EP1384539B1 - Metal matrix composite blade and process for its manufacture - Google Patents

Metal matrix composite blade and process for its manufacture Download PDF

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Publication number
EP1384539B1
EP1384539B1 EP03291800A EP03291800A EP1384539B1 EP 1384539 B1 EP1384539 B1 EP 1384539B1 EP 03291800 A EP03291800 A EP 03291800A EP 03291800 A EP03291800 A EP 03291800A EP 1384539 B1 EP1384539 B1 EP 1384539B1
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EP
European Patent Office
Prior art keywords
metal matrix
blade
core
reinforcing elements
casing
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.)
Expired - Lifetime
Application number
EP03291800A
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German (de)
French (fr)
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EP1384539A1 (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
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Forges de Bologne
SNECMA SAS
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Publication of EP1384539A1 publication Critical patent/EP1384539A1/en
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Publication of EP1384539B1 publication Critical patent/EP1384539B1/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 blade having a main direction along which extends a heart zone forming a core and a peripheral zone forming an envelope which surrounds said core, 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 of a second material having at least one metal matrix.
  • the present invention relates to obtaining a blade for which the metal matrix of the first material and / or the second material has aluminum as the base metal.
  • the present invention relates to a blade used in the aeronautical sector, in particular as a blade or a fixed blade of a compressor, particularly low pressure, or as a fan blade ("fan") of a jet engine .
  • titanium alloys are widely used for this purpose, which has the disadvantage of particular costs of raw material and a weight sometimes still considered too important.
  • DE-A-4137839 discloses the manufacture of a turbine blade by compression and forging of an aluminum alloy core, possibly reinforced with carbon fibers, and an erosion-resistant steel casing.
  • the present invention aims to overcome the disadvantages of these techniques of the prior art by providing a blade and its manufacturing process using metallurgical techniques simple to implement.
  • the present invention therefore relates to a blade according to claim 1.
  • said metal matrices of the 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 reinforcing elements dispersed in said metal matrix.
  • the characteristics of the interface between two materials forming a part, 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 In this respect, the identity of the base metal forming part of the composition of the first and second materials is of great importance in obtaining a core and an envelope forming between them a metallurgical bond having a high mechanical strength.
  • this arrangement makes it possible, by the presence of reinforcing elements, in at least one of the first material and the second material, to improve the properties of mechanical strength and, optionally, temperature resistance, of the part in which the part that is to be reinforced, while generally maintaining a density similar to that of the metal matrix.
  • first material (core) and the second material (envelope), or both the first material and the second material (core and envelope) is (are) constituted of a metal matrix composite comprising reinforcement elements dispersed in said metal matrix.
  • composition of the first material is different from that of the second material, at least as regards the proportion of the reinforcing elements.
  • the blade according to the invention can belong to a compressor, in particular low pressure, whether as a fixed blade or as a mobile blade.
  • Such a blade can be applied to the realization of a turbojet fan.
  • the present invention relates to the manufacturing process which makes it possible, by its implementation, to obtain said blade.
  • said step a) consists of jointly forming the core and the envelope by the powder metallurgy technique.
  • 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 directly forming the semi-finished product.
  • This first solution is particularly well suited to the situation in which it is desired to obtain a blade where said reinforcing 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, either decreasing from the center, or increasing from the center, between for example, a minimum of 0% to 10% and a maximum less than or equal to 50% in weight.
  • the sub-step a4) of the second solution of step a), consists in carrying out, preferably, a rolling or spinning of the assembly, that is to say by successive passages, in force and hot , between pairs of cylinders more and more close together or in dies of smaller and smaller section.
  • this step a) uses a technique that performs the compaction, in particular the pressurization between the core and the envelope, either at the time of their joint formation (first solution), or at the time of their initial formation. as separate pieces (second solution), so as to create between the materials constituting them a metallurgical type connection generating a good interface.
  • this metallurgical bond forms a more intimate contact than a mechanical bond, the first and second materials being so close that the inter-atomic forces come into play. Such an interface will allow the dawn to withstand satisfactory to the different constraints to which it is subjected.
  • the forging generally consists of a metallurgical operation whose object is to transform the ingots into blanks of determined shape by deformation of a metal brought to a temperature where it is sufficiently malleable, the deformation being obtained either by shock (pestle, sheep), or by pressure (presses with closed die) between two tools.
  • this forging step consists of stamping or stamping.
  • Other forging possibilities can also be used alone, or in combination with 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 the base metal and to a second material which 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: 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
  • step a4 passing through a smaller section orifice (rolling or spinning), as well as its good resistance to corrosion.
  • FIG. figure 1 An example of the possible applications of the blade according to the present invention is shown in FIG. figure 1 in the form of a double-flow turbojet engine 100.
  • This turbojet engine 100 comprises a conventional structure which comprises various elements arranged axially around the longitudinal axis 102, in fluid communication with each other, namely in particular a fan 104 and an accelerator 106.
  • turbojet comprises the other conventional elements of such a structure, namely a high pressure compressor, a combustion chamber, a high pressure turbine and a low pressure turbine, these various additional elements not being represented. for the sake of clarity.
  • the fan 104 and the accelerator 106 are rotated by the low-pressure turbine through the rotor axis 108.
  • the fan 104 comprises a series of radially extending blades 110 which are mounted on an annular disc 112: only one of these vanes appears on the 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 comprises several series of rotating blades 116 rotatably mounted on a disk 118 and between which are mounted series of blades 120.
  • the present invention relates to obtaining a blade that can constitute in particular each blade 110 of the blower 104 and / or each of the blades 116 and / or vanes 120 of the accelerator 106.
  • the blade according to the present invention can also constitute the blades and / or mobile blades of other elements of a turbojet, identical or different from that illustrated on the figure 1 , such as a compressor, in particular a low pressure compressor.
  • the blade according to the present invention can also find application in fields other than aeronautics for the formation of structural elements having to withstand mechanically while having a relatively lightly.
  • a blade composed of a core made of a first material formed of an aluminum-based alloy and of an envelope made of a second material formed of a metal matrix composite wherein the metal matrix is an aluminum alloy and the reinforcing elements are silicon carbide (SiC) particles.
  • an aluminum rod 10 is first formed by conventional techniques for manufacturing aluminum alloys.
  • the next step is to introduce the rod 10 inside the sleeve 20 to form an assembly 30: it is clear that at this stage there is a clearance, or even a space between the outer surface of the rod 10 and the surface inside the wall of the sleeve 20.
  • the assembly 30 appears as being introduced into the inlet 40 of a die 42.
  • This inlet 40 has a truncated cone shape with an angle at the center ⁇ forming the reduction angle.
  • This inlet 40 has an upstream diameter greater than the outside diameter of 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 of force and hot at the inlet 40 of the die 42, reduced in section by elongation, an interface being created between the rod 10 and the sleeve 20 which form jointly in this way a complex semi-product 32 at the outlet 44 of the die 42.
  • spinning step illustrated on the figure 2 may comprise several successive passages in dies with smaller and smaller diameters.
  • the reduction angle ⁇ is equal to 30 °, this reduction angle can vary generally between 1 ° and 45 ° and preferably between 5 and 35 °.
  • this spinning technique in particular when it is carried out by successively passing through series dies, makes it possible, by the pressure exerted between the surfaces in contact by friction, a good cohesion between the materials constituting the core and the 'envelope.
  • This exemplary embodiment was made with a rod 10 having a diameter of 30 mm made of an aluminum alloy of series 2024 T4, while the sleeve 20 had an outer diameter of 70 mm and an internal diameter of 40 mm while being made in a second material forming a metal matrix composite, the metal matrix being an aluminum alloy of series 2024 T4 and the reinforcing element being composed of silicon carbide particles having a mean size of 5 ⁇ m at 15% by weight.
  • Such spinning can be carried out at room temperature or hot, in particular with a temperature of the order of 400 ° C.
  • the subsequent step of the embodiment described in detail is to perform forging by stamping to give the almost final shape of the blade.
  • This stamping is performed by successive steps in matrices progressively tending to present the final shape of the blade under conditions of pressure and temperature adapted to the materials to maintain a good interface and a 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 were used in particular.
  • a blank (not shown) is obtained which is then machined to produce a finished product forming the blade according to the invention, in particular a blade such that those represented on the Figures 3 to 5 .
  • the blade 50 which is represented according to different shapes comprises a core 52 made in the first material initially constituting the rod 10, while the casing 54 surrounding the core 52 is made in the second material initially forming the sleeve. 20 of the whole 30 of the figure 2 .
  • the blade 50 has a regular distribution of the first material and the second material between the core 52 and the casing 54.
  • the aluminum alloy has been placed in the central part of the blade, which makes it possible to benefit from the bending properties of aluminum while at the surface, the matrix composite Al / SiC metal allows greater rigidity and better resistance to impact and erosion.
  • 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 realization of a blade made entirely of a metal matrix composite, which has a progressive composition of reinforcing elements from the center of the core towards 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)

Description

La présente invention concerne l'obtention d'une aube 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 blade having a main direction along which extends a heart zone forming a core and a peripheral zone forming an envelope which surrounds said core, 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 of a second material having at least one metal matrix.

Elle concerne plus précisément:

  • une aube 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 aube précitée.
It concerns more precisely:
  • a blade 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 method that allows the production, by its implementation, of said blade.

En particulier, de manière non limitative, la présente invention concerne l'obtention d'une aube 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 blade for which the metal matrix of the first material and / or the second material has aluminum as the base metal.

Dans une application préférée, mais non limitative, la présente invention concerne une aube 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 limited to, the present invention relates to a blade used in the aeronautical sector, in particular as a blade or a fixed blade of a compressor, particularly low pressure, or as a fan blade ("fan") of a jet engine .

Toutefois, la présente invention n'est pas destinée à être limitée à la réalisation d'aubes du secteur aéronautique.However, the present invention is not intended to be limited to the realization of blades of the aeronautical sector.

Spécifiquement, des aubes 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 vanes with good mechanical strength and temperature resistance characteristics are required for various types of applications.

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 specifically in jet engines, are searched for materials with optimum mechanical strength and temperature resistance characteristics, in particular for the manufacture of stationary and / or mobile vanes.

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 for this purpose, which has the disadvantage of particular costs of raw material and 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 the production of titanium hollow parts for lightening 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 production 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 part. According to this document of the prior art, 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, it is intended 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 part without particularly altering its density.

DE-A-4137839 divulgue la fabrication d'une aube de turbine par compression et forgeage d'un noyau en alliage d'aluminium, éventuellement renforcé par des fibres de carbone, et d'une enveloppe en acier résistant à l'érosion. DE-A-4137839 discloses the manufacture of a turbine blade by compression and forging of an aluminum alloy core, possibly reinforced with carbon fibers, and an erosion-resistant steel casing.

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 also detrimental from the point of view of the mass of the mechanical part and the cost of raw material while the hot isostatic pressing technique is cumbersome to implement.

La présente invention a pour objectif de pallier les inconvénients de ces techniques de l'art antérieur en proposant une aube 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 providing a blade and its manufacturing process using metallurgical techniques simple to implement.

Selon un de ses aspects, la présente invention concerne donc une aube selon la revendication 1.According to one of its aspects, the present invention therefore relates to a blade according to claim 1.

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.Typically, said metal matrices of the 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 reinforcing elements 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, it is understood that it is possible to obtain a part having a core and an envelope between which is formed an interface formed of a physico-chemical bond of very good quality because of the similarity between the first and second materials that contain 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 part, 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 In this respect, the identity of the base metal forming part of the composition of the first and second materials is of great importance in obtaining a core and an envelope forming between them a metallurgical bond having a high mechanical strength.

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 makes it possible, by the presence of reinforcing elements, in at least one of the first material and the second material, to improve the properties of mechanical strength and, optionally, temperature resistance, of the part in which the part that is to be reinforced, while generally maintaining a density similar to that of the metal matrix.

On note incidemment que selon l'application envisagée pour l'aube, 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 dawn, only one of the first material (core) and the second material (envelope), or both the first material and the second material (core and envelope) is (are) constituted of a metal matrix composite comprising reinforcement elements 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 regards the proportion of the reinforcing elements.

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

  • 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, 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 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, and said reinforcing elements being formed of particles 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.

L'aube selon l'invention peut appartenir à un compresseur, en particulier basse pression, que ce soit en tant qu'aube fixe ou en tant qu'aube mobile.The blade according to the invention can belong to a compressor, in particular low pressure, whether as a fixed blade or as a mobile blade.

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

Selon un autre aspect, aux termes de la revendication 15 la présente invention concerne le procédé de fabrication qui permet l'obtention, par sa mise en oeuvre, de ladite aube précitée.According to another aspect, according to claim 15, the present invention relates to the manufacturing process which makes it possible, by its implementation, to obtain said blade.

Concernant la réalisation de l'étape a), plusieurs solutions sont possible sans sortir du cadre de la présente invention.Regarding the realization 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 of jointly forming the core and the envelope by the powder metallurgy technique. 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 directly forming the semi-finished product.

Cette première solution est en particulier bien adaptée à la situation dans laquelle on souhaite obtenir une aube 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 suited to the situation in which it is desired to obtain a blade where said reinforcing 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, either decreasing from the center, or increasing from the center, between for example, a minimum of 0% to 10% and a maximum less than or equal to 50% in 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 l'aube ;
  • a2) former un manchon s'étendant selon une direction longitudinale dans ledit deuxième matériau, ledit manchon étant destinée à former l'enveloppe de l'aube 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 adapted to form said core placed at heart of dawn;
  • a2) forming a sleeve extending in a longitudinal direction in said second material, said sleeve being adapted to form the envelope of the blade 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 aube 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 suited to the situation in which it is desired to obtain a blade where said reinforcing elements are only present in one of said first and second materials, the other of said first and second materials being formed only of said metal matrix. We then favor the realization of the one of the core (first material) and the envelope (second material) which comprises the reinforcing elements 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.The sub-step a4) of the second solution of step a), consists in carrying out, preferably, a rolling or spinning of the assembly, that is to say by successive passages, in force and hot , between pairs of cylinders more and more close together or in dies of smaller and smaller section.

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 that performs the compaction, in particular the pressurization between the core and the envelope, either at the time of their joint formation (first solution), or at the time of their initial formation. as separate pieces (second solution), so as to create between the materials constituting them 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 l'aube 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 bond, the first and second materials being so close that the inter-atomic forces come into play. Such an interface will allow the dawn 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 realization 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.In fact, the forging generally consists of a metallurgical operation whose object is to transform the ingots into blanks of determined shape by deformation of a metal brought to a temperature where it is sufficiently malleable, the deformation being obtained either by shock (pestle, sheep), or by pressure (presses with closed die) 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 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 the base metal and to a second material which 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: 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 a base metal makes it possible to benefit from its good elongation properties, in particular for the forging step and also, in the case of the second solution of step a), when step a4) passing through a smaller section orifice (rolling or spinning), as well as its good resistance to corrosion.

L'invention sera mieux comprise, et les caractéristiques secondaires et leurs avantages apparaîtront au cours de la description de modes de réalisation de l'aube selon l'invention donnée ci-dessous à titre d'exemple.The invention will be better understood, and the secondary characteristics and their advantages will become apparent during the description of embodiments of the blade according to the invention given below by way of example.

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 drawings are only 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 l'aube 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 l'aube selon la présente invention, et
  • la figure 5 est une vue en perspective partielle avec coupe selon la direction longitudinale d'une autre aube selon la présente invention.
Reference will be made to the accompanying drawings, in which:
  • the figure 1 is a partial longitudinal sectional view of a double-flow turbojet engine showing a blower and an accelerator illustrating by way of example possible applications of the blade according to the present invention,
  • the figure 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,
  • the Figures 3 and 4 are perspective views of blades truncated at their radially outer end which illustrate possible applications of the blade according to the present invention, and
  • the figure 5 is a partial perspective view with section along the longitudinal direction of another blade according to the present invention.

Un exemple des applications possibles de l'aube 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 blade according to the present invention is shown in FIG. 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 various elements arranged axially around the longitudinal axis 102, in fluid communication with each other, namely in particular a fan 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 comprises the other conventional elements of such a structure, namely a high pressure compressor, a combustion chamber, a high pressure turbine and a low pressure turbine, these various additional elements not being 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 through 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 apparaît 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 fan 104 comprises a series of radially extending blades 110 which are mounted on an annular disc 112: only one of these vanes appears on the 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 comprises several series of rotating blades 116 rotatably mounted on a disk 118 and between which are mounted series of blades 120.

La présente invention concerne l'obtention d'une aube 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 blade that can constitute in particular each blade 110 of the blower 104 and / or each of the blades 116 and / or vanes 120 of the accelerator 106.

Egalement, l'aube 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 blade according to the present invention can also constitute the blades and / or mobile blades of other elements of a turbojet, identical or different from that illustrated on the figure 1 , such as a compressor, in particular a low pressure compressor.

Comme il a été mentionné précédemment, il convient de rappeler que l'aube 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 should be remembered that the blade according to the present invention can also find application in fields other than aeronautics for the formation of structural elements having to withstand mechanically while having a relatively lightly.

Un exemple de réalisation du procédé de fabrication selon la présente invention permettant l'obtention des aubes mentionnées précédemment va maintenant être décrit.An exemplary embodiment of the manufacturing method according to the present invention for obtaining the blades mentioned above 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 nonlimiting exemplary embodiment, it is considered the realization of a blade composed of a core made of a first material formed of an aluminum-based alloy and of an envelope made of a second material formed of a metal matrix composite wherein the metal matrix is an aluminum alloy and the reinforcing elements are silicon carbide (SiC) particles.

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, an aluminum rod 10 is first formed 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.Also manufactured is a sleeve made in the aforesaid second 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 the sleeve 20 to form an assembly 30: it is clear that at this stage there is a clearance, or even a space between the outer surface of the rod 10 and the surface inside 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, it is chosen to perform a spinning which is represented on the figure 2 .

Sur cette figure 2, l'ensemble 30 apparaît 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.On this figure 2 , the assembly 30 appears as being introduced into the inlet 40 of a die 42. This inlet 40 has a truncated cone shape with an angle at the center α forming the reduction angle. This inlet 40 has an upstream diameter greater than the outside diameter of 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.Consequently, the assembly 30 is, during the passage of force and hot at the inlet 40 of the die 42, reduced in section by elongation, an interface being created between the rod 10 and the sleeve 20 which form jointly in this way a complex semi-product 32 at the outlet 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 on the figure 2 may comprise several successive passages in dies 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 can vary generally 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, a section reduction is obtained 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 may be noted that this spinning technique, in particular when it is carried out by successively passing through series dies, makes it possible, by the pressure exerted between the surfaces in contact by friction, a 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 exemplary embodiment was made with a rod 10 having a diameter of 30 mm made of an aluminum alloy of series 2024 T4, while the sleeve 20 had an outer diameter of 70 mm and an internal diameter of 40 mm while being made in a second material forming a metal matrix composite, the metal matrix being an aluminum alloy of series 2024 T4 and the reinforcing element being composed of silicon carbide particles having a mean size of 5 μm at 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, in particular 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 embodiment described in detail is to perform forging by stamping to give the almost final shape of the blade.

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 stamping is performed by successive steps in matrices progressively tending to present the final shape of the blade under conditions of pressure and temperature adapted to the materials to maintain a good interface and a 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 were 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 l'aube selon l'invention, en particulier une aube telle que celles qui sont représentées sur les figures 3 à 5.At the end of these stamping forging steps of the half-product 32, a blank (not shown) is obtained which is then machined to produce a finished product forming the blade according to the invention, in particular a blade such that those represented on the 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 comprises a core 52 made in the first material initially constituting the rod 10, while the casing 54 surrounding the core 52 is made in the second material initially forming the sleeve. 20 of the whole 30 of the figure 2 .

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 Figures 3 and 4 as well as on the longitudinal section of the figure 5 , the blade 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 blade, and 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, it is understood that the aluminum alloy has been placed in the central part of the blade, which makes it possible to benefit from the bending properties of aluminum while at the surface, the matrix composite Al / SiC metal allows greater rigidity and better resistance to impact and erosion.

Il est bien entendu que, selon l'application à laquelle est destinée l'aube 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 for which the blade obtained according to the present invention is intended, in 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 aube 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 explained in the introductory part, the present invention also applies to the realization of a blade made entirely of a metal matrix composite, which has a progressive composition of reinforcing elements from the center of the core towards the periphery of the envelope.

Claims (19)

  1. A blade (50, 110) resulting from an initial step of compression followed by a forging step which imparts the quasi-final shape to the blade, said blade presenting a main direction along which there extend a central zone forming a core (52) and a peripheral zone forming a casing (54) which surrounds said core (52), said core (52) and said casing (54) presenting a metallurgical bond between each other resulting from said compression step, said core (52) is made of a first material presenting at least a metal matrix, and said casing (54) is made of a second material presenting at least a metal matrix, said metal matrix of the first material having aluminium as base metal, and at least one of said first and second materials being made of a metal matrix composite containing reinforcing elements dispersed in said metal matrix, characterized in that said metal matrix of the second material has aluminium as base metal.
  2. A blade (50, 110) according to claim 1, characterized in that said metal matrices of the first and second materials are respectively constituted by a first alloy and a second alloy, said first alloy and said second alloy being selected from aluminum-based alloys of the ASTM standards series 2000, 5000, 6000, or 7000.
  3. A blade (50, 110) according to claim 2, characterized in that said first alloy and said second alloy are selected from the same series of aluminum-based alloys selected from said ASTM standard series 2000, 5000, 6000, or 7000, and in particular from the 2000 series.
  4. A blade (50, 110) according to any one of claims 1 to 3, characterized in that said reinforcing elements are particles of silicon carbide (SiC), of alumina (Al2O3), or of metal carbide such as tungsten, boron, or titanium carbide.
  5. A blade (50, 110) according to claim 4, characterized in that said reinforcing elements represent no more than 50% by weight of the composition of said metal matrix composite.
  6. A blade (50, 110) according to claim 5, characterized in that said reinforcing elements represent 5 to 35 %, preferably 10% to 20%, and more preferably about 15% by weight of the composition of said metal matrix composite.
  7. A blade (50, 110) according to any one of claims 1 to 6, characterized in that one of said first and second materials is made of said metal matrix composite containing said reinforcing elements dispersed in said metal matrix, the other one of said first and second materials being made of said metal matrix only.
  8. A blade (50, 110) according to claim 7, characterized in that said first material is made of said metal matrix only which comprises aluminum as its base metal, and in that said second material is made of said metal matrix composite containing said reinforcing elements dispersed in said metal matrix, said metal matrix having aluminum as its base metal and said reinforcing elements being made of silicon carbide (SiC) particles.
  9. A blade (50, 110) according to any one of claims 1 to 6, characterized in that said first and second materials are made of said metal matrix composite containing said reinforcing elements dispersed in said metal matrix, said reinforcing elements representing different percentages by weight of the composition of said metal matrix composite in said core (52) and in said casing (54).
  10. A blade (50, 110) according to claim 9, characterized in that said reinforcing elements represent a percentage by weight of the composition of said metal matrix composite that varies progressively in said first material and in said second material going from the center of said core (52) towards the periphery of said casing (54).
  11. A blade (50, 110) according to claim 9 or claim 10, characterized in that for said reinforcing elements, said first material presents a percentage by weight of the composition of said metal matrix composite that is greater than in said second material.
  12. A blade (50, 110) according to claim 9 or claim 10, characterized in that for said reinforcing elements, said second material presents a percentage by weight of the composition of said metal matrix composite that is greater than in said first material.
  13. A low pressure compressor including stationary blades and/or moving blades according to any one of claims 1 to 12.
  14. A turbojet fan (104) including blades (110) according to any one of claims 1 to 12.
  15. A method of manufacturing a blade (50, 110) according to any one of claims 1 to 12, characterized in that it comprises the following successive steps:
    a) obtaining by compression a semi-finished product containing a core (52) and a casing (54), said core (52) and said casing (54) presenting a metallurgical bond between each other resulting from said intial compression step, said core (52) being made of a first material presenting at least an aluminium based metal matrix, and said casing (54) being made of a second material presenting at least an aluminium based metal matrix, and at least one of said first and second materials being made of a metal matrix composite containing reinforcing elements dispersed in said metal matrix;
    b) forging the semi-finished product containing said core (52) and said casing (54) which have been compressed together in the previous step a) to obtain a blank having the quasi-final shape of the blade; and
    c) machining said blank to provide a finished product forming said blade.
  16. A method of manufacture according to claim 15 for obtaining a blade according to claim 10, the method being characterized in that said step a) consists in forming the core (52) and the casing (54) conjointly by the powder metallurgy technique.
  17. A method of manufacture according to claim 15 for obtaining a blade according to any one of claims 1 to 9, characterized in that said step a) consists in performing the following substeps in succession:
    a1) using said first material to make a rod (10) extending in a longitudinal direction, said rod (10) serving to form said core (52) placed in the center of the blade;
    a2) using said second material to make a sleeve (20) extending in a longitudinal direction, said sleeve (20) serving to form the casing (54) of the blade by surrounding said core (52);
    a3) inserting the rod (10) into the sleeve (20) to form an assembly (30); and
    a4) passing said assembly (30) through an orifice of small section in order to reduce at least one dimension of said assembly in a direction perpendicular to said longitudinal direction in order to create a metallurgical bond between said rod (10) and said sleeve (20).
  18. A method according to claim 17, characterized in that said substep a4) consists in rolling or extrusion.
  19. A method according to any one of claims 15 to 18, characterized in that said step b) consists in die stamping.
EP03291800A 2002-07-25 2003-07-21 Metal matrix composite blade and process for its manufacture Expired - Lifetime EP1384539B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0209444A FR2842828B1 (en) 2002-07-25 2002-07-25 MECHANICAL PIECE, AND METHOD OF MANUFACTURING SUCH A MECHANICAL PIECE
FR0209444 2002-07-25

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EP1384539B1 true EP1384539B1 (en) 2010-02-10

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EP (1) EP1384539B1 (en)
JP (1) JP2005533931A (en)
CN (1) CN1671498B (en)
AU (1) AU2003269058A1 (en)
CA (1) CA2493445C (en)
DE (1) DE60331206D1 (en)
ES (1) ES2340372T3 (en)
FR (1) FR2842828B1 (en)
RU (1) RU2347648C2 (en)
UA (1) UA82069C2 (en)
WO (1) WO2004011687A2 (en)

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EP1384539A1 (en) 2004-01-28
CN1671498A (en) 2005-09-21
AU2003269058A1 (en) 2004-02-16
WO2004011687A2 (en) 2004-02-05
US7749342B2 (en) 2010-07-06
RU2005105069A (en) 2005-07-20
DE60331206D1 (en) 2010-03-25
CA2493445A1 (en) 2004-02-05
JP2005533931A (en) 2005-11-10
FR2842828B1 (en) 2005-04-29
CN1671498B (en) 2010-09-01
FR2842828A1 (en) 2004-01-30
ES2340372T3 (en) 2010-06-02
AU2003269058A8 (en) 2004-02-16
UA82069C2 (en) 2008-03-11
WO2004011687A3 (en) 2004-04-15
RU2347648C2 (en) 2009-02-27
US20060127693A1 (en) 2006-06-15
CA2493445C (en) 2011-06-14

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