EP3331657B1 - Method for producing a part consisting of a composite material - Google Patents
Method for producing a part consisting of a composite material Download PDFInfo
- Publication number
- EP3331657B1 EP3331657B1 EP16757320.3A EP16757320A EP3331657B1 EP 3331657 B1 EP3331657 B1 EP 3331657B1 EP 16757320 A EP16757320 A EP 16757320A EP 3331657 B1 EP3331657 B1 EP 3331657B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibers
- preform
- alloy
- metal
- sheath
- 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.)
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- 239000002131 composite material Substances 0.000 title claims description 13
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 239000000835 fiber Substances 0.000 claims description 142
- 229910052751 metal Inorganic materials 0.000 claims description 80
- 239000002184 metal Substances 0.000 claims description 80
- 229910045601 alloy Inorganic materials 0.000 claims description 70
- 239000000956 alloy Substances 0.000 claims description 70
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 38
- 238000000034 method Methods 0.000 claims description 34
- 239000000843 powder Substances 0.000 claims description 31
- 239000011230 binding agent Substances 0.000 claims description 24
- 239000011159 matrix material Substances 0.000 claims description 23
- 229910052759 nickel Inorganic materials 0.000 claims description 19
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 12
- 238000002844 melting Methods 0.000 claims description 12
- 230000008018 melting Effects 0.000 claims description 12
- 238000009792 diffusion process Methods 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 9
- 239000010936 titanium Substances 0.000 claims description 9
- 229910052719 titanium Inorganic materials 0.000 claims description 9
- 238000001746 injection moulding Methods 0.000 claims description 8
- 238000003466 welding Methods 0.000 claims description 8
- 229910010293 ceramic material Inorganic materials 0.000 claims description 6
- 229910000531 Co alloy Inorganic materials 0.000 claims description 5
- 230000002787 reinforcement Effects 0.000 claims description 5
- 239000007769 metal material Substances 0.000 claims description 4
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 239000010959 steel Substances 0.000 claims description 3
- 238000002347 injection Methods 0.000 description 28
- 239000007924 injection Substances 0.000 description 28
- 239000000203 mixture Substances 0.000 description 19
- 238000010438 heat treatment Methods 0.000 description 14
- 238000000465 moulding Methods 0.000 description 12
- 229910001026 inconel Inorganic materials 0.000 description 10
- 238000003754 machining Methods 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 229910010038 TiAl Inorganic materials 0.000 description 8
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 6
- 239000010941 cobalt Substances 0.000 description 6
- 229910017052 cobalt Inorganic materials 0.000 description 6
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 6
- -1 polyethylene Polymers 0.000 description 5
- 239000010964 304L stainless steel Substances 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 229910001092 metal group alloy Inorganic materials 0.000 description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 4
- 229910010271 silicon carbide Inorganic materials 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 239000000919 ceramic Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 230000004927 fusion Effects 0.000 description 3
- 239000011156 metal matrix composite Substances 0.000 description 3
- 229910001256 stainless steel alloy Inorganic materials 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000002202 Polyethylene glycol Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 229910052729 chemical element Inorganic materials 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
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- 238000007493 shaping process Methods 0.000 description 2
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229920001817 Agar Polymers 0.000 description 1
- 229910000838 Al alloy Inorganic materials 0.000 description 1
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- 235000021355 Stearic acid Nutrition 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
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- 229920002678 cellulose Polymers 0.000 description 1
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- 238000005253 cladding Methods 0.000 description 1
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- 238000007654 immersion Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920006324 polyoxymethylene Polymers 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 230000003381 solubilizing effect Effects 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
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- 238000010025 steaming Methods 0.000 description 1
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- 238000003756 stirring Methods 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
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Images
Classifications
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- 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
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/02—Pretreatment of the fibres or filaments
- C22C47/025—Aligning or orienting the fibres
-
- 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
- C22C47/14—Making alloys containing metallic or non-metallic fibres or filaments by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
- C22C49/04—Light metals
- C22C49/06—Aluminium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
- C22C49/08—Iron group metals
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
- C22C49/10—Refractory metals
- C22C49/11—Titanium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/14—Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
-
- 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
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/20—Refractory metals
- B22F2301/205—Titanium, zirconium or hafnium
-
- 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
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/1017—Multiple heating or additional steps
- B22F3/1021—Removal of binder or filler
-
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
- B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
Definitions
- the invention relates to a method for manufacturing a composite metal matrix part.
- One solution for improving the cohesion of the fibers with the metal matrix consists in using fibers consisting of a core of ceramic material and a metal sheath surrounding this core.
- the sheath may for example have been deposited by high speed coating.
- a heat diffusion welding treatment can then be performed to secure the fibers to a pre-shaped part, for example forged and / or machined.
- Such a solution is for example described in the document FR 2,886,180 .
- This solution works but it requires a large succession of operations: shaping of the initial part, machining of grooves to introduce the fibers, welding of a cover to close the part, and heat treatment of diffusion welding.
- the distribution of the fibers requires each time specific operations, making their distribution in multiple positions relatively long to achieve.
- EP 2 418 297 discloses a method of manufacturing an article of composite metal matrix material.
- EP 0 334 505 which discloses a composite material and an associated manufacturing method.
- the melting temperatures T 1 , T 2 and T 3 are expressed in ° C (degrees Celsius).
- denotes the absolute value of magnitude A.
- first and second preforms based on powders advantageously makes it possible to significantly simplify the manufacture of the composite material part, in particular because of the possibility of using the same heat treatment step both to densify the first and second preforms and forming the metal matrix as well as to make the sheath of the fibers integral with the metal matrix.
- Obtaining parts with satisfactory mechanical properties by such a simplified process is made possible by the use of materials having particular melting temperatures to ensure effective diffusion welding as mentioned above.
- the first binder and the second binder may be the same or different.
- the metal powder of the first alloy may be present in the first preform in a volume content of between 50% and 80% and the first binder may be present in the first preform in a volume content of between 20% and 50%.
- the metal powder of the second alloy may be present in the second preform in a volume content of between 50% and 80% and the second binder may be present in the second preform in a volume content of between 20% and 50%.
- the following two conditions can be verified:
- the first and second preforms may each be formed by implementing a metal injection molding process.
- the implementation of a metal injection molding process for forming the first and second preforms advantageously makes it possible to further simplify the process insofar as it is thus possible to obtain directly the first and second preforms to the desired ribs or practically to the desired ribs and therefore reduce the duration of the subsequent machining, or even to emancipate.
- the core of the fibers may, for example, be silicon carbide, zirconia or alumina.
- the metal sheath of the fibers, the first alloy and the second alloy may each consist mainly of a mass of the same metal element.
- the metal sheath of the fibers consists of at least 50% by weight of a chemical element X and that each of the first and second alloys consist of at least 50% by weight of this same element X.
- Such an embodiment advantageously makes it possible to further improve the compatibility between the metal sheath of the fibers and the metal matrix of the part obtained.
- the material forming the metal sheath of the fibers may be identical to the first alloy and / or the second alloy.
- the fibers may, in the stacked structure, be housed in grooves formed on the surface of the first preform and / or on the surface of the second preform.
- Such an embodiment advantageously makes it possible to use relatively thick fibers for the fibrous reinforcement of the part, the grooves compensating all or part of the thickness of these fibers.
- the metal sheath of all or part of the fibers may be in the form of a continuous layer of a metallic material.
- the metal sheath of all or part of the fibers may be in the form of a plurality of metal strands surrounding the core, for example helically wound around the core.
- the fibers may include a first set of fibers extending along a first direction and a second set of fibers extending along a second direction not parallel to the first direction.
- the following two conditions can be verified:
- Such an embodiment advantageously makes it possible to further improve the quality of the metal matrix obtained.
- the first alloy may be identical to the second alloy.
- the first alloy may be different from the second alloy.
- the first alloy and the second alloy may be chosen from: titanium-based alloys, nickel-based alloys, cobalt-based alloys, aluminum-based alloys or steels.
- FIG. 1A shows a molding cavity 3 which is defined between a mold 1 and a counter-mold 2 and in which a metal injection molding process is intended to be implemented in order to obtain the first or the second preform.
- the metal injection molding process is a technique known per se.
- the molding cavity 3 has the shape of the preform to be manufactured.
- An injection composition 5 is first injected under pressure into the molding cavity 3.
- the injection composition 5 comprises a powder of a metal alloy and a binder and is intended to form one of the first and second preforms.
- the metal alloy used in the injection composition 5 may, for example, be a titanium-based alloy, a nickel-based alloy, a cobalt-based alloy, an aluminum-based alloy, or an aluminum alloy. steel. Unless stated otherwise, a material said to be "based on a chemical element X" has the element X in a mass content greater than or equal to 50%.
- the binder can be chosen from: paraffins, thermoplastic resins, agar gel, cellulose, polyethylene, polyethylene glycol, polypropylene, stearic acid, polyoxymethylene and mixtures thereof.
- the volume content of the metal alloy powder in the injection composition may for example be between 50% and 80%.
- the volume content of the binder in the injection composition may for example be between 20% and 50%.
- the injection composition 5 may first be mixed at a temperature between 150 ° C and 200 ° C in a neutral atmosphere for example, and may then be injected into the molding cavity 3 at such a temperature.
- the injection composition 5 is injected into the molding cavity 3 through a single injection point 4.
- the mold 1 and the counter-mold 2 can be regulated in temperature.
- the mold 1 and the counter mold 2 can, for example, be maintained at a temperature between 30 ° C and 70 ° C to promote cooling of the blank.
- the blank thus produced is said in a "green state" or plastic. It is advantageous to perform the injection of the injection composition 5 in a molding cavity 3 in which the vacuum has been made, in order to facilitate the injection and to ensure the homogeneity of the blank that will be formed.
- each of the first and second preforms is obtained in two separate injections. These two injections can for example be performed one after the other in the same molding cavity or, alternatively, can be performed in two different molding cavities simultaneously or not.
- the blanks 6a and 6b of the first and second preforms are demolded as shown in FIG. figure 1C .
- the blanks 6a and 6b can be machined in the green state to remove burrs or cores or injection points.
- the machining performed may, in addition, be carried out in order to modify the surfaces of the blanks 6a and 6b intended to be placed next to each other in the following process and / or to provide grooves on the surface. surface of the first and / or second preforms as will be detailed below.
- a first preform 7a of a first part of the part to be manufactured is obtained, this first preform 7a comprising at least one metal powder of a first alloy and a first binder and a second preform 7b of a second part of the workpiece comprising at least one metal powder of a second alloy and a second binder.
- the powder of the first alloy and / or the powder of the second alloy may, for example, have a grain size D90 less than or equal to 150 ⁇ m (ie in this case at least 90% of the grains of the powder have a size less than or equal to at 150 ⁇ m).
- the present invention is not limited to carrying out a metal injection molding process in order to obtain the first and second preforms. Indeed, one can alternatively use a tape casting process ("tape casting") or a powder compaction process.
- the implementation of a metal injection molding process for forming the first and second preforms is advantageous in order to quickly obtain a blank of said preforms having dimensions close to desired ribs, thereby simplifying the step of machining of these blanks.
- the implementation of a metal injection molding process also advantageously makes it possible to quickly obtain preforms having relatively complex shapes.
- the part intended to be formed in the context of the process of the invention may for example be a turbomachine part, for example a turbomachine blade. As a variant, said part may have an axisymmetric shape and for example constitute a turbine ring, segmented or not.
- a step a) is then performed during which a plurality of fibers 10 are positioned on the surface of the first preform 7a as illustrated in FIG. figure 1E .
- the positioning of the fibers 10 on the first preform 7a may or may not be automated.
- Representatives Figures 2A and 2B the structure of the fibers 10 used.
- the Figure 2A is a view of a fiber 10 in cross section and the Figure 2B is a view of this fiber 10 in longitudinal section.
- the fibers 10 each comprise a core of ceramic material 10a coated with a metal sheath 10b.
- the metallic material forming the sheath 10b may be a metal or a metal alloy.
- the metal sheath 10b is in the form of a continuous layer of a metallic material, for example obtained by a high-speed coating process (EGV).
- the core of ceramic material 10a may for example be alumina, zirconia or silicon carbide.
- the core 10a may for example have a diameter (greater transverse dimension) greater than or equal to 1 micron, for example between 1 micron and 140 microns.
- the thickness of the metallic sheath 10b may, for its part, be greater than or equal to 1 ⁇ m, for example between 1 ⁇ m and 140 ⁇ m.
- the metal sheath is intended to form the interface between the core 10a of the fibers 10 and the metal matrix of the piece of composite material obtained.
- Figures 3A and 3B a fiber variant 10 'used in the context of the method according to the invention.
- the metal sheath 10'b is in the form of a plurality of metal strands 10'c surrounding the core 10'a.
- the metal strands 10'c can each be wound around the core 10'a.
- the diameter of the core 10'a and the thickness of the metal sheath 10'b may be as described above in connection with the Figures 2A and 2B .
- at least six metal strands 10'c can surround the core 10'a fibers 10 '.
- the fibers 10 may, once positioned on the first preform 7a, extend over the majority (more than 50%) of the length of the first preform 7a and for example extend, as illustrated, on the the entire length of the first preform 7a.
- the fibers 10 may, once positioned on the first preform 7a extend from a first end 17a of the first preform 7a to a second end 18a of the first preform 7a located on the side opposite the first end 17a.
- the fibers 10 may, once positioned on the first preform 7a, have areas of extra lengths 11 and 12 extending beyond the first preform 7a.
- the over-length zones 11 and 12 extend from opposite ends 17a and 18a of the first preform 7a.
- the fibers 10 are positioned during step a) along the axes of mechanical stress of the part to be obtained.
- the density of fibers 10 positioned on the first preform 7a may be greater than or equal to 5 fibers per centimeter width of the first preform 7a. This fiber density may be less than or equal to 10 fibers per centimeter width of the first preform 7a and for example be between 5 and 10 fibers per centimeter width of the first preform 7a.
- Figure 4A an example of possible positioning for the fibers 10 on the first preform 7a.
- the Figure 4A corresponds to a top view of the fibers 10 and the first preform 7a.
- the fibers 10 may, once positioned on the first preform 7a, be spaced from each other.
- the spacing e between the fibers 10 may, for example, be constant as illustrated in FIG. Figure 4A .
- the fibers 10 are, in the example of Figure 4A parallel to each other once positioned on the first preform 7a.
- the fibers 10 can, once positioned on the first preform 7a, extend substantially rectilinear (in a straight line).
- the spacing between the fibers positioned on the first preform may vary.
- the fibers may, once positioned on the first preform, be in contact with each other.
- Figure 4B a possible positioning variant for the fibers 10 on the first preform 7a.
- the fibers 10 comprise a first set of fibers 10 extending along a first direction X and a second set of fibers 10 extending along a second direction Y not parallel to the first direction X
- the first direction X can, for example, as illustrated in FIG. Figure 4B be perpendicular to the second Y direction.
- Figures 4A and 4B illustrate possible positioning examples for the fibers 10 on the first preform 7a, any arrangement of fibers on the first preform being conceivable within the scope of the invention.
- step b) during which the second preform 7b is approaching the first preform 7a covered by the fibers 10 and is positioned on the first preform 7a as illustrated in FIG. the figure 1F .
- step b) the fibers 10 are interposed between the first preform 7a and the second preform 7b.
- the fibers 10 are in contact with the first 7a and the second preform 7b.
- the second preform 7b covers the first preform 7a and the fibers 10.
- the positioning of the fibers made during step a) is not modified during the positioning of the second preform 7b. The details described above relative to the positioning of the fibers 10 remain valid after implementation of step b).
- the first 7a and second 7b preforms are, before positioning the fibers 10, without any fibrous reinforcing element.
- the fibers 10 are indeed intended to constitute the fibrous reinforcement of the composite part to be obtained and are present at the interface between the first 7a and second 7b preforms.
- the fibers 10 may extend over the majority (more than 50%) of the length of the overlap area of the first preform 7a by the second preform 7b and for example extend, as illustrated, over the entire length of this area.
- the overlap area of the first preform 7a by the second preform 7b corresponds to the area on which the first and second preforms 7a and 7b are superimposed.
- the fibers 10 may, once step b) performed, extend from a first end 17b of the second preform 7b to a second end 18b of the second preform 7b located on the opposite side to the first end 17b.
- the over-length areas 11 and 12 of the fibers 10 may extend beyond the overlap area of the first preform 7a by the second preform 7b as illustrated.
- the first alloy, the second alloy and the material constituting the fiber sheath are not chosen arbitrarily.
- the melting temperature T 1 of the first alloy, the melting temperature T 2 of the second alloy and the melting temperature T 3 of the metal cladding of the fibers satisfy the following two conditions:
- the first and second alloys and the metal sheath of the fibers may each be based on the same metal element.
- the first and second alloys may be identical and the material constituting the metal sheath of the fibers may be identical to the material constituting the first and second alloys.
- step b) may optionally include carrying out a heating step to assemble the first preform, the second preform and the fibers via the first and second preforms. second binders.
- This assembly step makes it possible to obtain a consolidated stacked structure comprising the first and second preforms as well as that the fibers interposed between said preforms.
- a machining step of the consolidated stacked structure can be carried out in order to adjust its dimensions to the desired dimensions for the final part.
- step c) The stacked structure obtained after implementation of step b) is then unbound (step c)).
- debinding there is selective removal of the first and second binders present in the stacked structure.
- step c) a chemical debinding of the stacked structure during which the stacked structure is brought into contact with one or more solvents for solubilizing all or part of the first and second binders.
- step c) thermal debinding it is possible to perform during step c) thermal debinding.
- thermal debinding can be performed in a sintering chamber so as not to have to move the stacked structure between step c) and step d).
- Thermal debinding can be performed after implementation of chemical debinding.
- the conditions for debinding used in the context of the present invention are known per se.
- a heat treatment step d) is then carried out on the unbound stacked structure in order to obtain the piece 15 made of metal matrix composite material 14 (see FIG. figure 1G ).
- the metal sheath of the fibers is assembled with the powders of the first and second alloys by diffusion welding and these powders are sintered to form the metal matrix.
- a treatment temperature greater than or equal to 1200 ° C., for example between 1250 ° C. and 1350 ° C.
- the duration during which this treatment temperature is imposed may for example be greater than or equal to 120 minutes, for example between 120 minutes and 180 minutes.
- Step d) makes it possible to densify the powders of the first and second alloys and to create bonds between the first and second preforms and the metal sheaths of the fibers.
- the fact of introducing sheathed fibers with a material compatible with the metal matrix makes it possible to improve the cohesion of the fibers with the metal matrix, thus optimizing the mechanical behavior of the part obtained.
- the over-length areas 11 and 12 of the fibers 10 have been eliminated. This elimination of the over-length zones 11 and 12 can be carried out after step d) or before step d), or even before step c).
- step d the part 15 has been obtained, it is possible to carry out an additional machining step thereof in order to adjust the dimensions of the part 15 to the desired ribs.
- the resulting piece can then undergo hot isostatic compaction treatment or any finishing treatment.
- the part obtained in the context of the process according to the invention may comprise one or more layers of fibers.
- Figures 5A to 5D an alternative method according to the invention wherein the first and second preforms are formed during the same injection step. More specifically, the injection composition 25 is injected into the molding cavity 23 defined between the mold 21 and the counter-mold 22 through the injection point 24. This injection method makes it possible to form a parent blank 26 which can then undergo a machining step. A step is then made to cut out the possibly machined mother blank in order to form the first 27a and second 27b preforms (see FIG. figure 5D ). The process is then continued in a manner similar to that described above once the first 27a and second 27b preforms obtained.
- FIG. 6A top view
- Figure 6B depicts a first preform 37a which is present on a support 30.
- the first preform 37a is present between two side walls 31 and 32 of the support 30 and fibers 10 are present on the first preform 37a and on the walls 31 and 32.
- each of the side walls 31 and 32 has openings 31a, 31b, 32a and 32b.
- Representatives Figures 6C View from above
- 6D longitudinal sectional view
- 6E cross-sectional view
- the elements positioning members 35 and 36 each have a plurality of teeth 39 between which the fibers 10 are accommodated and thus allowing the fibers 10 to be held in the desired orientation.
- the positioning elements 35 and 36 each have openings 35a, 35b, 36a and 36b which are positioned facing the openings 31a, 31b, 32a and 32b of the side walls 31 and 32 of the support 30.
- the positioning elements 35 and 36 are then fixed to the support 30 by fixing elements 40a, 40b, 41a and 41b in the form of screw-nut systems in the illustrated example.
- the second preform 37b is then positioned on the fibers 10 (see Figures 6H and 6I ) and the first preform 37a.
- the preforms 37a, 37b and the fibers 10 are then assembled by heat treatment through the binder (s) present in the preforms 37a and 37b as explained above.
- the consolidated stacked structure constituted by the first and second preforms 37a and 37b and the fibers 10 is then removed from the support 30 (see FIG. Figures 6J and 6K ) to undergo debinding and heat treatment according to step d) as explained above.
- the figure 7 illustrates an alternative embodiment in which the fibers 10 are, in the stacked structure, housed in grooves 42a and 42b formed on the surface of the first preform 37a and / or on the surface of the second preform 37b. All or part of the thickness of the fibers 10 can be accommodated in these grooves 42a and 42b. It is not beyond the scope of the invention when only one of the first and second preforms has such grooves on its surface.
- a mixture of a metal powder and a binder is produced.
- This mixture is composed of 60% by volume of a metal powder of TA6V alloy and 40% by volume of a mixture of polyethylene glycol, polyethylene and polypropylene constituting the binder.
- the D90 size of the TA6V metal powder used was less than 35 ⁇ m and this powder was obtained by atomization under argon.
- first and second preforms were obtained.
- the mixture was injected into two injection molds.
- the injection temperature of the mixture was of the order of 190 ° C and the molds were cooled to about 50 ° C.
- First and second blanks of part of the part to be obtained were obtained after injection and molding of the mixture in the molds. The two blanks were deburred and the injection cores were removed in order to obtain a first and a second preform each constituting the preform of a half of the part to be obtained.
- Fibers were then positioned on the surface of one of the two preforms.
- the fibers used consisted of a central core of silicon carbide 80 microns in diameter and a pure titanium sheath (99% titanium content in the sheath greater than 99%) of a thickness of 10 microns.
- the titanium sheath was deposited on the ceramic cores by high speed coating.
- the fibers were deposited in a number to cover 10% of the surface of the preform by depositing 10 fibers per 10 millimeters of preform width. Tooling has been used to facilitate the positioning of the fibers and their maintenance, the use of this tooling being optional.
- the second preform has been positioned on the first preform as well as on said fibers.
- the assembly constituted by the stacking of the two preforms with the fibers interposed between these two preforms and by the holding tooling was then placed in an oven maintained at 70 ° C. for one hour. This steaming made it possible to bind the two preforms together by means of the binder present in these preforms and to obtain the consolidated stacked structure.
- the consolidated stacked structure was then separated from the holding tool.
- This structure then underwent a first chemical debinding step by immersion in a demineralized water bath while stirring the bath. The bath temperature was 60 ° C. and this debinding step was carried out for 24 hours.
- the piece obtained was removed from the oven, the portions of the fibers protruding from the room were cut. The part can then possibly be machined to adjust its shape and dimensions to the desired application.
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Description
L'invention concerne un procédé de fabrication d'une pièce composite à matrice métallique.The invention relates to a method for manufacturing a composite metal matrix part.
Le renforcement de pièces métalliques par des fibres longues à base d'un matériau céramique tel que le carbure de silicium a été envisagé afin d'améliorer les propriétés mécaniques (limite élastique, module d'Young) de ces pièces. Cependant, l'intégration de fibres longues dans une matrice métallique par les procédés de mise en forme conventionnels (fonderie, forge, usinage) est complexe. En outre, la cohésion entre les fibres et la matrice métallique est généralement faible, du fait soit d'une faible diffusion entre ces deux éléments ou d'une réaction entre les fibres et la matrice.Reinforcement of metal parts by long fibers based on a ceramic material such as silicon carbide has been envisaged in order to improve the mechanical properties (elastic limit, Young's modulus) of these parts. However, the integration of long fibers in a metal matrix by conventional shaping processes (foundry, forging, machining) is complex. In addition, the cohesion between the fibers and the metal matrix is generally low, due to either a weak diffusion between these two elements or a reaction between the fibers and the matrix.
Une solution pour améliorer la cohésion des fibres à la matrice métallique consiste à utiliser des fibres constituées d'une âme en matériau céramique et d'une gaine métallique entourant cette âme. La gaine peut par exemple avoir été déposée par enduction grande vitesse. Un traitement thermique de soudage par diffusion peut alors être réalisé afin de solidariser les fibres à une pièce préalablement mise en forme par exemple forgée et/ou usinée. Une telle solution est par exemple décrite dans le document
Il existe donc un besoin pour disposer de procédés plus simples d'élaboration de pièces composites à matrice métallique renforcées par des fibres céramiques tout en conservant pour les pièces obtenues des propriétés mécaniques satisfaisantes.There is therefore a need for more simple methods for producing metal matrix composite parts reinforced with ceramic fibers while retaining satisfactory mechanical properties for the parts obtained.
A cet effet, l'invention propose, selon un premier aspect, un procédé de fabrication d'une pièce en matériau composite comprenant un renfort fibreux densifié par une matrice métallique, le procédé comprenant au moins les étapes suivantes :
- a) positionnement d'une pluralité de fibres comprenant une âme en matériau céramique enrobée par une gaine métallique sur une première préforme d'une première partie de la pièce à fabriquer, ladite première préforme comprenant au moins une poudre métallique d'un premier alliage et un premier liant,
- b) positionnement d'une deuxième préforme d'une deuxième partie de la pièce à fabriquer sur la première préforme afin d'obtenir une structure empilée, les fibres étant présentes entre la première préforme et la deuxième préforme dans ladite structure empilée, ladite deuxième préforme comprenant au moins une poudre métallique d'un deuxième alliage et un deuxième liant, la température de fusion T1 du premier alliage, la température de fusion T2 du deuxième alliage et la température de fusion T3 de la gaine métallique des fibres vérifiant les deux conditions suivantes : |T3 - T1|T1 ≤ 25% et |T3 - T2|/T2 ≤ 25%,
- c) élimination des premier et deuxième liants présents dans la structure empilée obtenue après mise en oeuvre de l'étape b) afin d'obtenir une structure empilée déliantée,
- d) traitement thermique de la structure empilée déliantée afin d'obtenir la pièce en matériau composite durant lequel la gaine métallique des fibres est assemblée avec les poudres des premier et deuxième alliages par soudage par diffusion et durant lequel les poudres des premier et deuxième alliages sont frittées afin de former la matrice métallique.
- a) positioning a plurality of fibers comprising a core of ceramic material coated with a metal sheath on a first preform of a first part of the part to be manufactured, said first preform comprising at least one metal powder of a first alloy and a first binder,
- b) positioning a second preform of a second part of the part to be manufactured on the first preform to obtain a stacked structure, the fibers being present between the first preform and the second preform in said stacked structure, said second preform comprising at least one metal powder of a second alloy and a second binder, the melting temperature T 1 of the first alloy, the melting temperature T 2 of the second alloy and the melting temperature T 3 of the metal sheath of the fibers satisfying the two conditions: | T 3 - T 1 | T 1 ≤ 25% and | T 3 - T 2 | / T 2 ≤ 25%,
- c) elimination of the first and second binders present in the stacked structure obtained after carrying out step b) in order to obtain a stacked structure unbound,
- d) heat treatment of the unbonded stacked structure in order to obtain the piece of composite material during which the metallic sheath of the fibers is assembled with the powder of the first and second alloys by diffusion bonding and during which the powders of the first and second alloys are sintered to form the metal matrix.
Sauf mention contraire, les températures de fusion T1, T2 et T3 sont exprimées en °C (degrés Celsius). Sauf mention contraire, la grandeur notée |A| désigne la valeur absolue de la grandeur A.Unless otherwise stated, the melting temperatures T 1 , T 2 and T 3 are expressed in ° C (degrees Celsius). Unless otherwise stated, the size noted | A | denotes the absolute value of magnitude A.
Le fait que les températures T1, T2 et T3 vérifient les deux inégalités ci-dessus permet de garantir une bonne compatibilité entre la gaine métallique des fibres et les première et deuxième poudres afin de réaliser un soudage par diffusion efficace et obtenir une interface de bonne qualité entre les fibres et la matrice métallique permettant ainsi de disposer d'une pièce présentant les propriétés mécaniques souhaitées.The fact that the temperatures T 1 , T 2 and T 3 satisfy the above two inequalities makes it possible to guarantee good compatibility between the metallic sheath of the fibers and the first and second powders in order to achieve efficient diffusion welding and to obtain an interface good quality between the fibers and the metal matrix thus allowing to have a part having the desired mechanical properties.
Le fait d'utiliser des première et deuxième préformes à base de poudres permet avantageusement de significativement simplifier la fabrication de la pièce en matériau composite du fait notamment de la possibilité de mettre à profit la même étape de traitement thermique à la fois pour densifier les première et deuxième préformes et former la matrice métallique ainsi que pour rendre solidaire la gaine des fibres à la matrice métallique. L'obtention de pièces présentant des propriétés mécaniques satisfaisantes par un tel procédé simplifié est rendue possible du fait de la mise en oeuvre de matériaux présentant des températures de fusion particulières afin de garantir un soudage par diffusion efficace comme mentionné plus haut.The fact of using first and second preforms based on powders advantageously makes it possible to significantly simplify the manufacture of the composite material part, in particular because of the possibility of using the same heat treatment step both to densify the first and second preforms and forming the metal matrix as well as to make the sheath of the fibers integral with the metal matrix. Obtaining parts with satisfactory mechanical properties by such a simplified process is made possible by the use of materials having particular melting temperatures to ensure effective diffusion welding as mentioned above.
Le premier liant et le deuxième liant peuvent être identiques ou différents. La poudre métallique du premier alliage peut être présente dans la première préforme en une teneur volumique comprise entre 50% et 80% et le premier liant peut être présent dans la première préforme en une teneur volumique comprise entre 20% et 50%. De même, la poudre métallique du deuxième alliage peut être présente dans la deuxième préforme en une teneur volumique comprise entre 50% et 80% et le deuxième liant peut être présent dans la deuxième préforme en une teneur volumique comprise entre 20% et 50%.The first binder and the second binder may be the same or different. The metal powder of the first alloy may be present in the first preform in a volume content of between 50% and 80% and the first binder may be present in the first preform in a volume content of between 20% and 50%. Similarly, the metal powder of the second alloy may be present in the second preform in a volume content of between 50% and 80% and the second binder may be present in the second preform in a volume content of between 20% and 50%.
De préférence, les deux conditions suivantes peuvent être vérifiées : |T3 - T1|/T1 ≤ 15% et |T3 - T2|/T2 ≤ 15%.Preferably, the following two conditions can be verified: | T 3 - T 1 | / T 1 ≤ 15% and | T 3 - T 2 | / T 2 ≤ 15%.
Le fait de vérifier ces deux inégalités permet avantageusement d'améliorer encore la qualité du soudage par diffusion réalisé permettant l'assemblage de la gaine métallique des fibres avec la matrice métallique et ainsi d'améliorer encore les propriétés mécaniques des pièces obtenues.The fact of verifying these two inequalities advantageously makes it possible to further improve the quality of the diffusion welding carried out allowing the assembly of the metal sheath of the fibers with the metal matrix and thus to further improve the mechanical properties of the parts obtained.
Dans un exemple de réalisation, les première et deuxième préformes peuvent chacune être formées par mise en oeuvre d'un procédé de moulage par injection de métal.In an exemplary embodiment, the first and second preforms may each be formed by implementing a metal injection molding process.
La mise en oeuvre d'un procédé de moulage par injection de métal (« Metal Injection Molding ») pour former les première et deuxième préformes permet avantageusement de simplifier encore plus le procédé dans la mesure où il est ainsi possible d'obtenir directement les première et deuxième préformes aux côtes souhaitées ou pratiquement aux côtes souhaitées et par conséquent de réduire la durée de l'usinage subséquent, voire de s'en affranchir.The implementation of a metal injection molding process for forming the first and second preforms advantageously makes it possible to further simplify the process insofar as it is thus possible to obtain directly the first and second preforms to the desired ribs or practically to the desired ribs and therefore reduce the duration of the subsequent machining, or even to emancipate.
L'âme des fibres peut, par exemple, être en carbure de silicium, en zircone ou en alumine.The core of the fibers may, for example, be silicon carbide, zirconia or alumina.
De préférence, la gaine métallique des fibres, le premier alliage et le deuxième alliage peuvent chacun être majoritairement constitués en masse d'un même élément métallique. En d'autres termes, il faut dans ce cas comprendre que la gaine métallique des fibres est constituée à au moins 50% en masse d'un élément chimique X et que chacun des premier et deuxième alliages sont constitués à au moins 50% en masse de ce même élément X.Preferably, the metal sheath of the fibers, the first alloy and the second alloy may each consist mainly of a mass of the same metal element. In other words, it is necessary in this case to understand that the metal sheath of the fibers consists of at least 50% by weight of a chemical element X and that each of the first and second alloys consist of at least 50% by weight of this same element X.
Un tel mode de réalisation permet avantageusement d'améliorer encore la compatibilité entre la gaine métallique des fibres et la matrice métallique de la pièce obtenue.Such an embodiment advantageously makes it possible to further improve the compatibility between the metal sheath of the fibers and the metal matrix of the part obtained.
En particulier, le matériau formant la gaine métallique des fibres peut être identique au premier alliage et/ou au deuxième alliage.In particular, the material forming the metal sheath of the fibers may be identical to the first alloy and / or the second alloy.
Dans un exemple de réalisation, les fibres peuvent, dans la structure empilée, être logées dans des rainures ménagées sur la surface de la première préforme et/ou sur la surface de la deuxième préforme.In an exemplary embodiment, the fibers may, in the stacked structure, be housed in grooves formed on the surface of the first preform and / or on the surface of the second preform.
Un tel exemple de réalisation permet avantageusement de mettre en oeuvre des fibres relativement épaisses pour le renfort fibreux de la pièce, les rainures compensant tout ou partie de l'épaisseur de ces fibres.Such an embodiment advantageously makes it possible to use relatively thick fibers for the fibrous reinforcement of the part, the grooves compensating all or part of the thickness of these fibers.
Dans un exemple de réalisation, la gaine métallique de tout ou partie des fibres peut être sous la forme d'une couche continue d'un matériau métallique.In an exemplary embodiment, the metal sheath of all or part of the fibers may be in the form of a continuous layer of a metallic material.
Dans un exemple de réalisation, la gaine métallique de tout ou partie des fibres peut être sous la forme d'une pluralité de brins métalliques entourant l'âme, par exemple enroulés de manière hélicoïdale autour de l'âme.In an exemplary embodiment, the metal sheath of all or part of the fibers may be in the form of a plurality of metal strands surrounding the core, for example helically wound around the core.
Dans un exemple de réalisation, les fibres peuvent comporter un premier ensemble de fibres s'étendant le long d'une première direction et un deuxième ensemble de fibres s'étendant le long d'une deuxième direction non parallèle à la première direction.In an exemplary embodiment, the fibers may include a first set of fibers extending along a first direction and a second set of fibers extending along a second direction not parallel to the first direction.
Avantageusement, les deux conditions suivantes peuvent être vérifiées : |T2 - T1|/T1 ≤ 25%, de préférence |T2 - T1|/T1 ≤ 15%. Un tel mode de réalisation permet avantageusement d'améliorer encore la qualité de la matrice métallique obtenue.Advantageously, the following two conditions can be verified: | T 2 - T 1 | / T 1 ≤ 25%, preferably | T 2 - T 1 | / T 1 ≤ 15%. Such an embodiment advantageously makes it possible to further improve the quality of the metal matrix obtained.
En particulier, le premier alliage peut être identique au deuxième alliage. En variante, le premier alliage peut être différent du deuxième alliage.In particular, the first alloy may be identical to the second alloy. Alternatively, the first alloy may be different from the second alloy.
Dans un exemple de réalisation, le premier alliage et le deuxième alliage peuvent être choisis parmi : les alliages à base de titane, les alliages à base de nickel, les alliages à base de cobalt, les alliages à base d'aluminium ou les aciers.In an exemplary embodiment, the first alloy and the second alloy may be chosen from: titanium-based alloys, nickel-based alloys, cobalt-based alloys, aluminum-based alloys or steels.
D'autres caractéristiques et avantages de l'invention ressortiront de la description suivante de modes particuliers de réalisation de l'invention, donnés à titre d'exemples non limitatifs, en référence aux dessins annexés, sur lesquels :
- les
figures 1A à 1G représentent différentes étapes d'un exemple de procédé selon l'invention, - les
figures 2A et 2B représentent la structure des fibres mises en oeuvre dans l'exemple de procédé illustré auxfigures 1A à 1G , - les
figures 3A et 3B représentent une variante de structure de fibres pouvant être mise en oeuvre dans le cadre d'un procédé selon l'invention, - la
figure 4A représente un exemple de positionnement possible des fibres sur la première préforme, - la
figure 4B représente un autre exemple de positionnement possible des fibres sur la première préforme, - les
figures 5A à 5D représentent différentes étapes d'une variante de procédé selon l'invention, - les
figures 6A à 6K représentent différentes étapes d'une variante de procédé selon l'invention, et - la
figure 7 illustre un détail d'une variante de réalisation selon l'invention.
- the
Figures 1A to 1G represent different steps of an exemplary method according to the invention, - the
Figures 2A and 2B represent the structure of the fibers used in the example of the process illustrated inFigures 1A to 1G , - the
Figures 3A and 3B represent a variant of fiber structure that can be used in the context of a process according to the invention, - the
Figure 4A represents an example of possible positioning of the fibers on the first preform, - the
Figure 4B represents another example of possible positioning of the fibers on the first preform, - the
Figures 5A to 5D represent different steps of an alternative process according to the invention, - the
Figures 6A to 6K represent different steps of an alternative process according to the invention, and - the
figure 7 illustrates a detail of an alternative embodiment of the invention.
On a représenté aux
Le liant peut être choisi parmi : les paraffines, les résines thermoplastiques, le gel d'agar, la cellulose, le polyéthylène, le polyéthylène glycol, le polypropylène, l'acide stéarique, le polyoxyméthylène et leurs mélanges. La teneur volumique de la poudre d'alliage métallique dans la composition d'injection 5 peut par exemple être comprise entre 50% et 80%. La teneur volumique du liant dans la composition d'injection 5 peut par exemple être comprise entre 20% et 50%. La composition d'injection 5 peut d'abord être mélangée à une température comprise entre 150°C et 200°C sous atmosphère neutre par exemple, et peut ensuite être injectée dans la cavité de moulage 3 à une telle température.The binder can be chosen from: paraffins, thermoplastic resins, agar gel, cellulose, polyethylene, polyethylene glycol, polypropylene, stearic acid, polyoxymethylene and mixtures thereof. The volume content of the metal alloy powder in the injection composition may for example be between 50% and 80%. The volume content of the binder in the injection composition may for example be between 20% and 50%. The
Dans l'exemple illustré, la composition d'injection 5 est injectée dans la cavité de moulage 3 au travers d'un unique point d'injection 4. Bien entendu, on ne sort pas du cadre de la présente invention lorsque la composition d'injection est injectée dans la cavité de moulage au travers d'une pluralité de points d'injections permettant l'injection simultanée ou non de la composition d'injection dans plusieurs parties de la cavité de moulage. Lors de l'injection, le moule 1 et le contre-moule 2 peuvent être régulés en température. Le moule 1 et le contre-moule 2 peuvent, par exemple, être maintenus à une température comprise entre 30°C et 70°C afin de favoriser le refroidissement de l'ébauche. L'ébauche ainsi réalisée est dite dans un « état vert » ou plastique. Il est avantageux de réaliser l'injection de la composition d'injection 5 dans une cavité de moulage 3 dans laquelle le vide a été fait, afin de faciliter l'injection et d'assurer l'homogénéité de l'ébauche qui sera formée.In the illustrated example, the
Dans l'exemple illustré en lien avec les
Une fois l'injection réalisée, les ébauches 6a et 6b des première et deuxième préformes sont démoulées comme illustré à la
La présente invention n'est pas limitée à la mise en oeuvre d'un procédé de moulage par injection de métal afin d'obtenir les première et deuxième préformes. En effet, on peut en variante utiliser un procédé de coulage en bande (« tape casting ») ou un procédé de compaction de poudre. La mise en oeuvre d'un procédé de moulage par injection de métal pour former les première et deuxième préformes est toutefois avantageuse afin de pouvoir obtenir rapidement une ébauche desdites préformes ayant des dimensions proches des côtes souhaitées, ce qui permet de simplifier l'étape d'usinage de ces ébauches. La mise en oeuvre d'un procédé de moulage par injection de métal permet en outre avantageusement d'obtenir rapidement des préformes ayant des formes relativement complexes. La pièce destinée à être formée dans le cadre du procédé de l'invention peut par exemple être une pièce de turbomachine, par exemple une aube de turbomachine. En variante, ladite pièce peut présenter une forme axisymétrique et par exemple constituer un anneau de turbine, segmenté ou non.The present invention is not limited to carrying out a metal injection molding process in order to obtain the first and second preforms. Indeed, one can alternatively use a tape casting process ("tape casting") or a powder compaction process. The implementation of a metal injection molding process for forming the first and second preforms, however, is advantageous in order to quickly obtain a blank of said preforms having dimensions close to desired ribs, thereby simplifying the step of machining of these blanks. The implementation of a metal injection molding process also advantageously makes it possible to quickly obtain preforms having relatively complex shapes. The part intended to be formed in the context of the process of the invention may for example be a turbomachine part, for example a turbomachine blade. As a variant, said part may have an axisymmetric shape and for example constitute a turbine ring, segmented or not.
On réalise ensuite une étape a) durant laquelle on positionne une pluralité de fibres 10 sur la surface de la première préforme 7a comme illustré à la
Comme illustré, les fibres 10 peuvent, une fois positionnées sur la première préforme 7a, s'étendre sur la majorité (plus de 50%) de la longueur de la première préforme 7a et par exemple s'étendre, comme illustré, sur l'intégralité de la longueur de la première préforme 7a. Les fibres 10 peuvent, une fois positionnées sur la première préforme 7a s'étendre d'une première extrémité 17a de la première préforme 7a à une deuxième extrémité 18a de la première préforme 7a située du côté opposé à la première extrémité 17a. Les fibres 10 peuvent, une fois positionnées sur la première préforme 7a, présenter des zones de sur-longueurs 11 et 12 s'étendant au-delà de la première préforme 7a. Dans l'exemple illustré à la
On a représenté à la
On a représenté à la
Une fois les fibres 10 positionnées sur la première préforme 7a, le procédé se poursuit par une étape b) durant laquelle la deuxième préforme 7b est approchée de la première préforme 7a recouverte par les fibres 10 et est positionnée sur la première préforme 7a comme illustré à la
Une fois l'étape b) réalisée, les fibres 10 peuvent s'étendre sur la majorité (plus de 50%) de la longueur de la zone de recouvrement de la première préforme 7a par la deuxième préforme 7b et par exemple s'étendre, comme illustré, sur l'intégralité de la longueur de cette zone. La zone de recouvrement de la première préforme 7a par la deuxième préforme 7b correspond à la zone sur laquelle les première et deuxième préformes 7a et 7b sont superposées. Les fibres 10 peuvent, une fois l'étape b) réalisée, s'étendre d'une première extrémité 17b de la deuxième préforme 7b à une deuxième extrémité 18b de la deuxième préforme 7b située du côté opposé à la première extrémité 17b. Les zones de sur-longueurs 11 et 12 des fibres 10 peuvent s'étendre au-delà de la zone de recouvrement de la première préforme 7a par la deuxième préforme 7b comme illustré.After step b), the
Comme mentionné plus haut, le premier alliage, le deuxième alliage et le matériau constituant la gaine des fibres ne sont pas choisis de manière arbitraire. En effet, la température de fusion T1 du premier alliage, la température de fusion T2 du deuxième alliage et la température de fusion T3 de la gaine métallique des fibres vérifient les deux conditions suivantes : |T3 - T1|/T1 ≤ 25% et |T3 - T2|/T2 ≤ 25%. La vérification de ces deux inégalités concernant l'écart relatif entre T3 et T1 d'une part et l'écart relatif entre T3 et T2 d'autre part permet avantageusement d'assurer un bon soudage par diffusion de la gaine métallique des fibres avec la matrice métallique formée à partir des poudres des premier et deuxième alliages et, par conséquent, d'optimiser les propriétés mécaniques de la pièce obtenue.As mentioned above, the first alloy, the second alloy and the material constituting the fiber sheath are not chosen arbitrarily. Indeed, the melting temperature T 1 of the first alloy, the melting temperature T 2 of the second alloy and the melting temperature T 3 of the metal cladding of the fibers satisfy the following two conditions: | T 3 - T 1 | / T 1 ≤ 25% and | T 3 - T 2 | / T 2 ≤ 25%. The verification of these two inequalities concerning the relative difference between T 3 and T 1 on the one hand and the relative difference between T 3 and T 2 on the other hand advantageously makes it possible to ensure a good diffusion bonding of the metallic sheath. fibers with the metal matrix formed from the powders of the first and second alloys and, consequently, to optimize the mechanical properties of the part obtained.
Avantageusement, on peut mettre en oeuvre les combinaisons suivantes :
- premier et deuxième alliages à base de nickel et gaine métallique des fibres à base de nickel,
- premier et deuxième alliages à base de fer et gaine métallique des fibres à base de fer,
- premier et deuxième alliages à base de titane et gaine métallique des fibres à base de titane,
- premier et deuxième alliages à base de cobalt et gaine métallique des fibres à base de cobalt,
- premier et deuxième alliages à base de fer et gaine métallique des fibres à base de nickel,
- premier et deuxième alliages à base de nickel et gaine métallique des fibres à base de fer,
- premier et deuxième alliages à base de cobalt et gaine métallique des fibres à base de nickel,
- premier et deuxième alliages à base de nickel et gaine métallique des fibres à base de cobalt.
- first and second nickel-based alloys and metallic sheath of the nickel-based fibers,
- first and second iron-based alloys and metallic sheath of iron-based fibers,
- first and second titanium-based alloys and metallic sheath of titanium-based fibers,
- first and second cobalt-based alloys and metallic sheath of cobalt-based fibers,
- first and second iron-based alloys and metallic sheath of the nickel-based fibers,
- first and second nickel-based alloys and metallic sheath of iron-based fibers,
- first and second cobalt-based alloys and metallic sheath of the nickel-based fibers,
- first and second nickel-based alloys and metallic sheath of cobalt-based fibers.
De préférence, les premier et deuxième alliages ainsi que la gaine métallique des fibres peuvent chacun être à base d'un même élément métallique. En particulier, les premier et deuxième alliages peuvent être identiques et le matériau constituant la gaine métallique des fibres peut être identique au matériau constituant les premier et deuxième alliages.Preferably, the first and second alloys and the metal sheath of the fibers may each be based on the same metal element. In particular, the first and second alloys may be identical and the material constituting the metal sheath of the fibers may be identical to the material constituting the first and second alloys.
On donne ci-dessous quelques exemples de combinaisons possibles qui peuvent être mises en oeuvre dans le cadre de l'invention :
- gaine métallique des fibres en TiAl 48-2-2 avec premier et deuxième alliages en TiAl 48-2-2,
- gaine métallique des fibres en Ta6V avec premier et deuxième alliages en TiAl 48-2-2,
- gaine métallique des fibres en titane T40 avec premier et deuxième alliages en TiAl 48-2-2,
- gaine métallique des fibres en Inconel® 718 avec premier et deuxième alliages en Inconel® 718,
- gaine métallique des fibres en Inconel® 625 avec premier et deuxième alliages en Inconel® 718,
- gaine métallique des fibres en nickel avec premier et deuxième alliages en Inconel® 718,
- gaine métallique des fibres en nickel avec premier et deuxième alliages en inox 304L,
- gaine métallique des fibres en inox 304L avec premier et deuxième alliages en inox 304L,
- gaine métallique des fibres en inox 316L avec premier et deuxième alliages en inox 304L.
- metallic sheath of TiAl 48-2-2 fibers with first and second TiAl 48-2-2 alloys,
- metal sheath of Ta6V fibers with first and second TiAl 48-2-2 alloys,
- metallic sheath of T40 titanium fibers with first and second TiAl 48-2-2 alloys,
- metallic sheath of Inconel® 718 fibers with first and second Inconel® 718 alloys,
- Metallic sheath of Inconel® 625 fibers with first and second Inconel® 718 alloys,
- metallic sheath of nickel fibers with first and second alloys in Inconel® 718,
- metallic sheath of nickel fibers with first and second 304L stainless steel alloys,
- metallic sheath of 304L stainless steel fibers with first and second 304L stainless steel alloys,
- metallic sheath of 316L stainless steel fibers with first and second 304L stainless steel alloys.
Une fois la deuxième préforme positionnée sur la première préforme, l'étape b) peut de manière optionnelle comporter la réalisation d'une étape de chauffage permettant d'assembler la première préforme, la deuxième préforme et les fibres par l'intermédiaire des premier et deuxième liants. Cette étape d'assemblage permet d'obtenir une structure empilée consolidée comprenant les première et deuxièmes préformes ainsi que les fibres intercalées entre lesdites préformes. Après mise en oeuvre de cette étape de chauffage, une étape d'usinage de la structure empilée consolidée peut être effectuée afin d'ajuster ses dimensions aux dimensions souhaitées pour la pièce finale.Once the second preform has been positioned on the first preform, step b) may optionally include carrying out a heating step to assemble the first preform, the second preform and the fibers via the first and second preforms. second binders. This assembly step makes it possible to obtain a consolidated stacked structure comprising the first and second preforms as well as that the fibers interposed between said preforms. After carrying out this heating step, a machining step of the consolidated stacked structure can be carried out in order to adjust its dimensions to the desired dimensions for the final part.
La structure empilée obtenue après mise en oeuvre de l'étape b) est alors déliantée (étape c)). Durant le déliantage, il y a élimination sélective des premier et deuxième liants présents dans la structure empilée. Il est possible de réaliser durant l'étape c) un déliantage chimique de la structure empilée durant lequel la structure empilée est mise en contact avec un ou plusieurs solvants permettant de solubiliser tout ou partie des premier et deuxième liants. En variante ou en combinaison, il est possible de réaliser durant l'étape c) un déliantage thermique. Dans ce cas, le déliantage thermique peut être réalisé dans une enceinte de frittage afin de ne pas avoir à déplacer la structure empilée entre l'étape c) et l'étape d). Le déliantage thermique peut être réalisé après mise en oeuvre du déliantage chimique. Les conditions permettant de réaliser le déliantage mis en oeuvre dans le cadre de la présente invention sont connues en soi.The stacked structure obtained after implementation of step b) is then unbound (step c)). During debinding, there is selective removal of the first and second binders present in the stacked structure. It is possible to perform during step c) a chemical debinding of the stacked structure during which the stacked structure is brought into contact with one or more solvents for solubilizing all or part of the first and second binders. Alternatively or in combination, it is possible to perform during step c) thermal debinding. In this case, thermal debinding can be performed in a sintering chamber so as not to have to move the stacked structure between step c) and step d). Thermal debinding can be performed after implementation of chemical debinding. The conditions for debinding used in the context of the present invention are known per se.
On réalise ensuite une étape d) de traitement thermique de la structure empilée déliantée afin d'obtenir la pièce 15 en matériau composite à matrice métallique 14 (voir
Par ailleurs, les zones de sur-longueurs 11 et 12 des fibres 10 ont été éliminées. Cette élimination des zones de sur-longueurs 11 et 12 peut être réalisée après l'étape d) ou avant l'étape d), voire avant l'étape c). Une fois la pièce 15 obtenue, on peut éventuellement réaliser une étape d'usinage supplémentaire de celle-ci afin d'ajuster les dimensions de la pièce 15 aux côtes souhaitées. La pièce 15 obtenue peut ensuite subir un traitement de compactage isostatique à chaud ou un quelconque traitement de finition.On the other hand, the
Dans une variante non illustrée de l'invention, on peut après placement de la deuxième préforme sur les fibres et la première préforme, positionner à nouveau sur la deuxième préforme du côté opposé à la première préforme des fibres à âme céramique gainée telles que décrites plus haut puis positionner une troisième préforme comprenant une poudre métallique d'un alliage et un liant. L'ensemble peut alors subir un déliantage suivi d'un traitement thermique selon l'étape d) afin d'obtenir la pièce en matériau composite. Ainsi, la pièce obtenue dans le cadre du procédé selon l'invention peut comporter une ou plusieurs couches de fibres.In a non-illustrated variant of the invention, it is possible after placing the second preform on the fibers and the first preform, to position again on the second preform on the opposite side to the first preform of the sheathed ceramic core fibers as described above. top then position a third preform comprising a metal powder of an alloy and a binder. The assembly can then undergo debinding followed by a heat treatment according to step d) in order to obtain the piece of composite material. Thus, the part obtained in the context of the process according to the invention may comprise one or more layers of fibers.
On a représenté aux
On a représenté aux
La
On réalise tout d'abord un mélange d'une poudre métallique et d'un liant. Ce mélange est composé à 60% en volume d'une poudre métallique de l'alliage TA6V et à 40% en volume d'un mélange de polyéthylène glycol, de polyéthylène et de polypropylène constituant le liant. La taille D90 de la poudre métallique de TA6V utilisée était inférieure à 35 µm et cette poudre a été obtenue par atomisation sous argon.Firstly, a mixture of a metal powder and a binder is produced. This mixture is composed of 60% by volume of a metal powder of TA6V alloy and 40% by volume of a mixture of polyethylene glycol, polyethylene and polypropylene constituting the binder. The D90 size of the TA6V metal powder used was less than 35 μm and this powder was obtained by atomization under argon.
A partir de ce mélange de poudre de TA6V et de liant, une première et une deuxième préformes ont été obtenues. Pour cela, le mélange a été injecté dans deux moules d'injection. La température d'injection du mélange était de l'ordre de 190°C et les moules étaient refroidis à 50°C environ. Une première et une deuxième ébauches d'une partie de la pièce à obtenir ont été obtenues après injection et moulage du mélange dans les moules. Les deux ébauches ont été ébavurées et les carottes d'injection ont été éliminées afin d'obtenir une première et une deuxième préformes constituant chacune la préforme d'une moitié de la pièce à obtenir.From this mixture of TA6V powder and binder, first and second preforms were obtained. For this, the mixture was injected into two injection molds. The injection temperature of the mixture was of the order of 190 ° C and the molds were cooled to about 50 ° C. First and second blanks of part of the part to be obtained were obtained after injection and molding of the mixture in the molds. The two blanks were deburred and the injection cores were removed in order to obtain a first and a second preform each constituting the preform of a half of the part to be obtained.
Des fibres ont alors été positionnées sur la surface d'une des deux préformes. Les fibres utilisées étaient constituées d'une âme centrale en carbure de silicium de 80 microns de diamètre et d'une gaine en titane pur (teneur massique en titane dans la gaine supérieure à 99 %) d'une épaisseur de 10 microns. La gaine de titane a été déposée sur les âmes en céramique par enduction grande vitesse. Les fibres ont été déposées en un nombre permettant de recouvrir 10 % de la surface de la préforme en déposant 10 fibres pour 10 millimètres de largeur de préforme. Un outillage a été utilisé pour faciliter le positionnement des fibres et leur maintien, l'utilisation de cet outillage étant optionnelle.Fibers were then positioned on the surface of one of the two preforms. The fibers used consisted of a central core of silicon carbide 80 microns in diameter and a pure titanium sheath (99% titanium content in the sheath greater than 99%) of a thickness of 10 microns. The titanium sheath was deposited on the ceramic cores by high speed coating. The fibers were deposited in a number to cover 10% of the surface of the preform by depositing 10 fibers per 10 millimeters of preform width. Tooling has been used to facilitate the positioning of the fibers and their maintenance, the use of this tooling being optional.
Une fois les fibres positionnées sur la première préforme, la deuxième préforme a été positionnée sur la première préforme ainsi que sur lesdites fibres. L'ensemble constitué par l'empilement des deux préformes avec les fibres intercalées entre ces deux préformes et par l'outillage de maintien a alors été placé dans une étuve maintenue à 70°C pendant une heure. Cet étuvage a permis de lier les deux préformes entre elles par l'intermédiaire du liant présent dans ces préformes et d'obtenir la structure empilée consolidée. La structure empilée consolidée a alors été séparée de l'outillage de maintien. Cette structure a alors subi une première étape de déliantage chimique par immersion dans un bain d'eau déminéralisée sous agitation du bain. La température du bain était de 60°C et cette étape de déliantage a été effectuée pendant 24 heures.Once the fibers are positioned on the first preform, the second preform has been positioned on the first preform as well as on said fibers. The assembly constituted by the stacking of the two preforms with the fibers interposed between these two preforms and by the holding tooling was then placed in an oven maintained at 70 ° C. for one hour. This steaming made it possible to bind the two preforms together by means of the binder present in these preforms and to obtain the consolidated stacked structure. The consolidated stacked structure was then separated from the holding tool. This structure then underwent a first chemical debinding step by immersion in a demineralized water bath while stirring the bath. The bath temperature was 60 ° C. and this debinding step was carried out for 24 hours.
Une fois ce déliantage à l'eau déminéralisée effectué, la structure partiellement déliantée a été placée sur une plaque en zircone et introduite dans un four afin de subir un traitement thermique permettant de finaliser thermiquement le déliantage. Le traitement thermique a ensuite été poursuivi afin de fritter les poudres métalliques afin de former la matrice de la pièce ainsi que de solidariser la gaine métallique des fibres à ladite matrice. Une atmosphère d'argon à 20 mbar de pression a été imposée durant ce traitement thermique. Le traitement thermique effectué présentait les caractéristiques suivantes :
- passage de 20°C à 200°C avec une rampe à 5°C /minute,
- passage de 200°C à 350°C avec une rampe à 2°C/
minute et 1 heure de maintien à 350°C, - passage de 350°C à 470°C avec une rampe à 2°C/
minute et 1 heure de maintien à 470°C, - passage de 470°C à 1250°C avec une rampe à 5°C/minute et 3 heures de maintien à 1250°C,
- passage de 1250°C à 80°C avec une rampe de refroidissement à 10°C/minute.
- from 20 ° C to 200 ° C with a ramp at 5 ° C / minute,
- passage from 200 ° C. to 350 ° C. with a ramp at 2 ° C./minute and 1 hour hold at 350 ° C.,
- passage from 350 ° C to 470 ° C with a ramp at 2 ° C / minute and 1 hour of maintenance at 470 ° C,
- passage from 470 ° C to 1250 ° C with a ramp at 5 ° C / minute and 3 hours of holding at 1250 ° C,
- passage from 1250 ° C to 80 ° C with a cooling ramp at 10 ° C / minute.
Une fois ce traitement thermique réalisé, la pièce obtenue a été sortie du four, les portions des fibres dépassant de la pièce ont été découpées. La pièce peut alors éventuellement subir un usinage afin d'ajuster sa forme et ses dimensions à l'application souhaitée.Once this heat treatment performed, the piece obtained was removed from the oven, the portions of the fibers protruding from the room were cut. The part can then possibly be machined to adjust its shape and dimensions to the desired application.
L'expression « compris(e) entre ... et ... » ou « allant de ... à ... » doit se comprendre comme incluant les bornes.The expression "understood between ... and ..." or "from ... to ..." must be understood as including the boundaries.
Claims (11)
- A method of fabricating a part (15) out of composite material comprising fiber reinforcement densified by a metal matrix (14), the method comprising at least the following steps:a) positioning a plurality of fibers (10; 10') comprising a core (10a; 10'a) made of ceramic material coated by a metal sheath (10b; 10'b) on a first preform (7a; 27a; 37a) for a first portion of the part to be fabricated, said first preform (7a; 27a; 37a) comprising at least a metal powder of a first alloy and a first binder;b) positioning a second preform (7b; 27b; 37b) for a second portion of the part to be fabricated on the first preform (7a; 27a; 37a) in order to obtain a stack structure, the fibers (10; 10') being present between the first preform (7a; 27a; 37a) and the second preform (7b; 27b; 37b) in said stack structure, said second preform (7b; 27b; 37b) comprising at least a metal powder of a second alloy and a second binder, the melting temperature T1 of the first alloy, the melting temperature T2 of the second alloy, and the melting temperature T3 of the metal sheath (10b; 10'b) of the fibers (10; 10') satisfying the following two conditions: |T3 - T1|/T1 ≤ 25%, and |T3 - T2|/T2 ≤ 25%, the melting temperatures T1, T2 and T3 being expressed in degrees Celsius;c) eliminating the first and second binders present in the stack structure obtained after performing step b) in order to obtain a debindered stack structure; andd) heat treating the debindered stack structure in order to obtain the composite material part (15) wherein the metal sheath (10b; 10'b) of the fibers (10; 10') is assembled with the powders of the first and second alloys by diffusion welding and wherein the powders of the first and second alloys are sintered in order to form the metal matrix (14).
- A method according to claim 1, wherein the following two conditions are satisfied: |T3 - T1|/T1 ≤ 15%, and |T3 - T2 /T2 ≤ 15%.
- A method according to claim 1 or claim 2, wherein the first (7a; 27a; 37a) and second (7b; 27b; 37b) preforms are each formed by performing a metal injection molding method.
- A method according to any one of claims 1 to 3, wherein the metal sheath (10b; 10'b) of the fibers (10; 10'), the first alloy, and the second alloy are each constituted in the majority by weight by a same metal element.
- A method according to any one of claims 1 to 4, wherein the material forming the metal sheath (10b; 10'b) of the fibers (10; 10') is identical to the first alloy and/or the second alloy.
- A method according to any one of claims 1 to 5, wherein the fibers (10) are received, in the stack structure, in grooves (42a; 42b) formed in the surface of the first preform (37a) and/or in the surface of the second preform (37b).
- A method according to any one of claims 1 to 6, wherein the metal sheath (10b) of all or some of the fibers (10) is in the form of a continuous layer of a metal material.
- A method according to any one of claims 1 to 7, wherein the metal sheath (10'b) of all or some of the fibers (10') is in the form of respective pluralities of metal strands (10'c) surrounding the cores (10'a).
- A method according to any one of claims 1 to 8, wherein the fibers comprise a first set of fibers extending along a first direction (X) and a second set of fibers extending along a second direction (Y) that is not parallel to the first direction (X).
- A method according to any one of claims 1 to 9, wherein the first alloy is identical to the second alloy.
- A method according to any one of claims 1 to 10, wherein the first alloy and the second alloy are selected from: titanium-based alloys, nickel-based alloys, cobalt-based alloys, aluminum-based alloys, and steels.
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