EP2443265A1 - Method for making a metal part including a fibrous annular reinforcement - Google Patents

Method for making a metal part including a fibrous annular reinforcement

Info

Publication number
EP2443265A1
EP2443265A1 EP10738003A EP10738003A EP2443265A1 EP 2443265 A1 EP2443265 A1 EP 2443265A1 EP 10738003 A EP10738003 A EP 10738003A EP 10738003 A EP10738003 A EP 10738003A EP 2443265 A1 EP2443265 A1 EP 2443265A1
Authority
EP
European Patent Office
Prior art keywords
cavity
blank
metal
winding
wire
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
EP10738003A
Other languages
German (de)
French (fr)
Other versions
EP2443265B1 (en
Inventor
Patrick Dunleavy
Jean-Michel Patrick Maurice Franchet
Gilles Charles Casimir Klein
Richard Masson
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 Landing Systems SAS
Original Assignee
Messier Bugatti Dowty SA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Messier Bugatti Dowty SA filed Critical Messier Bugatti Dowty SA
Publication of EP2443265A1 publication Critical patent/EP2443265A1/en
Application granted granted Critical
Publication of EP2443265B1 publication Critical patent/EP2443265B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C14/00—Alloys based on titanium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/02—Pretreatment of the fibres or filaments
    • C22C47/04—Pretreatment of the fibres or filaments by coating, e.g. with a protective or activated covering
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/02—Pretreatment of the fibres or filaments
    • C22C47/06—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
    • C22C47/062—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element from wires or filaments only
    • C22C47/064—Winding wires
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • Y10T29/49337—Composite blade
    • 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
    • Y10T29/49481—Wheel making
    • Y10T29/4949—Material winding, e.g., reel, spool
    • 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
    • Y10T29/49801—Shaping fiber or fibered material

Definitions

  • the invention relates to a metal part having an annular portion including a coaxial annular fiber reinforcement, in the form of a coil of composite material enclosed in a metal matrix.
  • the invention relates more particularly to the manufacture of such a piece with improved strength. It also relates to a metal part enclosing such a coaxial annular reinforcement.
  • the ceramic is, for example, silicon carbide wire which has a tensile or compressive strength greater than that of a metal, such as titanium for example.
  • the document FR 2 886 290 proposes to carry out the winding directly on a part of the blank forming the winding mandrel. It is therefore an "external" winding of the most classic. More precisely, this part has two shoulders. The radially innermost shoulder forms a lateral bearing surface for the winding. The adjacent cylindrical portion forms the base surface on which the winding is made. It has a rectangular shape in right cross section. After winding, complete the blank by complementary metal parts, including an outer ring and a side cover having a pin coming into contact with the winding.
  • the hot isostatic pressing operation is known per se; it consists of placing the aforementioned assembly in a box and subjecting this assembly, for several hours, to a high pressure of the order of 1000 bar and at a temperature of the order of 1000 0 C. After this operation , the piece, of a single block, is machined to the desired shape and dimensions.
  • the different parts of the blank and the sheathing of the ceramic wire are of the same metal so that the finished part is provided with a wound composite insert embedded in a homogeneous metal matrix.
  • the zone reinforced by the winding has a generally rectangular cross section.
  • this reinforced area surrounded by exclusively metal parts, occupies as large a volume as possible.
  • This rectangular cross section insert arrangement may not be completely satisfactory in the direction of the forces applied to the workpiece. While the strength of the fibers is excellent tangentially both in tension and in compression, it is lower than that of pure metal when the forces are applied in a direction transverse to the fibers. By way of examples, this is particularly the case when the annular part thus produced is a rotating part equipped with vanes, such as a turbine disk, in particular for an airplane turbojet engine. Another piece subjected to transverse forces is the "rotating sleeve" connected to jacks in a landing gear mechanism. With a part provided with a winding with a rectangular straight cross-section, breaks are possible in the outer part of the reinforced zone.
  • the basic idea of the invention is to establish a "zone of progressivity" of pure metal in this outer radial region, laterally between the periphery and the zone where the turns are located.
  • a coiled portion having a trapezoidal or triangle-shaped cross-section at least in its radially outermost portion is capable of responding to the data of the problem.
  • a half wave shape may also be considered provided that the proportion of pure metal increases radially outwardly of the workpiece, all other things being equal.
  • Another difficulty is then to make the part because the "external" winding as described above is difficult to envisage.
  • the invention also proposes a new approach to winding, called “internal winding”.
  • the invention relates to a method for manufacturing an annular axisymmetric metal piece reinforced by inclusion therein of a coaxial annular reinforcement in the form of a composite material coil, characterized in that it comprises the steps of ;
  • annular metal blank of said part - practice or complete a cavity opening on a coaxial inner face of said blank and having a right cross section of axial length decreasing radially outwardly over at least a part of its height
  • the reinforcing wire is composed of a ceramic core, sheathed with metal.
  • the shape of the coil thus obtained that is to say, in fine, the shape of the zone provided with ceramic fibers makes it possible to reserve radially outwards of said zone and on either side thereof larger masses of pure metal (titanium for example) allowing a substantially radial force to be transferred "progressively" in the fibers along directions turning it into an effort more and more oriented tangentally
  • the coil can be stabilized during its formation by welds joining certain turns together by their metal sheath.
  • the winding of the reinforcing wire is initiated by fixing an end thereof to the bottom of the cavity and the winding is continued by rotating the blank about its axis while feeding the wire at a controlled speed with respect to the speed of rotation of the blank.
  • the feeding speed of the wire is such that it urges said blank in the direction of rotation thereof.
  • FIGS. 1, 2, 3A and 4 to 6 illustrate, by cross-sectional views, the various steps of the method of manufacturing an annular axisymmetric metal piece reinforced by winding a reinforcing wire;
  • FIG. 3B is a partial perspective view illustrating the phase of FIG. 3A;
  • annular piece such as a rotor disc
  • metal blank 11 for example titanium
  • axisymmetric here cross section rectangular right
  • this section may have a different shape depending on the geometry of the final part that is desired.
  • the blank has a coaxial inner face 12, here cylindrical.
  • Figure 2 consists in practicing, in the mass of the blank, for example by machining, a cavity 14 opening (opening) on said coaxial inner face 12.
  • the blank can be rotated about the X axis and introducing a cutting tool through the accessible central portion of said blank. Material is removed until an annular cavity opens on said coaxial inner face of the blank. Note It is possible to start from an already hollow blank, the machining operation simply being to complete the cavity for Iu! give the shape and dimensions.
  • the cavity 14 has a right cross section of axial length decreasing radially outwardly over at least a portion of its height.
  • the cavity has (in a straight cross-section and in a radial direction from inside to outside) a rectangular shape 15 extended by a trapezoidal shape 16.
  • This second portion of the cavity could have a triangular shape or any other form whose axial length (along the X axis) decreases from the inside to the outside.
  • This operation is carried out by introducing the wire through the opening of the cavity and depositing it from the cylindrical bottom 23 of the cavity by adjacent turns then by successive layers of turns until they are completely filled. the whole space of the cavity, by a coil of contiguous turns 25.
  • the wire is fed via a rigid tubular guide 27 movable in a controlled manner parallel to the X axis (to form a layer) and radially recessed (to develop the following successive layers).
  • the guide 27 is oriented as shown in Figs. 3A and 3B, i.e., its end 27a is at a small angle to the circumferential winding direction of the turns.
  • the winding of the wire 21 is initiated by fixing (by welding) one end thereof to the cylindrical bottom wall 23 of the cavity, near one end thereof, and the blank 11 is rotated around its end.
  • X axis, and feeding the wire at a controlled speed relative to the speed of rotation of the blank It is possible, for example, to continuously adjust the speed at which the wire 21 is brought so that this speed is always substantially equal to the winding speed. taking into account the speed of rotation of the blank and the diameter of the layer of turns during winding.
  • the feed speed of the wire is such that it solicits the roughing in the direction of rotation of the latter.
  • the wire 21 may be pushed inside the guide 27 by a drive rotary roller drive system (not shown) with possibility of longitudinal sliding so that said wire is in slight compression between its output of the guide 27 and the point where it takes its place in the winding.
  • the blank 11 is mounted in free rotation and that it is the stress exerted on the wire itself which drives it in rotation during the winding.
  • the turns are stabilized at given winding intervals, by welding points or lines joining the metal sheaths of certain turns.
  • the weld can be an electrical or induction weld, under vacuum or in a neutral atmosphere of argon.
  • a welding process as described in FR 2 886 290 can be implemented.
  • FIG. 4 consists of closing the cavity 14 filled by the coil 25.
  • a cylindrical metal wall 30, here made of titanium is placed in register with the opening of the cavity.
  • This wall here has the same length as the axial length of the opening so that during hot isostatic compression, it can deform radially outwardly penetrate the cavity, compacting the winding itself.
  • the cylindrical annular wall 30 can be dimensioned so that its diameter is slightly greater than that of the central opening of the blank but while carrying this annular wall at a low temperature (by dipping it in liquid nitrogen, for example ) before putting it in place.
  • the annular wall 30 engages the cavity by starting to compact the coil.
  • the closure of said cavity comprises its evacuation with hermetic closure by a welded metal sheet 32.
  • This metal sheet is welded on both sides of the opening of the cavity, before the hot isostatic pressing operation.
  • the actual hot isostatic pressing operation is then carried out, consisting, for example, in placing the blank, modified as shown in FIG. 4, in a box for several hours, bringing the pressure to 1000 bar and the temperature to be reached. 1000 0 C, approximately.
  • FIG. 5 It can be seen that the annular wall 30 is engaged in the cavity, driving the metal foil 32.
  • the assembly forms only a single block with a large part of the volume occupied by a winding. high strength ceramic wire, embedded in a metal matrix resulting from the melting of the metal sheath of the wire used during winding.
  • a series of machining operations (FIG. 6) are then carried out, with the purpose of defining, from the blank transformed by the hot isostatic pressing operation, the contour of the desired part (shown in dashed line in FIG. 6). ).
  • the final piece 36 of FIG. 7 comprises purely metallic external lateral zones (17a, 18a), making it possible to increase the transverse mechanical strength of the part and locally to limit the breaks of stiffness favoring breaks. These so-called “progressivity" zones have the effect of bringing the efforts gradually, by shearing, into the fibrous reinforcement (the winding) in order to convert the forces in tension / compressive strength for which the resistance of the wound zone is optimal.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)

Abstract

The invention relates to a reinforcement for an axisymmetric annular metal part by the inclusion of a composite material winding. The invention involves preparing a metal blank (11) of the part, forming a cavity (14) therein which opens onto a coaxial inner surface thereof and has a straight cross-section with an axial length that decreases from the inside towards the outside, winding a reinforcement wire (21) within the cavity, closing said cavity, subjecting the assembly to a hot isostatic compression process, and machining the blank so as to produce the final part.

Description

Procédé de fabrication d'une pièce métallique incorporant un renfort annulaire fibreux Process for manufacturing a metal part incorporating a fibrous annular reinforcement
L'invention se rapporte à une pièce métallique présentant une partie annulaire englobant un renfort annulaire coaxial fibreux, sous forme d'une bobine en matériau composite englobée dans une matrice métallique. L'invention concerne plus particulièrement la fabrication d'une telle pièce bénéficiant d'une résistance améliorée. Elle concerne également une pièce métallique renfermant un tel renfort annulaire coaxial.The invention relates to a metal part having an annular portion including a coaxial annular fiber reinforcement, in the form of a coil of composite material enclosed in a metal matrix. The invention relates more particularly to the manufacture of such a piece with improved strength. It also relates to a metal part enclosing such a coaxial annular reinforcement.
Il est connu de réduire la masse d'une pièce métallique annulaire tout en lui assurant une résistance très importante en traction ou compression tangentielle, en incorporant des fibres de matériau composite comme par exemple en céramique dans la masse métallique. La céramique est par exemple du carbure de silicium en fil qui présente une résistance à la traction ou à la compression supérieure à celle d'un métal, comme le titane par exemple.It is known to reduce the mass of an annular metal part while providing a very high resistance in tangential tension or compression, by incorporating fibers of composite material such as ceramic in the metal mass. The ceramic is, for example, silicon carbide wire which has a tensile or compressive strength greater than that of a metal, such as titanium for example.
Pour obtenir une telle pièce, on peut réaliser un bobinage de fil de céramique enduit de métal à l'intérieur d'une ébauche de la pièce. Par exemple, le document FR 2 886 290 propose de réaliser le bobinage directement sur une partie de l'ébauche formant mandrin de bobinage. Il s'agit donc d'un bobinage "externe" des plus classiques. Plus précisément, cette partie comporte deux épaulements. L'épaulement le plus interne radialement forme une surface d'appui latérale pour le bobinage. La partie cylindrique adjacente forme la surface de base sur laquelle on réalise le bobinage. Celui-ci a une forme rectangulaire en section transversale droite. Après bobinage, on complète l'ébauche par des parties métalliques complémentaires, notamment un anneau extérieur et un couvercle latéral présentant un tenon venant au contact du bobinage. Cet ensemble est ensuite soumis à une étape de compression isostatique à chaud au cours de laquelle Ie couvercle, notamment, est déformé en sorte que le bobinage soit comprimé par le tenon. L'opération de compression isostatique à chaud est connue en soi ; elle consiste à placer l'ensemble précité dans un caisson et à soumettre cet ensemble, pendant plusieurs heures, à une pression élevée de l'ordre de 1 000 bars et à une température de l'ordre de 1 0000C. Après cette opération, la pièce, d'un seul bloc, est usinée à la forme et aux dimensions souhaitées. Généralement, les différentes parties de l'ébauche et Ie gainage du fil de céramique sont du même métal en sorte que Ia pièce finie se trouve pourvue d'un insert composite bobiné, noyé dans une matrice métallique homogène. La zone renforcée par Ie bobinage a une section transversale droite globalement rectangulaire. Pour alléger Ia pièce et augmenter Ia résistance à Ia traction/compression dans le sens tangentiel, il est souhaitable que cette zone renforcée, entourée de parties exclusivement métalliques, occupe un volume aussi important que possible. Cet agencement à însert de section droite rectangulaire peut ne pas être complètement satisfaisant suivant la direction des efforts qui sont appliqués à la pièce. Alors que Ia résistance des fibres est excellente tangentiellement tant à la traction qu'à la compression, elle est inférieure à celle du métal pur lorsque les efforts sont appliqués dans un sens transverse aux fibres. A titre d'exemples, c'est particulièrement Ie cas lorsque Ia pièce annulaire ainsi fabriquée est une pièce tournante munie d'aubes, comme un disque de turbine, notamment pour un turboréacteur d'avion. Une autre pièce soumise à des efforts transversaux est le "manchon tournant" relié à des vérins dans un mécanisme d'atterrisseur. Avec une pièce munie d'un bobinage à section transversale droite rectangulaire, des ruptures sont possibles dans Ia partie extérieure de la zone renforcée.To obtain such a part, it is possible to produce a winding of metal-coated ceramic wire inside a blank of the part. For example, the document FR 2 886 290 proposes to carry out the winding directly on a part of the blank forming the winding mandrel. It is therefore an "external" winding of the most classic. More precisely, this part has two shoulders. The radially innermost shoulder forms a lateral bearing surface for the winding. The adjacent cylindrical portion forms the base surface on which the winding is made. It has a rectangular shape in right cross section. After winding, complete the blank by complementary metal parts, including an outer ring and a side cover having a pin coming into contact with the winding. This assembly is then subjected to a hot isostatic pressing step during which the cover, in particular, is deformed so that the winding is compressed by the tenon. The hot isostatic pressing operation is known per se; it consists of placing the aforementioned assembly in a box and subjecting this assembly, for several hours, to a high pressure of the order of 1000 bar and at a temperature of the order of 1000 0 C. After this operation , the piece, of a single block, is machined to the desired shape and dimensions. Generally, the different parts of the blank and the sheathing of the ceramic wire are of the same metal so that the finished part is provided with a wound composite insert embedded in a homogeneous metal matrix. The zone reinforced by the winding has a generally rectangular cross section. To lighten the part and increase the tensile strength / compression in the tangential direction, it is desirable that this reinforced area, surrounded by exclusively metal parts, occupies as large a volume as possible. This rectangular cross section insert arrangement may not be completely satisfactory in the direction of the forces applied to the workpiece. While the strength of the fibers is excellent tangentially both in tension and in compression, it is lower than that of pure metal when the forces are applied in a direction transverse to the fibers. By way of examples, this is particularly the case when the annular part thus produced is a rotating part equipped with vanes, such as a turbine disk, in particular for an airplane turbojet engine. Another piece subjected to transverse forces is the "rotating sleeve" connected to jacks in a landing gear mechanism. With a part provided with a winding with a rectangular straight cross-section, breaks are possible in the outer part of the reinforced zone.
L'idée de base de l'invention consiste à établir une "zone de progressivité" en métal pur dans cette région radiale externe, latéralement entre la périphérie et Ia zone où se trouvent les spires. Ceci conduit, selon l'invention, à conformer Ie bobinage de façon que celui-ci présente une section transversale droite de longueur axiale décroissant radialement vers l'extérieur au moins dans une zone radiale extérieure de la pièce axisymé- trique. Par exemple, une partie bobinée ayant une section transversale en forme de trapèze ou de triangle au moins dans sa partie radialement Ia plus extérieure est susceptible de répondre aux données du problème. Une forme en demi-onde peut aussi être envisagée pourvu que la proportion de métal pur augmente radialement vers l'extérieur de Ia pièce, toutes choses égales par ailleurs. Une autre difficulté est alors de réaliser la pièce car le bobinage "externe" tel que décrit ci-dessus est difficile à envisager. L'invention propose aussi une nouvelle approche du bobinage, dit "bobinage interne".The basic idea of the invention is to establish a "zone of progressivity" of pure metal in this outer radial region, laterally between the periphery and the zone where the turns are located. This leads, according to the invention, to conform the winding so that it has a right cross section of axial length decreasing radially outwardly at least in an outer radial zone of the axisymmetric part. For example, a coiled portion having a trapezoidal or triangle-shaped cross-section at least in its radially outermost portion is capable of responding to the data of the problem. A half wave shape may also be considered provided that the proportion of pure metal increases radially outwardly of the workpiece, all other things being equal. Another difficulty is then to make the part because the "external" winding as described above is difficult to envisage. The invention also proposes a new approach to winding, called "internal winding".
Plus précisément, l'invention concerne un procédé de fabrication d'une pièce métallique annulaire axisymétrique renforcée par inclusion dans celle-ci d'un renfort annulaire coaxial sous forme de bobine en matériau composite, caractérisé en ce qu'il comprend les étapes consistant à ;More specifically, the invention relates to a method for manufacturing an annular axisymmetric metal piece reinforced by inclusion therein of a coaxial annular reinforcement in the form of a composite material coil, characterized in that it comprises the steps of ;
- élaborer une ébauche métallique annulaire de ladite pièce, - pratiquer ou achever une cavité ouvrant sur une face intérieure coaxiale de ladite ébauche et présentant une section transversale droite de longueur axiale décroissant radialement vers l'extérieur sur au moins une partie de sa hauteur,- Develop an annular metal blank of said part, - practice or complete a cavity opening on a coaxial inner face of said blank and having a right cross section of axial length decreasing radially outwardly over at least a part of its height,
- enrouler un fil de renfort dans ladite cavité de façon à remplir sensiblement tout l'espace de celle-ci par une bobine,- winding a reinforcing thread in said cavity so as to fill substantially all the space thereof by a coil,
- fermer ladite cavité par un élément de paroi métallique,closing said cavity by a metal wall element,
- soumettre l'ensemble à un processus de compression isostatique à chaud, et- subject the assembly to a process of hot isostatic compression, and
- usiner ladite ébauche pour obtenir la géométrie finale de ladite pièce.machining said blank to obtain the final geometry of said part.
On entend par "section transversale droite", une section dans un plan contenant l'axe de la pièce axisymétrique considérée, plus précisément l'axe de l'ébauche dans la définition qui précède.The term "right cross section", a section in a plane containing the axis of the axisymmetrical part considered, more precisely the axis of the blank in the above definition.
Selon une caractéristique avantageuse, le fil de renfort est composé d'une âme en céramique, gainée de métal.According to an advantageous characteristic, the reinforcing wire is composed of a ceramic core, sheathed with metal.
La forme du bobinage ainsi obtenu, c'est-à-dire, in fine, la forme de la zone munie de fibres de céramique permet de réserver radialement vers l'extérieur de ladite zone et de part et d'autre de celle-ci des masses plus importantes de métal pur (titane par exemple) permettant à un effort essentiellement radial de se transférer "progressivement" dans les fibres suivant des directions le transformant en effort de plus en plus orienté tangentïellementThe shape of the coil thus obtained, that is to say, in fine, the shape of the zone provided with ceramic fibers makes it possible to reserve radially outwards of said zone and on either side thereof larger masses of pure metal (titanium for example) allowing a substantially radial force to be transferred "progressively" in the fibers along directions turning it into an effort more and more oriented tangentally
On peut stabiliser la bobine au cours de sa formation par des soudures réunissant certaines spires entre elles par leur gaine de métal. Pour procéder au bobinage dit "interne" on amorce le bobinage du fil de renfort en fixant une extrémité de celui-ci au fond de la cavité et on poursuit Ie bobinage en faisant tourner l'ébauche autour de son axe tout en alimentant le fil à une vitesse contrôlée par rapport à Ia vitesse de rotation de l'ébauche.The coil can be stabilized during its formation by welds joining certain turns together by their metal sheath. To proceed with the so-called "internal" winding, the winding of the reinforcing wire is initiated by fixing an end thereof to the bottom of the cavity and the winding is continued by rotating the blank about its axis while feeding the wire at a controlled speed with respect to the speed of rotation of the blank.
Avantageusement, la vitesse d'alimentation du fil est telle qu'il sollicite ladite ébauche dans le sens de rotation de celle-ci.Advantageously, the feeding speed of the wire is such that it urges said blank in the direction of rotation thereof.
L'invention sera mieux comprise et d'autres avantages de celle- ci apparaîtront plus clairement à la lumière de la description qui va suivre illustrant un procédé de fabrication d'une pièce métallique annulaire axisymétrique renforcée par un bobinage coaxial, donnée uniquement à titre d'exemples et faite en référence aux dessins annexés, dans lesquels :The invention will be better understood and other advantages thereof will appear more clearly in the light of the following description illustrating a method of manufacturing an axisymmetric annular metal part reinforced by a coaxial winding, given solely as a examples and with reference to the accompanying drawings, in which:
- les figures 1, 2, 3A et 4 à 6 illustrent par des vues en coupe transversale droite les différentes étapes du procédé de fabrication d'une pièce métallique annulaire axisymétrique renforcée par bobinage d'un fil de renfort ; - la figure 3B est une vue partielle en perspective illustrant la phase de la figure 3A ; etFIGS. 1, 2, 3A and 4 to 6 illustrate, by cross-sectional views, the various steps of the method of manufacturing an annular axisymmetric metal piece reinforced by winding a reinforcing wire; FIG. 3B is a partial perspective view illustrating the phase of FIG. 3A; and
- la figure 7 représente la pièce ainsi obtenue.- Figure 7 shows the part thus obtained.
En se reportant aux dessins, on va décrire un procédé permettant de réaliser une pièce annulaire telle qu'un disque de rotor, à partir d'une ébauche métallique 11, par exemple en titane, elle-même annulaire et axisymétrique, ici à section transversale droite rectangulaire, comme représenté sur la figure 1. L'axe de révolution de l'ébauche est référencé X.Referring to the drawings, there will be described a method for producing an annular piece such as a rotor disc, from a metal blank 11, for example titanium, itself annular and axisymmetric, here cross section rectangular right, as shown in Figure 1. The axis of revolution of the blank is referenced X.
Bien entendu, cette section peut avoir une forme différente en fonction de la géométrie de la pièce finale que l'on désire obtenir.Of course, this section may have a different shape depending on the geometry of the final part that is desired.
L'ébauche comporte une face intérieure coaxiale 12, ici cylindrique.The blank has a coaxial inner face 12, here cylindrical.
Il s'agit à la fois d'alléger ladite pièce finale tout en lui conférant une résistance mécanique accrue. Après l'élaboration d'une telle ébauche, l'étape suivanteThis is both to lighten said final piece while giving it increased mechanical strength. After developing such a draft, the next step
(figure 2) consiste à pratiquer, dans la masse de l'ébauche, par exemple par usinage, une cavité 14 ouvrant (débouchant) sur ladite face intérieure coaxiale 12. On peut par exemple faire tourner l'ébauche autour de l'axe X et introduire un outil de coupe par la partie centrale, accessible, de ladite ébauche. On enlève de la matière jusqu'à obtenir une cavité annulaire ouvrant sur ladite face intérieure coaxiale de l'ébauche. Il est à noter qu'on peut partir d'une ébauche déjà creuse, l'opération d'usinage consistant simplement à achever Ia cavité pour Iu! donner Ia forme et les dimensions voulues.(Figure 2) consists in practicing, in the mass of the blank, for example by machining, a cavity 14 opening (opening) on said coaxial inner face 12. For example, the blank can be rotated about the X axis and introducing a cutting tool through the accessible central portion of said blank. Material is removed until an annular cavity opens on said coaxial inner face of the blank. Note It is possible to start from an already hollow blank, the machining operation simply being to complete the cavity for Iu! give the shape and dimensions.
Selon une caractéristique importante, la cavité 14 présente une section transversale droite de longueur axiale décroissant radialement vers l'extérieur sur au moins une partie de sa hauteur. Dans l'exemple, Ia cavité a (selon une section transversale droite et suivant une direction radiale de l'intérieur vers l'extérieur) une forme rectangulaire 15 prolongée par une forme trapézoïdale 16. Cette seconde partie de la cavité pourrait avoir une forme triangulaire ou toute autre forme dont Ia longueur axiale (selon l'axe X) décroît de l'intérieur vers l'extérieur.According to an important characteristic, the cavity 14 has a right cross section of axial length decreasing radially outwardly over at least a portion of its height. In the example, the cavity has (in a straight cross-section and in a radial direction from inside to outside) a rectangular shape 15 extended by a trapezoidal shape 16. This second portion of the cavity could have a triangular shape or any other form whose axial length (along the X axis) decreases from the inside to the outside.
II en résulte une réserve de métal pur dans les zones latérales 17, 18 indiquées en pointillé, par rapport à ce qui serait obtenu si la cavité avait une section transversale droite rectangulaire. L'opération suivante consiste à enrouler in situ un fil de renfortThis results in a reserve of pure metal in the side zones 17, 18 indicated in dotted line, compared to what would be obtained if the cavity had a rectangular cross section. The next step is to wind a reinforcement wire in situ
21, ici en céramique (carbure de silicium) enrobé de métal. Le métal est ici du titane, c'est-à-dire le même métal que celui qui constitue l'ébauche. Cette opération, illustrée à la figure 3A, s'effectue en introduisant le fil par l'ouverture de la cavité et en le déposant à partir du fond cylindrique 23 de la cavité par spires adjacentes puis par couches successives de spires jusqu'à remplir entièrement tout l'espace de Ia cavité, par une bobine de spires jointives 25.21, here ceramic (silicon carbide) coated with metal. The metal is here titanium, that is to say the same metal as that which constitutes the blank. This operation, illustrated in FIG. 3A, is carried out by introducing the wire through the opening of the cavity and depositing it from the cylindrical bottom 23 of the cavity by adjacent turns then by successive layers of turns until they are completely filled. the whole space of the cavity, by a coil of contiguous turns 25.
Pour le bobinage, on peut procéder ainsi. On alimente Ie fil via un guide tubulaire rigide 27 déplaçable de façon contrôlée parallèlement à l'axe X (pour former une couche) et radialement en retrait (pour élaborer les couches successives suivantes). Le guide 27 est orienté comme représenté sur les figures 3A et 3B, c'est-à-dire que son extrémité 27Â fait un angle faible par rapport à la direction circonférentielle d'enroulement des spires. On amorce Ie bobinage du fil 21 en fixant (par soudure) une extrémité de celui-ci à Ia paroi de fond cylindrique 23 de Ia cavité, près d'une extrémité de celle-ci et on fait tourner l'ébauche 11 autour de son axe X, et en alimentant Ie fil à une vitesse contrôlée par rapport à la vitesse de rotation de l'ébauche. On peut par exempte ajuster en permanence Ia vitesse à laquelle le fil 21 est amené, pour que cette vitesse soit toujours sensiblement égale à la vitesse d'enroulement, compte tenu de la vitesse de rotation de l'ébauche et du diamètre de Ia couche de spires en cours de bobinage.For winding, this can be done. The wire is fed via a rigid tubular guide 27 movable in a controlled manner parallel to the X axis (to form a layer) and radially recessed (to develop the following successive layers). The guide 27 is oriented as shown in Figs. 3A and 3B, i.e., its end 27a is at a small angle to the circumferential winding direction of the turns. The winding of the wire 21 is initiated by fixing (by welding) one end thereof to the cylindrical bottom wall 23 of the cavity, near one end thereof, and the blank 11 is rotated around its end. X axis, and feeding the wire at a controlled speed relative to the speed of rotation of the blank. It is possible, for example, to continuously adjust the speed at which the wire 21 is brought so that this speed is always substantially equal to the winding speed. taking into account the speed of rotation of the blank and the diameter of the layer of turns during winding.
On pourra aussi faire en sorte que la vitesse d'alimentation du fil soit telle qu'il sollicite l'ébauche dans le sens de rotation de celle-ci. Par exemple, le fil 21 pourra être poussé à l'intérieur du guide 27 par un système d'entraînement à galets rotatifs moteurs (non représenté) avec possibilité de glissement longitudinal en sorte que ledit fil soit en légère compression entre sa sortie du guide 27 et le point où il prend sa place dans le bobinage. On peut même envisager que l'ébauche 11 soit montée en rotation libre et que ce soit la sollicitation exercée sur le fil lui-même qui l'entraîne en rotation pendant le bobinage.It will also be possible to ensure that the feed speed of the wire is such that it solicits the roughing in the direction of rotation of the latter. For example, the wire 21 may be pushed inside the guide 27 by a drive rotary roller drive system (not shown) with possibility of longitudinal sliding so that said wire is in slight compression between its output of the guide 27 and the point where it takes its place in the winding. It can even be envisaged that the blank 11 is mounted in free rotation and that it is the stress exerted on the wire itself which drives it in rotation during the winding.
Pour éviter le foisonnement, les spires sont stabilisées à intervalles de bobinage donnés, par des points ou lignes de soudure joignant les gaines métalliques de certaines spires. De façon connue en soi, la soudure peut être une soudure électrique ou par induction, sous vide ou sous atmosphère neutre d'argon. Un processus de soudure tel que décrit dans FR 2 886 290 peut être mis en œuvre.To avoid expansion, the turns are stabilized at given winding intervals, by welding points or lines joining the metal sheaths of certain turns. In a manner known per se, the weld can be an electrical or induction weld, under vacuum or in a neutral atmosphere of argon. A welding process as described in FR 2 886 290 can be implemented.
L'opération suivante, figure 4, consiste à refermer la cavité 14 remplie par la bobine 25. Par exemple, on met en place une paroi annulaire cylindrique métallique 30, ici en titane, en regard de l'ouverture de la cavité. Cette paroi a ici la même longueur que la longueur axiale de l'ouverture en sorte que pendant la compression isostatique à chaud, elle pourra en se déformant radialement vers l'extérieur pénétrer dans la cavité, en compactant le bobinage lui-même. On peut dimensionner la paroi annulaire cylindrique 30 en faisant en sorte que son diamètre soit légèrement supérieur à celui de l'ouverture centrale de l'ébauche mais en portant cette paroi annulaire à basse température (en la plongeant dans de l'azote liquide par exemple) avant de la mettre en place. Ainsi, même avant le début de l'opération de compression isostatîque à chaud, la paroi annulaire 30 s'engage dans la cavité en commençant à compacter le bobinage.The following operation, FIG. 4, consists of closing the cavity 14 filled by the coil 25. For example, a cylindrical metal wall 30, here made of titanium, is placed in register with the opening of the cavity. This wall here has the same length as the axial length of the opening so that during hot isostatic compression, it can deform radially outwardly penetrate the cavity, compacting the winding itself. The cylindrical annular wall 30 can be dimensioned so that its diameter is slightly greater than that of the central opening of the blank but while carrying this annular wall at a low temperature (by dipping it in liquid nitrogen, for example ) before putting it in place. Thus, even before the start of the hot isostatic compression operation, the annular wall 30 engages the cavity by starting to compact the coil.
Avantageusement, la fermeture de ladite cavité comprend sa mise sous vide avec fermeture hermétique par une feuille métallique 32 soudée. Cette feuille métallique est soudée de part et d'autre de l'ouverture de la cavité, avant l'opération de compression isostatique à chaud.Advantageously, the closure of said cavity comprises its evacuation with hermetic closure by a welded metal sheet 32. This metal sheet is welded on both sides of the opening of the cavity, before the hot isostatic pressing operation.
On procède ensuite à l'opération de compression isostatique à chaud proprement dite, consistant, par exemple, à placer l'ébauche, modifiée comme représente figure 4, dans un caisson pendant plusieurs heures en portant Ia pression à 1 000 bars et Ia température à 1 0000C, environ.The actual hot isostatic pressing operation is then carried out, consisting, for example, in placing the blank, modified as shown in FIG. 4, in a box for several hours, bringing the pressure to 1000 bar and the temperature to be reached. 1000 0 C, approximately.
Le résultat est représenté figure 5. On voit que Ia paroi annulaire 30 s'est engagée dans Ia cavité, entraînant Ia feuille métallique 32. L'ensemble ne forme plus qu'un seul bloc avec une grande partie du volume occupé par un bobinage de fil en céramique à haute résistance, noyé dans une matrice métallique résultant de la fusion de la gaine métallique du fil utilisé pendant Ie bobinage.The result is shown in FIG. 5. It can be seen that the annular wall 30 is engaged in the cavity, driving the metal foil 32. The assembly forms only a single block with a large part of the volume occupied by a winding. high strength ceramic wire, embedded in a metal matrix resulting from the melting of the metal sheath of the wire used during winding.
On procède ensuite à une succession d'usinages (figure 6) ayant pour but, à partir de l'ébauche transformée par l'opération de compression isostatique à chaud de définir le contour 35 de Ia pièce voulue (représenté en pointillé sur la figure 6). La pièce finale 36 de la figure 7 comporte des zones latérales externes (17a, 18a) purement métalliques, permettant d'augmenter la résistance mécanique transversale de la pièce et de limiter localement les sauts de raideur favorisant les ruptures. Ces zones dites "de progressivité" ont pour effet de faire rentrer les efforts progressivement, par cisaillement, dans le renfort fibreux (le bobinage) afin de convertir les efforts en traction/ compression cïrconférentielle pour lesquels Ia résistance de Ia zone bobinée est optimale. A series of machining operations (FIG. 6) are then carried out, with the purpose of defining, from the blank transformed by the hot isostatic pressing operation, the contour of the desired part (shown in dashed line in FIG. 6). ). The final piece 36 of FIG. 7 comprises purely metallic external lateral zones (17a, 18a), making it possible to increase the transverse mechanical strength of the part and locally to limit the breaks of stiffness favoring breaks. These so-called "progressivity" zones have the effect of bringing the efforts gradually, by shearing, into the fibrous reinforcement (the winding) in order to convert the forces in tension / compressive strength for which the resistance of the wound zone is optimal.

Claims

REVENDICAπONS REVENDICAπONS
1. Procédé de fabrication d'une pièce métallique annulaire axisymétrique renforcée par inclusion dans celle-ci d'un renfort annulaire coaxial sous forme de bobine en matériau composite, comprenant les étapes consistant à :A method of manufacturing a reinforced axisymmetric annular metal part by inclusion therein of a coaxial annular reinforcement in the form of a composite material coil, comprising the steps of:
- élaborer une ébauche métallique annulaire (11) de ladite pièce,- developing an annular metal blank (11) of said part,
- pratiquer ou achever une cavité (14) ouvrant sur une face intérieure coaxiale de ladite ébauche et présentant une section transversale droite de longueur axiale décroissant radialement vers l'extérieur sur au moins une partie de sa hauteur,- practice or complete a cavity (14) opening on a coaxial inner face of said blank and having a right cross section of axial length decreasing radially outwardly over at least a portion of its height,
- enrouler un fil de renfort (21) dans ladite cavité de façon à remplir sensiblement tout l'espace de celle-ci par une bobine, caractérisé en ce qu'il comprend en outre les étapes consistant à ;- winding a reinforcing wire (21) in said cavity so as to fill substantially all the space thereof by a coil, characterized in that it further comprises the steps of;
- fermer ladite cavité en mettant en place une paroi cylindrique métallique (30) en regard de l'ouverture de ladite cavité, puis,closing said cavity by placing a metal cylindrical wall (30) opposite the opening of said cavity, then,
- soumettre l'ensemble à un processus de compression isostatique à chaud, et - usiner ladite ébauche pour obtenir la géométrie finale de ladite pièce.subjecting the assembly to a hot isostatic pressing process, and machining said blank to obtain the final geometry of said part.
2. Procédé selon la revendication 1, caractérisé en ce que ledit fil de renfort (21) est composé d'une âme en matériau composite telle que de la céramique, gainée de métal et en ce qu'on stabilise la bobine en cours de formation par des soudures réunissant certaines spires entre elles par leur gaine de métal,2. Method according to claim 1, characterized in that said reinforcing wire (21) is composed of a core of composite material such as ceramic, sheathed in metal and in that stabilizes the coil being formed by welds joining certain turns together by their metal sheath,
3. Procédé selon la revendication 1 ou 2, caractérisé en ce qu'on amorce le bobinage du fil de renfort en fixant une extrémité de celui-ci au fond (23) de la cavité et en ce qu'on poursuit le bobinage en faisant tourner ladite ébauche autour de son axe (X) en alimentant le fil à une vitesse contrôlée par rapport à la vitesse de rotation de l'ébauche.3. Method according to claim 1 or 2, characterized in that initiates the winding of the reinforcing wire by fixing one end thereof to the bottom (23) of the cavity and that the winding is continued by making rotating said blank about its axis (X) by feeding the wire at a controlled speed with respect to the speed of rotation of the blank.
4. Procédé selon la revendication 3, caractérisé en ce que la vitesse d'alimentation du fil (21) est telle qu'il sollicite ladite ébauche dans le sens de rotation de celle-ci. 4. Method according to claim 3, characterized in that the feeding speed of the wire (21) is such that it solicits said blank in the direction of rotation thereof.
5. Procédé selon l'une des revendications précédentes, caractérisé en ce qu'on conforme ladite cavité ouverte de façon à lui donner une section transversale au moins en partie triangulaire ou trapézoïdale (16), au moins dans la partie radiale la plus externe de celle-ci,5. Method according to one of the preceding claims, characterized in that said open cavity so as to give it a cross section at least partly triangular or trapezoidal (16), at least in the outermost radial portion thereof,
6. Procédé selon l'une des revendications précédentes, caractérisé en ce que la fermeture de ladite cavité comprend sa mise sous vide avec fermeture hermétique par une feuille métallique (32) soudée de part et d'autre de l'ouverture de ladite cavité, avant l'opération de compression isostatique à chaud. 6. Method according to one of the preceding claims, characterized in that the closure of said cavity comprises its vacuum sealing with sealing by a metal sheet (32) welded on either side of the opening of said cavity, before the hot isostatic compression operation.
EP10738003.2A 2009-06-16 2010-06-14 Process for the manufacture of a metallic workpiece incorporating an annular fibrous reinforcement Active EP2443265B1 (en)

Applications Claiming Priority (2)

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FR0954029A FR2946550A1 (en) 2009-06-16 2009-06-16 PROCESS FOR MANUFACTURING A METAL PIECE INCORPORATING A FIBROUS ANNULAR REINFORCEMENT.
PCT/FR2010/051179 WO2010146293A1 (en) 2009-06-16 2010-06-14 Method for making a metal part including a fibrous annular reinforcement

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JP2003138352A (en) 2001-10-29 2003-05-14 Mitsubishi Heavy Ind Ltd Method for forming metal matrix composite
GB0327044D0 (en) * 2003-11-18 2004-04-07 Rolls Royce Plc A method of manufacturing a fibre reinforced metal matrix composite article and a cassette for use therein
GB0327002D0 (en) * 2003-11-20 2003-12-24 Rolls Royce Plc A method of manufacturing a fibre reinforced metal matrix composite article
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BRPI1015560A2 (en) 2016-04-26
EP2443265B1 (en) 2013-04-17
CN102459681A (en) 2012-05-16
CA2764774C (en) 2018-02-20
FR2946550A1 (en) 2010-12-17
WO2010146293A1 (en) 2010-12-23
US20120124838A1 (en) 2012-05-24
CN102459681B (en) 2015-07-01

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