface 45 centered on the axis 2.
  • the means 35 for exerting centrifugal pressure 36 will advantageously be a radially expandable mandrel made of a material with a high coefficient of thermal expansion, the expansion being obtained by heating said mandrel 35.
  • the mandrel 35 is delimited radially outwards by a cylindrical surface 46 and fits inside the cylindrical surface 45 of the vertical wall 44 with a reduced clearance between the surfaces 45 and 46.
  • the present device also includes a shaped belt 47 cylindrical centered on the axis 2 and resting by one of its sides 48 on the lower plate 32 of the press.
  • the belt 47 has a cylindrical and concave inner wall 49 centered on the axis 2 which surrounds the matrix 31, which is opposite the vertical wall 44 and which delimits radially outwards the space in which the ring 1.
  • the annular piston 33 also fits between the wall 44 of the matrix 31 and the wall 49 of the belt.
  • This belt 47 is made of a resistant material and having a low coefficient of thermal expansion, for example carbon fibers. This belt 47 prevents the radial expansion of the blank 3 and the plug 14 during isothermal forging, which improves the efficiency of the centrifugal pressure 36 while maintaining the fibers to prevent their stressing.
  • the rotor is made of TA6V titanium alloy and the reinforcing fibers of silicon carbide SiC covered with a carbon deposit. Isothermal forging takes place at 950 ° C under a pressure of 600 bars for 50 minutes.
  • the reinforcing fiber 60 is taken from a supply reel 61.
  • the fiber 60 plunges into a tank 62 containing a bath 63 of liquid organic binder, passes around a return pulley 64 immersed in the solution 63 and emerges from this solution 63 coated with a certain amount of binder solution.
  • the fiber 65 then passes through the drying hub 65, for example a tube heated with an electrical resistance, in order to harden the coating of organic binder while retaining sufficient ability to stick to neighboring fibers.
  • the drying hub 65 for example a tube heated with an electrical resistance
  • the fiber 66 thus coated then bypasses a deflection pulley 67 and is wound on the mandrel 68 to form the fiber preform 12A.
  • the thickness of the coating is determined by the viscosity and therefore the concentration and the temperature of the solution 63, while its degree of drying and therefore its hardness are determined by the intensity of the heating in the heating tube. 65 and the duration of the passage of the fiber through this tube 65.
  • the mandrel 68 rotates around the geometric axis of rotation 69.
  • This mandrel 68 comprises two circular flanges 70 arranged on either side of a circular hub 71, as well as a means (not shown) for positioning and driving in rotation about the axis 69 of said flanges 70 and of said hub 71.
  • the two flanges 70 each have a flat and radial side face 72, said faces 72 facing one another to form an annular groove 73 open on the periphery 74 of the mandrel and delimited internally by the hub 71.
  • the faces 72 are connected to the periphery 74 of the mandrel 68 by a radius 75, so as not to risk tearing off the coating 76 of the fibers 60.
  • the coated fiber 6 is wound in a spiral in the groove 73 to form the 12A fiber preform.
  • the space formed between the turns being equal to twice the thickness of the coating 76 of the fiber 60.
  • the spacing of the faces 72 is equal to or slightly greater than the diameter of the coated fibers 66, and the diameter of the hub 71 is equal to the inside diameter of the fiber preform 12A to be produced.
  • one of the flanges 70 is removable to allow the preform 12A thus wound to be removed, and the hub 71 has the shape of a truncated cone whose small diameter is turned towards the side of the removable flange 70 , in order to facilitate the withdrawal of the preform 12A.
  • the drying of the coating 76 must be sufficient for this coating 76 to acquire a hardness allowing it not to deform significantly during winding, but not too much.
  • the tension of the fiber 66 during winding on the mandrel 68 causes the adjacent turns of coated fiber 66 to stick together along the contact line 77 between these turns. This bonding ensures the cohesion of the preform during its withdrawal from the mandrel, during its transport, and during its introduction into the annular groove 8 of the blank 3 of the rotor.
  • the faces 72 and the periphery of the hub 71 are made of a hard, non-adhesive material such as Teflon.
  • the concentration and the temperature of the organic binder bath 63, the heating of the coated fiber 66 and the tension of said coated fiber 66 can be determined by current experiments for those skilled in the art.
  • the binder bath 63 is a solution of polymethyl methacrylate of general chemical formula (CH2C (CH3) (CO2CH3) -) n (commonly called PMMA) in acetone.
  • PMMA is pyrolyzable between 400 ° C and 600 ° C.
  • the stack of fiber preforms 12A and filler metal washers 12B is fairly compact. Therefore, and in order to facilitate the evacuation of the gases produced by the pyrolysis of the binder, it is preferable to perforate the washers 12B of filler metal separating the fiber preforms 12A. In order not to modify the respective proportions of fiber and metal, and also so as not to risk bringing the fibers of two neighboring preforms 12A into contact through the perforations of the washers 12B, these perforations will preferably be carried out without removing material , for example using a metal tip or a blade.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Forging (AREA)
  • Powder Metallurgy (AREA)

Abstract

Process making it possible to produce by isothermal forging circular articles reinforced with fibres over chosen portions of their section, the other portions remaining available for performing the other functions of the article. The invention is noteworthy in that it consists chiefly in producing grooves (8) in a blank (3) of the article (1), in producing preforms (12) from reinforcing fibre and from added metal to the dimensions of the grooves (8), in closing these grooves (8) using plugs (14) and in forming the article (1) by isothermal forging. Application to high-performance rotors such as the rotors of turbine engines employed in aeronautics. <IMAGE>

Description

L'invention concerne un procédé comportant un forgeage isotherme et permettant d'obtenir des pièces circulaires métalliques renforcées intérieurement par des fibres sur une ou plusieurs parties choisies de leur section. L'invention concerne aussi l'obtention des préformes de fibres de renfort mises en oeuvre dans ce procédé. Ces pièces circulaires ainsi obtenues sont notamment utilisées comme ébauches pour la réalisation de rotors à haut rapport résistance/masse tels les rotors de turbomachine utilisés en aéronautique.The invention relates to a method comprising isothermal forging and making it possible to obtain circular metal parts internally reinforced with fibers on one or more selected parts of their section. The invention also relates to obtaining the preforms of reinforcing fibers used in this process. These circular parts thus obtained are used in particular as blanks for the production of rotors with a high resistance / mass ratio such as the turbomachine rotors used in aeronautics.

Les rotors de turbomachines ont une forme générale de révolution autour d'un axe de rotaion et ils comportent à leur périphérie ou latéralement une pluralité d'aubes faisant office de compresseur ou de turbine. Ces rotors tournent généralement à une vitesse élevée et sont soumis à des sollicitations importantes provenant principalement de la force centrifuge, mais aussi des vibrations de la machine et de l'ingestion accidentelle de corps étranger.Turbomachinery rotors have a general shape of revolution around a rotational axis and they comprise, at their periphery or laterally, a plurality of blades acting as compressor or turbine. These rotors generally rotate at high speed and are subjected to significant stresses mainly coming from centrifugal force, but also from machine vibrations and accidental ingestion of foreign bodies.

La conception de ces rotors est un compromis entre la performance aérodynamique ou hydrodynamique, la résistance et la masse.The design of these rotors is a compromise between aerodynamic or hydrodynamic performance, resistance and mass.

Afin d'améliorer le rapport résistance/masse, on est conduit à renforcer ces rotors par des anneaux ou bandages réalisés dans des matériaux plus résistants et présentant un module d'élasticité appelé aussi module de Young supérieur.In order to improve the resistance / mass ratio, it is necessary to reinforce these rotors by rings or bandages made of more resistant materials and having a modulus of elasticity also called a higher Young's modulus.

On connait des anneaux de renfort pour rotor ayant une structure fibreuse et plus particulièrement des fibres en carbure de silicium, en carbure de bore ou autre matériau à haute résistance, ces fibres étant noyées dans une matrice métallique. Le brevet FR 2 607 071 en donne un exemple de réalisation. Dans ce brevet, des fibres de carbure de silicium (Sic) sont assemblées en un ruban hélicoïdal ou préforme, entre les spires duquel on intercale un autre ruban réalisé dans le matériau de la matrice. L'ensemble est pressé à haute température, les forces de pression diffusent le matériau de la matrice entre les fibres, ce qui assure la cohésion de l'ensemble.Reinforcement rings are known for a rotor having a fibrous structure and more particularly fibers made of silicon carbide, boron carbide or other high-resistance material, these fibers being embedded in a matrix metallic. The patent FR 2 607 071 gives an exemplary embodiment thereof. In this patent, silicon carbide fibers (Sic) are assembled into a helical ribbon or preform, between the turns of which another ribbon produced in the matrix material is interposed. The assembly is pressed at high temperature, the pressure forces diffuse the matrix material between the fibers, which ensures the cohesion of the assembly.

Dans une autre forme de réalisation, les préformes sont constituées chacune d'une seule fibre enroulée suivant une spirale plane. Ce procédé permet une remarquable régularité du rayon de courbure de la fibre, pour une meilleure résistance de l'anneau.In another embodiment, the preforms each consist of a single fiber wound in a flat spiral. This process allows a remarkable regularity of the radius of curvature of the fiber, for a better resistance of the ring.

La fibre peut être maintenue en position avant le pressage par des bandes ou des fils rayonnants passant alternativement en-dessous et en-dessus des fibres à maintenir, à la façon des fils d'un tissu. Cette solution délicate à mettre en oeuvre présente aussi l'inconvénient de faire onduler les fibres et de réduire ainsi leur capacité à résister à un effort de traction.The fiber can be held in position before pressing by bands or radiating threads passing alternately below and above the fibers to be held, like the threads of a fabric. This solution, which is difficult to implement, also has the drawback of causing the fibers to wave and thus reduce their ability to withstand a tensile force.

Pour éviter cet inconvénient, le brevet EP 0 490 629 propose de graver une rainure en spirale dans du feuillard en matériau de la matrice, à déposer la fibre dans la rainure et à maintenir cette fibre en position par projection d'un liant organique ou par projection plasma de métal de la matrice, ce qui constitue une préforme contenant à la fois de la fibre et du métal de la matrice. Cette solution ne présente plus comme précédemment l'inconvénient de faire onduler les fibres, mais elle est coûteuse et délicate à mettre en oeuvre, car les rainures dans lesquelles la fibre doit être introduite n'ont qu'une largeur très faible. L'anneau est ensuite réalisé par compression à chaud, avec une température et une pression suffisante pour que le métal pénètre entre les fibres et se soude autour d'elles. Si un liant organique est utilisé il est détruit par pyrolyse pendant la montée en température, ce liant étant choisi pour ne laisser qu'un minimum de résidus carbonés après pyrolyse.To avoid this drawback, patent EP 0 490 629 proposes to engrave a spiral groove in a strip of matrix material, to deposit the fiber in the groove and to maintain this fiber in position by projection of an organic binder or by plasma projection of matrix metal, which constitutes a preform containing both fiber and metal of the matrix. This solution no longer has the disadvantage of waving the fibers as previously, but it is costly and difficult to implement, because the grooves into which the fiber must be introduced have only a very small width. The ring is then produced by hot compression, with a temperature and a pressure sufficient for the metal to penetrate between the fibers and weld around them. If an organic binder is used it is destroyed by pyrolysis during the rise in temperature, this binder being chosen to leave only a minimum of carbonaceous residues after pyrolysis.

Le renforcement de rotors avec de tels anneaux peut se faire par montage mécanique de l'anneau sur le rotor, ce montage présentant inévitablement des jeux. L'anneau ne participe donc à l'effort que lorsque le rotor est suffisamment déformé pour que ces jeux soient comblés.Reinforcement of rotors with such rings can be done by mechanical mounting of the ring on the rotor, this mounting inevitably having clearances. The ring therefore participates in the effort only when the rotor is sufficiently deformed for these clearances to be filled.

Les anneaux peuvent aussi être frettés sur les rotors. Cette solution assure une excellente cohésion entre l'anneau et le rotor, mais présente l'inconvénient de mettre l'anneau en précontrainte de traction, ce qui diminue sa capacité à maintenir le rotor. De plus, la géométrie du rotor doit être agencée pour recevoir l'anneau.The rings can also be hooped on the rotors. This solution ensures excellent cohesion between the ring and the rotor, but has the drawback of putting the ring in prestress, which reduces its ability to hold the rotor. In addition, the geometry of the rotor must be arranged to receive the ring.

Les anneaux de renfort peuvent aussi être glissés sur la périphérie des rotors ou introduits dans des rainures usinées dans ces rotors, puis brasés ou soudés par un moyen quelconque au rotor. Cette solution assure une excellente cohésion de l'anneau de renfort avec le reste du rotor, mais présente l'inconvénient d'imposer aux fibres deux cycles thermiques, ce qui augmente leur dégradation. Par exemple, le carbure de silicium SiC souvent utilisé pour réaliser des fibres de renfort peut réagir à haute température avec le métal de la matrice. Pour réduire ce phénomène, les fibres peuvent être recouvertes d'une couche de carbone, mais cette couche diffuse elle-même dans le métal de la matrice et en modifie la structure métallurgique. La réaction de la matière de la fibre avec la matrice n'est en conséquence que retardée.The reinforcement rings can also be slid over the periphery of the rotors or introduced into grooves machined in these rotors, then brazed or welded by any means to the rotor. This solution ensures excellent cohesion of the reinforcing ring with the rest of the rotor, but has the drawback of imposing on the fibers two thermal cycles, which increases their degradation. For example, the silicon carbide SiC often used to make reinforcing fibers can react at high temperature with the metal of the matrix. To reduce this phenomenon, the fibers can be covered with a layer of carbon, but this layer diffuses itself in the metal of the matrix and modifies its metallurgical structure. The reaction of the fiber material with the matrix is therefore only delayed.

On connait par ailleurs le procédé évolué de forgeage isotherme qui consiste, dans une enceinte sous vide ou en atmosphère contrôlée, à chauffer la pièce jusqu'à une température à laquelle le métal peut se déformer de manière superplastique, à disposer cette pièce dans une matrice chauffée à la même température et à exercer sur la pièce une pression continue. Ce procédé autorise une structure métallurgique remarquable et très homogène de la pièce. Il permet aussi de réaliser l'ébauche de la pièce en plusieurs parties qui se souderont entre elles pendant le forgeage.We also know the advanced process of isothermal forging which consists, in a vacuum chamber or in a controlled atmosphere, heating the part to a temperature at which the metal can deform so superplastic, placing this part in a matrix heated to the same temperature and exerting continuous pressure on the part. This process allows a remarkable and very homogeneous metallurgical structure of the part. It also allows the blank to be produced in several parts which will be welded together during forging.

Pour résoudre ce problème, l'invention propose de réaliser des pièces circulaires métalliques renforcées par des fibres selon le procédé suivant :

  • réalisation d'une ébauche de la pièce,
  • réalisation dans l'ébauche d'au moins une rainure annulaire ouverte au moins suivant la direction axiale,
  • réalisation de préformes de fibres aux dimensions des rainures,
  • introduction des préformes dans les rainures,
  • pyrolyse du liant organique retenant les fibres,
  • forgeage isotherme de l'ébauche avec les préformes, ce qui permet de réaliser en un seul cycle thermique la compression des préformes, le soudage des zones fibreuses au reste de la pièce et le formage par forgeage de cette pièce.
To solve this problem, the invention proposes to produce circular metal parts reinforced with fibers according to the following method:
  • creation of a draft of the part,
  • production in the blank of at least one annular groove open at least in the axial direction,
  • production of fiber preforms with the dimensions of the grooves,
  • introduction of the preforms into the grooves,
  • pyrolysis of the organic binder retaining the fibers,
  • isothermal forging of the blank with the preforms, which allows compression of the preforms, the welding of the fibrous zones to the rest of the part and the forming by forging of this part in a single thermal cycle.

Dans un mode de réalisation préféré, les préformes comportent à la fois de la fibre et du métal d'apport, ce métal d'apport ayant une température de forgeage isotherme voisine ou un peu inférieure à celle du métal de la pièce et étant soudable avec le métal de la pièce. Les espaces laissés entre les préformes et les parois des rainures seront avantageusement comblés avec du métal d'apport en poudre.In a preferred embodiment, the preforms comprise both fiber and filler metal, this filler metal having an isothermal forging temperature close to or slightly lower than that of the metal of the part and being weldable with the metal of the piece. The spaces left between the preforms and the walls of the grooves will advantageously be filled with powdered filler metal.

Il est aussi avantageux d'obturer les rainures par un couvercle arrivant au contact des préformes et dépassant de ces rainures. Le forgeage isotherme étant effectué dans la direction axiale, ce couvercle permet de démarrer le forgeage isotherme par la compression des préformes. Ce couvercle sera de préférence dans un matériau ayant une température de forgeage isotherme voisine ou un peu supérieure à celle de la matière de la pièce, ledit matériau étant aussi soudable à ladite matière de la pièce.It is also advantageous to close the grooves with a cover which comes into contact with the preforms and protrudes from these grooves. The isothermal forging being carried out in the axial direction, this cover makes it possible to start the isothermal forging by the compression of the preforms. This cover will preferably in a material having an isothermal forging temperature close to or slightly higher than that of the material of the part, said material also being weldable to said material of the part.

Les préformes seront avantageusement un empilement de rondelles de fibres enroulées en spirales monocouches et de feuillards de métal de matrice.The preforms will advantageously be a stack of fiber washers wound in monolayer spirals and of matrix metal strips.

Le forgeage isotherme suivant une direction axiale sera avantageusement combiné avec un forgeage isotherme radial afin d'obtenir une compression pratiquement isostatique, c'est à dire homogène dans toutes les directions, ladite compression isostatique améliorant l'homogénéïté du soudage de la zone fibreuse avec le reste de la pièce. Le forgeage radial peut être obtenu par une pression centrifuge exercée par l'intérieur de la pièce.Isothermal forging in an axial direction will advantageously be combined with radial isothermal forging in order to obtain a substantially isostatic compression, that is to say homogeneous in all directions, said isostatic compression improving the homogeneity of the welding of the fibrous zone with the rest of the room. Radial forging can be obtained by centrifugal pressure exerted from inside the part.

Dans un mode de réalisation préféré, la matrice de forgeage isotherme est annulaire avec une section en L dont l'ouverture est' tournée vers l'extérieur. Cette matrice est entourée d'une ceinture réalisée dans un matériau à faible coefficient de dilatation thermique et un mandrin à expansion est disposé dans sa partie centrale. Un piston annulaire pénètre entre la paroi verticale de la matrice en L et la ceinture, pour permettre le forgeage de la pièce.In a preferred embodiment, the isothermal forging die is annular with an L-shaped section, the opening of which is turned towards the outside. This matrix is surrounded by a belt made of a material with a low coefficient of thermal expansion and an expansion mandrel is arranged in its central part. An annular piston penetrates between the vertical wall of the L-shaped die and the belt, to allow the forging of the part.

Le procédé de réalisation des préformes de fibres comporte notamment les opérations suivantes :

  • enrobage de la fibre par un liant organique,
  • durcissement de l'enrobage,
  • bobinage en spirale à spires jointives de la fibre sur un mandrin, en une seule couche plane et radiale.
The process for producing fiber preforms notably includes the following operations:
  • coating the fiber with an organic binder,
  • hardening of the coating,
  • spiral winding with contiguous turns of the fiber on a mandrel, in a single flat and radial layer.

Le durcissement de l'enrobage est juste suffisant pour éviter son écrasement pendant le bobinage. Ainsi, les spires jointives se collent entre elles pendant le bobinage sous l'effet de la tension de la fibre, ce qui assure la cohésion de la préforme après sa sortie du mandrin de bobinage.The hardening of the coating is just sufficient to prevent it from being crushed during winding. So the turns contiguous ones stick to each other during the winding under the effect of the tension of the fiber, which ensures the cohesion of the preform after its exit from the winding mandrel.

Les préformes de fibre peuvent être économiquement réalisées à l'aide d'un dispositif comportant notamment une bobine d'alimentation en fibre, une cuve de solution de liant, un dispositif de séchage de la fibre enrobée tel un tube chauffé par une résistance électrique, ainsi qu'un mandrin comportant deux flasques plans et parallèles dont l'écoutement est égal ou légèrement supérieur au diamètre de la fibre enrobée.The fiber preforms can be economically produced using a device comprising in particular a fiber supply reel, a tank of binder solution, a device for drying the coated fiber such as a tube heated by an electrical resistance, as well as a mandrel comprising two planar and parallel flanges whose listening is equal to or slightly greater than the diameter of the coated fiber.

Le procédé faisant l'objet de la présente invention ne doit pas être confondu avec les procédés d'obtention d'anneaux de renfort tels que celui qui est décrit dans le brevet FR 2 607 071 déjà cité. Ce procédé objet de l'invention consiste en effet à inclure des structures fibreuses de renforcement dans des pièces tout en réservant de la matière pour assurer les fonctions de la pièce, et à compresser ensuite ces structures fibreuses à l'intérieur de la pièce pendant le forgeage de ladite pièce.The process which is the subject of the present invention should not be confused with the processes for obtaining reinforcement rings such as that which is described in patent FR 2 607 071 already cited. This process which is the subject of the invention consists in fact in including fibrous reinforcing structures in parts while reserving material to ensure the functions of the part, and then in compressing these fibrous structures inside the part during forging said piece.

Le brevet FR 2 607 071 se limite au contraire à l'obtention de pièce entièrement fibreuses qui doivent ensuite être rapportées sur les pièces à renforcer.Patent FR 2 607 071 is, on the contrary, limited to obtaining entirely fibrous parts which must then be added to the parts to be reinforced.

Par rapport à la réalisation d'anneaux séparés, comme par exemple dans le brevet FR 2 607 071 déjà cité, le procédé objet de la présente invention a ainsi l'avantage de réaliser en un seul cycle thermique la compression des préformes et la liaison intime, semblable au soudage, de la zone renforcée par les fibres avec le reste de la matière de la pièce. La suppression d'un cycle thermique ménage les fibres de renfort et autorise une production plus économique des pièces.Compared to the production of separate rings, as for example in the patent FR 2 607 071 already cited, the process which is the subject of the present invention thus has the advantage of achieving in a single thermal cycle the compression of the preforms and the intimate connection. , similar to welding, of the area reinforced by the fibers with the rest of the material of the part. The elimination of a thermal cycle protects the reinforcing fibers and allows more economical production of the parts.

Le procédé offre aussi une grande latitude dans le choix des zones à renforcer. On peut en effet disposer ces zones à différents endroits de la section de la pièce, telles le centre, la périphérie ou les flancs. On répartira la matière de la pièce selon les fonctions à assurer. Par exemple, dans le cas d'un rotor de turbomachine à circulation axiale du fluide, on prévoira de la matière à la périphérie pour l'usinage des aubes et sur les flancs pour l'usinage des brides de raccordement aux autres étages de la machine, et aussi par exemple pour l'usinage de labyrinthes d'étanchéité ou de gorges de fixation de masses d'équilibrages.The process also offers great latitude in the choice of areas to be reinforced. We can indeed have these areas different places in the section of the part, such as the center, the periphery or the sides. The material of the part will be distributed according to the functions to be performed. For example, in the case of a turbomachine rotor with axial circulation of the fluid, material will be provided at the periphery for machining the blades and on the flanks for machining the flanges connecting to the other stages of the machine , and also for example for the machining of sealing labyrinths or grooves for fixing balancing masses.

Le procédé est aussi économique car il évite un cycle thermique ainsi que l'usinage précis de l'anneau de renfort et du logement destiné à le recevoir sur la pièce. La réalisation des préformes est aussi particulièrement simple.The process is also economical because it avoids a thermal cycle as well as precise machining of the reinforcing ring and the housing intended to receive it on the part. The production of the preforms is also particularly simple.

L'invention sera mieux comprise au vu d'un exemple de mise en oeuvre du procédé pour obtenir un rotor à aubes de turbomachine, donné à titre non limitatif de l'invention, ainsi que des figures annexées.The invention will be better understood in view of an example of implementation of the method for obtaining a turbine engine vane rotor, given without limitation of the invention, as well as the appended figures.

La figure 1 représente une vue en coupe de l'ébauche du rotor et des préformes, le tout disposé dans la matrice de forgeage isotherme.Figure 1 shows a sectional view of the rotor blank and the preforms, all arranged in the isothermal forging die.

La figure 2 schématise les étapes d'enrobage de la fibre et de bobinage des préformes.Figure 2 shows schematically the steps of coating the fiber and winding the preforms.

La figure 3 représente une coupe partielle du mandrin de bobinage des préformes.FIG. 3 represents a partial section of the mandrel for winding the preforms.

On se reportera en premier lieu à la figure 1.We will first refer to Figure 1.

Le rotor est usiné dans l'anneau 1 qui a une forme générale de révolution autour de l'axe géométrique 2. L'anneau 1 est obtenu par les opérations 1 à 7 ci-dessous, et le rotor usiné à l'opération 8.The rotor is machined in the ring 1 which has a general shape of revolution around the geometric axis 2. The ring 1 is obtained by operations 1 to 7 below, and the rotor machined in operation 8.

1) Réalisation d'une première ébauche 3 en forme d'anneau suivant l'axe géométrique 2. Cette ébauche 3 est délimitée axialement par deux flancs 4 et 5 et radialement par une surface intérieure de révolution 6 et une surface extérieure de révolution 7.1) Making a first blank 3 in the form of a ring along the geometric axis 2. This blank 3 is delimited axially by two sides 4 and 5 and radially by an inner surface of revolution 6 and an outer surface of revolution 7.

2) Réalisation dans l'un des flancs 4 ou 5, ou dans les deux flancs 4 et 5 de l'ébauche 3 d'au moins une rainure annulaire 8 d'axe 2.2) Production in one of the sides 4 or 5, or in the two sides 4 and 5 of the blank 3 of at least one annular groove 8 of axis 2.

Dans une forme de réalisation préférée et plus économique, une seule rainure annulaire 8 est réalisée dans un flanc 4.In a preferred and more economical embodiment, a single annular groove 8 is produced in a sidewall 4.

La rainure 8 comporte une section en U ouverte sur le flanc 4 suivant une direction parallèle à l'axe 2. La rainure 8 comporte un fond 9 circulaire, plan et radial à l'axe 2, ledit fond 9 étant adjacent à une paroi intérieure 10 et une paroi extérieure 11 cylindriques autour de l'axe 2 et se prolongeant jusqu'au flanc 4 pour former l'ouverture de la rainure 8. On comprend que la rainure 8 définit à l'intérieur de l'anneau 1 l'espace annulaire dans lequel seront disposé les fibres de renfort. La rainure 8 permet aussi d'accéder à cet espace pour y déposer les fibres et le métal d'apport.The groove 8 has a U-shaped section open on the sidewall 4 in a direction parallel to the axis 2. The groove 8 has a circular bottom 9, planar and radial to the axis 2, said bottom 9 being adjacent to an interior wall 10 and an outer wall 11 cylindrical around the axis 2 and extending to the side 4 to form the opening of the groove 8. It is understood that the groove 8 defines inside the ring 1 the space annular in which will be arranged the reinforcing fibers. The groove 8 also provides access to this space for depositing the fibers and the filler metal therein.

Remarquons que si l'on voulait disposer les fibres à la périphérie de la pièce cette rainure prendrait alors la forme d'un L ouvert radialement et axialement.Note that if we wanted to arrange the fibers at the periphery of the part, this groove would then take the form of an L open radially and axially.

3) Réalisation des préformes 12 de fibre et de métal d'apport. Les préformes 12 sont une mise en forme suffisamment rigide de la fibre et du métal d'apport pour que ces deux matériaux puissent être transportés sur le lieu de forgeage et disposés dans les rainures 8.3) Production of fiber and filler metal preforms 12. The preforms 12 are a sufficiently rigid shaping of the fiber and of the filler metal so that these two materials can be transported to the place of forging and placed in the grooves 8.

Il est connu de réaliser des préformes 12 contenant à la fois de la fibre et du métal d'apport. Il est aussi connu de réaliser des préformes 2 de deux catégories différentes, soit des préformes 12A contenant la fibre et des préformes 12B distinctes contenant le métal d'apport. Les préformes 12A et 12B ont la forme d'une rondelle plate aux dimensions de la rainure 8.It is known to produce preforms 12 containing both fiber and filler metal. It is also known to produce preforms 2 of two different categories, either preforms 12A containing the fiber and separate preforms 12B containing the filler metal. The preforms 12A and 12B have the shape of a flat washer with the dimensions of the groove 8.

4) Introduction dans la rainure 8 des préformes 12. Dans le cas où les préformes 12 sont différentes, les préformes 12a de fibre et les préformes 12B de métal d'apport seront introduites alternativement, chaque préforme 12B de métal séparant deux préformes 12A de fibre.4) Introduction into the groove 8 of the preforms 12. In the case where the preforms 12 are different, the fiber preforms 12a and the filler metal preforms 12B will be introduced alternately, each metal preform 12B separating two fiber preforms 12A .

5) Introduction dans les espaces 13 laissés entre les préformes 12 et les parois 10 et 11 de la rainure 8 de poudre de métal d'apport en quantité suffisante pour remplir ces espaces 13.5) Introduction into the spaces 13 left between the preforms 12 and the walls 10 and 11 of the groove 8 of powder of filler metal in sufficient quantity to fill these spaces 13.

Ceci permettra au moment du passage et du formage isotherme de mieux combler ces espaces 13, et ainsi d'assurer une meilleure continuité entre la matière de l'anneau 1 dans la zone fibreuse et la matière en-dehors de la zone fibreuse.This will allow at the time of passage and isothermal forming to better fill these spaces 13, and thus to ensure better continuity between the material of the ring 1 in the fibrous zone and the material outside the fibrous zone.

6) Réalisation et introduction dans la rainure 8 d'un bouchon 14 pour obturer ladite rainure 8. Le bouchon 14 comporte un fond 15 venant par gravité au contact des préformes 12. Dans une forme de réalisation préférée, le bouchon 14 émerge de la rainure 8 afin de démarrer l'opération de forgeage isotherme de l'anneau par une phase de compression des préformes 12 de fibre et de métal d'apport.6) Production and introduction into the groove 8 of a plug 14 for closing said groove 8. The plug 14 has a bottom 15 coming by gravity in contact with the preforms 12. In a preferred embodiment, the plug 14 emerges from the groove 8 in order to start the isothermal forging operation of the ring by a phase of compression of the fiber and filler metal preforms 12.

Le bouchon 14 a la forme d'un anneau d'axe 2 avec un fond 15 circulaire, plan et radial à l'axe 2.The plug 14 has the shape of a ring of axis 2 with a circular bottom 15, plane and radial to axis 2.

Le fond 15 est adjacent à une paroi cylindrique intérieure 16 dont le diamètre est un peu supérieur à celui de la paroi 10 de la rainure 8, et aussi adjacent à une paroi cylindrique extérieure 17 dont le diamètre est un peu inférieur à celui de la paroi 11 de la rainure 8, le bouchon 14 pouvant ainsi pénétrer dans la rainure 8 avec un jeu suffisant. Le bouchon 14 est aussi délimité axialement par une surface 18 opposée au fond 15. La surface 18 peut être circulaire, plane et radiale à l'axe 2, mais on peut aussi lui donner une forme différente selon le profil de l'anneau 1 et la déformation souhaitée du métal pendant le forgeage.The bottom 15 is adjacent to an inner cylindrical wall 16 whose diameter is slightly greater than that of the wall 10 of the groove 8, and also adjacent to an outer cylindrical wall 17 whose diameter is a little less than that of the wall 11 of the groove 8, the plug 14 thus being able to penetrate the groove 8 with sufficient play. The plug 14 is also axially delimited by a surface 18 opposite the bottom 15. The surface 18 can be circular, planar and radial to the axis 2, but it can also be given a different shape depending on the profile of the ring 1 and the desired deformation of the metal during forging.

Dans une forme de réalisation préférée, la partie du bouchon 14 extérieure à la rainure 8 présente une excroissance 19 prolongeant radialement le bouchon 14. L'excroissance 19 est délimitée axialement par la surface 18 du bouchon 14 opposée au fond 15, et par la surface 20 en regard du flanc 4 de l'ébauche 3 et de forme complémentaire audit flanc 4, et entourant le bouchon 14. L'excroissance 19 est aussi délimitée radialement à l'axe 2 par une surface cylindrique intérieure 21 dans le prolongement de la surface 6 de l'ébauche 3, et par une surface cylindrique extérieure 22 dans le prolongement de la surface 7.In a preferred embodiment, the part of the plug 14 external to the groove 8 has a protrusion 19 extending radially the plug 14. The protrusion 19 is delimited axially by the surface 18 of the plug 14 opposite the bottom 15, and by the surface 20 opposite the side 4 of the blank 3 and of shape complementary to said side 4, and surrounding the plug 14. The protuberance 19 is also delimited radially to the axis 2 by an internal cylindrical surface 21 in the extension of the surface 6 of the blank 3, and by an external cylindrical surface 22 in the extension of the surface 7.

Cette surface 18 constituera après forgeage le deuxième flanc de l'anneau 1 et opposé au flanc 5.This surface 18 will constitute after forging the second side of the ring 1 and opposite to the side 5.

Lorsque le bouchon 14 est simplement posé sur les préformes 12, le flanc 4 et la surface 20 sont écartés pour permettre la compression des préformes 12.When the plug 14 is simply placed on the preforms 12, the sidewall 4 and the surface 20 are separated to allow compression of the preforms 12.

La surface 13 de l'excroissance présente aussi une dépression circulaire 23 s'étendant jusqu'à la surface 22. Elle permettra un fluage radial du métal pendant le forgeage.The surface 13 of the projection also has a circular depression 23 extending to the surface 22. It will allow a radial creep of the metal during forging.

7) Chauffage et forgeage isotherme de l'ébauche 3 avec le préformes 12 dans la rainure 8 et le bouchon 14.7) Isothermal heating and forging of the blank 3 with the preforms 12 in the groove 8 and the plug 14.

L'ébauche 3 est posée sur son flanc 5 dans une machine 31 disposée elle même sur le plateau inférieur 32 d'une presse hydraulique.The blank 3 is placed on its side 5 in a machine 31 itself arranged on the lower plate 32 of a hydraulic press.

Un piston 33 pénètre dans la matrice et vient transmettre sur la surface 18 du bouchon 14 la pression 34 exercée parallèlement à l'axe 2 par le plateau supérieur de la presse non représenté sur la figure 1.A piston 33 penetrates into the matrix and transmits on the surface 18 of the plug 14 the pressure 34 exerted parallel to the axis 2 by the upper plate of the press not shown in FIG. 1.

Dans un premier temps, le fond 15 du bouchon 14 vient presser sous l'effet de la pression 34 les préformes 12, provoquant le fluage et l'agglomération du métal d'apport entre les fibres. Au fur et à mesure que le métal d'apport vient combler les espaces entre les fibres des préformes 12, la hauteur totale des préformes 12 diminue et le bouchon 14 pénètre dans la rainure jusqu'à ce que la surface 20 de l'excroissance 19 arrive au contact du flanc 4 de l'ébauche 3. La pression 34 s'exerce alors axialement sur toute la matière de l'anneau 1 qui prend progressivement la forme imposée par la matrice 31 et le piston 33. En pratique, la déformation du couvercle 14 commence avant la compression complète des préformes 12.Initially, the bottom 15 of the plug 14 presses under the effect of the pressure 34 the preforms 12, causing the creep and the agglomeration of the filler metal between the fibers. As the filler metal fills the spaces between the fibers of the preforms 12, the total height of the preforms 12 decreases and the plug 14 enters the groove until the surface 20 of the protrusion 19 comes into contact with the sidewall 4 of the blank 3. The pressure 34 is then exerted axially on all the material of the ring 1 which gradually takes the shape imposed by the matrix 31 and the piston 33. In practice, the deformation of the cover 14 begins before the preforms 12 are fully compressed.

Sous l'effet de la pression 34, le métal de l'ébauche 3, la poudre de métal d'apport introduite dans les espaces 13 et le métal d'apport des préformes 12 finissent de remplir complètement l'espace entre les fibres, arrivent en contact mutuel et se soudent entre eux, réalisant ainsi la compression des fibres et du métal pendant le forgeage isotherme de l'anneau.Under the effect of the pressure 34, the metal of the blank 3, the filler metal powder introduced into the spaces 13 and the filler metal of the preforms 12 completely fill the space between the fibers, arrive in mutual contact and weld together, thereby achieving compression of the fibers and metal during isothermal forging of the ring.

On choisira de préférence un métal d'apport ayant des températures de forgeage isotherme voisines ou un peu inférieures à celle du métal de l'ébauche, afin que la brasure et le métal d'apport aient une plasticité plus importante qui facilite la pénétration du métal entre les fibres. Ce métal d'apport doit évidemment être soudable avec celui de la pièce. Avantageusement les métaux de la pièce, des préformes et de la poudre pourront être identiques, mais ce n'est pas une nécessité.Preferably, a filler metal will be chosen having isothermal forging temperatures close to or slightly lower than that of the blank metal, so that the solder and the filler metal have greater plasticity which facilitates the penetration of the metal. between the fibers. This filler metal must obviously be weldable with that of the part. Advantageously, the metals of the part, the preforms and the powder may be identical, but this is not a necessity.

Le métal du bouchon 14 aura de préférence une température de forgeage isotherme voisine ou supérieure à la température de forgeage du métal de l'ébauche 3 et du métal d'apport des préformes 12, de façon à ce qu'il soit un peu moins plastique qu'eux pour permettre d'améliorer le pressage des préformes 12 au fond de la rainure 8, et notamment de démarrer la compression des préformes 12 avant le forgeage isotherme proprement dit de l'anneau 1.The metal of the plug 14 will preferably have an isothermal forging temperature close to or higher than the forging temperature of the metal of the blank 3 and the filler metal of the preforms 12, so that it is a little less plastic. than them in order to improve the pressing of the preforms 12 at the bottom of the groove 8, and in particular to start the compression of the preforms 12 before the isothermal forging proper of the ring 1.

Dans une autre forme de réalisation, les métaux de l'ébauche 3 et du bouchon 14, ainsi que le métal d'apport des préformes 12 et de la poudre sont identiques, ce qui améliore l'homogénéïté et la résistance de l'anneau 1.In another embodiment, the metals of the blank 3 and of the plug 14, as well as the filler metal of the preforms 12 and of the powder are identical, which improves the homogeneity and the resistance of the ring 1 .

Il est avantageux aussi d'exercer par un moyen 35 sur l'ébauche 3 une pression 36 radiale combinée à la pression axiale 34, afin de générer à l'intérieur de la pièce une pression isostatique, c'est à dire uniforme dans toute les directions. Cette pression isostatique améliore le soudage du métal de l'ébauche 3 et du bouchon 14 autour des préformes 12 et permet de réduire la quantité de poudre de métal d'apport à introduire dans les espaces 13, ce qui améliore l'homogénéïte de l'anneau 1.It is also advantageous to exert by a means 35 on the blank 3 a radial pressure 36 combined with the axial pressure 34, in order to generate inside the part an isostatic pressure, that is to say uniform in all the directions. This isostatic pressure improves the welding of the metal of the blank 3 and of the plug 14 around the preforms 12 and makes it possible to reduce the quantity of filler metal powder to be introduced into the spaces 13, which improves the homogeneity of the ring 1.

Le piston 33 est en appui sur le bouchon 14 par sa surface 37. Cette surface 37 comporte une surépaisseur 38 ayant la même forme que la dépression 23, mais la hauteur de la surépaisseur 38 est inférieure à la profondeur de la dépression 23. De ce fait, il subsiste un espace 39 entre ladite surépaisseur 38 et ladite dépression 23, et cet espace 39 sera comblé pendant le forgeage isotherme par le déplacement suivant une direction radiale de la matière du bouchon 14 à proximité de la surface 18 en contact avec le piston 33. Ce déplacement de matière donne aux grains de métal une forme allongée appelée fibrage qui en augmente la résistance.The piston 33 is supported on the plug 14 by its surface 37. This surface 37 includes an additional thickness 38 having the same shape as the depression 23, but the height of the additional thickness 38 is less than the depth of the depression 23. From this fact, there remains a space 39 between said excess thickness 38 and said depression 23, and this space 39 will be filled during isothermal forging by the displacement in a radial direction of the material of the plug 14 near the surface 18 in contact with the piston 33. This displacement of material gives the metal grains an elongated shape called fiberizing which increases their resistance.

Rappelons que le dispositif de forgeage isotherme de l'anneau 1 comporte une matrice 31 posée sur le plateau inférieur 32 d'une presse, un piston 33 sur lequel le plateau supérieur non représenté de la presse exerce une pression axiale 34, ledit piston 33 pénétrant dans ladite matrice 31, et un moyen 35 exercant une pression centrifuge 36 sur la matrice 31.Recall that the isothermal forging device of the ring 1 comprises a matrix 31 placed on the lower plate 32 of a press, a piston 33 on which the upper plate (not shown) of the press exerts an axial pressure 34, said piston 33 penetrating in said matrix 31, and a means 35 exerting a centrifugal pressure 36 on the matrix 31.

Dans une forme de réalisation préférée, la matrice 31 a une forme annulaire autour de l'axe 2 avec une section en L dont l'ouverture est tournée vers le dessus et vers l'extérieur.In a preferred embodiment, the matrix 31 has an annular shape around the axis 2 with an L-shaped section, the opening of which faces upwards and outwards.

La branche horizontale 41 du L est en bas et forme par sa surface supérieure le fond 42 de la matrice 31.The horizontal branch 41 of the L is at the bottom and forms by its upper surface the bottom 42 of the matrix 31.

La branche verticale 43 du L est tournée vers l'axe géométrique 2 et constitue la paroi verticale 44 de la matrice 31.The vertical branch 43 of the L faces the geometric axis 2 and constitutes the vertical wall 44 of the matrix 31.

A l'opposé de cette paroi 44, la matrice 31 est délimitée radialement vers l'axe 2 par une surface cylindrique concave 45 centrée sur l'axe 2.Opposite this wall 44, the matrix 31 is delimited radially towards the axis 2 by a concave cylindrical surface 45 centered on the axis 2.

Le moyen 35 permettant d'exercer la pression centrifuge 36 sera avantageusement un mandrin radialement expansible réalisé dans un matériau à fort coefficient de dilatation thermique, l'expansion étant obtenue par le chauffage dudit mandrin 35. Le mandrin 35 est délimité radialement vers l'extérieur par une surface cylindrique 46 et s'emboite à l'intérieur de la surface cylindrique 45 de la paroi verticale 44 avec un jeu réduit entre les surfaces 45 et 46.The means 35 for exerting centrifugal pressure 36 will advantageously be a radially expandable mandrel made of a material with a high coefficient of thermal expansion, the expansion being obtained by heating said mandrel 35. The mandrel 35 is delimited radially outwards by a cylindrical surface 46 and fits inside the cylindrical surface 45 of the vertical wall 44 with a reduced clearance between the surfaces 45 and 46.

On comprend que lorsque le mandrin 35 se dilate sous l'effet de la chaleur, la surface 46 du mandrin 35 vient pousser la matrice 31 sur sa surface 45, provoquant ainsi la pression centrifuge 36.It is understood that when the mandrel 35 expands under the effect of heat, the surface 46 of the mandrel 35 pushes the die 31 on its surface 45, thus causing centrifugal pressure 36.

Le présent dispositif comporte aussi une ceinture 47 de forme cylindrique centrée sur l'axe 2 et reposant par l'un de ses flancs 48 sur le plateau inférieur 32 de la presse. La ceinture 47 comporte une paroi intérieure 49 cylindrique et concave centrée sur l'axe 2 qui entoure la matrice 31, qui se trouve en regard de la paroi verticale 44 et qui délimite radialement vers l'extérieur l'espace dans lequel est forgé l'anneau 1. Le piston annulaire 33 vient aussi s'insérer entre la paroi 44 de la matrice 31 et la paroi 49 de la ceinture.The present device also includes a shaped belt 47 cylindrical centered on the axis 2 and resting by one of its sides 48 on the lower plate 32 of the press. The belt 47 has a cylindrical and concave inner wall 49 centered on the axis 2 which surrounds the matrix 31, which is opposite the vertical wall 44 and which delimits radially outwards the space in which the ring 1. The annular piston 33 also fits between the wall 44 of the matrix 31 and the wall 49 of the belt.

Cette ceinture 47 est réalisée en un matériau résistant et présentant un faible coefficient de dilatation thermique par exemple en fibres de carbone. Cette ceinture 47 empêche la dilatation radiale de l'ébauche 3 et du bouchon 14 pendant le forgeage isotherme, ce qui améliore l'efficacité de la pression centrifuge 36 tout en maintenant les fibres pour empêcher leur mise en contrainte.This belt 47 is made of a resistant material and having a low coefficient of thermal expansion, for example carbon fibers. This belt 47 prevents the radial expansion of the blank 3 and the plug 14 during isothermal forging, which improves the efficiency of the centrifugal pressure 36 while maintaining the fibers to prevent their stressing.

Dans cet exemple, le rotor est en alliage de titane TA6V et les fibres de renfort en carbure de silicium SiC recouvertes d'un dépôt de carbone. Le forgeage isotherme s'effectue à 950°C sous une pression de 600 bars pendant 50 minutes.In this example, the rotor is made of TA6V titanium alloy and the reinforcing fibers of silicon carbide SiC covered with a carbon deposit. Isothermal forging takes place at 950 ° C under a pressure of 600 bars for 50 minutes.

8) Usinage final du rotor, à partir de l'anneau 1 ainsi obtenu. Dans le cas d'un rotor axial de turbomachine, les aubes non représentées seront usinées dans la surépaisseur de matière 55 disposée entre les préformes 12 et la surface extérieure 7, alors que les brides non représentées de liaison avec les autres étages de la turbomachine seront usinées dans les surépaisseurs de matière 56A et 56B disposées entre les préformes 12 et les flancs 5 ou 18.8) Final machining of the rotor, starting from the ring 1 thus obtained. In the case of an axial rotor of a turbomachine, the blades not shown will be machined in the extra thickness of material 55 disposed between the preforms 12 and the external surface 7, while the flanges not shown for connection with the other stages of the turbomachine will be machined in the extra thicknesses of material 56A and 56B arranged between the preforms 12 and the sides 5 or 18.

On se reportera maintenant à la figure 2.We will now refer to Figure 2.

La fibre de renfort 60 est prise sur une bobine d'alimentation 61. La fibre 60 plonge dans une cuve 62 contenant un bain 63 de liant organique liquide, passe autour d'une poulie de renvoi 64 immergée dans la solution 63 et émerge de cette solution 63 enrobée d'une certaine quantité de solution de liant.The reinforcing fiber 60 is taken from a supply reel 61. The fiber 60 plunges into a tank 62 containing a bath 63 of liquid organic binder, passes around a return pulley 64 immersed in the solution 63 and emerges from this solution 63 coated with a certain amount of binder solution.

La fibre 65, passe ensuite dans le moyeu de séchage 65, par exemple un tube chauffé avec une résistance électrique, afin de durcir l'enrobage de liant organique tout en lui conservant une aptitude suffisante à se coller aux fibres voisines.The fiber 65 then passes through the drying hub 65, for example a tube heated with an electrical resistance, in order to harden the coating of organic binder while retaining sufficient ability to stick to neighboring fibers.

La fibre 66 ainsi enrobée contourne ensuite une poulie de renvoi 67 et est bobinée sur le mandrin 68 pour constituer la préforme de fibre 12A. Avec ce procédé, l'épaisseur de l'enrobage est déterminée par la viscosité et donc la concentration et la température de la solution 63, alors que son degré de séchage et donc sa dureté sont déterminés par l'intensité du chauffage dans le tube chauffant 65 et la durée du passage de la fibre dans ce tube 65.The fiber 66 thus coated then bypasses a deflection pulley 67 and is wound on the mandrel 68 to form the fiber preform 12A. With this process, the thickness of the coating is determined by the viscosity and therefore the concentration and the temperature of the solution 63, while its degree of drying and therefore its hardness are determined by the intensity of the heating in the heating tube. 65 and the duration of the passage of the fiber through this tube 65.

On se reportera maintenant à la figure 3.We will now refer to Figure 3.

Le mandrin 68 tourne autour de l'axe géométrique de rotation 69. Ce mandrin 68 comporte deux flasques circulaires 70 disposés de part et d'autre d'un moyeu circulaire 71, ainsi qu'un moyen non représenté de positionnement et d'entrainement en rotation autour de l'axe 69 desdits flasques 70 et dudit moyeu 71.The mandrel 68 rotates around the geometric axis of rotation 69. This mandrel 68 comprises two circular flanges 70 arranged on either side of a circular hub 71, as well as a means (not shown) for positioning and driving in rotation about the axis 69 of said flanges 70 and of said hub 71.

Les deux flasques 70 comportent chacun une face latérale 72 plane et radiale, lesdites faces 72 étant en regard l'une de l'autre pour former une rainure annulaire 73 ouverte sur la périphérie 74 du mandrin et délimitée intérieurement par le moyeu 71. Les faces 72 se raccordent à la périphérie 74 du mandrin 68 par un rayon 75, afin de ne pas risquer d'arracher l'enrobage 76 des fibres 60.The two flanges 70 each have a flat and radial side face 72, said faces 72 facing one another to form an annular groove 73 open on the periphery 74 of the mandrel and delimited internally by the hub 71. The faces 72 are connected to the periphery 74 of the mandrel 68 by a radius 75, so as not to risk tearing off the coating 76 of the fibers 60.

La fibre enrobée 6 est enroulée en spirale dans la rainure 73 pour constituer la préforme de fibre 12A. L'espace formé entre les spires étant égal à deux fois l'épaisseur de l'enrobage 76 de la fibre 60.The coated fiber 6 is wound in a spiral in the groove 73 to form the 12A fiber preform. The space formed between the turns being equal to twice the thickness of the coating 76 of the fiber 60.

L'écartement des faces 72 est égal ou un peu supérieur au diamètre des fibres enrobées 66, et le diamètre du moyeu 71 est égal au diamètre intérieur de la préforme 12A de fibre à réaliser.The spacing of the faces 72 is equal to or slightly greater than the diameter of the coated fibers 66, and the diameter of the hub 71 is equal to the inside diameter of the fiber preform 12A to be produced.

Dans un mode de réalisation préféré, l'un des flasques 70 est amovible pour permettre de retirer la préforme 12A ainsi bobinée, et le moyeu 71 a la forme d'un tronc de cône dont le petit diamètre est tourné du côté du flasque 70 amovible, afin de faciliter le retrait de la préforme 12A.In a preferred embodiment, one of the flanges 70 is removable to allow the preform 12A thus wound to be removed, and the hub 71 has the shape of a truncated cone whose small diameter is turned towards the side of the removable flange 70 , in order to facilitate the withdrawal of the preform 12A.

Le séchage de l'enrobage 76 doit être suffisant pour que cet enrobage 76 puisse acquérir une dureté lui permettant de ne pas se déformer de façon significative pendant le bobinage, mais pas trop toutefois. De ce fait, la tension de la fibre 66 pendant le bobinage sur le mandrin 68 provoque le collage des spires adjacentes de fibre enrobée 66 suivant la ligne de contact 77 entre ces spires. Ce collage assure la cohésion de la préforme pendant son retrait du mandrin, pendant son transport, et pendant son introduction dans la rainure annulaire 8 de l'ébauche 3 du rotor.The drying of the coating 76 must be sufficient for this coating 76 to acquire a hardness allowing it not to deform significantly during winding, but not too much. As a result, the tension of the fiber 66 during winding on the mandrel 68 causes the adjacent turns of coated fiber 66 to stick together along the contact line 77 between these turns. This bonding ensures the cohesion of the preform during its withdrawal from the mandrel, during its transport, and during its introduction into the annular groove 8 of the blank 3 of the rotor.

Les faces 72 et la périphérie du moyeu 71 sont en un matériau dur et non adhésif tel le téflon.The faces 72 and the periphery of the hub 71 are made of a hard, non-adhesive material such as Teflon.

La concentration et la tempérture du bain de liant organique 63, le chauffage de la fibre enrobée 66 et la tension de ladite fibre enrobée 66 peuvent être déterminés par des expérimentations courantes pour l'homme de métier. Dans le présent exemple de réalisation, le bain de liant 63 est une solution de polyméthyle-métacrylate de formule chimique générale (CH₂C(CH₃) (CO₂CH₃)-)n (appelé couramment PMMA) dans de l'acétone. Le PMMA est pyrolysable entre 400°C et 600°C.The concentration and the temperature of the organic binder bath 63, the heating of the coated fiber 66 and the tension of said coated fiber 66 can be determined by current experiments for those skilled in the art. In the present embodiment, the binder bath 63 is a solution of polymethyl methacrylate of general chemical formula (CH₂C (CH₃) (CO₂CH₃) -) n (commonly called PMMA) in acetone. PMMA is pyrolyzable between 400 ° C and 600 ° C.

De ce fait, pendant le chauffage du rotor 1 avant l'opération de forgeage isotherme, un palier de une heure à 2 heures environ est effectué vers 500° pour pyrolyser le liant et éliminer les gaz résultant de cette pyrolyse.Therefore, during the heating of the rotor 1 before the isothermal forging operation, a plateau of one hour to 2 hours approximately is performed at around 500 ° to pyrolyze the binder and remove the gases resulting from this pyrolysis.

L'empilage des préformes de fibre 12A et des rondelles de métal d'apport 12B est assez compact. De ce fait, et afin de faciliter l'évacuation des gaz produits par la pyrolyse du liant, on préférera perforer les rondelles 12B de métal d'apport séparant les préformes de fibre 12A. Afin de ne pas modifier les proportions respectives de fibre et de métal, et afin aussi de ne pas risquer de mettre en contact les fibres de deux préformes voisines 12A à travers les perforations des rondelles 12B, ces perforations seront de préférence réalisées sans enlèvement de matière, par exemple à l'aide d'une pointe métallique ou d'une lame.The stack of fiber preforms 12A and filler metal washers 12B is fairly compact. Therefore, and in order to facilitate the evacuation of the gases produced by the pyrolysis of the binder, it is preferable to perforate the washers 12B of filler metal separating the fiber preforms 12A. In order not to modify the respective proportions of fiber and metal, and also so as not to risk bringing the fibers of two neighboring preforms 12A into contact through the perforations of the washers 12B, these perforations will preferably be carried out without removing material , for example using a metal tip or a blade.

Claims (20)

Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres, ledit procédé comportant des opérations de mise en forme des fibres, de compression des fibres avec un alliage métallique et de formage de cette pièce (1) par forgeage isotherme, caractérisé en ce qu'il comporte les opérations suivantes : - réalisation d'une ébauche (3) de la pièce (1), - réalisation d'au moins une rainure (8) dans l'ébauche (3); ladite rainure (8) étant annulaire et ouverte au moins dans la direction axiale - réalisation de préformes (12) de fibre et de métal d'apport; - introduction dans la rainure (8) des préformes (12) de fibre et de métal d'apport ; - forgeage isotherme de l'ébauche (3) ; ladite opération de forgeage isotherme permettant ainsi de réaliser simultanément la compression des préformes (12), le soudage des préformes (12) comprimées avec le reste de la pièce (1) ainsi que le forgeage isotherme de cette pièce (1). Method for obtaining a circular metal part reinforced with fibers, said method comprising operations for shaping the fibers, compressing the fibers with a metal alloy and forming this part (1) by isothermal forging, characterized in what it involves the following operations: - making a blank (3) of the part (1), - Production of at least one groove (8) in the blank (3); said groove (8) being annular and open at least in the axial direction - production of fiber and filler metal preforms (12); - introduction into the groove (8) of preforms (12) of fiber and filler metal; - isothermal forging of the blank (3); said isothermal forging operation thus making it possible to simultaneously compress the preforms (12), the welding of the compressed preforms (12) with the rest of the part (1) as well as the isothermal forging of this part (1). Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 1, caractérisé en ce que les espaces (13) restant entre les préformes (12) et les parois (10) et (11) de la rainure (8) sont comblés de poudre soudable au métal de la pièce.Process for obtaining a circular metal part reinforced with fibers according to claim 1, characterized in that the spaces (13) remaining between the preforms (12) and the walls (10) and (11) of the groove ( 8) are filled with powder weldable to the metal of the part. Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 1 ou 2 caractérisé en ce que la poudre et le métal d'apport des préformes (12) ont des températures de forgeage isotherme voisines ou inférieures à celle du métal de l'ébauche (3).Process for obtaining a circular metal part reinforced with fibers according to claim 1 or 2, characterized in that the powder and the filler metal of the preforms (12) have isothermal forging temperatures close to or lower than that of blank metal (3). Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à l'une quelconque des revendications 1 à 3, caractérisé en ce que la rainure (8) est obturée par un bouchon (14).Method for obtaining a circular metal part reinforced with fibers according to any one of Claims 1 to 3, characterized in that the groove (8) is closed by a plug (14). Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 4, caractérisé en ce que le bouchon (14) arrive au contact des préformes (12) dans la rainure (8), et en ce qu'il est réalisé dans un métal présentant une température de forgeage isotherme voisine ou supérieure à celle du métal d'apport des préformes (12) de façon à ce que la compression desdites préformes (12) prenne de l'avance sur le forgeage isotherme de la pièce (1).Process for obtaining a circular metal part reinforced with fibers according to claim 4, characterized in that the plug (14) comes into contact with the preforms (12) in the groove (8), and in that it is made of a metal having an isothermal forging temperature close to or higher than that of the filler metal of the preforms (12) so that the compression of said preforms (12) takes precedence over the isothermal forging of the part (1). Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à l'une quelconque des revendications 1 à 5, caractérisé en ce que l'opération de forgeage isotherme est effectuée à la presse suivant une direction parallèle à l'axe géométrique (2) de la pièce (1).Process for obtaining a circular metal part reinforced with fibers according to any one of Claims 1 to 5, characterized in that the isothermal forging operation is carried out with the press in a direction parallel to the geometric axis (2) of part (1). Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 6, caractérisé en ce que un fluage de métal de l'anneau (1) suivant une direction radiale est effectué sur au moins un flanc (18) de cette pièce (1) pendant l'opération de forgeage isotherme, afin d'augmenter encore la résistance de cette pièce (1).Process for obtaining a circular metal part reinforced with fibers according to claim 6, characterized in that a metal creep of the ring (1) in a radial direction is carried out on at least one side (18) of this part (1) during the isothermal forging operation, in order to further increase the resistance of this part (1). Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à l'une quelconque des revendications 1 à 7, caractérisé en ce que la pièce (1) est soumise à une pression centrifuge (36) pendant le forgeage isotherme.Method for obtaining a circular metal part reinforced with fibers according to any one of Claims 1 to 7, characterized in that the part (1) is subjected to centrifugal pressure (36) during isothermal forging. Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 8, caractérisé en ce que l'ébauche (3) est entourée d'une ceinture (47) présentant un faible coefficient de dilatation thermique, de façon à empêcher la mise en contrainte des fibres des préformes (12) pendant le forgeage isotherme.Method for obtaining a fiber-reinforced metal circular part according to claim 8, characterized in that the blank (3) is surrounded by a belt (47) having a low coefficient of thermal expansion, so as to preventing stressing of the fibers of the preforms (12) during isothermal forging. Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres, conformément à l'une quelconque des revendications 1 à 9, caractérisé en ce que l'on réalise des préformes de fibre (12A) distinctes des préformes de métal d'apport (12B), lesdites préformes de fibre (12A) et lesdites préformes de métal (12B) ayant chacune la forme d'une rondelle plate évidée en son centre, et en ce que les préformes de fibre (12A) et les préformes de métal (12B) sont empilées alternativement dans la rainure (8), de sorte que chaque préforme de métal (12B) sépare deux préformes de fibre (12A).Process for obtaining a circular metal part reinforced with fibers, according to any one of Claims 1 to 9, characterized in that fiber preforms (12A) are produced which are separate from the filler metal preforms (12B), said fiber preforms (12A) and said metal preforms (12B) each having the shape of a flat washer hollowed out at its center, and in that the fiber preforms (12A) and the metal preforms ( 12B) are alternately stacked in the groove (8), so that each metal preform (12B) separates two fiber preforms (12A). Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conformément à la revendication 10, caractérisé en ce que les préformes de métal 12B sont perforées sans perte de matière.Method for obtaining a circular metal part reinforced with fibers in accordance with claim 10, characterized in that the metal preforms 12B are perforated without loss of material. Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 10 ou 11 caractérisé en ce que l'obtention des préformes de fibre (12A) comporte notamment les opérations suivantes : - enrobage de la fibre (60) par une couche de liant, - bobinage de la fibre ainsi enrobée (66) sur un mandrin (68). Process for obtaining a circular metal part reinforced with fibers according to claim 10 or 11, characterized in that the obtaining of the fiber preforms (12A) comprises in particular the following operations: - coating of the fiber (60) with a layer of binder, - winding of the fiber thus coated (66) on a mandrel (68). Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 12 caractérisé en ce que le bobinage de la fibre enrobée (66) sur le mandrin (68) est effectué en une seule couche plane et radiale.Method for obtaining a circular metal part reinforced with fibers according to claim 12, characterized in that the winding of the coated fiber (66) on the mandrel (68) is carried out in a single plane and radial layer. Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 12 ou 13 caractérisé en ce que l'enrobage de la fibre (60) est réalisé par trempage de ladite fibre (60) dans une solution (63) de liant organique, suivi d'un séchage.Method for obtaining a circular metal part reinforced with fibers according to claim 12 or 13 characterized in that the coating of the fiber (60) is carried out by soaking said fiber (60) in a solution (63) organic binder, followed by drying. Procédé d'obtention d'une pièce circulaire métallique renforcée par des fibres conforme à la revendication 14 caractérisé en ce que la solution (63) est du polyméthylmétachrylate de formule chimique (CH₂C(CH₃)(CO₂CH₃)-n dissous dans de l'acétone.Process for obtaining a circular metal part reinforced with fibers according to Claim 14, characterized in that the solution (63) is polymethylmetachrylate of chemical formula (CH₂C (CH₃) (CO₂CH₃) -n dissolved in acetone . Dispositif de forgeage isotherme conçu pour la mise en oeuvre du procédé d'obtention conforme à l'une quelconque des revendications 1 à 15 caractérisé en ce qu'il comporte : - une matrice annulaire (31) ayant une section en L dont la branche horizontale forme le fond (42) de ladite matrice (31), et dont la branche verticale (43) est vers l'axe géométrique (2) de la matrice (31) et en constitue la paroi verticale (44), - une ceinture (47) entourant la matrice (31) et réalisée en matériau à faible coefficient de dilatation thermique, - un piston annulaire (33) qui s'insère entre la paroi verticale (44) de la matrice (31) et la ceinture (47), afin de transmettre l'effort axial de pressage (34), - un mandrin radialement expansible (35) disposé à l'intérieur de la paroi verticale (44) et exerçant pendant le forgeage isotherme la pression centrifuge (36) sur ladite paroi verticale (44). Isothermal forging device designed for implementing the production process according to any one of claims 1 to 15, characterized in that it comprises: - an annular matrix (31) having an L-shaped section whose horizontal branch forms the bottom (42) of said matrix (31), and whose vertical branch (43) is towards the geometric axis (2) of the matrix ( 31) and constitutes its vertical wall (44), - a belt (47) surrounding the matrix (31) and made of material with a low coefficient of thermal expansion, - an annular piston (33) which is inserted between the vertical wall (44) of the matrix (31) and the belt (47), in order to transmit the axial pressing force (34), - A radially expandable mandrel (35) disposed inside the vertical wall (44) and exerting during isothermal forging the centrifugal pressure (36) on said vertical wall (44). Dispositif conçu pour la mise en oeuvre du procédé d'obtention conforme à l'une quelconque des revendications 1 à 16 caractérisé en ce qu'il comporte une bobine (61) d'alimentation en fibre (60), une cuve (62) contenant un bain de liant (63), un moyen de séchage (65) et un mandrin (68) pour bobiner la fibre enrobée (66).Device designed for the implementation of the obtaining method according to any one of claims 1 to 16 characterized in that it comprises a reel (61) for supplying fiber (60), a tank (62) containing a binder bath (63), a drying means (65) and a mandrel (68) for winding the coated fiber (66). Dispositif conforme à la revendication 17, caractérisé en ce que le mandrin (68) comporte un moyeu (71) flanqué de deux flasques (70) plans et radiaux à l'axe géométrique de rotation (69) du mandrin (68), lesdits flasques (69) étant écartés d'une distance égale ou un peu supérieure au diamètre de la fibre enrobée (66), l'un au moins desdits flasques (70) étant amovible pour permettre de retirer la préforme (12A) obtenue.Device according to claim 17, characterized in that the mandrel (68) comprises a hub (71) flanked by two flanges (70) planes and radial to the geometric axis of rotation (69) of the mandrel (68), said flanges (69) being spaced apart by a distance equal to or slightly greater than the diameter of the coated fiber (66), at least one of said flanges (70) being removable to allow the preform (12A) obtained to be removed. Dispositif conforme à la revendication 18, caractérisé en ce que le moyeu (71) du mandrin (68) a la forme d'un tronc de cône dont le petit diamètre est situé du côté du flasque (70) qui est amovible, pour faciliter le retrait de la préforme (12A).Device according to claim 18, characterized in that the hub (71) of the mandrel (68) has the shape of a truncated cone whose small diameter is located on the side of the flange (70) which is removable, to facilitate the withdrawal of the preform (12A). Dispositif conforme à l'une quelconque des revendications 18 ou 19, caractérisé en ce que les surfaces (72) des flasques (70) en contact avec la fibre enrobée (66) sont en un matériau dur et non adhésif tel le téflon.Device according to any one of claims 18 or 19, characterized in that the surfaces (72) of the flanges (70) in contact with the coated fiber (66) are made of a hard, non-adhesive material such as Teflon.
EP94402806A 1993-12-08 1994-12-07 Process for preparing a circular fiberreinforced metallic workpiece Expired - Lifetime EP0657554B1 (en)

Applications Claiming Priority (2)

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FR9314698 1993-12-08
FR9314698A FR2713662B1 (en) 1993-12-08 1993-12-08 Process for obtaining a circular metal part reinforced with fibers.

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EP0657554A1 true EP0657554A1 (en) 1995-06-14
EP0657554B1 EP0657554B1 (en) 2000-08-02

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EP (1) EP0657554B1 (en)
JP (1) JP3194678B2 (en)
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FR (1) FR2713662B1 (en)

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CN102083613A (en) * 2008-04-29 2011-06-01 康蒂特克橡胶工业有限公司 Method and apparatus for manufacturing fibre-reinforced hoses
CN102581557A (en) * 2012-02-23 2012-07-18 滁州安迈达特种铝业有限公司 Processing technology for seamless plug of handle of refrigerator door

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CN102083613B (en) * 2008-04-29 2013-12-25 康蒂特克橡胶工业有限公司 Method and apparatus for manufacturing fibre-reinforced hoses
CN102581557A (en) * 2012-02-23 2012-07-18 滁州安迈达特种铝业有限公司 Processing technology for seamless plug of handle of refrigerator door

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US5642851A (en) 1997-07-01
FR2713662B1 (en) 1996-01-12
DE69425418D1 (en) 2000-09-07
DE69425418T2 (en) 2001-03-15
JPH07197108A (en) 1995-08-01
JP3194678B2 (en) 2001-07-30
EP0657554B1 (en) 2000-08-02
US5562245A (en) 1996-10-08
FR2713662A1 (en) 1995-06-16

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