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
  • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
  • F01D25/005—Selecting particular materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
  • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
  • B29C73/14—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using elements composed of two parts joined together after having been placed one on each side of the article
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
  • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
  • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
  • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
  • B29C73/10—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
• • 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
  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/71—Ceramic products containing macroscopic reinforcing agents
  • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
  • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
• • 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
  • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
  • C04B37/008—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
• • 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
  • F01D21/00—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for
  • F01D21/04—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for responsive to undesired position of rotor relative to stator or to breaking-off of a part of the rotor, e.g. indicating such position
  • F01D21/045—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for responsive to undesired position of rotor relative to stator or to breaking-off of a part of the rotor, e.g. indicating such position special arrangements in stators or in rotors dealing with breaking-off of part of rotor
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B11/00—Making preforms
  • B29B11/14—Making preforms characterised by structure or composition
  • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/748—Machines or parts thereof not otherwise provided for
  • B29L2031/7504—Turbines
• • 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
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/48—Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• • 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
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/48—Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
  • C04B2235/483—Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
• • 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
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
  • C04B2235/52—Constituents or additives characterised by their shapes
  • C04B2235/5208—Fibers
  • C04B2235/5252—Fibers having a specific pre-form
• • 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
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
  • C04B2235/616—Liquid infiltration of green bodies or pre-forms
• • 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
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
  • C04B2235/94—Products characterised by their shape
• • 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
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
  • C04B2237/32—Ceramic
  • C04B2237/38—Fiber or whisker reinforced
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2220/00—Application
  • F05D2220/30—Application in turbines
  • F05D2220/32—Application in turbines in gas turbines
  • F05D2220/323—Application in turbines in gas turbines for aircraft propulsion, e.g. jet engines
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2220/00—Application
  • F05D2220/30—Application in turbines
  • F05D2220/36—Application in turbines specially adapted for the fan of turbofan engines
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2230/00—Manufacture
  • F05D2230/80—Repairing, retrofitting or upgrading methods
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2300/00—Materials; Properties thereof
• • 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

• the invention relates to gas turbine composite material parts, and more particularly, but not exclusively, gas turbine housings for aeronautical engines such as fan housings.
• the fan housing performs several functions. It defines in particular the air inlet duct in the engine, possibly supports an abradable material facing the blades of the fan and / or a sound wave absorption structure for the acoustic treatment at the engine inlet. and incorporates or supports a retention shield.
• the housings like the fan housing, are now made of composite material, that is to say from a fiber preform densified by an organic matrix, which makes it possible to produce parts having a lower overall mass than these same parts when they are made of metallic material while having a mechanical strength at least equivalent if not greater.
• the manufacture of a fan casing in composite material is described in particular in document US Pat. No. 8,322,971.
• 2007/0095457 consists in sticking a fibrous patch pre-impregnated on the area
• the patch may consist of one or more fibrous folds.
• this type of solution presents a risk of delamination of the glued patch. It is, therefore, necessary to form additional mechanical connections between the patch and the part made of composite material, for example with members of the bolting type. The addition of such connections leads to an increase in the mass of the part and impacts the initial composite material structure of the part (making passages in the composite material part for the insertion of the connecting members). This problem also arises for the repair or resumption of manufacture of other parts made of gas turbine composite material.
• the aim of the invention is to provide a solution for the repair or resumption of manufacture of a gas turbine part made of composite material, for example a casing, which does not have the drawbacks of the prior art.
• a gas turbine part made of composite material comprising a fibrous reinforcement having a three-dimensional weaving between a plurality of warp yarns and a plurality of weft yarns, said fibrous reinforcement being densified by a matrix, said densified fiber reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that the fibrous reinforcement densified by the matrix comprises at at least one recessed portion extending over the entire thickness of the fibrous reinforcement and in that a filling part made of composite material is present in the free volume of the part delimited by said at least one recessed portion, the filling part comprising a fiber preform having a three-dimensional weave, said fiber preform being densified by a matrix.
• a filling piece comprising a fiber preform exhibiting a three-dimensional weave, it is possible to carry out repairs or rework which exhibit high resistance to delamination.
• the repair of a damaged area or the recovery of a non-compliant area in the part is therefore particularly robust while having a very limited impact on the overall mass of the part.
• each recessed portion has at least two vis-à-vis edges each comprising first and second bevels, the filling part made of composite material comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the facing edges and a second part having a complementary geometry of the other part of the volume of the part of the recessed portion defined between the second bevels of the facing edges.
• each vis-à-vis edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the recessed portion. . This optimizes the transmission of mechanical loads on the bonding interface between the filling part and the composite material structure of the part.
• the first and second parts of the filling piece are linked together by weaving. This makes it possible to further strengthen the mechanical strength of the filling part.
• the piece of the invention According to a fourth characteristic of the piece of the invention, the piece of
• filler further comprises at least one fastener extending into said filler piece. It is thus possible to strengthen the strength of the filling part if necessary, and this without impacting the composite structure of the part since the fixing member (s) are fully integrated into the filling part.
• the invention also relates to an aeronautical gas turbine engine having a part according to the invention, for example a fan casing, as well as an aircraft comprising one or more of these aeronautical engines.
• a further subject of the invention is a method for repairing a part made of composite material for a gas turbine having a shape of revolution, the part comprising a fibrous reinforcement having a three-dimensional weaving between a plurality of warp yarns and a plurality of weft thread, said fibrous reinforcement being densified by a matrix, said densified fibrous reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that it comprises:
• the production of the recessed portion comprises the formation of at least two facing edges each comprising first and second bevels, the fiber preform of the filling piece comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the opposite edges and a second part having a complementary geometry of the other part of the volume of the defined recessed portion between the second bevels of the opposite edges.
• each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the portion. hollowed out.
• the first and second parts of the fiber preform of the filling part are linked together by weaving.
• the latter further comprises the integration of at least one fixing member in the filling part.
• the invention also relates to a method of manufacturing a part made of composite material for a gas turbine, the method comprising the weaving in one piece by three-dimensional weaving of a fibrous texture in the form of a strip, the shaping of said texture by winding on a support tool so as to form a fibrous reinforcement of the part and the densification of the fibrous reinforcement by a matrix, said densified fibrous reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that it comprises:
• the production of the hollowed-out portion comprises the formation of at least two facing edges each comprising first and second bevels, the fiber preform of the filling piece comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the opposite edges and a second part having a complementary geometry of the other part of the volume of the defined recessed portion between the second bevels of the opposite edges.
• each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the recessed portion.
• Figure 1 is a perspective view of an aircraft engine comprising a fan casing
• Figure 2 is a half-view in axial section of the fan housing of the engine of Figure 1,
• Figure 3 is a partial perspective view of the fan casing of Figure 1 showing the production of a recessed portion in the fan casing
• Figure 4 is a radial sectional view of the recessed portion illustrated in Figure 3 along the sectional plane IV,
• Figure 5 is a radial sectional view of the recessed portion illustrated in Figure 3 showing the placement of a fiber preform of a filler piece in the recessed portion,
• FIG. 6 schematically illustrates a three-dimensional weaving weave of the interlock type used to make a part of the fiber preform of a filler piece
• Figure 7 is a radial sectional view showing the presence of a filling part in the recessed portion illustrated in Figure 3,
• Figure 8 is a radial sectional view showing the presence of a filling piece provided with a fixing member in the recessed portion illustrated in Figure 3,
• FIG. 9 schematically illustrates a three-dimensional weaving weave of the interlock type used to make a fiber preform for a one-piece filler piece.
• Such an engine as shown very schematically in FIG. 1 comprises, from upstream to downstream in the direction of the gas flow, a fan 1 placed at the inlet of the engine, a compressor 2, a combustion chamber 3, a high-pressure turbine 4 and a low-pressure turbine 5.
• the engine is housed inside a housing comprising several parts
• the fan 1 is surrounded by a fan casing 10 having a shape of revolution.
• Figure 2 shows the profile (in axial section) of the fan casing 10 which is here made of a composite material with an organic matrix, that is to say from a reinforcement of fibers, for example of carbon, glass, aramid or ceramic, densified with a polymer matrix, for example epoxy, bismaleimide or polyimide.
• the fibrous reinforcement is made from a fibrous texture in the form of a strip obtained by three-dimensional weaving in a single piece, the texture being shaped by winding on a support tool. The fibrous reinforcement thus formed is then densified by a matrix.
• the manufacture of such a casing is described in particular in document US Pat. No. 8,322,971.
• the internal surface 11 of the casing defines the air inlet duct of the engine.
• the casing 10 made of composite material has a shape of revolution and extends in width between a downstream end 17 and an upstream end 18 in an axial direction D A and in thickness between an internal surface 11 and an outer surface 12 in a radial direction D R.
• the casing 10 can be provided with external flanges 14, 15 at its upstream and downstream ends in order to allow its assembly and its connection with other elements. Between its upstream 17 and downstream 18 ends, the casing 10 has a variable thickness, a part 16 of the casing having a greater thickness than the end parts by gradually connecting to the latter.
• Part 16 extends on either side of the location of the blower, upstream and downstream, in order to form a retention zone capable of retaining debris, particles or objects ingested at the inlet of the engine, or from damage to fan blades, and thrown radially by rotation of the fan, to prevent them from passing through the casing and damaging other parts of the aircraft.
• the housing 10 has a damaged area 20 resulting, for example, from debris of a blade projected onto the internal surface 11 of the housing.
• the housing is machined at the damaged area 20 in order to remove the affected composite material.
• the removal of the composite material is carried out on a determined surface of the casing covering at least the area identified as damaged and over the entire thickness of the casing.
• a recessed portion 30 which opens out both on the internal surface 11 and on the external surface 12 of the housing 10.
• the edges 31, 32, 33 and 34 of the recessed portion each comprise respectively a first bevel like the bevels 310 and 330 illustrated in FIG. 4 respectively for the edges 31 and 33 and a second bevel like the bevels 311 and 331 illustrated in FIG. 4 respectively for the edges 31 and 33.
• the recessed portion 30 delimits a free volume of material 35 intended to be occupied by a filling part as explained below.
• a fiber preform of a filling piece intended to be placed in the volume delimited by the recessed portion 30 is produced by three-dimensional weaving.
• a fiber preform for a filling piece 40 is composed of a first part 41 and a second part 42.
• the three-dimensional weaving of the fiber preform of the filling piece can be carried out with an interlock type weave with several layers of warp threads and weft threads.
• FIG. 6 shows an example of interlock weaves for the first part 41 of the fiber preform of the filling piece 40.
• the weft threads are in section.
• a three-dimensional weaving with interlock weave is a weaving in which each warp thread connects several layers of weft threads together, the paths of the warp threads being identical.
• a gradual increase / decrease in thickness is obtained by adding / removing one or more layers of warp and weft yarns.
• the second part 42 of the fiber preform of the filling piece 40 can be made with the same weaving weave.
• Other three-dimensional weaving modes can be envisaged, such as, for example, multi-layer weaves with multi-satin or multi-canvas weaves. Armors of this type are described in document US 2010/0144227.
• the fibrous filling part preform is preferably woven with fibers of the same type as those used to produce the fibrous reinforcement of the casing.
• the fiber preform of the filling piece 40 is placed in the free volume 35 delimited by the recessed portion 30.
• the first and second parts 41 and 42 of the fiber preform 40 each have a geometry adapted to the part of the free volume 35 to be filled. More precisely, in the example described here and as illustrated in FIG. 5, the first part 41 has a geometry complementary to the part of the free volume 35 of the recessed portion defined between the first bevels of the edges facing each other. screw (first bevels 310 and 330 of the edges 31 and 33 illustrated in Figure 5) while the second part 42 has a geometry complementary to the other part of the free volume 35 of the recessed portion 30 defined between the second bevels of the edges in vis-à-vis (second bevels 311 and 331 of the edges 31 and 33 illustrated in Figure 5).
• Each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the housing at the level of the recessed portion.
• the edges 31 and 33 each extend respectively over a length L31 and L33 which is equal to at least ten times the value of the thickness E 10 of the housing 10 at the level of the recessed portion 30. This makes it possible to optimize the transmission of mechanical loads on the bonding interface between the filling part and the composite material structure of the casing.
• the fiber fill preform 40 is impregnated with a matrix precursor resin.
• the impregnation of the preform 40 can be carried out before or after the placement of the fiber preform of the filling piece 40 in the recessed portion 30.
• the resin is preferably chosen so as to correspond to a matrix precursor of the same type as the resin. matrix with which the fibrous reinforcement of the casing is densified.
• the resin is then transformed into a matrix, for example by heat treatment, in order to obtain, as shown in FIG. 7, a part of filling in composite material 50 comprising a 3D woven fiber preform densified by a matrix, the filling part 50 occupying the free volume defined by the recessed portion.
• the filling piece made of composite material 50 comprises a first part 51 having a geometry complementary to part of the volume of the recessed portion defined between the first bevels 310 and 330 of the facing edges 31 and 33 and a second part 52 with geometry
• the filling part 50 integrates completely into the structure of the housing.
• a bonding agent can further be deposited on the bonding interface between the filling piece and the edges of the recessed portion in order to strengthen the bonding interface.
• the mechanical strength of the part can be reinforced by the integration of one or more fixing members in the filling part, such as for example the member 60 shown in FIG. 8 which comprises a screw 61 passing through the filling part 50 and a clamping nut 62 cooperating with the free end of the screw 61.
• the fixing member (s) have no impact on the structure of the casing because they are not in contact with it but only with the filling piece.
• the first and second parts of the fiber preform of the filling piece can be linked together by weaving.
• FIG. 9 shows an example of interlock weaves of a fiber preform for a filling piece 70 in which the first and second parts 71 and 72 are linked together by weaving.
• the weft threads are in section.
• the deformability of the fiber preform 70 is used to insert it into the free volume defined by the recessed portion.
• the invention also applies to the rework or retouching of the manufacture of a housing made of composite material.
• the production of a casing in composite material begins with the formation of a fibrous texture in the form of a strip obtained by three-dimensional weaving such as for example a weaving with an "interlock" weave or a weaving according to one of the weaves described. in document US 2010/0144227.
• the fibrous structure can in particular be woven from son of carbon fibers, ceramic such as silicon carbide, glass or aramid.
• the fibrous reinforcement of the casing is formed by winding on a mandrel of the fibrous texture, the mandrel having a profile corresponding to that of the casing to be produced.
• the fibrous reinforcement constitutes a complete tubular fibrous preform of the casing forming a single piece.
• the mandrel has an external surface whose profile corresponds to the internal surface of the casing to be produced and two flanges to form parts of the fiber preform corresponding to the flanges of the casing.
• the fibrous reinforcement is then densified with a matrix.
• the densification of the fibrous reinforcement consists in filling the porosity of the reinforcement, in all or part of the volume thereof, with the material constituting the matrix.
• the matrix can be obtained in a manner known per se using the liquid process.
• the liquid process consists in impregnating the fibrous reinforcement with a
• liquid composition containing an organic precursor of the matrix material.
• the organic precursor is usually in the form of a polymer, such as a resin, optionally diluted in a solvent.
• the fiber reinforcement is placed in a sealable mold with a housing in the shape of the final molded part. Then, the liquid matrix precursor, for example a resin, is injected into the entire housing to impregnate the entire fibrous part of the reinforcement.
• the transformation of the precursor into an organic matrix is carried out by heat treatment, generally by heating the mold, after removal of any solvent and crosslinking of the polymer, the reinforcement still being kept in the mold having a shape corresponding to that of the part to be produced.
• the organic matrix can in particular be obtained from epoxy resins, such as, for example, the high performance epoxy resin sold, or from liquid precursors of carbon or ceramic matrices.
• the heat treatment consists in pyrolyzing the organic precursor to transform the organic matrix into a carbon or ceramic matrix depending on the precursor used and the pyrolysis conditions.
• liquid carbon precursors can be resins with a relatively high coke content, such as phenolic resins
• liquid ceramic precursors, especially of SiC can be polycarbosilane (PCS) type resins. or polytitanocarbosilane (PTCS) or polysilazane (PSZ).
• PCS polycarbosilane
• PTCS polytitanocarbosilane
• PSZ polysilazane
• Densification of the fibrous reinforcement can be carried out by the well-known transfer molding process called RTM (“Resin Transfer Molding”).
• RTM Resin Transfer Molding
• the fibrous reinforcement is placed in a mold having the shape of the casing to be produced.
• a thermosetting resin is injected into the internal space delimited between the piece of rigid material and the mold and which includes the fibrous reinforcement.
• a pressure gradient is generally established in this internal space between the place where the resin is injected and the discharge orifices of the latter in order to control and optimize the impregnation of the reinforcement by the resin.
• the resin used can be, for example, an epoxy resin.
• Resins suitable for RTM processes are well known. They preferably have a low viscosity to facilitate their injection into the fibers. The choice of the temperature class and / or the chemical nature of the resin is determined according to the thermomechanical stresses to which the part must be subjected. Once the resin has been injected into all the reinforcement, it is polymerized by heat treatment in accordance with the RTM process.
• the part After injection and polymerization, the part is demolded. In the end, the part is trimmed to remove the excess resin and the chamfers are machined to obtain a housing made of composite material like the housing 10 illustrated in Figures 1 and 2.
• the casing may have defects such as, for example, one or more so-called “dry” areas corresponding to parts of the casing where the fibrous reinforcement is devoid of a matrix or does not contain sufficient matrix.
• the method of manufacturing a casing made of composite material according to the invention further comprises the following steps:
• the removal of the composite material is carried out on a determined surface of the casing covering at least the non-conforming zone and over the entire thickness of the casing.
• a recessed portion is thus obtained which opens out both on the internal surface and on the external surface of the casing, like the recessed portion 30 illustrated in FIGS. 3 and 4, the edges of which each comprise respectively first and second bevels.
• the recessed portion defines a free volume of material intended to be occupied by a filling part as explained below.
• the fiber preform of the filling piece is obtained by weaving
• three-dimensional and can be formed of two distinct parts like the first and second parts 41 and 42 of the fiber preform of the filling part 40 illustrated in FIG. 5, or of two parts linked together by weaving like the first and second parts 71 and 72 of the workpiece fiber preform
• the fibrous filling part preform is preferably woven with fibers of the same type as those used to produce the fibrous reinforcement of the casing.
• the first and second parts of the fiber preform of the filling part each have a geometry adapted to the part of the free volume defined by the recessed portion to be filled as already described above. Once the fiber preform of the filler piece has been produced, it is placed in the free volume delimited by the recessed portion.
• the fiber fill preform is impregnated with a matrix precursor resin.
• the impregnation of the preform can be carried out before or after the placement of the fiber preform of the filler piece in the recessed portion.
• the resin is preferably chosen so as to correspond to a matrix precursor of the same nature as the matrix with which the fibrous reinforcement of the casing is densified.
• the resin is then transformed into a matrix, for example by heat treatment, in order to obtain a filling part made of composite material comprising a 3D woven fiber preform densified by a matrix such as the filling part made of composite material 50 shown. in FIG. 7, the filling part occupying the free volume defined by the recessed portion.
• the mechanical strength of the part can be reinforced by the integration of one or more fixing members in the filling part, such as for example the member 60 shown in FIG. 8 which comprises a screw 61 passing through the filling part 50 and a clamping nut 62 cooperating with the free end of the screw 61.
• the fixing member (s) have no impact on the structure of the casing because they are not in contact with it but only with the filling piece.

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• 2019
  • 2019-03-01 FR FR1902143A patent/FR3093298B1/fr active Active
• 2020
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