EP0761977A1 - High temperature composite material impellor, particularly of small diameter, and its manufacturing method - Google Patents

High temperature composite material impellor, particularly of small diameter, and its manufacturing method Download PDF

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Publication number
EP0761977A1
EP0761977A1 EP96401835A EP96401835A EP0761977A1 EP 0761977 A1 EP0761977 A1 EP 0761977A1 EP 96401835 A EP96401835 A EP 96401835A EP 96401835 A EP96401835 A EP 96401835A EP 0761977 A1 EP0761977 A1 EP 0761977A1
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EP
European Patent Office
Prior art keywords
blades
turbine
flange
composite material
preform
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
EP96401835A
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German (de)
French (fr)
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EP0761977B1 (en
Inventor
Jean-Pierre Maumus
Guy Martin
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
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Societe Europeenne de Propulsion SEP SA
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Publication of EP0761977A1 publication Critical patent/EP0761977A1/en
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F01D5/04—Blade-carrying members, e.g. rotors for radial-flow machines or engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/34—Rotor-blade aggregates of unitary construction, e.g. formed of sheet laminae
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/28—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps
    • F04D29/284—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for compressors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/50—Building or constructing in particular ways
    • F05D2230/53—Building or constructing in particular ways by integrally manufacturing a component, e.g. by milling from a billet or one piece construction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/22—Non-oxide ceramics
    • F05D2300/224—Carbon, e.g. graphite
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced
    • F05D2300/6033—Ceramic matrix composites [CMC]
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49318—Repairing or disassembling
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y10T29/49321—Assembling individual fluid flow interacting members, e.g., blades, vanes, buckets, on rotary support member
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y10T29/49325—Shaping integrally bladed rotor

Definitions

  • the present invention relates to turbines, and more particularly those intended to operate at high temperatures, typically above 1000 ° C.
  • these turbines are made of metal, generally made up of several elements assembled by welding.
  • the use of metal has several drawbacks.
  • the high mass of the rotating parts requires large shaft lines and very powerful motors and imposes anyway a limitation of the speed of rotation.
  • a temperature limitation is added due to the risk of metal creep.
  • the sensitivity of the metal to thermal shock can cause cracks or deformation. This results in imbalances in the rotating mass favoring a reduction in the service life of the turbines and their drive motors.
  • significant thermal shocks can occur, in particular in the event of massive injection of a cold gas, to cause the temperature to drop rapidly inside an oven in order to reduce the duration treatment cycles.
  • thermostructural composite materials In order to avoid the problems encountered with metals, other materials have already been proposed for making turbines, in particular thermostructural composite materials. These materials generally consist of a fibrous reinforcement texture, or preform, densified by a matrix and are characterized by their mechanical properties which make them suitable for constituting structural elements and by their capacity to maintain these properties up to high temperatures.
  • thermostructural composite materials are carbon-carbon composites (CC) made of carbon fiber reinforcement and a carbon matrix, and ceramic matrix composites (CMC) made of carbon fiber reinforcement carbon or ceramic and a ceramic matrix.
  • thermostructural composite materials Compared to metals, thermostructural composite materials have the essential advantages of a much lower density and great stability at high temperatures. The reduction in mass and the elimination of risk of creep can allow high speeds of rotation and, by the same token, very high ventilation rates without requiring oversizing of the drive members. In addition, thermostructural composite materials have a very high resistance to thermal shock.
  • Thermostructural composite materials therefore have significant performance advantages, but their use is limited due to their fairly high cost. In addition to the materials used, the cost comes essentially from the difficulties encountered in producing fibrous preforms, in particular when the parts to be manufactured have complex shapes, which is the case with turbines, and by the duration of the densification cycles.
  • an object of the present invention is to provide a turbine architecture particularly suited to its production in thermostructural composite material in order to benefit from the advantages of this material but with a manufacturing cost as reduced as possible.
  • the turbine is for its essential part formed of only two parts, which simplifies assembly, and each part is produced from a fibrous preform having a simple shape.
  • This is so for the second part, since it simply forms a flange, so that the second fibrous preform can be constituted by a plate.
  • the first part it is produced by machining from a first preform constituted by a plate.
  • the first fibrous preform is machined in the consolidated state, partially densified, and the densification by the matrix is continued after machining.
  • small diameter turbine here is meant a turbine whose diameter of the outer ring does not exceed about 500 mm.
  • the turbine is assembled only by mutual tightening of the first part and the second part at their central parts. It has been found that this single tightening ensures the assembly of the turbine in all operating configurations, thanks to the rigidity of the composite material. This is all the more true as the diameter of the turbine is smaller. It is therefore not necessary to use clamping elements of the screw type entering the two parts. This is an important advantage because, otherwise, the hardware used should have been made of composite material, to withstand high temperatures and have a coefficient of thermal expansion compatible with that of the assembled parts, which would have increased the cost so significant.
  • the fiber preforms are produced using techniques known per se.
  • the first fibrous preform, as well as the second can be produced from a flat stack of strata of a two-dimensional fibrous texture and bonding of the strata together by needling.
  • the first fibrous preform can be produced from a winding of a strip of two-dimensional fibrous texture in superimposed layers and bonding of the layers to each other by needling.
  • the invention relates to a turbine comprising a plurality of blades arranged between two flanges and delimiting circulation passages between an inner ring and an outer ring, the blades and flanges being of thermostructural composite material, the turbine being characterized in that it comprises a first and a second part, each made in a single monobloc part of thermostructural composite material, the first part forming a first flange and the blades, while the second part forms the second applied flange against the blades of the first part.
  • FIG. 1 illustrates in section a turbine 10 comprising two monoblock parts 20, 30 of thermostructural composite material assembled by mutual clamping on a shaft 12.
  • the material constituting the parts 20 and 30 is for example a carbon-carbon composite material (CC) or a ceramic matrix composite material such as a C-SiC composite material (carbon fiber reinforcement and silicon carbide matrix).
  • the part 20 (FIGS. 1 to 3) comprises a plurality of blades 22 which are located on an internal face 24a of an annular flange 24 in the form of a disc.
  • the blades 22 extend between the outer circumference and the inner circumference of the flange 24, substantially perpendicular thereto.
  • the heels 22 has blades 22 are connected to a central part forming a hub 26 whose inner diameter is substantially less than that of the flange 24.
  • the hub 26 also has a thickness less than the length of the blades 22, and is spaced from the flange 24, along the axis a of the turbine, so that the outer face 24b of the flange, on the one hand, and the external face 26 b of the hub with the longitudinal edges 22b of the blades 22, on the other hand, form the opposite faces of the part 20.
  • the part 30 constitutes an annular flange in the form of a disc whose external diameter is equal to that of the flange 24 and whose internal diameter is equal to that of the hub 26.
  • the part 30 is applied against the external face 26b of the hub 26 and against the longitudinal edges 22b of the blades 22.
  • the mutual tightening of the parts 20 and 30 is carried out by locking between a shoulder 12a of the shaft 12 and a ring 14, at by means of a nut 15.
  • the suction by the turbine is carried out from the space 16 which is located between the flange 24 and the hub 26, and is surrounded by the inner ring 17 of the turbine at the feet of the blades 22.
  • the ejection of the sucked fluid is carried out through the outer ring 19 of the turbine at the ends of the blades 22, after circulation through the passages 18 delimited by the blades 22 and the flanges 24 and 30.
  • thermostructural composite material means that the only clamping force at the level of the central parts of the parts 20 and 30 is sufficient to keep them assembled, including during the operation of the turbine, no detachment being observed. As already indicated, this is all the more true since the present invention applies preferably to turbines of small diameter, that is to say of external diameter not exceeding about 500 mm.
  • the surfaces of the hub 26 and of the flange 30 on which the shoulder 12a and the ring 14 are supported have a frustoconical shape, as do the corresponding faces of the shoulder 12a and of the ring 14
  • These frustoconical bearing faces have substantially coincident vertices located on the axis A of the turbine.
  • the part 20 is produced from a fibrous structure in the form of a plate 200 (phase 41).
  • a fibrous structure is manufactured by example by flat stacking of layers of two-dimensional fibrous texture, such as sheet of wires or cables, fabric, etc., and bonding of the layers between them by needling.
  • a process for manufacturing such fibrous structures is described in document FR-A-2 584 106.
  • a first preform 201 of annular shape is cut from the plate 200, the dimensions of the preform 201 being chosen as a function of those of the part 20 to be produced (phase 42).
  • the preform 201 is subjected to a first stage of densification by the matrix of the thermostructural composite material to be produced (phase 43). Densification is carried out so as to consolidate the preform, that is to say to bond together the fibers of the preform sufficiently to allow the handling and machining of the consolidated preform. Densification is carried out in a manner known per se by chemical vapor infiltration, or by liquid, that is to say impregnation with a precursor of the matrix in the liquid state and transformation of the precursor.
  • the consolidated preform is subjected to a first machining phase during which the blades are formed from one face of the preform (phase 44), then to a second machining phase during which it is hollowed out. its center from the opposite face, so as to form the suction zone while leaving the hub part (phase 45).
  • the consolidated and machined preform 202 is then subjected to one or more densification cycles until the desired degree of densification by the matrix is obtained (phase 46).
  • phase 47 The preform thus finally densified is subjected to a final machining to bring it to the precise dimensions of the part 20 (phase 47).
  • the preform of the part 20 is produced from a cylindrical fibrous structure 200 ′ produced by winding a strip of two-dimensional fibrous texture in layers superimposed on a mandrel and bonding of the layers together by needling (phase 51).
  • a process for manufacturing fibrous structures of this type is described in document FR-A-2 584 107.
  • Preforms 201 'of annular shape are cut from the cylindrical structure 200' along radial planes (phase 52).
  • Each preform 201 ′ is then treated in the same way as the preform 201 in FIG. 4.
  • the part 30 is produced from a fibrous structure in the form of a plate 300.
  • This structure is for example produced by stacking flat layers of two-dimensional fibrous texture and bonding the strata together by needling ( phase 61).
  • a preform 301 of annular shape is cut from the plate 300, the dimensions of the preform being chosen as a function of those of the part 30 to be produced (phase 62).
  • the preform 301 is densified by the matrix, the densification being carried out by chemical infiltration in the vapor phase or by the liquid route (phase 63).
  • the densified preform is subjected to final machining in order to be brought to the dimensions of the part 30 (phase 64).
  • the turbine 110 of FIG. 7 is essentially formed from two parts 120, 130 of thermostructural composite material. It differs from the turbine of FIG. 1 in that, in part 120, the blades 122 have a decreasing height between the inner ring 117 and the outer ring 119 of the turbine. This decreasing height makes it possible to compensate for the fact that the width of the passages 118 bordered by the blades 122 increases between the inner ring and the outer ring, so that the inlet and outlet sections of the passages 118 are substantially equal.
  • the flange 130 applied against the part 120 then has a disc shape in its central part 130a applied against the hub 126 and a frustoconical shape in its peripheral part applied against the blades 122.
  • the flange 130 For the production of the flange 130, it is possible to start from an annular fibrous preform in the form of a disc which is put into the desired shape by means of a tool, and consolidated by partial densification while being maintained in the tool. After consolidation, the preform can be removed from the tooling to continue densification.
  • the present invention applies more particularly to turbines having relatively small diameters.
  • the flow of the turbine can be increased or decreased, for a given diameter, by increasing or decreasing the height of the passages, that is to say the thickness of the turbine.
  • the loss of material during the machining of the blades being greater the higher their height, it is preferable for cost reasons to limit the thickness of the turbine, for example by not exceeding about 100 mm .
  • a solution for increasing the flow rate then consists in coupling two turbines 10 ', 10 "on the same axis as illustrated in FIG. 8.
  • Each turbine 10', 10" comprises two monobloc pieces of thermostructural composite material, a first piece 20 ', 20 “forming blades 22 ', 22", flange 24', 24 "and hub 26 ', 26", and a second part 30', 30 "forming flange.
  • the turbine 10 ' is similar to the turbine 10 in FIG. 1, while the turbine 10 "is distinguished by the arrangement of the blades.
  • the arrangement of the blades 22" on the part 20 is symmetrical with respect to a radial plane of the arrangement of the blades 22 'on the part 20'.
  • the blades 22 ', 22 define circulation passages oriented in the same way around the axis common to the turbines.
  • the parts 20 ', 30', 30 "and 20" are assembled by mutual tightening on a common shaft 12 'between a shoulder 12'a and a ring 14', by means of a nut 15 '.
  • the surfaces of the hubs 26 'and 26 "on which the shoulder 12' a and the ring 14 'rest have a frustoconical shape, as do the corresponding faces of the shoulder 12'a and the ring 14'.
  • An additional ring 14 "of triangular section is interposed between the flanges 30 'and 30", the surfaces of these bearing on the ring 14 "having a frustoconical shape.
  • the frustoconical bearing surfaces of the flange 30 'on the ring 14 "and of the hub 26' on the shoulder 12'a have substantially coincident vertices situated on the axis of the turbines, as do the bearing surfaces of the flange 30 "on the ring 14" and the hub 26 "on the ring 14 '. In this way, dimensional variations of thermal origin between the parts of the turbines, on the one hand, and the shaft and the clamping rings, on the other hand, can be compensated by sliding parallel to the frustoconical bearing surfaces, in the same way as with the turbine 10 in FIG. 1.

Abstract

The turbine (10) consists of a number of blades (22) disposed between two flanges (24,30), the blades and the flanges being made out of a composite material of a carbon fibre in a matrix of carbon or ceramic. The first piece (20) is made as a single mono-bloc piece from a composite material forming the first flange (24) and the blades (22). It is first consolidated in a mould and then machined. The second piece forming the second flange (30) is machined from a composite material formed in a mould and consolidated. The two parts (20,30) are then assembled with the blades (22) in contact with the second flange (30) and clamped up centrally.

Description

La présente invention concerne les turbines, et plus particulièrement celles destinées à fonctionner à des températures élevées, typiquement supérieures à 1 000°C.The present invention relates to turbines, and more particularly those intended to operate at high temperatures, typically above 1000 ° C.

Un domaine d'application de telles turbines est le brassage des gaz ou la ventilation dans des fours ou installations similaires utilisés pour réaliser des traitements physico-chimiques à températures élevées, le milieu ambiant étant par exemple constitué de gaz neutres ou inertes.One field of application of such turbines is the mixing of gases or ventilation in ovens or similar installations used to carry out physicochemical treatments at high temperatures, the ambient medium being for example made up of neutral or inert gases.

De façon habituelle, ces turbines sont en métal, généralement constituées de plusieurs éléments assemblés par soudage. L'utilisation de métal entraîne plusieurs inconvénients. Ainsi, la masse élevée des parties tournantes requiert des lignes d'arbres importantes et des moteurs très puissants et impose de toute façon une limitation de la vitesse de rotation. S'ajoute une limitation en température du fait du risque de fluage du métal.Usually, these turbines are made of metal, generally made up of several elements assembled by welding. The use of metal has several drawbacks. Thus, the high mass of the rotating parts requires large shaft lines and very powerful motors and imposes anyway a limitation of the speed of rotation. A temperature limitation is added due to the risk of metal creep.

De plus, la sensibilité du métal aux chocs thermiques peut entraîner la formation de criques ou des déformations. Il en résulte des déséquilibres de la masse tournante favorisant une diminution de la durée de vie des turbines et de leurs moteurs d'entraînement. Or, dans les applications évoquées plus haut, des chocs thermiques importants peuvent se produire, notamment en cas d'injection massive d'un gaz froid, pour faire baisser rapidement la température à l'intérieur d'un four en vue de réduire la durée de cycles de traitement.In addition, the sensitivity of the metal to thermal shock can cause cracks or deformation. This results in imbalances in the rotating mass favoring a reduction in the service life of the turbines and their drive motors. However, in the applications mentioned above, significant thermal shocks can occur, in particular in the event of massive injection of a cold gas, to cause the temperature to drop rapidly inside an oven in order to reduce the duration treatment cycles.

Afin d'éviter les problèmes rencontrés avec les métaux, d'autres matériaux ont déjà été proposés pour réaliser des turbines, en particulier des matériaux composites thermostructuraux. Ces matériaux sont généralement constitués d'une texture de renfort fibreux, ou préforme, densifiée par une matrice et sont caractérisés par leurs propriétés mécaniques qui les rendent aptes à constituer des éléments structuraux et par leur capacité à conserver ces propriétés jusqu'à des températures élevées. Des exemples usuels de matériaux composites thermostructuraux sont les composites carbone-carbone (C-C) constitués d'un renfort en fibres de carbone et d'une matrice en carbone, et les composites à matrice céramique (CMC) constitués d'un renfort en fibres de carbone ou céramique et d'une matrice céramique.In order to avoid the problems encountered with metals, other materials have already been proposed for making turbines, in particular thermostructural composite materials. These materials generally consist of a fibrous reinforcement texture, or preform, densified by a matrix and are characterized by their mechanical properties which make them suitable for constituting structural elements and by their capacity to maintain these properties up to high temperatures. . Common examples of thermostructural composite materials are carbon-carbon composites (CC) made of carbon fiber reinforcement and a carbon matrix, and ceramic matrix composites (CMC) made of carbon fiber reinforcement carbon or ceramic and a ceramic matrix.

Par rapport aux métaux, les matériaux composites thermostructuraux présentent les avantages essentiels d'une densité bien inférieure et d'une grande stabilité aux températures élevées. La diminution de masse et la suppression du risque de fluage peuvent autoriser des vitesses de rotation élevées et, par là même, de très forts débits de ventilation sans demander un surdimensionnement des organes d'entraînement. En outre, les matériaux composites thermostructuraux présentent une très grande résistance aux chocs thermiques.Compared to metals, thermostructural composite materials have the essential advantages of a much lower density and great stability at high temperatures. The reduction in mass and the elimination of risk of creep can allow high speeds of rotation and, by the same token, very high ventilation rates without requiring oversizing of the drive members. In addition, thermostructural composite materials have a very high resistance to thermal shock.

Les matériaux composites thermostructuraux présentent donc des avantages importants au plan des performances, mais leur emploi est limité en raison de leur coût assez élevé. Outre les matières utilisées, le coût provient essentiellement des difficultés rencontrées pour réaliser des préformes fibreuses, notamment lorsque les pièces à fabriquer ont des formes complexes, ce qui est le cas des turbines, et de la durée des cycles de densification.Thermostructural composite materials therefore have significant performance advantages, but their use is limited due to their fairly high cost. In addition to the materials used, the cost comes essentially from the difficulties encountered in producing fibrous preforms, in particular when the parts to be manufactured have complex shapes, which is the case with turbines, and by the duration of the densification cycles.

Aussi, un but de la présente invention est de proposer une architecture de turbine particulièrement adaptée à sa réalisation en matériau composite thermostructural afin de bénéficier des avantages de ce matériau mais avec un coût de fabrication aussi réduit que possible.Also, an object of the present invention is to provide a turbine architecture particularly suited to its production in thermostructural composite material in order to benefit from the advantages of this material but with a manufacturing cost as reduced as possible.

Selon un de ses aspects, la présente invention a pour objet un procédé de fabrication d'une turbine comprenant une pluralité de pales disposées entre deux flasques annulaires et délimitant des passages de circulation entre une couronne intérieure et une couronne extérieure, les pales et les flasques étant en matériau composite thermostructural, procédé selon lequel :

  • (a) on réalise une première pièce en une seule partie monobloc en matériau composite thermostructural formant un premier flasque et les pales en mettant en oeuvre les étapes consistant à :
    • fabriquer une première préforme fibreuse sous forme de plaque ayant des dimensions externes choisies en fonction de celles de la première pièce à réaliser,
    • densifier la première préforme fibreuse par une matrice de façon au moins partielle, de sorte que la préforme soit au moins consolidée, et
    • usiner la première préforme fibreuse au moins partiellement densifiée pour lui donner la forme de la première pièce ;
  • (b) on réalise une deuxième pièce formant le deuxième flasque en une seule partie monobloc en matériau composite thermostructural par fabrication d'une deuxième préforme fibreuse, densification de celle-ci par une matrice, et usinage pour former le deuxième flasque, et
  • (c) on assemble la turbine en appliquant la deuxième pièce contre les pales de la première pièce.
According to one of its aspects, the present invention relates to a process for manufacturing a turbine comprising a plurality of blades arranged between two annular flanges and delimiting circulation passages between an inner ring and an outer ring, the blades and side plates being of thermostructural composite material, process according to which:
  • (a) a first part is produced in a single monobloc part made of thermostructural composite material forming a first flange and the blades by implementing the steps consisting in:
    • manufacture a first fibrous preform in the form of a plate having external dimensions chosen as a function of those of the first part to be produced,
    • densifying the first fibrous preform with a matrix at least partially, so that the preform is at least consolidated, and
    • machining the first at least partially densified fiber preform to give it the shape of the first part;
  • (b) a second part is formed forming the second flange in a single monobloc part made of thermostructural composite material by manufacturing a second fibrous preform, densification of the latter by a matrix, and machining to form the second flange, and
  • (c) the turbine is assembled by applying the second part against the blades of the first part.

Ainsi, la turbine est pour sa partie essentielle formée de seulement deux pièces, ce qui simplifie l'assemblage, et chaque pièce est réalisée à partir d'une préforme fibreuse ayant une forme simple. Il en est ainsi pour la deuxième pièce, puisqu'elle forme simplement un flasque, de sorte que la deuxième préforme fibreuse peut être constituée par une plaque. Quant à la première pièce, elle est réalisée par usinage à partir d'une première préforme constituée par une plaque. De préférence, la première préforme fibreuse est usinée à l'état consolidé, partiellement densifié, et la densification par la matrice est poursuivie après usinage.Thus, the turbine is for its essential part formed of only two parts, which simplifies assembly, and each part is produced from a fibrous preform having a simple shape. This is so for the second part, since it simply forms a flange, so that the second fibrous preform can be constituted by a plate. As for the first part, it is produced by machining from a first preform constituted by a plate. Preferably, the first fibrous preform is machined in the consolidated state, partially densified, and the densification by the matrix is continued after machining.

L'usinage de la première pièce entraîne des pertes substantielles de matière, de sorte que la présente invention convient plus particulièrement, bien que non exclusivement, pour des turbines de petit diamètre. Par turbine de petit diamètre, on entend ici une turbine dont le diamètre de la couronne extérieure ne dépasse pas environ 500 mm.The machining of the first part leads to substantial losses of material, so that the present invention is more particularly, although not exclusively, suitable for small diameter turbines. By small diameter turbine here is meant a turbine whose diameter of the outer ring does not exceed about 500 mm.

Selon une autre particularité avantageuse du procédé conforme à l'invention, la turbine est assemblée uniquement par serrage mutuel de la première pièce et de la deuxième pièce au niveau de leurs parties centrales. Il a été constaté que ce seul serrage assure l'assemblage de la turbine dans toutes configurations de fonctionnement, grâce à la rigidité du matériau composite. Ceci est d'autant plus vrai que le diamètre de la turbine est plus petit. Il n'est donc pas nécessaire de faire appel à des éléments de serrage du type vis pénétrant dans les deux pièces. Il s'agit d'un avantage important car, sinon, la visserie utilisée aurait dû être en matériau composite, pour tenir aux températures élevées et avoir un coefficient de dilatation thermique compatible avec celui des pièces assemblées, ce qui aurait alourdi le coût de façon significative.According to another advantageous feature of the method according to the invention, the turbine is assembled only by mutual tightening of the first part and the second part at their central parts. It has been found that this single tightening ensures the assembly of the turbine in all operating configurations, thanks to the rigidity of the composite material. This is all the more true as the diameter of the turbine is smaller. It is therefore not necessary to use clamping elements of the screw type entering the two parts. This is an important advantage because, otherwise, the hardware used should have been made of composite material, to withstand high temperatures and have a coefficient of thermal expansion compatible with that of the assembled parts, which would have increased the cost so significant.

Les préformes fibreuses sont réalisées en utilisant des techniques connues en soi. Ainsi, la première préforme fibreuse, de même que la deuxième, peut être réalisée à partir d'un empilement à plat de strates d'une texture fibreuse bidimensionnelle et liaison des strates entre elles par aiguilletage.The fiber preforms are produced using techniques known per se. Thus, the first fibrous preform, as well as the second, can be produced from a flat stack of strata of a two-dimensional fibrous texture and bonding of the strata together by needling.

En variante, et du fait qu'elle doit avoir une épaisseur assez grande, la première préforme fibreuse peut être réalisée à partir d'un enroulement d'une bande de texture fibreuse bidimensionnelle en couches superposées et liaison des couches entre elles par aiguilletage.Alternatively, and because it must have a fairly large thickness, the first fibrous preform can be produced from a winding of a strip of two-dimensional fibrous texture in superimposed layers and bonding of the layers to each other by needling.

Selon un autre de ses aspects, l'invention a pour objet une turbine comprenant une pluralité de pales disposées entre deux flasques et délimitant des passages de circulation entre une couronne intérieure et une couronne extérieure, les pales et les flasques étant en matériau composite thermostructural, la turbine étant caractérisée en ce qu'elle comporte une première et une deuxième pièce, chacune réalisée en une seule partie monobloc en matériau composite thermostructural, la première pièce formant un premier flasque et les pales, tandis que la deuxième pièce forme le deuxième flasque appliqué contre les pales de la première pièce.According to another of its aspects, the invention relates to a turbine comprising a plurality of blades arranged between two flanges and delimiting circulation passages between an inner ring and an outer ring, the blades and flanges being of thermostructural composite material, the turbine being characterized in that it comprises a first and a second part, each made in a single monobloc part of thermostructural composite material, the first part forming a first flange and the blades, while the second part forms the second applied flange against the blades of the first part.

Avantageusement, elles sont assemblées uniquement par serrage mutuel au niveau de leurs parties centrales.Advantageously, they are assembled only by mutual tightening at their central parts.

D'autres particularités et avantages de l'invention ressortiront à la lecture de la description faite ci-après, à titre indicatif mais non limitatif, en référence aux dessins annexés, sur lesquels :

  • la figure 1 est une vue en coupe montrant une turbine conforme à l'invention montée sur un arbre ;
  • la figure 2 est une vue en perspective montrant une première pièce constitutive de la turbine de la figure 1 ;
  • la figure 3 est une vue en coupe partielle selon les plans III-III de la figure 2 ;
  • la figure 4 montre des étapes successives d'élaboration d'une première pièce constitutive de la turbine de la figure 1 ;
  • la figure 5 montre des étapes successives relatives à une variante de fabrication de préforme pour l'élaboration d'une première pièce constitutive de la turbine de la figure 1 ;
  • la figure 6 montre des étapes successives d'élaboration d'une deuxième pièce constitutive de la turbine de la figure 1 ;
  • la figure 7 est une vue en coupe montrant une variante de réalisation d'une turbine selon l'invention ; et
  • la figure 8 est une vue en coupe montrant une autre variante de réalisation d'une turbine selon l'invention.
Other features and advantages of the invention will emerge on reading the description given below, by way of indication but not limitation, with reference to the appended drawings, in which:
  • Figure 1 is a sectional view showing a turbine according to the invention mounted on a shaft;
  • Figure 2 is a perspective view showing a first component of the turbine of Figure 1;
  • Figure 3 is a partial sectional view along planes III-III of Figure 2;
  • Figure 4 shows successive stages in the development of a first component part of the turbine of Figure 1;
  • Figure 5 shows successive steps relating to a variant preform manufacturing for the development of a first component of the turbine of Figure 1;
  • Figure 6 shows successive stages in the development of a second component part of the turbine of Figure 1;
  • Figure 7 is a sectional view showing an alternative embodiment of a turbine according to the invention; and
  • Figure 8 is a sectional view showing another alternative embodiment of a turbine according to the invention.

La figure 1 illustre en coupe une turbine 10 comprenant deux pièces monoblocs 20, 30 en matériau composite thermostructural assemblées par serrage mutuel sur un arbre 12. Le matériau constitutif des pièces 20 et 30 est par exemple un matériau composite carbone-carbone (C-C) ou un matériau composite à matrice céramique tel qu'un matériau composite C-SiC (renfort en fibres de carbone et matrice en carbure de silicium).FIG. 1 illustrates in section a turbine 10 comprising two monoblock parts 20, 30 of thermostructural composite material assembled by mutual clamping on a shaft 12. The material constituting the parts 20 and 30 is for example a carbon-carbon composite material (CC) or a ceramic matrix composite material such as a C-SiC composite material (carbon fiber reinforcement and silicon carbide matrix).

La pièce 20 (figures 1 à 3) comprend une pluralité de pales 22 qui sont situées sur une face interne 24a d'un flasque annulaire 24 en forme de disque. Les pales 22 s'étendent entre la circonférence extérieure et la circonférence intérieure du flasque 24, sensiblement perpendiculairement à celui-ci. Les talons 22a des pales 22 se raccordent à une partie centrale formant moyeu 26 dont le diamètre intérieur est sensiblement inférieur à celui du flasque 24. Le moyeu 26 a en outre une épaisseur inférieure à la longueur des pales 22, et est espacé du flasque 24, le long de l'axe A de la turbine, de sorte que la face externe 24b du flasque, d'une part, et la face externe 26b du moyeu avec les bords longitudinaux 22b des pales 22, d'autre part, forment les faces opposées de la pièce 20.The part 20 (FIGS. 1 to 3) comprises a plurality of blades 22 which are located on an internal face 24a of an annular flange 24 in the form of a disc. The blades 22 extend between the outer circumference and the inner circumference of the flange 24, substantially perpendicular thereto. The heels 22 has blades 22 are connected to a central part forming a hub 26 whose inner diameter is substantially less than that of the flange 24. The hub 26 also has a thickness less than the length of the blades 22, and is spaced from the flange 24, along the axis a of the turbine, so that the outer face 24b of the flange, on the one hand, and the external face 26 b of the hub with the longitudinal edges 22b of the blades 22, on the other hand, form the opposite faces of the part 20.

La pièce 30 constitue un flasque annulaire en forme de disque dont le diamètre extérieur est égal à celui du flasque 24 et dont le diamètre intérieur est égal à celui du moyeu 26.The part 30 constitutes an annular flange in the form of a disc whose external diameter is equal to that of the flange 24 and whose internal diameter is equal to that of the hub 26.

La pièce 30 est appliquée contre la face externe 26b du moyeu 26 et contre les bords longitudinaux 22b des pales 22. Le serrage mutuel des pièces 20 et 30 est réalisé par blocage entre un épaulement 12a de l'arbre 12 et une bague 14, au moyen d'un écrou 15.The part 30 is applied against the external face 26b of the hub 26 and against the longitudinal edges 22b of the blades 22. The mutual tightening of the parts 20 and 30 is carried out by locking between a shoulder 12a of the shaft 12 and a ring 14, at by means of a nut 15.

L'aspiration par la turbine est réalisée à partir de l'espace 16 qui est situé entre le flasque 24 et le moyeu 26, et est entouré par la couronne intérieure 17 de la turbine au niveau des pieds des pales 22. L'éjection du fluide aspiré s'effectue à travers la couronne extérieure 19 de la turbine au niveau des extrémités de pales 22, après circulation à travers les passages 18 délimités par les pales 22 et les flasques 24 et 30.The suction by the turbine is carried out from the space 16 which is located between the flange 24 and the hub 26, and is surrounded by the inner ring 17 of the turbine at the feet of the blades 22. The ejection of the sucked fluid is carried out through the outer ring 19 of the turbine at the ends of the blades 22, after circulation through the passages 18 delimited by the blades 22 and the flanges 24 and 30.

La rigidité du matériau composite thermostructural fait que le seul effort de serrage au niveau des parties centrales des pièces 20 et 30 suffit à les maintenir assemblées, y compris pendant le fonctionnement de la turbine, aucun décollement n'étant observé. Comme déjà indiqué, ceci est d'autant plus vrai que la présente invention s'applique de façon préférentielle à des turbines de petit diamètre, c'est-à-dire de diamètre extérieur ne dépassant pas environ 500 mm.The rigidity of the thermostructural composite material means that the only clamping force at the level of the central parts of the parts 20 and 30 is sufficient to keep them assembled, including during the operation of the turbine, no detachment being observed. As already indicated, this is all the more true since the present invention applies preferably to turbines of small diameter, that is to say of external diameter not exceeding about 500 mm.

Comme montré sur la figure 1, les surfaces du moyeu 26 et du flasque 30 sur lesquelles s'appuient l'épaulement 12a et la bague 14 ont une forme tronconique, de même que les faces correspondantes de l'épaulement 12a et de la bague 14. Ces faces d'appui tronconiques ont des sommets sensiblement confondus situés sur l'axe A de la turbine. De la sorte, des différences de dilatation d'origine thermique entre, d'une part, les pièces 20 et 30 et, d'autre part, l'arbre 12 et la bague 14, se traduiront par un glissement, sans effet destructif.As shown in FIG. 1, the surfaces of the hub 26 and of the flange 30 on which the shoulder 12a and the ring 14 are supported have a frustoconical shape, as do the corresponding faces of the shoulder 12a and of the ring 14 These frustoconical bearing faces have substantially coincident vertices located on the axis A of the turbine. In this way, thermal expansion differences between, on the one hand, the parts 20 and 30 and, on the other hand, the shaft 12 and the ring 14, will result in a slip, without destructive effect.

Des étapes successives d'un processus de fabrication de la pièce 20 sont montrées sur la figure 4. La pièce 20 est réalisée à partir d'une structure fibreuse en forme de plaque 200 (phase 41). Une telle structure est fabriquée par exemple par empilement à plat de strates de texture fibreuse bidimensionnelle, telle que nappe de fils ou de câbles, tissu,..., et liaison des strates entre elles par aiguilletage. Un procédé de fabrication de structures fibreuses de ce type est décrit dans le document FR-A-2 584 106.Successive steps in a process for manufacturing the part 20 are shown in FIG. 4. The part 20 is produced from a fibrous structure in the form of a plate 200 (phase 41). Such a structure is manufactured by example by flat stacking of layers of two-dimensional fibrous texture, such as sheet of wires or cables, fabric, etc., and bonding of the layers between them by needling. A process for manufacturing such fibrous structures is described in document FR-A-2 584 106.

Une première préforme 201 de forme annulaire est découpée dans la plaque 200, les dimensions de la préforme 201 étant choisies en fonction de celles de la pièce 20 à réaliser (phase 42).A first preform 201 of annular shape is cut from the plate 200, the dimensions of the preform 201 being chosen as a function of those of the part 20 to be produced (phase 42).

La préforme 201 est soumise à une première étape de densification par la matrice du matériau composite thermostructural à réaliser (phase 43). La densification est réalisée de manière à consolider la préforme, c'est-à-dire à lier entre elles les fibres de la préforme de façon suffisante pour permettre la manipulation et l'usinage de la préforme consolidée. La densification est réalisée de façon connue en soi par infiltration chimique en phase vapeur, ou par voie liquide, c'est-à-dire imprégnation par un précurseur de la matrice à l'état liquide et transformation du précurseur.The preform 201 is subjected to a first stage of densification by the matrix of the thermostructural composite material to be produced (phase 43). Densification is carried out so as to consolidate the preform, that is to say to bond together the fibers of the preform sufficiently to allow the handling and machining of the consolidated preform. Densification is carried out in a manner known per se by chemical vapor infiltration, or by liquid, that is to say impregnation with a precursor of the matrix in the liquid state and transformation of the precursor.

La préforme consolidée est soumise à une première phase d'usinage au cours de laquelle les pales sont formées à partir d'une face de la préforme (phase 44), puis à une deuxième phase d'usinage au cours de laquelle elle est évidée en son centre à partir de la face opposée, de manière à former la zone d'aspiration en laissant subsister la partie de moyeu (phase 45).The consolidated preform is subjected to a first machining phase during which the blades are formed from one face of the preform (phase 44), then to a second machining phase during which it is hollowed out. its center from the opposite face, so as to form the suction zone while leaving the hub part (phase 45).

La préforme consolidée et usinée 202 est ensuite soumise à un ou plusieurs cycles de densification jusqu'à obtenir le degré souhaité de densification par la matrice (phase 46).The consolidated and machined preform 202 is then subjected to one or more densification cycles until the desired degree of densification by the matrix is obtained (phase 46).

La préforme ainsi finalement densifiée est soumise à un usinage final pour l'amener aux cotes précises de la pièce 20 (phase 47).The preform thus finally densified is subjected to a final machining to bring it to the precise dimensions of the part 20 (phase 47).

On a envisagé ci-avant l'usinage de la préforme après consolidation et avant densification complète, ce qui favorise la densification finale puisque celle-ci est plus difficile à réaliser de façon homogène dans des structures fibreuses épaisses. Il n'est toutefois pas exclu de réaliser l'usinage de la préforme après densification complète.We considered above the machining of the preform after consolidation and before complete densification, which promotes the final densification since it is more difficult to achieve homogeneously in thick fibrous structures. It is not however excluded to carry out the machining of the preform after complete densification.

Suivant une autre variante (figure 5), la préforme de la pièce 20 est réalisée à partir d'une structure fibreuse cylindrique 200' fabriquée par bobinage d'une bande de texture fibreuse bidimensionnelle en couches superposées sur un mandrin et liaison des couches entre elles par aiguilletage (phase 51). Un procédé de fabrication de structures fibreuses de ce type est décrit dans le document FR-A-2 584 107.According to another variant (FIG. 5), the preform of the part 20 is produced from a cylindrical fibrous structure 200 ′ produced by winding a strip of two-dimensional fibrous texture in layers superimposed on a mandrel and bonding of the layers together by needling (phase 51). A process for manufacturing fibrous structures of this type is described in document FR-A-2 584 107.

Des préformes 201' de forme annulaire sont découpées dans la structure cylindrique 200' suivant des plans radiaux (phase 52).Preforms 201 'of annular shape are cut from the cylindrical structure 200' along radial planes (phase 52).

Chaque préforme 201' est ensuite traitée de la même façon que la préforme 201 de la figure 4.Each preform 201 ′ is then treated in the same way as the preform 201 in FIG. 4.

Comme montré par la figure 6, la pièce 30 est réalisée à partir d'une structure fibreuse en forme de plaque 300. Cette structure est par exemple fabriquée par empilement à plat de strates de texture fibreuse bidimensionnelle et liaison des strates entre elles par aiguilletage (phase 61).As shown in FIG. 6, the part 30 is produced from a fibrous structure in the form of a plate 300. This structure is for example produced by stacking flat layers of two-dimensional fibrous texture and bonding the strata together by needling ( phase 61).

Une préforme 301 de forme annulaire est découpée dans la plaque 300, les dimensions de la préforme étant choisies en fonction de celles de la pièce 30 à réaliser (phase 62).A preform 301 of annular shape is cut from the plate 300, the dimensions of the preform being chosen as a function of those of the part 30 to be produced (phase 62).

La préforme 301 est densifiée par la matrice, la densification étant réalisée par infiltration chimique en phase vapeur ou par voie liquide (phase 63).The preform 301 is densified by the matrix, the densification being carried out by chemical infiltration in the vapor phase or by the liquid route (phase 63).

La préforme densifiée est soumise à un usinage final afin d'être amenée aux cotes de la pièce 30 (phase 64).The densified preform is subjected to final machining in order to be brought to the dimensions of the part 30 (phase 64).

D'autres formes de réalisation d'une turbine utilisant deux pièces monoblocs en matériau composite thermostructural définissant deux flasques des pales et un moyeu pourront être adoptées.Other embodiments of a turbine using two monobloc pieces of thermostructural composite material defining two flanges of the blades and a hub may be adopted.

La turbine 110 de la figure 7 est formée essentiellement de deux pièces 120, 130 en matériau composite thermostructural. Elle se distingue de la turbine de la figure 1 en ce que, dans la pièce 120, les pales 122 ont une hauteur décroissante entre la couronne intérieure 117 et la couronne extérieure 119 de la turbine. Cette hauteur décroissante permet de compenser le fait que la largeur des passages 118 bordés par les pales 122 croît entre la couronne intérieure et la couronne extérieure, de manière que les sections d'entrée et de sortie des passages 118 soient sensiblement égales.The turbine 110 of FIG. 7 is essentially formed from two parts 120, 130 of thermostructural composite material. It differs from the turbine of FIG. 1 in that, in part 120, the blades 122 have a decreasing height between the inner ring 117 and the outer ring 119 of the turbine. This decreasing height makes it possible to compensate for the fact that the width of the passages 118 bordered by the blades 122 increases between the inner ring and the outer ring, so that the inlet and outlet sections of the passages 118 are substantially equal.

Le flasque 130 appliqué contre la pièce 120 présente alors une forme de disque dans sa partie centrale 130a appliquée contre le moyeu 126 et une forme tronconique dans sa partie périphérique appliquée contre les pales 122.The flange 130 applied against the part 120 then has a disc shape in its central part 130a applied against the hub 126 and a frustoconical shape in its peripheral part applied against the blades 122.

Pour la réalisation du flasque 130, on peut partir d'une préforme fibreuse annulaire en forme de disque qui est mise dans la forme voulue au moyen d'un outillage, et consolidée par densification partielle en étant maintenue dans l'outillage. Après consolidation, la préforme peut être retirée de l'outillage afin de poursuivre la densification.For the production of the flange 130, it is possible to start from an annular fibrous preform in the form of a disc which is put into the desired shape by means of a tool, and consolidated by partial densification while being maintained in the tool. After consolidation, the preform can be removed from the tooling to continue densification.

Comme déjà indiqué, la présente invention s'applique plus particulièrement aux turbines ayant des diamètres relativement petits. Le débit de la turbine peut être augmenté ou diminué, pour un diamètre donné, en augmentant ou diminuant la hauteur des passages, c'est-à-dire l'épaisseur de la turbine. La perte de matière lors de l'usinage des pales étant d'autant plus grande que leur hauteur est plus élevée, il est préférable pour des raisons de coût de limiter l'épaisseur de la turbine, par exemple en ne dépassant pas environ 100 mm.As already indicated, the present invention applies more particularly to turbines having relatively small diameters. The flow of the turbine can be increased or decreased, for a given diameter, by increasing or decreasing the height of the passages, that is to say the thickness of the turbine. The loss of material during the machining of the blades being greater the higher their height, it is preferable for cost reasons to limit the thickness of the turbine, for example by not exceeding about 100 mm .

Une solution pour augmenter le débit consiste alors à accoupler deux turbines 10', 10" sur un même axe comme illustré par la figure 8. Chaque turbine 10', 10" comprend deux pièces monoblocs en matériau composite thermostructural, une première pièce 20', 20" formant pales 22', 22", flasque 24', 24" et moyeu 26', 26", et une deuxième pièce 30', 30" formant flasque.A solution for increasing the flow rate then consists in coupling two turbines 10 ', 10 "on the same axis as illustrated in FIG. 8. Each turbine 10', 10" comprises two monobloc pieces of thermostructural composite material, a first piece 20 ', 20 "forming blades 22 ', 22", flange 24', 24 "and hub 26 ', 26", and a second part 30', 30 "forming flange.

La turbine 10' est semblable à la turbine 10 de la figure 1, tandis que la turbine 10" s'en distingue par la disposition des pales. En effet, la disposition des pales 22" sur la pièce 20" est symétrique par rapport à un plan radial de la disposition des pales 22' sur la pièce 20'. De la sorte, lorsque les turbines 10', 10" sont accolées par contact mutuel entre les faces externes des flasques 24', 24", les pales 22', 22" définissent des passages de circulation orientés de la même façon autour de l'axe commun aux turbines.The turbine 10 'is similar to the turbine 10 in FIG. 1, while the turbine 10 "is distinguished by the arrangement of the blades. In fact, the arrangement of the blades 22" on the part 20 "is symmetrical with respect to a radial plane of the arrangement of the blades 22 'on the part 20'. In this way, when the turbines 10 ', 10 "are joined by mutual contact between the external faces of the flanges 24', 24", the blades 22 ', 22 "define circulation passages oriented in the same way around the axis common to the turbines.

Les pièces 20', 30', 30" et 20" sont assemblées par serrage mutuel sur un arbre commun 12' entre un épaulement 12'a et une bague 14', au moyen d'un écrou 15'. Les surfaces des moyeux 26' et 26" sur lesquelles s'appuient l'épaulement 12'a et la bague 14' ont une forme tronconique, de même que les faces correspondantes de l'épaulement 12'a et de la bague 14'. Une bague supplémentaire 14" à section triangulaire est interposée entre les flasques 30' et 30", les surfaces de ceux-ci s'appuyant sur la bague 14" ayant une forme tronconique. Les surfaces d'appui tronconiques du flasque 30' sur la bague 14" et du moyeu 26' sur l'épaulement 12'a ont des sommets sensiblement confondus situés sur l'axe des turbines, de même que les surfaces d'appui du flasque 30" sur la bague 14" et du moyeu 26" sur la bague 14'. De la sorte, des variations dimensionnelles d'origine thermique entre les pièces des turbines, d'une part, et l'arbre et les bagues de serrage, d'autre part, peuvent être compensées par glissement parallèlement aux surfaces d'appui tronconiques, de la même façon qu'avec la turbine 10 de la figure 1.The parts 20 ', 30', 30 "and 20" are assembled by mutual tightening on a common shaft 12 'between a shoulder 12'a and a ring 14', by means of a nut 15 '. The surfaces of the hubs 26 'and 26 "on which the shoulder 12' a and the ring 14 'rest have a frustoconical shape, as do the corresponding faces of the shoulder 12'a and the ring 14'. An additional ring 14 "of triangular section is interposed between the flanges 30 'and 30", the surfaces of these bearing on the ring 14 "having a frustoconical shape. The frustoconical bearing surfaces of the flange 30 'on the ring 14 "and of the hub 26' on the shoulder 12'a have substantially coincident vertices situated on the axis of the turbines, as do the bearing surfaces of the flange 30 "on the ring 14" and the hub 26 "on the ring 14 '. In this way, dimensional variations of thermal origin between the parts of the turbines, on the one hand, and the shaft and the clamping rings, on the other hand, can be compensated by sliding parallel to the frustoconical bearing surfaces, in the same way as with the turbine 10 in FIG. 1.

Claims (16)

Procédé de fabrication d'une turbine comprenant une pluralité de pales disposées entre deux flasques, les pales et les flasques étant en matériau composite thermostructural, caractérisé en ce que : (a) on réalise une première pièce en une seule partie monobloc en matériau composite thermostructural formant un premier flasque et les pales en mettant en oeuvre les étapes consistant à : - fabriquer une première préforme fibreuse sous forme de plaque ayant des dimensions extemes choisies en fonction de celles de la première pièce à réaliser, - densifier la première préforme fibreuse par une matrice de façon au moins partielle, de sorte que la préforme soit au moins consolidée, et - usiner la première préforme fibreuse au moins partiellement densifiée pour lui donner la forme de la première pièce ; (b) on réalise une deuxième pièce formant le deuxième flasque en une seule partie monobloc en matériau composite thermostructural par fabrication d'une deuxième préforme fibreuse, densification de celle-ci par une matrice, et usinage pour former le deuxième flasque, et (c) on assemble la turbine en appliquant la deuxième pièce contre les pales de la première pièce. Method of manufacturing a turbine comprising a plurality of blades arranged between two flanges, the blades and the flanges being of thermostructural composite material, characterized in that: (a) a first part is produced in a single monobloc part made of thermostructural composite material forming a first flange and the blades by implementing the steps consisting in: manufacturing a first fibrous preform in the form of a plate having external dimensions chosen as a function of those of the first part to be produced, densifying the first fibrous preform with a matrix at least partially, so that the preform is at least consolidated, and - Machining the first fibrous preform at least partially densified to give it the shape of the first part; (b) a second part is formed forming the second flange in a single monobloc part made of thermostructural composite material by manufacturing a second fibrous preform, densification of the latter by a matrix, and machining to form the second flange, and (c) the turbine is assembled by applying the second part against the blades of the first part. Procédé selon la revendication 1, caractérisé en ce que la première préforme fibreuse est usinée à l'état consolidé, partiellement densifié, et la densification par la matrice est poursuivie après usinage.Method according to claim 1, characterized in that the first fibrous preform is machined in the consolidated state, partially densified, and the densification by the matrix is continued after machining. Procédé selon l'une quelconque des revendications 1 et 2, caractérisé en ce que l'usinage de la première préforme fibreuse en forme de plaque au moins partiellement densifiée comprend la réalisation des pales par usinage à partir d'une face de la plaque, et la réalisation d'une zone d'aspiration par évidage d'une partie centrale de la plaque, à partir de la face opposée, en laissant subsister un moyeu central.Process according to any one of Claims 1 and 2, characterized in that the machining of the first at least partially densified plate-shaped fibrous preform comprises producing the blades by machining from one face of the plate, and the creation of a suction zone by hollowing out a central part of the plate, from the opposite face, leaving a central hub. Procédé selon l'une quelconque des revendications 1 à 3, caractérisé en ce que la première préforme fibreuse est réalisée à partir d'un empilement à plat de strates d'une texture fibreuse bidimensionnelle et liaison des strates entre elles par aiguilletage.Method according to any one of Claims 1 to 3, characterized in that the first fibrous preform is produced from a flat stack of strata of a two-dimensional fibrous texture and bonding of the strata to each other by needling. Procédé selon l'une quelconque des revendications 1 à 3, caractérisé en ce que la première préforme fibreuse est réalisée à partir d'un enroulement d'une bande de texture fibreuse bidimensionnelle en couches superposées et liaison des couches entre elles par aiguilletage.Method according to any one of Claims 1 to 3, characterized in that the first fibrous preform is produced from a winding of a two-dimensional fibrous texture strip in superimposed layers and bonding of the layers together by needling. Procédé selon l'une quelconque des revendications 1 à 5, caractérisé en ce que la deuxième préforme fibreuse est réalisée à partir d'un empilement à plat de strates d'une texture fibreuse bidimensionnelle et liaison des strates entre elles par aiguilletage.Method according to any one of Claims 1 to 5, characterized in that the second fibrous preform is produced from a flat stack of strata of a two-dimensional fibrous texture and bonding of the strata to each other by needling. Procédé selon l'une quelconque des revendications 1 à 6, caractérisé en ce que la turbine est assemblée uniquement par serrage mutuel de la première pièce et de la deuxième pièce au niveau de leurs parties centrales.Method according to any one of claims 1 to 6, characterized in that the turbine is assembled only by mutual clamping of the first part and the second part at their central parts. Turbine comprenant une pluralité de pales (22) disposées entre deux flasques (24,30) et délimitant des passages de circulation entre une couronne intérieure (17) et une couronne extérieure (19), les pales et les flasques étant en matériau composite thermostructural,
caractérisée en ce qu'elle comporte une première et une deuxième pièce, chacune réalisée en une seule partie monobloc en matériau composite thermostructural, la première pièce (20) formant un premier flasque (24) et les pales (22), tandis que la deuxième pièce forme le deuxième flasque (30) appliqué contre les pales (22) de la première pièce.Turbine comprising a plurality of blades (22) disposed between two flanges (24.30) and delimiting circulation passages between an inner ring (17) and an outer ring (19), the blades and flanges being of thermostructural composite material,
characterized in that it comprises a first and a second part, each made in a single monobloc part of thermostructural composite material, the first part (20) forming a first flange (24) and the blades (22), while the second piece forms the second flange (30) applied against the blades (22) of the first piece. Turbine selon la revendication 8, caractérisée en ce que la première pièce (20) et la deuxième pièce (30) sont assemblées uniquement par serrage mutuel au niveau de leurs parties centrales.Turbine according to claim 8, characterized in that the first part (20) and the second part (30) are assembled only by mutual clamping at their central parts. Turbine selon l'une quelconque des revendications 8 et 9, caractérisée en ce que, dans la première pièce, les pales (22) s'étendent entre la circonférence extérieure et la circonférence intérieure et d'un côté d'une partie annulaire en forme de disque formant le premier flasque (24), et sont raccordées au niveau de leurs pieds à une partie centrale formant moyeu (26).Turbine according to any one of claims 8 and 9, characterized in that, in the first part, the blades (22) extend between the outer circumference and the inner circumference and on one side of a shaped annular part disc forming the first flange (24), and are connected at their feet to a central portion forming a hub (26). Turbine selon la revendication 10, caractérisée en ce que la partie centrale formant moyeu (26) a une épaisseur inférieure à la largeur des pales (22).Turbine according to claim 10, characterized in that the central hub part (26) has a thickness less than the width of the blades (22). Turbine selon l'une quelconque des revendications 10 et 11, caractérisée en ce que, dans la première pièce, la partie formant flasque annulaire (24) et la partie formant moyeu (26) sont sur deux faces opposées de la pièce.Turbine according to any one of claims 10 and 11, characterized in that, in the first part, the annular flange part (24) and the hub part (26) are on two opposite faces of the part. Turbine selon l'une quelconque des revendications 10 à 12, caractérisée en ce que, dans la première pièce, la partie centrale formant moyeu (26) a un diamètre intérieur inférieur à celui de la partie annulaire formant flasque (24).Turbine according to any one of Claims 10 to 12, characterized in that, in the first part, the central part forming the hub (26) has an internal diameter smaller than that of the annular part forming the flange (24). Turbine selon l'une quelconque des revendications 8 à 13, caractérisée en ce que la première et la deuxième pièce (20, 30) sont assemblées par serrage mutuel exercé contre des surfaces d'appui appartenant respectivement à la première et à la deuxième pièce, au niveau de leurs parties centrales, lesdites surfaces d'appui ayant une forme tronconique avec des sommets sensiblement confondus et situés sur l'axe de la turbine.Turbine according to any one of Claims 8 to 13, characterized in that the first and the second part (20, 30) are assembled by mutual clamping exerted against bearing surfaces belonging respectively to the first and to the second part, at their central parts, said bearing surfaces having a frustoconical shape with vertices substantially coincident and located on the axis of the turbine . Turbine selon l'une quelconque des revendications 8 à 14, caractérisée en ce que les pales (22) ont une hauteur décroissante entre la couronne intérieure et la couronne extérieure de manière à délimiter des passages ayant des sections de sorties sensiblement égales aux sections d'entrée.Turbine according to any one of claims 8 to 14, characterized in that the blades (22) have a decreasing height between the inner ring and the outer ring so as to delimit passages having outlet sections substantially equal to the sections of Entrance. Turbine selon l'une quelconque des revendications 8 à 15, caractérisée en ce qu'elle comprend plusieurs ensembles coaxiaux comprenant chacune une première pièce (20', 20") et une deuxième pièce (30', 30") assemblés uniquement par serrage mutuel au niveau de leurs parties centrales.Turbine according to any one of Claims 8 to 15, characterized in that it comprises several coaxial assemblies each comprising a first part (20 ', 20 ") and a second part (30', 30") assembled only by mutual tightening at the level of their central parts.
EP96401835A 1995-08-30 1996-08-28 High temperature composite material impellor, particularly of small diameter, and its manufacturing method Expired - Lifetime EP0761977B1 (en)

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FR9510205 1995-08-30
FR9510205A FR2738303B1 (en) 1995-08-30 1995-08-30 TURBINE OF THERMOSTRUCTURAL COMPOSITE MATERIAL, IN PARTICULAR WITH A SMALL DIAMETER, AND METHOD FOR THE PRODUCTION THEREOF

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FR2738303B1 (en) 1997-11-28
UA28036C2 (en) 2000-10-16
DE69611582T2 (en) 2001-08-23
US6029347A (en) 2000-02-29
US5775878A (en) 1998-07-07
ES2155178T3 (en) 2001-05-01
EP0761977B1 (en) 2001-01-17
FR2738303A1 (en) 1997-03-07
RU2141564C1 (en) 1999-11-20
DE69611582D1 (en) 2001-02-22
JPH09125901A (en) 1997-05-13
JP3484299B2 (en) 2004-01-06

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