EP1384539A1 - Metal matrix composite part and process for its manufacture - Google Patents

Metal matrix composite part and process for its manufacture Download PDF

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Publication number
EP1384539A1
EP1384539A1 EP03291800A EP03291800A EP1384539A1 EP 1384539 A1 EP1384539 A1 EP 1384539A1 EP 03291800 A EP03291800 A EP 03291800A EP 03291800 A EP03291800 A EP 03291800A EP 1384539 A1 EP1384539 A1 EP 1384539A1
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EP
European Patent Office
Prior art keywords
metal matrix
mechanical part
core
metal
reinforcing elements
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
EP03291800A
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German (de)
French (fr)
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EP1384539B1 (en
Inventor
Isabelle Peslerbe
Jacques Tschofen
Anne Thenaisie
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
Forges de Bologne
Original Assignee
Forges de Bologne
SNECMA Moteurs SA
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Publication of EP1384539A1 publication Critical patent/EP1384539A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2204/00—End product comprising different layers, coatings or parts of cermet
    • 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
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • 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
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • Y10T29/49909—Securing cup or tube between axially extending concentric annuli
    • Y10T29/49913—Securing cup or tube between axially extending concentric annuli by constricting outer annulus
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736—Al-base component

Definitions

  • the present invention relates to obtaining a coin having a main direction along which extend a heart zone forming a core and a peripheral zone forming an envelope surrounding said core, said core and said envelope having a metallurgical bond between them, said core being made of a first material having at least one matrix metal and said envelope being made of a second material having at least one metal matrix.
  • the present invention relates to obtaining a mechanical part for which the matrix of the first material and / or the second material aluminum as base metal.
  • the invention relates to a mechanical part used in the sector aeronautics, particularly as a moving or fixed blade of a compressor, especially low pressure, or as a dawn blower ("fan”) of turbojet.
  • the present invention is not intended to be limited to the realization of blades or to be applied only to the sector aeronautics: other types of mechanical parts may be envisaged, in particular in the machine tool sectors or in the automotive sector, such as crankcases, tubes, cylinders or wearing parts in the field of braking.
  • titanium alloys are widely used in This has the disadvantages of significant costs of raw material as well as a weight sometimes still considered too important.
  • the present invention aims to overcome the disadvantages of these techniques of the prior art by proposing a piece mechanics and its manufacturing process using techniques metallurgical simple to implement.
  • the present invention thus relates to a mechanical part with a main direction along which extend a heart zone forming a core and a zone peripheral forming an envelope surrounding said core, said core and said envelope having a metallurgical bond between them, said core being made of a first material having at least one metal matrix and said envelope being made in a second material having at least one metal matrix.
  • said metal matrices of first and second materials have the same base metal and at least one of said first and second materials is formed of a metal matrix composite comprising elements of reinforcement dispersed in said metal matrix.
  • the characteristics of the interface between two materials forming a room, which can therefore be described as complex, are of great importance, especially when at least one of these materials is a metal matrix composite: the identity between the re-entrant base metal in the composition of the first and second materials is in this regard of great importance in obtaining a core and an envelope forming between them a metallurgical bond presenting a great mechanical resistance.
  • this arrangement allows, by the presence of reinforcement elements, in at least one of the first material and the second material, to improve the strength properties mechanical and, possibly, withstand temperature, of the piece in the part that we wish to strengthen, while at the same time density similar to that of the metal matrix.
  • both the first material and the second material (core and shell) is (are) made up of a metal matrix composite comprising elements of reinforcement dispersed in said metal matrix.
  • the composition of the first material is different from that of the second material, at least as far as the proportion of reinforcement elements.
  • a blade consisting of said mechanical part.
  • Such a dawn can belong to a compressor, especially low pressure, whether as a fixed dawn or as dawn mobile.
  • the present invention relates to the manufacturing process which makes it possible, by means of its implementation, to obtain said aforesaid mechanical part.
  • said step a) consists in forming jointly the core and the envelope by the metallurgical technique of powders.
  • this technique which implements the compression of a powder in a matrix, followed by a heat treatment called "sintering", it is thus possible to obtain a metal part forming directly the semi-finished product.
  • This first solution is particularly well adapted to the situation in which one wishes to obtain a mechanical part where said reinforcement elements represent a percentage by weight of the composition of said progressive metal matrix composite in said first material (core) and in said second material (envelope), from the center of said core to the periphery of said envelope, or decreasing from the center, either increasing from the center, entering through example, a minimum of 0% to 10% and a maximum less than or equal to 50% by weight.
  • This second solution is particularly well adapted to situation in which one wishes to obtain a mechanical part where said reinforcing elements are only present in one of the first and second materials, the other of said first and second materials being formed only of said metal matrix.
  • Sub-step a4) of the second solution of step a), consists of preferably rolling or spinning all, that is to say by successive passages, in force and hot, between pairs of cylinders more and more close together or in sectors of section smaller and smaller.
  • this step a) uses a technique performing the compaction, in particular the pressurization between the core and envelope, at the time of their joint formation (first solution), either at the moment of their initial training as a separate parts (second solution), so as to create between materials constituting a metallurgical type connection generating a good interface.
  • forging generally consists of metallurgical operation whose purpose is to convert ingots into shaped blanks by deformation of a metal carried to a temperature where it is sufficiently malleable, the deformation being obtained either by shock (pestle, sheep) or by pressure (presses with closed matrix) between two tools.
  • this forging step consists of stamping or stamping.
  • Other forging possibilities can also be used alone, or in combination with the stamping: press forging, pestle ...
  • the manufacturing method according to the present invention applies to a first material which is formed only of said metal matrix which comprises aluminum as base metal and a second material which is formed of said matrix composite metal comprising said reinforcing elements dispersed in said metal matrix, said metal matrix having aluminum as base metal and said reinforcing elements being formed of silicon carbide particles (SiC): this preferential choice makes it possible to benefit from a very good interaction between an aluminum alloy and SiC particles, as explained in US 6,135,195, for a material whose price is lower than that of titanium.
  • SiC silicon carbide particles
  • step a) the choice of aluminum as base metal allows benefit from its good elongation properties, especially for the forging step and also, in the case of the second solution of step a), during step a4) of passage in a more sectional orifice reduced (rolling or spinning), as well as its good resistance to corrosion.
  • Figure 1 An example of the possible applications of the mechanical part according to the present invention is shown in Figure 1 in the form of a double-flow turbojet engine 100.
  • This turbojet engine 100 comprises a conventional structure which comprises different elements arranged axially around the axis longitudinal 102, in fluid communication with each other, namely in particular a blower 104 and an accelerator 106.
  • turbojet engine includes the others conventional elements of such a structure, namely a compressor high pressure, a combustion chamber, a high pressure turbine and a low pressure turbine, these different additional elements not represented for the sake of clarity.
  • the fan 104 and the accelerator 106 are rotated by the low pressure turbine thanks to the rotor axis 108.
  • the blower 104 comprises a series of blades 110 extending radially mounted on an annular disc 112: only one of these vanes appear in Figure 1. It is understood that the disc 112 and the blades 110 are rotatably mounted about the axis 102 of the motor 100.
  • the motor 100 further comprises a fan casing 114.
  • the accelerator 106 includes several sets of blades 116 in rotation mounted on a disc 118 and between which are mounted series of vanes 120.
  • the present invention relates to obtaining a coin mechanics that can constitute in particular each of the blades 110 of the blower 104 and / or each of the blades 116 and / or vanes 120 of the accelerator 106.
  • the mechanical part according to the present invention can also constitute the blades and / or mobiles of other elements of a turbojet engine, identical or different from that illustrated in FIG. a compressor, in particular a low pressure compressor.
  • the mechanical part according to the present invention can also find application in areas other than that of aeronautics for the formation of structural elements to resist mechanically while having a relatively light structure.
  • an aluminum rod 10 is first formed an aluminum rod 10 by conventional techniques for manufacturing aluminum alloys.
  • the next step is to introduce the rod 10 inside of the sleeve 20 to form an assembly 30: it is clear that at this stage it there is a clearance, or even a space between the outer surface of the rod 10 and the inner surface of the wall of the sleeve 20.
  • the assembly 30 appears to be introduced in the input 40 of a die 42.
  • This input 40 has a shape of truncated cone with an angle at the center ⁇ forming the angle of reduction.
  • This inlet 40 has an upstream diameter greater than the diameter outside the sleeve 20, while the downstream diameter of the inlet 40 has a diameter smaller than the diameter of the rod 10.
  • the assembly 30 is, during the passage in force and at the inlet 40 of the die 42, reduced in section by lengthening, an interface being created between the rod 10 and the sleeve 20 which together form in this way a complex semi-product 32 at the exit 44 of the die 42.
  • the reduction angle ⁇ is equal to 30 °, this reduction angle being able to vary in a general way between 1 ° and 45 ° and preferably between 5 and 35 °.
  • this spinning technique in particular when it is carried out by the successive passage in series dies, allows, by the pressure exerted between the surfaces in contact by friction, good cohesion between the materials constituting the core and the envelope.
  • This embodiment has been realized with a rod 10 having a diameter of 30 mm made of an aluminum alloy of 2024 T4 series, while the sleeve 20 had an outer diameter of 70 mm and an inside diameter of 40 mm being realized in a second material forming a metal matrix composite, the matrix metal alloy being a 2024 T4 series aluminum alloy and the reinforcement being composed of silicon carbide particles of a average size of 5 ⁇ m to 15% by weight.
  • Such spinning can be carried out at room temperature or hot, especially with a temperature of the order of 400 ° C.
  • the subsequent step of the exemplary embodiment described in detail is to perform forging by stamping to give the almost definitive shape of dawn.
  • This mastering is achieved by successive steps in matrices gradually tending to present the final shape of dawn under pressure and temperature conditions adapted to materials to maintain a good interface and good adhesion between the core and the envelope: a temperature of the order of 430 ° C and a pressure of the order of 100 MPa have been used in particular.
  • a blank (not shown) is obtained which is then machined to lead to a finished product forming the mechanical part according to the invention, in particular a blade such as those represented in Figures 3 to 5.
  • the blade 50 which is represented according to different shapes has a core 52 made of the first material initially constituting the rod 10, while the envelope 54 surrounding the core 52 is made in the second material initially forming the sleeve 20 of the assembly 30 of FIG.
  • dawn 50 has a regular distribution of the first material and the second material between the core 52 and the casing 54.
  • the present invention is not limited to the use of reinforcing elements in the form of silicon carbide particles, alumina particles (Al 2 O 3 ) or metal carbides, such as tungsten carbide, tungsten carbide, boron carbide or titanium carbide can also be used.
  • the present invention also applies to the production of a part mechanical made entirely of a metal matrix composite, which has a progressive composition of reinforcing elements from the center of the nucleus to the periphery of the envelope.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

Mechanical component has an aluminum based matrix incorporating a core and an envelope with a metallurgical linkage made from two different composite materials. A mechanical component (50) presents a principal direction along which extends a heart zone forming a core (52) and a peripheral zone forming an envelope (54) surrounding the core. The core and envelope have between them a metallurgical linkage, with the core being made of a first material with a metal matrix and the envelope being made from a second material with a metal matrix. The metal matrices have the same base metal and at least one of the first and second materials is formed of a composite with a metal matrix incorporating some reinforcing elements dispersed in the metal matrix. An Independent claim is also included for a method for the fabrication of such a mechanical component.

Description

La présente invention concerne l'obtention d'une pièce mécanique présentant une direction principale le long de laquelle s'étendent une zone de coeur formant un noyau et une zone périphérique formant une enveloppe qui entoure ledit noyau, ledit noyau et ladite enveloppe présentant entre eux une liaison métallurgique, ledit noyau étant réalisé dans un premier matériau présentant au moins une matrice métallique et ladite enveloppe étant réalisée dans un deuxième matériau présentant au moins une matrice métallique.The present invention relates to obtaining a coin having a main direction along which extend a heart zone forming a core and a peripheral zone forming an envelope surrounding said core, said core and said envelope having a metallurgical bond between them, said core being made of a first material having at least one matrix metal and said envelope being made of a second material having at least one metal matrix.

Elle concerne plus précisément:

  • une pièce mécanique réalisée avec deux parties formées d'un noyau réalisé dans un premier matériau présentant au moins une matrice métallique et d'une enveloppe réalisée dans un deuxième matériau présentant au moins une matrice métallique; et
  • un procédé de fabrication qui permet l'obtention, par sa mise en oeuvre, de ladite pièce mécanique précitée.
It concerns more precisely:
  • a mechanical part made with two parts formed of a core made of a first material having at least one metal matrix and an envelope made of a second material having at least one metal matrix; and
  • a manufacturing process which makes it possible to obtain, by its implementation, said aforementioned mechanical part.

En particulier, de manière non limitative, la présente invention concerne l'obtention d'une pièce mécanique pour laquelle la matrice métallique du premier matériau et/ou du deuxième matériau présente l'aluminium comme métal de base.In particular, without limitation, the present invention relates to obtaining a mechanical part for which the matrix of the first material and / or the second material aluminum as base metal.

Dans une application préférée, mais non limitative, la présente invention concerne une pièce mécanique utilisée dans le secteur aéronautique, en particulier comme aube mobile ou fixe d'un compresseur, notamment basse pression, ou bien comme aube de soufflante (« fan ») de turboréacteur.In a preferred application, but not limiting, this The invention relates to a mechanical part used in the sector aeronautics, particularly as a moving or fixed blade of a compressor, especially low pressure, or as a dawn blower ("fan") of turbojet.

Toutefois, la présente invention n'est pas destinée à être limitée à la réalisation d'aubes ni à n'être appliquée seulement au secteur aéronautique : d'autres types de pièces mécaniques peuvent être envisagées, notamment dans les secteurs des machines-outils ou dans le secteur automobile, comme des carters, des tubes, des cylindres ou des pièces d'usure dans le domaine du freinage.However, the present invention is not intended to be limited to the realization of blades or to be applied only to the sector aeronautics: other types of mechanical parts may be envisaged, in particular in the machine tool sectors or in the automotive sector, such as crankcases, tubes, cylinders or wearing parts in the field of braking.

Spécifiquement, des pièces mécaniques de plus en plus légères et présentant de bonnes caractéristiques de résistance mécanique et de tenue en température sont requises, pour des applications de divers types.Specifically, increasingly light mechanical parts and having good characteristics of mechanical strength and Temperature resistance is required for applications of various types.

Ainsi, en particulier dans le domaine aéronautique, et plus précisément dans les turboréacteurs, sont recherchés des matériaux avec des caractéristiques de résistance mécanique et de tenue à la température optimales, notamment pour la fabrication des aubes fixes et/ou mobiles.Thus, particularly in the aeronautical field, and more precisely in turbojets, are searched for materials with mechanical strength and temperature resistance characteristics optimal, especially for the manufacture of blades and / or mobiles.

A l'heure actuelle, les alliages de titane sont largement utilisés à cet effet, ce qui a notamment pour inconvénients des coûts important de matière première ainsi qu'un poids parfois encore considéré comme trop important.At present, titanium alloys are widely used in This has the disadvantages of significant costs of raw material as well as a weight sometimes still considered too important.

Des solutions visant à la réalisation de pièces creuses en titane permettant d'alléger les structures sont aussi utilisées, ce qui engendre des techniques de fabrication relativement sophistiquées et coûteuses.Solutions for making titanium hollow parts to lighten the structures are also used, which generates relatively sophisticated and expensive manufacturing techniques.

On peut se référer au document US 6 218 026 qui propose la réalisation d'une pièce mécanique hybride composée notamment de deux alliages différents de titane respectivement disposés à l'emplacement de parties interne et externe de la pièce. Selon ce document de l'art antérieur, la partie interne et la partie externe sont reliées entre elles par une liaison métallurgique obtenue par pressage isostatique à chaud.We can refer to the document US 6 218 026 which proposes the realization of a hybrid mechanical part composed in particular of two different titanium alloys respectively arranged at the location of internal and external parts of the room. According to this art document front, the inner part and the outer part are interconnected by a metallurgical bond obtained by hot isostatic pressing.

En tout état de cause, on vise à obtenir une pièce mécanique dont le module d'élasticité est plus important dans la partie interne que dans la partie externe afin d'améliorer les propriétés mécaniques de la pièce sans altérer particulièrement sa densité.In any case, we aim to obtain a mechanical part whose modulus of elasticity is greater in the inner part than in the outer part in order to improve the mechanical properties of the piece without particularly altering its density.

Toutefois, l'intervention d'un alliage de titane est par ailleurs préjudiciable du point de vue de la masse de la pièce mécanique et du coût de matière première tandis que la technique de pressage isostatique à chaud est lourde à mettre en oeuvre.However, the intervention of a titanium alloy is moreover detrimental from the point of view of the mass of the mechanical part and the cost of raw material while isostatic pressing technique hot is heavy to implement.

La présente invention a pour objectif de pallier les inconvénients de ces techniques de l'art antérieur en proposant une pièce mécanique et son procédé de fabrication à l'aide de techniques métallurgiques simples à mettre en oeuvre.The present invention aims to overcome the disadvantages of these techniques of the prior art by proposing a piece mechanics and its manufacturing process using techniques metallurgical simple to implement.

Selon un de ses aspects, la présente invention concerne donc une pièce mécanique présentant une direction principale le long de laquelle s'étendent une zone de coeur formant un noyau et une zone périphérique formant une enveloppe qui entoure ledit noyau, ledit noyau et ladite enveloppe présentant entre eux une liaison métallurgique, ledit noyau étant réalisé dans un premier matériau présentant au moins une matrice métallique et ladite enveloppe étant réalisée dans un deuxième matériau présentant au moins une matrice métallique. According to one of its aspects, the present invention thus relates to a mechanical part with a main direction along which extend a heart zone forming a core and a zone peripheral forming an envelope surrounding said core, said core and said envelope having a metallurgical bond between them, said core being made of a first material having at least one metal matrix and said envelope being made in a second material having at least one metal matrix.

De façon caractéristique, lesdites matrices métalliques du premier et du deuxième matériaux présentent le même métal de base et l'un au moins parmi lesdits premier et deuxième matériaux est formé d'un composite à matrice métallique comprenant des éléments de renforcement dispersés dans ladite matrice métallique.Characteristically, said metal matrices of first and second materials have the same base metal and at least one of said first and second materials is formed of a metal matrix composite comprising elements of reinforcement dispersed in said metal matrix.

De cette manière, on comprend qu'il est possible d'obtenir une pièce présentant un noyau et une enveloppe entre lesquelles est formée une interface formée d'une liaison physico-chimique de très bonne qualité du fait de la similitude entre les premier et deuxième matériaux qui comportent le même métal de base.In this way, we understand that it is possible to obtain a a piece having a core and an envelope between which is formed an interface formed by a physico-chemical link of very good quality because of the similarity between the first and second materials that have the same base metal.

Les caractéristiques de l'interface entre deux matériaux formant une pièce, que l'on peut donc qualifier de complexe, sont d'une grande importance, en particulier lorsque l'un au moins de ces matériaux est un composite à matrice métallique : l'identité entre le métal de base rentrant dans la composition des premier et deuxième matériaux est à cet égard d'une grande importance dans l'obtention d'un noyau et d'une enveloppe formant entre eux une liaison métallurgique présentant une grande résistance mécanique.The characteristics of the interface between two materials forming a room, which can therefore be described as complex, are of great importance, especially when at least one of these materials is a metal matrix composite: the identity between the re-entrant base metal in the composition of the first and second materials is in this regard of great importance in obtaining a core and an envelope forming between them a metallurgical bond presenting a great mechanical resistance.

En outre, cet agencement permet, par la présence des éléments de renforcement, dans l'un au moins parmi le premier matériau et le deuxième matériau, d'améliorer les propriétés de résistance mécanique et, éventuellement de tenue en température, de la pièce dans la partie que l'on souhaite renforcer, tout en conservant globalement une densité similaire à celle de la matrice métallique.In addition, this arrangement allows, by the presence of reinforcement elements, in at least one of the first material and the second material, to improve the strength properties mechanical and, possibly, withstand temperature, of the piece in the part that we wish to strengthen, while at the same time density similar to that of the metal matrix.

On note incidemment que selon l'application envisagée pour la pièce mécanique, soit l'un seulement parmi le premier matériau (noyau) et le deuxième matériau (enveloppe), soit à la fois le premier matériau et le deuxième matériau (noyau et enveloppe), est (sont) constitué(s) d'un composite à matrice métallique comprenant des éléments de renforcement dispersés dans ladite matrice métallique.Incidentally, according to the application envisaged for the mechanical part, ie only one of the first material (core) and the second material (envelope), both the first material and the second material (core and shell), is (are) made up of a metal matrix composite comprising elements of reinforcement dispersed in said metal matrix.

Dans ce dernier cas, la composition du premier matériau est différente de celle du deuxième matériau, au moins en ce qui concerne la proportion des éléments de renforcement.In the latter case, the composition of the first material is different from that of the second material, at least as far as the proportion of reinforcement elements.

Les dispositions suivantes sont de préférence adoptées, de manière indépendante ou combinée :

  • ledit métal de base est l'aluminium ;
  • lesdites matrices métalliques du premier et du deuxième matériaux sont respectivement formées d'un premier alliage et d'un deuxième alliage, ledit premier alliage et ledit deuxième alliage appartenant aux alliages à base d'aluminium des séries 2000, 5000, 6000 ou 7000 selon les normes ASTM ; de préférence, ledit premier alliage et ledit deuxième alliage appartiennent à la même série d'alliage à base d'aluminium parmi lesdites séries 2000, 5000, 6000 ou 7000 selon les normes ASTM, en particulier à la série 2000 ;
  • éléments de renforcement sont des particules de carbure de silicium (SiC), d'alumine (Al2O3) ou de carbure métallique tel que carbure de tungstène, de bore ou de titane ;
  • lesdits éléments de renforcement représentent au plus 50% en poids de la composition dudit composite à matrice métallique ; de préférence, lesdits éléments de renforcement représentent entre 5 et 35%, de préférence entre 10 et 20%, et de préférence de l'ordre de 15% en poids de la composition dudit composite à matrice métallique ;
  • l'un parmi lesdits premier et deuxième matériaux est formé dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, l'autre parmi lesdits premier et deuxième matériaux étant formé seulement de ladite matrice métallique ;
  • ledit premier matériau est formé seulement de ladite matrice métallique qui comporte l'aluminium comme métal de base et ledit deuxième matériau est formé dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, ladite matrice métallique ayant l'aluminium comme métal de base et lesdits éléments de renforcement étant formés de particules de carbure de silicium (SiC) : ce choix préférentiel permet de bénéficier de la bonne tenue à l'érosion et à l'impact de l'Al/SiC et de sa rigidité plus importante ;
  • lesdits premier et deuxième matériaux sont formés dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, lesdits éléments de renforcement représentant un pourcentage en poids de la composition dudit composite à matrice métallique différent dans ledit noyau et dans ladite enveloppe ;
  • lesdits éléments de renforcement représentent un pourcentage en poids de la composition dudit composite à matrice métallique progressif dans ledit premier matériau et dans ledit deuxième matériau, depuis le centre dudit noyau vers la périphérie de ladite enveloppe ;
  • ledit premier matériau présente, pour lesdits éléments de renforcement, un pourcentage en poids de la composition dudit composite à matrice métallique plus important que dans ledit deuxième matériau;
  • ledit deuxième matériau présente, pour lesdits éléments de renforcement, un pourcentage en poids de la composition dudit composite à matrice métallique plus important que dans ledit premier matériau.
The following provisions are preferably adopted, independently or in combination:
  • said base metal is aluminum;
  • said metal matrices of the first and second materials are respectively formed of a first alloy and a second alloy, said first alloy and said second alloy belonging to the 2000, 5000, 6000 or 7000 series aluminum alloys according to the ASTM standards; preferably, said first alloy and said second alloy belong to the same series of aluminum-based alloys of said 2000, 5000, 6000 or 7000 series according to ASTM standards, in particular to the 2000 series;
  • reinforcing elements are particles of silicon carbide (SiC), alumina (Al 2 O 3 ) or metal carbide such as tungsten carbide, boron or titanium;
  • said reinforcing elements represent at most 50% by weight of the composition of said metal matrix composite; preferably, said reinforcing elements represent between 5 and 35%, preferably between 10 and 20%, and preferably of the order of 15% by weight of the composition of said metal matrix composite;
  • one of said first and second materials is formed of said metal matrix composite comprising said reinforcing elements dispersed in said metal matrix, the other of said first and second materials being formed only of said metal matrix;
  • said first material is formed only of said metal matrix which comprises aluminum as a base metal and said second material is formed of said metal matrix composite comprising said reinforcing elements dispersed in said metal matrix, said metal matrix having aluminum as metal base and said reinforcing elements being formed of particles of silicon carbide (SiC): this preferential choice makes it possible to benefit from the good resistance to erosion and the impact of Al / SiC and its greater rigidity ;
  • said first and second materials are formed from said metal matrix composite comprising said reinforcing elements dispersed in said metal matrix, said reinforcing elements representing a percentage by weight of the composition of said different metal matrix composite in said core and said envelope;
  • said reinforcing elements represent a percentage by weight of the composition of said progressive metal matrix composite in said first material and in said second material, from the center of said core to the periphery of said envelope;
  • said first material has, for said reinforcing elements, a percentage by weight of the composition of said metal matrix composite greater than in said second material;
  • said second material has, for said reinforcing elements, a percentage by weight of the composition of said metal matrix composite greater than in said first material.

Selon une application préférentielle, mais non limitative, de la pièce mécanique selon l'invention, on considère une aube constituée de ladite pièce mécanique.According to a preferential, but not limiting, application of mechanical part according to the invention, a blade consisting of said mechanical part.

Une telle aube peut appartenir à un compresseur, en particulier basse pression, que ce soit en tant qu'aube fixe ou en tant qu'aube mobile.Such a dawn can belong to a compressor, especially low pressure, whether as a fixed dawn or as dawn mobile.

Egalement, une telle aube peut s'appliquer à la réalisation d'une soufflante de turboréacteur.Also, such a dawn can be applied to the realization of a turbojet blower.

Selon un autre aspect, la présente invention concerne le procédé de fabrication qui permet l'obtention, par sa mise en oeuvre, de ladite pièce mécanique précitée.In another aspect, the present invention relates to the manufacturing process which makes it possible, by means of its implementation, to obtain said aforesaid mechanical part.

De manière générale, le procédé de fabrication selon la présente invention permet l'obtention d'une pièce mécanique, par la mise en oeuvre des étapes suivantes :

  • a) on réalise par compactage un demi-produit contenant un noyau et une enveloppe, ledit noyau et ladite enveloppe présentant entre eux une liaison métallurgique, ledit noyau étant réalisé dans un premier matériau présentant au moins une matrice métallique et ladite enveloppe étant réalisée dans un deuxième matériau présentant au moins une matrice métallique, lesdites matrices métalliques du premier et du deuxième matériaux présentant le même métal de base et en l'un au moins parmi lesdits premier et deuxième matériaux étant formé d'un composite à matrice métallique comprenant des éléments de renforcement dispersés dans ladite matrice métallique,
  • b) on réalise le forgeage du demi-produit pour obtenir une ébauche, et
  • c) on usine ladite ébauche pour aboutir à un produit fini formant ladite pièce mécanique.
    • In general, the manufacturing method according to the present invention makes it possible to obtain a mechanical part, by carrying out the following steps:
  • a) is produced by compacting a semi-product containing a core and an envelope, said core and said envelope having between them a metallurgical bond, said core being made of a first material having at least one metal matrix and said envelope being made in a second material having at least one metal matrix, said metal matrices of the first and second materials having the same base metal and at least one of said first and second materials being formed of a metal matrix composite comprising reinforcement dispersed in said metal matrix,
  • b) forging the semi-finished product to obtain a blank, and
  • c) the blank is machined to result in a finished product forming said mechanical part.

    • Concernant la réalisation de l'étape a), plusieurs solutions sont possible sans sortir du cadre de la présente invention.Regarding the completion of step a), several solutions are possible without departing from the scope of the present invention.

    Selon une première solution, ladite étape a) consiste à former conjointement le noyau et l'enveloppe par la technique de métallurgie des poudres. Selon cette technique, qui met en ouvre la compression d'une poudre dans une matrice, suivie d'un traitement thermique dit « frittage», il est ainsi possible d'obtenir une pièce métallique formant directement le demi-produit.According to a first solution, said step a) consists in forming jointly the core and the envelope by the metallurgical technique of powders. According to this technique, which implements the compression of a powder in a matrix, followed by a heat treatment called "sintering", it is thus possible to obtain a metal part forming directly the semi-finished product.

    Cette première solution est en particulier bien adaptée à la situation dans laquelle on souhaite obtenir une pièce mécanique où lesdits éléments de renforcement représentent un pourcentage en poids de la composition dudit composite à matrice métallique progressif dans ledit premier matériau (noyau) et dans ledit deuxième matériau (enveloppe), depuis le centre dudit noyau vers la périphérie de ladite enveloppe, soit en diminuant depuis le centre, soit en augmentant depuis le centre, entre par exemple, un minimum de 0% à 10% et un maximum inférieur ou égale à 50% en poids.This first solution is particularly well adapted to the situation in which one wishes to obtain a mechanical part where said reinforcement elements represent a percentage by weight of the composition of said progressive metal matrix composite in said first material (core) and in said second material (envelope), from the center of said core to the periphery of said envelope, or decreasing from the center, either increasing from the center, entering through example, a minimum of 0% to 10% and a maximum less than or equal to 50% by weight.

    Cette première solution ne se limite toutefois pas au cas de figure qui précède et il peut s'appliquer également aux deux cas mentionnés ci-après :

    • lesdits premier et deuxième matériaux sont formés dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, lesdits éléments de renforcement représentant un pourcentage en poids de la composition dudit composite à matrice métallique différent dans ledit noyau et dans ladite enveloppe,
    • l'un parmi lesdits premier et deuxième matériaux est formé dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, l'autre parmi lesdits premier et deuxième matériaux étant formé seulement de ladite matrice métallique.
    This first solution, however, is not limited to the above case and can also be applied to the two cases mentioned below:
    • said first and second materials are formed of said metal matrix composite comprising said reinforcing elements dispersed in said metal matrix, said reinforcing elements representing a percentage by weight of the composition of said different metal matrix composite in said core and said envelope,
    • one of said first and second materials is formed of said metal matrix composite comprising said reinforcing elements dispersed in said metal matrix, the other of said first and second materials being formed only of said metal matrix.

    Selon une deuxième solution, ladite étape a) consiste à réaliser successivement les sous-étapes suivantes :

  • a1) former une tige s'étendant selon une direction longitudinale dans ledit premier matériau, ladite tige étant destinée à former ledit noyau placé au coeur de la pièce mécanique ;
  • a2) former un manchon s'étendant selon une direction longitudinale dans ledit deuxième matériau, ledit manchon étant destinée à former l'enveloppe de la pièce mécanique en entourant ledit noyau ;
  • a3) introduire la tige dans le manchon pour former un ensemble, et
  • a4) passer à travers un orifice de section réduite ledit ensemble pour diminuer au moins une dimension dudit ensemble selon une direction perpendiculaire à ladite direction longitudinale et afin de créer une liaison métallurgique entre ladite tige et le dit manchon.
    • According to a second solution, said step a) consists in successively performing the following substeps:
  • a1) forming a rod extending in a longitudinal direction in said first material, said rod being intended to form said core placed in the heart of the mechanical part;
  • a2) forming a sleeve extending in a longitudinal direction in said second material, said sleeve being intended to form the envelope of the mechanical part by surrounding said core;
  • a3) introducing the rod into the sleeve to form an assembly, and
  • a4) passing through an orifice of reduced section said assembly to reduce at least one dimension of said assembly in a direction perpendicular to said longitudinal direction and to create a metallurgical connection between said rod and said sleeve.

    • Cette deuxième solution est en particulier bien adaptée à la situation dans laquelle on souhaite obtenir une pièce mécanique où lesdits éléments de renforcement ne sont présents que dans l'un parmi lesdits premier et deuxième matériaux, l'autre parmi lesdits premier et deuxième matériaux étant formé seulement de ladite matrice métallique. On privilégie alors la réalisation de celui parmi le noyau (premier matériau) et l'enveloppe (deuxième matériau) qui comporte les éléments de renforcement par la technique de métallurgie des poudres.This second solution is particularly well adapted to situation in which one wishes to obtain a mechanical part where said reinforcing elements are only present in one of the first and second materials, the other of said first and second materials being formed only of said metal matrix. We then privileges the realization of the one among the core (first material) and the envelope (second material) which contains the elements of reinforcement by the powder metallurgy technique.

    La sous-étape a4) de la deuxième solution de l'étape a), consiste à effectuer, de préférence, un laminage ou un filage de l'ensemble, c'est-à-dire par passages successifs, en force et à chaud, entre des paires de cylindres de plus en plus rapprochés ou dans des filières de section de plus en plus petite.Sub-step a4) of the second solution of step a), consists of preferably rolling or spinning all, that is to say by successive passages, in force and hot, between pairs of cylinders more and more close together or in sectors of section smaller and smaller.

    D'une manière générale, cette étape a) utilise une technique réalisant le compactage, en particulier la mise sous pression entre le noyau et l'enveloppe, soit au moment de leur formation conjointe (première solution), soit au moment de leur formation initiale en tant que pièces séparées (deuxième solution), de manière à créer entre les matériaux les constituant une liaison de type métallurgique engendrant une bonne interface.In general, this step a) uses a technique performing the compaction, in particular the pressurization between the core and envelope, at the time of their joint formation (first solution), either at the moment of their initial training as a separate parts (second solution), so as to create between materials constituting a metallurgical type connection generating a good interface.

    Il est entendu que cette liaison de type métallurgique forme un contact plus intime qu'une liaison mécanique, les premier et deuxième matériaux étant si proches que les forces inter-atomiques entrent en jeu. Une telle interface permettra à la pièce mécanique de résister de manière satisfaisante aux différentes contraintes auxquelles elle est soumise.It is understood that this metallurgical bond forms a more intimate contact than a mechanical connection, the first and second materials are so close that inter-atomic forces come into play. Such an interface will allow the mechanical part to withstand satisfactory to the different constraints to which it is subjected.

    Concernant la réalisation de l'étape b) de forgeage, plusieurs solutions sont possible sans sortir du cadre de la présente invention. Regarding the completion of the forging step b), several Solutions are possible without departing from the scope of the present invention.

    En effet, le forgeage consiste d'une manière générale en une opération métallurgique qui a pour objet de transformer les lingots en ébauches de forme déterminée par déformation d'un métal porté à une température où il est suffisamment malléable, la déformation étant obtenue soit par choc (pilon, mouton), soit par pression (presses avec matrice fermée) entre deux outils.Indeed, forging generally consists of metallurgical operation whose purpose is to convert ingots into shaped blanks by deformation of a metal carried to a temperature where it is sufficiently malleable, the deformation being obtained either by shock (pestle, sheep) or by pressure (presses with closed matrix) between two tools.

    Selon une solution préférentielle, cette étape de forgeage consiste en un matriçage ou estampage. D'autres possibilités de forgeage peuvent également être utilisées seules, ou en combinaison avec le matriçage : forgeage sous presse, par pilon...According to a preferred solution, this forging step consists of stamping or stamping. Other forging possibilities can also be used alone, or in combination with the stamping: press forging, pestle ...

    En particulier, le procédé de fabrication selon la présente invention s'applique à un premier matériau qui est formé seulement de ladite matrice métallique qui comporte l'aluminium comme métal de base et à un deuxième matériau qui est formé dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, ladite matrice métallique ayant l'aluminium comme métal de base et lesdits éléments de renforcement étant formés de particules de carbure de silicium (SiC) : ce choix préférentiel permet de bénéficier d'une très bonne interaction entre un alliage d'aluminium et des particules de SiC, comme il est expliqué dans US 6 135 195, pour un matériau dont le prix est plus faible que celui du titane.In particular, the manufacturing method according to the present invention applies to a first material which is formed only of said metal matrix which comprises aluminum as base metal and a second material which is formed of said matrix composite metal comprising said reinforcing elements dispersed in said metal matrix, said metal matrix having aluminum as base metal and said reinforcing elements being formed of silicon carbide particles (SiC): this preferential choice makes it possible to benefit from a very good interaction between an aluminum alloy and SiC particles, as explained in US 6,135,195, for a material whose price is lower than that of titanium.

    En outre, le choix de l'aluminium comme métal de base permet de bénéficier de ses bonnes propriétés d'allongement, notamment pour l'étape de forgeage et également, dans le cas de la deuxième solution de l'étape a), lors de l'étape a4) de passage dans un orifice de section plus réduite (laminage ou filage), ainsi que de sa bonne tenue à la corrosion.In addition, the choice of aluminum as base metal allows benefit from its good elongation properties, especially for the forging step and also, in the case of the second solution of step a), during step a4) of passage in a more sectional orifice reduced (rolling or spinning), as well as its good resistance to corrosion.

    L'invention sera mieux comprise, et les caractéristiques secondaires et leurs avantages apparaítront au cours de la description de modes de réalisation de la pièce mécanique selon l'invention donnée ci-dessous à titre d'exemple.The invention will be better understood, and the characteristics and their advantages will become apparent during the description of embodiments of the mechanical part according to the invention given below for exemple.

    Il est entendu que la description et les dessins ne sont donnés qu'à titre indicatif et non limitatif.It is understood that the description and the drawings are not given as indicative and not limiting.

    Il sera fait référence aux dessins annexés, dans lesquels :

    • la figure 1 est une vue en section longitudinale partielle d'un turboréacteur double-flux montrant une soufflante et un accélérateur illustrant à titre d'exemple des applications possibles de la pièce mécanique selon la présente invention,
    • la figure 2 est une vue en coupe longitudinale de l'agencement permettant la réalisation de l'une des étapes du procédé de fabrication selon la présente invention selon l'une des solutions possibles,
    • les figures 3 et 4 sont des vues en perspective d'aubes tronquées à leur extrémité radialement externe qui illustrent des applications possibles de la pièce mécanique selon la présente invention, et
    • la figure 5 est une vue en perspective partielle avec coupe selon la direction longitudinale d'une autre aube pouvant former la pièce mécanique selon la présente invention.
    Reference will be made to the accompanying drawings, in which:
    • FIG. 1 is a partial longitudinal sectional view of a double-flow turbojet engine showing a fan and an accelerator illustrating by way of example possible applications of the mechanical part according to the present invention,
    • FIG. 2 is a longitudinal sectional view of the arrangement for carrying out one of the steps of the manufacturing method according to the present invention according to one of the possible solutions,
    • Figures 3 and 4 are perspective views of blades truncated at their radially outer end which illustrate possible applications of the mechanical part according to the present invention, and
    • Figure 5 is a partial perspective view with section along the longitudinal direction of another blade that can form the mechanical part according to the present invention.

    Un exemple des applications possibles de la pièce mécanique selon la présente invention est représenté à la figure 1 sous la forme d'un turboréacteur double-flux 100.An example of the possible applications of the mechanical part according to the present invention is shown in Figure 1 in the form of a double-flow turbojet engine 100.

    Ce turboréacteur 100 comprend une structure conventionnelle qui comporte différents éléments disposés axialement autour de l'axe longitudinal 102, en communication de fluide entre eux, à savoir notamment une soufflante 104 et un accélérateur 106.This turbojet engine 100 comprises a conventional structure which comprises different elements arranged axially around the axis longitudinal 102, in fluid communication with each other, namely in particular a blower 104 and an accelerator 106.

    Il est entendu qu'un tel turboréacteur comprend les autres éléments conventionnels d'une telle structure, à savoir un compresseur haute pression, une chambre de combustion, une turbine haute pression et une turbine basse pression, ces différents éléments supplémentaires n'étant pas représentés pour des raisons de clarté.It is understood that such a turbojet engine includes the others conventional elements of such a structure, namely a compressor high pressure, a combustion chamber, a high pressure turbine and a low pressure turbine, these different additional elements not represented for the sake of clarity.

    La soufflante 104 et l'accélérateur 106 sont menés en rotation par la turbine basse pression grâce à l'axe de rotor 108.The fan 104 and the accelerator 106 are rotated by the low pressure turbine thanks to the rotor axis 108.

    La soufflante 104 comprend une série d'aubes 110 s'étendant radialement qui sont montées sur un disque annulaire 112 : une seule de ces aubes apparaít sur la figure 1. Il est entendu que le disque 112 et les aubes 110 sont montés en rotation autour de l'axe 102 du moteur 100.The blower 104 comprises a series of blades 110 extending radially mounted on an annular disc 112: only one of these vanes appear in Figure 1. It is understood that the disc 112 and the blades 110 are rotatably mounted about the axis 102 of the motor 100.

    Le moteur 100 comporte en outre un carter de soufflante 114.The motor 100 further comprises a fan casing 114.

    L'accélérateur 106 comprend plusieurs séries d'aubes mobiles 116 en rotation montées sur un disque 118 et entre lesquelles sont montées des séries d'aubes fixes 120.The accelerator 106 includes several sets of blades 116 in rotation mounted on a disc 118 and between which are mounted series of vanes 120.

    La présente invention concerne l'obtention d'une pièce mécanique pouvant constituer en particulier chacune des aubes 110 de la soufflante 104 et/ou chacune des aubes mobiles 116 et/ou des aubes fixes 120 de l'accélérateur 106.The present invention relates to obtaining a coin mechanics that can constitute in particular each of the blades 110 of the blower 104 and / or each of the blades 116 and / or vanes 120 of the accelerator 106.

    Egalement, la pièce mécanique selon la présente invention peut également constituer les aubes fixes et/ou mobiles d'autres éléments d'un turboréacteur, identique ou différent de celui illustré sur la figure 1, tel qu'un compresseur, en particulier un compresseur basse pression.Also, the mechanical part according to the present invention can also constitute the blades and / or mobiles of other elements of a turbojet engine, identical or different from that illustrated in FIG. a compressor, in particular a low pressure compressor.

    Comme il a été mentionné précédemment, il convient de rappeler que la pièce mécanique selon la présente invention peut également trouver application dans d'autres domaines que celui de l'aéronautique pour la formation d'éléments structurels devant résister mécaniquement tout en présentant une structure relativement légère.As mentioned above, it is necessary to remember that the mechanical part according to the present invention can also find application in areas other than that of aeronautics for the formation of structural elements to resist mechanically while having a relatively light structure.

    Un exemple de réalisation du procédé de fabrication selon la présente invention permettant l'obtention des aubes mentionnées précédemment va maintenant être décrit.An embodiment of the manufacturing process according to the present invention to obtain the mentioned blades previously will now be described.

    Dans cet exemple de réalisation non limitatif, on considère la réalisation d'une aube composé d'un noyau réalisé dans un premier matériau formé d'un alliage à base d'aluminium et d'une enveloppe réalisée dans un deuxième matériau formé d'un composite à matrice métallique dans lequel la matrice métallique est un alliage à base d'aluminium et les éléments de renforcement sont des particules de carbure de silicium (SiC).In this non-limiting exemplary embodiment, we consider the realization of a dawn composed of a nucleus realized in a first material formed of an aluminum-based alloy and an envelope made of a second material made of a matrix composite metal in which the metal matrix is an alloy-based of aluminum and the reinforcing elements are particles of silicon carbide (SiC).

    Dans ce cas, est tout d'abord formée une tige 10 en aluminium par les techniques classiques de fabrication des alliages en aluminium.In this case, is first formed an aluminum rod 10 by conventional techniques for manufacturing aluminum alloys.

    Est également fabriqué un manchon 20 réalisé dans le deuxième matériau précité formant un composé à matrice métallique qui peut être obtenu par la technique de métallurgie des poudres.Is also manufactured a sleeve 20 made in the second aforementioned material forming a metal matrix compound which can be obtained by the powder metallurgy technique.

    La prochaine étape consiste à introduire la tige 10 à l'intérieur du manchon 20 afin de former un ensemble 30 : il est clair qu'à ce stade il existe un jeu, voire un espace entre la surface extérieure de la tige 10 et la surface intérieure de la paroi du manchon 20.The next step is to introduce the rod 10 inside of the sleeve 20 to form an assembly 30: it is clear that at this stage it there is a clearance, or even a space between the outer surface of the rod 10 and the inner surface of the wall of the sleeve 20.

    Afin de solidariser entre eux la tige 10 et le manchon 20 de l'ensemble 30, tout en réalisant une bonne interface entre ces deux éléments, on choisit d'effectuer un filage qui est représenté sur la figure 2.In order to join together the rod 10 and the sleeve 20 of the assembly 30, while achieving a good interface between these two elements, one chooses to perform a spinning which is represented in FIG.

    Sur cette figure 2, l'ensemble 30 apparaít comme étant introduit dans l'entrée 40 d'une filière 42. Cette entrée 40 présente une forme de tronc de cône avec un angle au centre α formant l'angle de réduction. Cette entrée 40 présente un diamètre amont supérieur au diamètre extérieur du manchon 20, tandis que le diamètre aval de l'entrée 40 présente un diamètre inférieur au diamètre de la tige 10.In this FIG. 2, the assembly 30 appears to be introduced in the input 40 of a die 42. This input 40 has a shape of truncated cone with an angle at the center α forming the angle of reduction. This inlet 40 has an upstream diameter greater than the diameter outside the sleeve 20, while the downstream diameter of the inlet 40 has a diameter smaller than the diameter of the rod 10.

    En conséquence, l'ensemble 30 est, lors du passage en force et à chaud au niveau de l'entrée 40 de la filière 42, réduit en section par allongement, une interface étant créée entre la tige 10 et le manchon 20 qui forment conjointement de cette manière un demi-produit complexe 32 à la sortie 44 de la filière 42.As a result, the assembly 30 is, during the passage in force and at the inlet 40 of the die 42, reduced in section by lengthening, an interface being created between the rod 10 and the sleeve 20 which together form in this way a complex semi-product 32 at the exit 44 of the die 42.

    Il est entendu que l'étape de filage illustrée sur la figure 2 peut comporter plusieurs passages successifs dans des filières présentant des diamètres de plus en plus petits.It is understood that the spinning step illustrated in FIG. have several successive passages in pathways with smaller and smaller diameters.

    Dans l'exemple de réalisation illustré, l'angle de réduction α est égal à 30°, cet angle de réduction pouvant varier d'une manière générale entre 1° et 45° et de préférence entre 5 et 35°.In the exemplary embodiment illustrated, the reduction angle α is equal to 30 °, this reduction angle being able to vary in a general way between 1 ° and 45 ° and preferably between 5 and 35 °.

    De cette manière, on obtient une réduction de section entre l'ensemble 30 et le demi-produit complexe 32 de l'ordre de 10 à 70 % et, de préférence, entre 20 et 60 %.In this way, we obtain a reduction of section between the assembly 30 and the complex semi-product 32 of the order of 10 to 70% and, preferably between 20 and 60%.

    On peut relever que cette technique de filage, notamment lorsqu'elle est effectuée par le passage successif dans des filières en série, permet, par la pression exercée entre les surfaces en contact par friction, une bonne cohésion entre les matériaux constituant le noyau et l'enveloppe.It can be noted that this spinning technique, in particular when it is carried out by the successive passage in series dies, allows, by the pressure exerted between the surfaces in contact by friction, good cohesion between the materials constituting the core and the envelope.

    Cet exemple de réalisation a été réalisé avec une tige 10 présentant un diamètre de 30 mm réalisée dans un alliage d'aluminium de série 2024 T4, tandis que le manchon 20 présentait un diamètre extérieur de 70 mm et un diamètre intérieur de 40 mm en étant réalisé dans un deuxième matériau formant un composite à matrice métallique, la matrice métallique étant un alliage d'aluminium de série 2024 T4 et l'élément de renforcement étant composé de particules de carbure de silicium d'une taille moyenne de 5 µm à hauteur de 15 % en poids.This embodiment has been realized with a rod 10 having a diameter of 30 mm made of an aluminum alloy of 2024 T4 series, while the sleeve 20 had an outer diameter of 70 mm and an inside diameter of 40 mm being realized in a second material forming a metal matrix composite, the matrix metal alloy being a 2024 T4 series aluminum alloy and the reinforcement being composed of silicon carbide particles of a average size of 5 μm to 15% by weight.

    Un tel filage peut être effectué à température ambiante ou bien à chaud, en particulier avec une température de l'ordre de 400°C.Such spinning can be carried out at room temperature or hot, especially with a temperature of the order of 400 ° C.

    Après le filage, l'étape ultérieure de l'exemple de réalisation décrit de manière détaillée consiste à effectuer un forgeage par matriçage en vue de donner la forme quasi-définitive de l'aube. After spinning, the subsequent step of the exemplary embodiment described in detail is to perform forging by stamping to give the almost definitive shape of dawn.

    Ce matriçage est réalisé par des étapes successives dans des matrices tendant progressivement à présenter la forme définitive de l'aube dans des conditions de pression et de température adaptées aux matériaux pour maintenir une bonne interface et une bonne adhésion entre le noyau et l'enveloppe : une température de l'ordre de 430°C et une pression de l'ordre de 100 MPa ont notamment été utilisées.This mastering is achieved by successive steps in matrices gradually tending to present the final shape of dawn under pressure and temperature conditions adapted to materials to maintain a good interface and good adhesion between the core and the envelope: a temperature of the order of 430 ° C and a pressure of the order of 100 MPa have been used in particular.

    A l'issue de ces étapes de forgeage par matriçage du demi-produit 32, on obtient une ébauche (non représentée) qui est ensuite usinée pour aboutir à un produit fini formant la pièce mécanique selon l'invention, en particulier une aube telle que celles qui sont représentées sur les figures 3 à 5.At the end of these forging steps by stamping the semi-finished product 32, a blank (not shown) is obtained which is then machined to lead to a finished product forming the mechanical part according to the invention, in particular a blade such as those represented in Figures 3 to 5.

    Sur ces figures, l'aube 50 qui est représentée conformément à différentes formes comporte un noyau 52 réalisé dans le premier matériau constituant initialement la tige 10, tandis que l'enveloppe 54 entourant le noyau 52 est réalisée dans le deuxième matériau formant initialement le manchon 20 de l'ensemble 30 de la figure 2.In these figures, the blade 50 which is represented according to different shapes has a core 52 made of the first material initially constituting the rod 10, while the envelope 54 surrounding the core 52 is made in the second material initially forming the sleeve 20 of the assembly 30 of FIG.

    Comme on peut le voir sur les parties en coupe transversale des figures 3 et 4 ainsi que sur la zone en coupe longitudinale de la figure 5, l'aube 50 présente une régularité de répartition du premier matériau et du deuxième matériau entre le noyau 52 et l'enveloppe 54.As can be seen in the cross-sectional sections of the FIGS. 3 and 4 as well as on the longitudinal sectional area of FIG. 5, dawn 50 has a regular distribution of the first material and the second material between the core 52 and the casing 54.

    Ce résultat très satisfaisant est obtenu, contre toute attente, par des techniques relativement simples à mettre en oeuvre, ce qui génère des propriétés mécaniques homogènes, notamment dans les différentes parties du voile 50a de l'aube, ainsi qu'une continuité entre les propriétés mécaniques de l'aube entre la voile 50a et le pied 50b de l'aube (voir figure 5).This very satisfactory result is obtained, against all odds, by relatively simple techniques to implement, which generates homogeneous mechanical properties, especially in the different parts of the veil 50a of the dawn, as well as a continuity between the properties mechanical dawn between the sail 50a and the foot 50b of dawn (see Figure 5).

    Dans cet exemple de réalisation, on comprend qu'on a placé l'alliage en aluminium dans la partie centrale de l'aube, ce qui permet de bénéficier des propriétés de flexion de l'aluminium alors qu'en surface, le composite à matrice métallique Al/SiC permet une plus grande rigidité et une meilleure tenue à l'impact et à l'érosion.In this embodiment, we understand that we have placed the aluminum alloy in the central part of the blade, which allows benefit from the bending properties of aluminum while at the surface, the metal matrix composite Al / SiC allows greater rigidity and better resistance to impact and erosion.

    Il est bien entendu que, selon l'application à laquelle est destinée la pièce mécanique obtenue selon la présente invention, notamment de la partie requérant la rigidité la plus importante, on peut choisir de placer le composite à matrice métallique Al/SiC dans le noyau (au coeur de la pièce mécanique) ou bien dans l'enveloppe (en surface de la pièce mécanique).It is understood that, depending on the application to which intended for the mechanical part obtained according to the present invention, particular of the part requiring the greatest rigidity, it is possible to choose to place the Al / SiC metal matrix composite in the core (in the heart of the mechanical part) or in the envelope (on the surface of the mechanical part).

    La présente invention n'est pas limitée à l'utilisation d'éléments de renforcement sous la forme de particules de carbure de silicium, des particules d'alumine (Al2O3) ou des carbures métalliques, tels que le carbure de tungstène, le carbure de tungstène, le carbure de bore ou le carbure de titane, pouvant également être utilisés.The present invention is not limited to the use of reinforcing elements in the form of silicon carbide particles, alumina particles (Al 2 O 3 ) or metal carbides, such as tungsten carbide, tungsten carbide, boron carbide or titanium carbide can also be used.

    Egalement, comme il a été exposé dans la partie d'introduction, la présente invention s'applique également à la réalisation d'une pièce mécanique réalisée entièrement en un composite à matrice métallique, lequel présente une composition progressive en éléments de renforcement depuis le centre du noyau vers la périphérie de l'enveloppe.Also, as discussed in the introductory section, the present invention also applies to the production of a part mechanical made entirely of a metal matrix composite, which has a progressive composition of reinforcing elements from the center of the nucleus to the periphery of the envelope.

    Claims (21)

    Pièce mécanique (50, 110) présentant une direction principale le long de laquelle s'étendent une zone de coeur formant un noyau (52) et une zone périphérique formant une enveloppe (54) qui entoure ledit noyau (52), ledit noyau (52) et ladite enveloppe (54) présentant entre eux une liaison métallurgique, ledit noyau (52) étant réalisé dans un premier matériau présentant au moins une matrice métallique et ladite enveloppe (54) étant réalisée dans un deuxième matériau présentant au moins une matrice métallique, caractérisée en ce que lesdites matrices métalliques du premier et du deuxième matériaux présentent le même métal de base et en ce que l'un au moins parmi lesdits premier et deuxième matériaux est formé d'un composite à matrice métallique comprenant des éléments de renforcement dispersés dans ladite matrice métallique.A mechanical part (50, 110) having a main direction along which extends a heart zone forming a core (52) and a peripheral zone forming an envelope (54) which surrounds said core (52), said core (52) ) and said casing (54) having a metallurgical connection between them, said core (52) being made of a first material having at least one metal matrix and said casing (54) being made of a second material having at least one metal matrix, characterized in that said metal matrices of the first and second materials have the same base metal and in that at least one of said first and second materials is formed of a metal matrix composite comprising reinforcing elements dispersed in said metal matrix. Pièce mécanique (50, 110) selon la revendication 1, caractérisée en ce que ledit métal de base est l'aluminium.Mechanical part (50, 110) according to claim 1, characterized in that said base metal is aluminum. Pièce mécanique (50, 110) selon la revendication 2, caractérisée en ce que lesdites matrices métalliques du premier et du deuxième matériaux sont respectivement formées d'un premier alliage et d'un deuxième alliage, ledit premier alliage et ledit deuxième alliage appartenant aux alliages à base d'aluminium des séries 2000, 5000, 6000 ou 7000 selon les normes ASTM.Mechanical part (50, 110) according to claim 2, characterized in that said metal matrices of the first and second materials are respectively formed of a first alloy and a second alloy, said first alloy and said second alloy belonging to the alloys aluminum based 2000, 5000, 6000 or 7000 series according to ASTM standards. Pièce mécanique (50, 110) selon la revendication 3, caractérisée en ce que ledit premier alliage et ledit deuxième alliage appartiennent à la même série d'alliage à base d'aluminium parmi lesdites séries 2000, 5000, 6000 ou 7000 selon les normes ASTM, en particulier à la série 2000.Mechanical part (50, 110) according to claim 3, characterized in that said first alloy and said second alloy belong to the same series of aluminum-based alloy of said series 2000, 5000, 6000 or 7000 according to ASTM standards , in particular to the 2000 series. Pièce mécanique (50, 110) selon l'une quelconque des revendications 1 à 4, caractérisée en ce que lesdits éléments de renforcement sont des particules de carbure de silicium (SiC), d'alumine (Al2O3) ou de carbure métallique tel que carbure de tungstène, de bore ou de titane.Mechanical part (50, 110) according to any one of claims 1 to 4, characterized in that said reinforcing elements are particles of silicon carbide (SiC), alumina (Al 2 O 3 ) or metal carbide such as tungsten carbide, boron or titanium. Pièce mécanique (50, 110) selon la revendication 5, caractérisée en ce que lesdits éléments de renforcement représentent au plus 50% en poids de la composition dudit composite à matrice métallique.Mechanical part (50, 110) according to claim 5, characterized in that said reinforcing elements represent at most 50% by weight of the composition of said metal matrix composite. Pièce mécanique (50, 110) selon la revendication 6, caractérisée en ce que lesdits éléments de renforcement représentent entre 5 et 35%, de préférence entre 10 et 20%, et de préférence de l'ordre de 15% en poids de la composition dudit composite à matrice métallique.Mechanical part (50, 110) according to claim 6, characterized in that said reinforcing elements represent between 5 and 35%, preferably between 10 and 20%, and preferably of the order of 15% by weight of the composition said metal matrix composite. Pièce mécanique (50, 110) selon l'une quelconque des revendications 1 à 7, caractérisée en ce que l'un parmi lesdits premier et deuxième matériaux est formé dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, l'autre parmi lesdits premier et deuxième matériaux étant formé seulement de ladite matrice métallique.Mechanical part (50, 110) according to any one of claims 1 to 7, characterized in that one of said first and second materials is formed of said metal matrix composite comprising said reinforcing elements dispersed in said metal matrix, other of said first and second materials being formed only of said metal matrix. Pièce mécanique (50, 110) selon la revendication 8, caractérisée en ce que ledit premier matériau est formé seulement de ladite matrice métallique qui comporte l'aluminium comme métal de base et en ce que ledit deuxième matériau est formé dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, ladite matrice métallique ayant l'aluminium comme métal de base et lesdits éléments de renforcement étant formés de particules de carbure de silicium (SiC).Mechanical part (50, 110) according to claim 8, characterized in that said first material is formed only of said metal matrix which comprises aluminum as the base metal and in that said second material is formed of said metal matrix composite comprising said reinforcing elements dispersed in said metal matrix, said metal matrix having aluminum as the base metal and said reinforcing elements being formed of silicon carbide (SiC) particles. Pièce mécanique (50, 110) selon l'une quelconque des revendications 1 à 7, caractérisée en ce que lesdits premier et deuxième matériaux sont formés dudit composite à matrice métallique comprenant lesdits éléments de renforcement dispersés dans ladite matrice métallique, lesdits éléments de renforcement représentant un pourcentage en poids de la composition dudit composite à matrice métallique différent dans ledit noyau (52) et dans ladite enveloppe (54).Mechanical part (50, 110) according to any one of claims 1 to 7, characterized in that said first and second materials are formed of said metal matrix composite comprising said reinforcing elements dispersed in said metal matrix, said reinforcing elements representing a percentage by weight of the composition of said different metal matrix composite in said core (52) and said envelope (54). Pièce mécanique (50, 110) selon la revendication 10, caractérisée en ce que lesdits éléments de renforcement représentent un pourcentage en poids de la composition dudit composite à matrice métallique progressif dans ledit premier matériau et dans ledit deuxième matériau, depuis le centre dudit noyau (52) vers la périphérie de ladite enveloppe (54).Mechanical part (50, 110) according to claim 10, characterized in that said reinforcing elements represent a percentage by weight of the composition of said progressive metal matrix composite in said first material and in said second material, from the center of said core ( 52) to the periphery of said envelope (54). Pièce mécanique (50, 110) selon la revendication 10 ou 11, caractérisée en ce que ledit premier matériau présente, pour lesdits éléments de renforcement, un pourcentage en poids de la composition dudit composite à matrice métallique plus important que dans ledit deuxième matériau.Mechanical part (50, 110) according to claim 10 or 11, characterized in that said first material has, for said reinforcing elements, a percentage by weight of the composition of said metal matrix composite greater than in said second material. Pièce mécanique (50, 110) selon la revendication 10 ou 11, caractérisée en ce que ledit deuxième matériau présente, pour lesdits éléments de renforcement, un pourcentage en poids de la composition dudit composite à matrice métallique plus important que dans ledit premier matériau.Mechanical part (50, 110) according to claim 10 or 11, characterized in that said second material has, for said reinforcing elements, a percentage by weight of the composition of said metal matrix composite greater than in said first material. Aube (50, 110) constituée d'une pièce mécanique selon l'une quelconque des revendications 1 à 13.Aube (50, 110) consisting of a mechanical part according to one any of claims 1 to 13. Compresseur basse pression comprenant des aubes fixes et/ou mobiles selon la revendication 14.Low pressure compressor comprising stationary vanes and / or mobile according to claim 14. Soufflante (104) de turboréacteur comprenant des aubes (110) selon la revendication 14.Blower (104) for a turbojet comprising vanes (110) according to claim 14. Procédé de fabrication d'une pièce mécanique (50, 110) selon l'une quelconque des revendications 1 à 13, caractérisé en ce qu'il comporte successivement les étapes suivantes : a) on réalise par compactage un demi-produit contenant un noyau (52) et une enveloppe (54), ledit noyau (52) et ladite enveloppe (54) présentant entre eux une liaison métallurgique, ledit noyau (52) étant réalisé dans un premier matériau présentant au moins une matrice métallique et ladite enveloppe (54) étant réalisée dans un deuxième matériau présentant au moins une matrice métallique, lesdites matrices métalliques du premier et du deuxième matériaux présentant le même métal de base et l'un au moins parmi lesdits premier et deuxième matériaux étant formé d'un composite à matrice métallique comprenant des éléments de renforcement dispersés dans ladite matrice métallique, b) on réalise le forgeage du demi-produit pour obtenir une ébauche, et c) on usine ladite ébauche pour aboutir à un produit fini formant ladite pièce mécanique . A method of manufacturing a mechanical part (50, 110) according to any one of claims 1 to 13, characterized in that it comprises successively the following steps: a) is produced by compacting a semi-product containing a core (52) and an envelope (54), said core (52) and said envelope (54) having a metallurgical bond between them, said core (52) being formed in a first material having at least one metal matrix and said envelope (54) being made of a second material having at least one metal matrix, said metal matrices of the first and second materials having the same base metal and at least one of said first and second materials being formed of a metal matrix composite comprising reinforcing elements dispersed in said metal matrix, b) forging the semi-finished product to obtain a blank, and c) the blank is machined to result in a finished product forming said mechanical part. Procédé de fabrication selon la revendication 17 en vue de l'obtention d'une pièce mécanique selon la revendication 11, caractérisé en ce que ladite étape a) consiste à former conjointement le noyau (52) et l'enveloppe (54) par la technique de métallurgie des poudres.Manufacturing method according to claim 17 to obtain a mechanical part according to claim 11, characterized in that said step a) consists of jointly forming the core (52) and the casing (54) by the technique metallurgy of powders. Procédé de fabrication selon la revendication 17 en vue de l'obtention d'une pièce mécanique selon l'une quelconque des revendications 1 à 10, caractérisé en ce que ladite étape a) consiste à réaliser successivement les sous-étapes suivantes : a1) former une tige (10) s'étendant selon une direction longitudinale dans ledit premier matériau, ladite tige (10) étant destinée à former ledit noyau (52) placé au coeur de la pièce mécanique ; a2) former un manchon (20) s'étendant selon une direction longitudinale dans ledit deuxième matériau, ledit manchon (20) étant destinée à former l'enveloppe (54) de la pièce mécanique en entourant ledit noyau (52) ; a3) introduire la tige (10) dans le manchon (20) pour former un ensemble (30), et a4) passer à travers un orifice de section réduite ledit ensemble (30) pour diminuer au moins une dimension dudit ensemble selon une direction perpendiculaire à ladite direction longitudinale et afin de créer une liaison métallurgique entre ladite tige (10) et le dit manchon (20). Manufacturing method according to claim 17 to obtain a mechanical part according to any one of claims 1 to 10, characterized in that said step a) consists in successively performing the following substeps: a1) forming a rod (10) extending in a longitudinal direction in said first material, said rod (10) being intended to form said core (52) placed in the heart of the mechanical part; a2) forming a sleeve (20) extending in a longitudinal direction in said second material, said sleeve (20) being intended to form the envelope (54) of the mechanical part surrounding said core (52); a3) introducing the rod (10) into the sleeve (20) to form an assembly (30), and a4) passing through a reduced section orifice said assembly (30) to reduce at least one dimension of said assembly in a direction perpendicular to said longitudinal direction and to create a metallurgical connection between said rod (10) and said sleeve (20); ). Procédé selon l'une quelconque des revendications 17 à 19, caractérisé en ce que ladite sous-étape a4) consister à effectuer un laminage ou un filage.Process according to any one of Claims 17 to 19, characterized in that the said sub-step a4) consists of rolling or spinning. Procédé selon l'une quelconque des revendications 17 à 20, caractérisé en ce que ladite étape b) consister à effectuer un matriçage.Method according to any one of claims 17 to 20, characterized in that said step b) consist in carrying out a stamping.
    EP03291800A 2002-07-25 2003-07-21 Metal matrix composite blade and process for its manufacture Expired - Lifetime EP1384539B1 (en)

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    EP3460188A1 (en) * 2017-09-22 2019-03-27 Rolls-Royce plc Aerofoil component and method
    WO2020007916A1 (en) * 2018-07-04 2020-01-09 Rolls-Royce Plc Method and tool set for manufacturing a composite component

    Also Published As

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    CN1671498A (en) 2005-09-21
    UA82069C2 (en) 2008-03-11
    US7749342B2 (en) 2010-07-06
    RU2347648C2 (en) 2009-02-27
    FR2842828A1 (en) 2004-01-30
    CA2493445A1 (en) 2004-02-05
    CA2493445C (en) 2011-06-14
    DE60331206D1 (en) 2010-03-25
    AU2003269058A8 (en) 2004-02-16
    RU2005105069A (en) 2005-07-20
    CN1671498B (en) 2010-09-01
    WO2004011687A3 (en) 2004-04-15
    EP1384539B1 (en) 2010-02-10
    WO2004011687A2 (en) 2004-02-05
    AU2003269058A1 (en) 2004-02-16
    ES2340372T3 (en) 2010-06-02
    FR2842828B1 (en) 2005-04-29
    US20060127693A1 (en) 2006-06-15
    JP2005533931A (en) 2005-11-10

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