Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
  • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
  • F01D5/005—Repairing methods or devices
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/0072—Heat treatment
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/4572—Partial coating or impregnation of the surface of the substrate
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
  • C04B41/5093—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with elements other than metals or carbon
  • C04B41/5096—Silicon
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
  • C04B41/81—Coating or impregnation
  • C04B41/85—Coating or impregnation with inorganic materials
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00982—Uses not provided for elsewhere in C04B2111/00 as construction elements for space vehicles or aeroplanes
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
  • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
  • F01D5/12—Blades
  • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
  • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
• • 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
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T50/00—Aeronautics or air transport
  • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Definitions

• Thermostructural composite materials are known for their good mechanical properties and their ability to retain these properties at high temperatures. They include carbon / carbon composite materials (C / C) formed of a carbon fiber reinforcement densified by a carbon matrix and ceramic matrix composite materials (CMC) formed of a reinforcement of refractory fibers (carbon or ceramic ) densified by an at least partially ceramic matrix.
• CMC are the C / SiC composites (carbon fiber reinforcement and silicon carbide matrix), the C / C-SiC composites (carbon fiber reinforcement and matrix comprising a carbon phase, generally closer to the fibers , and a silicon carbide phase) and SiC / SiC composites (reinforcing fibers and silicon carbide matrix).
• An interphase layer may be interposed between reinforcing fibers and matrix to improve the mechanical strength of the material.
• thermostructural composite material parts The usual processes for obtaining thermostructural composite material parts are the liquid process and the gaseous process.
• the liquid process consists in producing a fibrous preform having substantially the shape of a part to be produced, and intended to constitute the reinforcement of the composite material, and to impregnate this preform with a liquid composition containing a precursor of the matrix material.
• the precursor is usually in the form of a polymer, such as a resin, optionally diluted in a solvent.
• the conversion of the precursor into the refractory phase is carried out by heat treatment after removal of the optional solvent and crosslinking of the polymer. Several successive impregnation cycles can be performed to achieve the desired degree of densification.
• liquid carbon precursors may be relatively high coke level resins, such as phenolic resins
• liquid ceramic precursors, especially of SiC may be polycarbosilane (PCS) or polytitanocarbosilane (PTCS) or polysilazane (PSZ) type resins.
• the gaseous process consists of chemical vapor infiltration.
• the fibrous preform corresponding to a part to be produced is placed in an oven in which a gaseous reaction phase is admitted.
• the pressure and the temperature prevailing in the furnace and the composition of the gas phase are chosen so as to allow the diffusion of the gas phase within the porosity of the preform to form the matrix by deposition, in contact with the fibers, of a solid material resulting from a decomposition of a constituent of the gas phase or a reaction between several constituents.
• gaseous carbon precursors may be cracked carbon-yielding hydrocarbons, such as methane, and a gaseous precursor of ceramics, in particular SiC, may be methyltrichlorosilane (MTS) giving SiC by decomposition of the MTS (optionally in the presence of hydrogen).
• MTS methyltrichlorosilane
• thermostructural composite materials find applications in various fields, to produce parts to be subjected to significant thermomechanical stresses, for example in the aeronautical, space or nuclear fields.
• thermostructural composite material parts systematically have an open internal porosity, that is to say communicating with the outside of the room. Porosity comes from the inevitably incomplete nature of densification of fibrous preforms. It results in the presence of pores of greater or lesser dimensions that communicate with each other.
• the parts generally have a very satisfactory mechanical strength.
• the composite material parts may be subjected locally to very high mechanical stresses as is the case for example of the foot of an aircraft engine blade where concentrating the efforts of matting and compression suffered by dawn.
• the presence of porosity in the part of the part thus solicited can locally weaken the mechanical strength of the part. There is, therefore, a need to locally strengthen a piece of thermostructural composite material.
• thermostructural composite material parts which constitute fixing portions or friction with other parts, in particular metal, and which therefore suffer greater mechanical forces than the rest of the room .
• the object of the invention is to propose a solution that makes it possible to locally reinforce a porous composite material part.
• the infiltration composition comprising at least silicon
• the method of the invention it is possible to treat only one or more portions of a part that require reinforcement. It is thus possible locally to strengthen a part at a given portion which is subject to significant mechanical stresses relative to the rest of the room.
• the infiltration composition infiltrates by capillary action only in the targeted portion and not beyond it, since a quantity of infiltration composition determined according to the volume of the portion to be infiltrated is used. We thus limit the increase of the material of the piece compared to a total infiltration of the material of the type of "melt infiltration” or "slurry casting” type.
• the infiltration composition comprises silicon or one of its alloys such as SiTi, SiMo or SiNB.
• it further comprises a step of machining the portion of the treated part.
• the part is made of thermostructural ceramic matrix composite material.
• the piece of composite material may in particular correspond to an aeronautical engine blade having at least one blade root and a blade, the portion to be treated corresponding to the foot of said blade.
• the local reinforcement of the blade root makes it possible to simplify its manufacturing range and to envisage the suppression of the use of an insert in this part of the blade.
• Other parts of the blade can be reinforced with the method of the invention such as the inter-blade contact or friction portions, the thin portions such as the trailing edges, the contact portions with the stator parts of the motor such as darts, local portions such as anti-tilt walls, etc.
• the piece of composite material treated with the method of the invention may also correspond to a structural part comprising at least one connecting portion intended to be mechanically linked to another part, the connecting portion corresponding to a portion to be treated. This improves the rigidity of the material of the part in the connection areas and its resistance to clamping forces.
• the method of the invention can be further used to treat a composite material part comprising at least one bearing portion intended to be in contact with a metal sealing part, the bearing part corresponding to a portion to be treated. This results in a bearing portion more resistant to friction with the metal part, which ensures a maintenance of the seal over time.
• the composite material of the part comprises a self-healing matrix, that is to say with boron or one of its compounds, the infiltration of the scope portion avoids interactions between the boron and the metal material (s) of the sealing piece.
• the invention also relates to a method of repairing a composite material part comprising at least one damaged portion present on the surface of the workpiece, each damaged portion being treated in accordance with the treatment method of the invention.
• This method makes it possible in particular to resume a surface state of a piece of composite material in a damaged portion, for example after an impact with another object.
• FIGS. 1A, 1B and 2 are schematic views showing the local infiltration of a blade root according to a treatment method of the invention
• FIGS. 3A and 3B are microscopic photographs showing a blade root respectively before and after local infiltration according to the treatment method of the invention.
• FIGS. 4 and 5 are schematic views showing the local infiltration of a blade root with the formation of lateral surface coatings according to a treatment method of the invention
• FIGS. 6 to 8 are diagrammatic views showing the repair of a damaged blade portion in accordance with a repair method of the invention.
• FIG. 9 and 10 are schematic views showing the local infiltration of connecting portions of a structural part according to a treatment method of the invention.
• the treatment method of the present invention generally applies to composite material parts.
• piece of composite material is meant any part comprising a fiber reinforcement densified by a matrix.
• the fibrous reinforcement is made from a fibrous structure made by weaving, assembling, knitting, etc. fibers such as ceramic fibers, for example silicon carbide (SiC), carbon fibers or even fibers made of a refractory oxide, for example alumina (Al 2 O 3 ).
• the fibrous structure is then densified by a matrix which may be in particular a ceramic matrix forming a ceramic matrix composite material (CMC), or a carbon matrix forming in the case of a reinforcement carbon fiber carbon / carbon composite material (C / C).
• the matrix of the composite material is obtained in a manner known per se according to the method using a liquid route, a gaseous route or a combination of its two routes.
• the method of the invention consists in treating (for example strengthening) or locally repairing composite material parts by melting an infiltration composition.
• a local treatment for example of reinforcement
• the invention proposes to locally supplement the densification of the composite material of the part by locally filling the residual porosity in the zone in question with the infiltration composition.
• a local repair proposes to fill the damaged area with the infiltration composition.
• the infiltration composition is placed directly in contact with the pores opening on the surface of the part.
• no coating likely to block all or part of the pores opening on the surface of the workpiece and to prevent the penetration of the infiltration composition into the porosity of the composite material of the workpiece is previously performed on the piece before the placement and melting of the infiltration composition.
• no ceramic coating of the type described in WO 2010/069346 is formed prior to placement and melting of the infiltration composition.
• such a ceramic coating closes most of the pores opening on the surface of the composite material of the part and prevents good penetration of the infiltration composition into the material of the part. In such a case, he it is therefore not possible to locally supplement the densification of the composite material of the part or to allow a good attachment in the piece of the filling material obtained from the infiltration composition in the case of the repair of a damaged area.
• FIGS. 1A and 1B illustrate a blade 100 of a low pressure turbine (LP) impeller which comprises a blade 120 and a foot 130 formed by a portion of greater thickness, for example with a bulbous section.
• the blade 100 is intended to be mounted on a metal turbine rotor (not shown) by engagement of the foot 130 in a correspondingly shaped housing provided at the periphery of the rotor.
• the blade is here made of thermostructural composite material comprising a reinforcement of silicon carbide (SiC) fibers obtained by three-dimensional weaving or multilayer in one piece of silicon carbide son, the reinforcement being densified by a matrix also of SiC.
• SiC silicon carbide
• the foot 130 is the part of the dawn where concentrates the efforts of matting and compression undergone by the dawn. This part of the blade should, therefore, have an increased mechanical strength compared to the rest of the blade.
• the blade root is reinforced by filling the porosity present at the foot.
• a silicon-based infiltration composition is used, that is to say a composition comprising silicon or a silicon alloy such as, for example, SiTi, SiMo or SiNB.
• the infiltration composition is in solid form.
• the infiltration composition is molded in the form of a bead 10 disposed on the end portion 130a of the foot 130.
• the amount of treatment composition here the volume of the bead 10, is determined as a function of volume of porosity to fill in the foot 130.
• the assembly is heated to a temperature greater than or equal to the melting temperature of the infiltration composition which, by melting, spreads by capillarity along the fibers in the present porosity. in the foot 130.
• the pores being communicating and emerging for some on the surface, the infiltration composition also spreads on the surface of the foot 130. The dawn thus infiltrated at the level of its foot is then cooled.
• a blade 100 with a foot 130 whose porosity is filled by the infiltration composition is thus obtained, which makes it possible to strengthen the blade root, in particular with respect to the compressive stresses. and matting.
• FIG. 3A is a photograph of a blade root section made of thermostructural composite material comprising a reinforcement of SiC fibers densified by a matrix also of SiC. There is the presence of many P pores present in the material.
• Figure 3B shows a blade root similar to that of Figure 3A but after treatment thereof with an infiltration composition under the same conditions as those described above. It is observed that most of the pores have been filled by the infiltration composition which thus gives the blade root increased mechanical strength, in particular with respect to compression and matting efforts.
• a protective coating may be further formed on all or part of the outer surface of the portion of the part infiltrated with the treatment composition.
• a support material capable of impregnating the infiltration composition by capillarity.
• Such a material may be in particular a powder of refractory particles such as SiC particles or a texture made with fibers preferably of the same nature as those constituting the reinforcement of the workpiece.
• FIG. 4 illustrates a blade 200 comprising a blade 220 and a foot 230.
• the blade is here made of a thermostructural composite material comprising a reinforcement obtained by three-dimensional or multi-layer weaving in one piece of SiC threads, the reinforcement being densified by a matrix also of SiC.
• a predetermined amount of silicon-based infiltration composition molded in the form of a bead 210, is placed on the end portion 230a of the foot 230 while two layers 215 and 216 of a SiC powder are respectively deposited on the side faces of the foot 230.
• the assembly is then raised to a temperature greater than or equal to the melting temperature of the infiltration composition which is then spreads both in the porosity of the material present at the level of the blade root and in the layers 215 and 216.
• a blade 200 with a foot 230 whose porosity is filled by the infiltration composition and which comprises on its side faces a protective coating 217 consisting of SiC grains bonded together by the infiltration composition.
• the protective coating 217 thus obtained can be machined after its formation in order to adjust the geometry of the blade root to the required tolerances.
• the matrix contains one or more boron-based elements that can alter the metallic material of the disk or the impeller on which the blades are mounted.
• the protective coating thus formed on the surface of the blade root makes it possible to avoid direct contact between the borated elements of the matrix and the disk or metal wheel.
• the blade 300 has at its blade 320 a damaged area 321 resulting from a shock and resulting in a surface defect on the light that should be filled.
• a pellet 323 of a silicon-based infiltration composition corresponding to the necessary amount of composition to fill the damaged area .
• the assembly is then heated to a temperature to melt the tablet 323 and to spread the infiltration composition in the damaged area. Once the assembly has cooled, a blade 300 having a regular surface level is obtained thanks to the presence of a filling material 324 consisting of the infiltration composition 323.
• FIG. 9 represents a piece of structure 400 of revolution which comprises connecting flanges 401 and 402 mechanical.
• the structural part 400 is made from a carbon fiber reinforcement densified by a matrix also carbon.
• a predetermined amount of silicon-based infiltration composition 410 is placed on each portion corresponding to the mechanical link flanges 401 and 402 in order to infiltrate the areas covered by the connecting flanges.
• the infiltration composition is in the form of a powder mixed with fugitive binder to allow its application, for example by brush, on the areas to be infiltrated.
• the assembly is then brought to a temperature sufficient to melt the infiltration composition which diffuses into the porosity of the composite material at the zones corresponding to the connecting flanges 401 and 402.
• the structural part 400 comprises reinforced portions 403 and 404 at its mechanical connection flanges thus ensuring better strength of the part in its connection areas vis-à-vis including clamping forces and matting, the connection working mainly in shear.
• the method of the invention can be further used to treat a composite material part comprising at least one bearing portion intended to be in contact with a metal sealing part, the bearing part corresponding to a portion to be treated.
• the bearing portion (s) are coated with a silicon-based infiltration composition which is then melted to infiltrate the composite material of the workpiece at or the parts of scope to strengthen.
• the infiltration composition used in the treatment method of the invention comprises silicon or a silicon alloy such as, for example, SiTi, SiMo or SiNB.
• the infiltration composition can in particular, to correspond to a silicon-based brazing composition used for assembling composite material parts together. Silicon-based brazing compositions are described in particular in documents EP 806 402 or US Pat. No. 5,975,407.
• the choice of the nature of the infiltration composition is carried out in particular according to the chemical compatibility and its coefficient of thermal expansion. with those of the material of the part to be infiltrated.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Inorganic Chemistry (AREA)
• General Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• Turbine Rotor Nozzle Sealing (AREA)
• Ceramic Products (AREA)
• Porous Artificial Stone Or Porous Ceramic Products (AREA)

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• 2012
  • 2012-10-09 FR FR1259600A patent/FR2996550B1/fr active Active
• 2013
  • 2013-10-08 EP EP13786692.7A patent/EP2906517A1/fr not_active Withdrawn
  • 2013-10-08 WO PCT/FR2013/052388 patent/WO2014057205A1/fr active Application Filing
  • 2013-10-08 US US14/434,496 patent/US20150275671A1/en not_active Abandoned
  • 2013-10-08 CN CN201380054447.0A patent/CN104955789A/zh active Pending
  • 2013-10-08 RU RU2015116900A patent/RU2015116900A/ru not_active Application Discontinuation
  • 2013-10-08 JP JP2015536203A patent/JP2016500630A/ja not_active Withdrawn
  • 2013-10-08 CA CA2887464A patent/CA2887464A1/en not_active Abandoned
  • 2013-10-08 BR BR112015007891A patent/BR112015007891A2/pt not_active IP Right Cessation

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