EP4192690A1 - Verfahren zur generativen fertigung zur herstellung einer struktur - Google Patents

Verfahren zur generativen fertigung zur herstellung einer struktur

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Publication number
EP4192690A1
EP4192690A1 EP21752074.1A EP21752074A EP4192690A1 EP 4192690 A1 EP4192690 A1 EP 4192690A1 EP 21752074 A EP21752074 A EP 21752074A EP 4192690 A1 EP4192690 A1 EP 4192690A1
Authority
EP
European Patent Office
Prior art keywords
reinforcement
layer
deposition
matrix
energy radiation
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.)
Pending
Application number
EP21752074.1A
Other languages
English (en)
French (fr)
Inventor
Arnaud DELEHOUZE
Eric Bouillon
Stéphane Roger André GOUJARD
Marc MONTAUDON
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Ceramics SA
Original Assignee
Safran Ceramics SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Safran Ceramics SA filed Critical Safran Ceramics SA
Publication of EP4192690A1 publication Critical patent/EP4192690A1/de
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • 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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/159—Processes of additive manufacturing using only gaseous substances, e.g. vapour deposition
    • 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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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    • C04B35/62884—Coating the powders or the macroscopic reinforcing agents by gas phase techniques
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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    • 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
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    • 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
    • C04B2235/5264—Fibers characterised by the diameter of the fibers
    • 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
    • C04B2235/602—Making the green bodies or pre-forms by moulding
    • C04B2235/6026—Computer aided shaping, e.g. rapid prototyping
    • 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
    • C04B2235/614—Gas 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
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C04B2235/665—Local sintering, e.g. laser sintering
    • 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
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/22—Manufacture essentially without removing material by sintering
    • 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
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
    • F05D2230/234—Laser welding
    • 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
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • 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
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • F05D2230/314—Layer deposition by chemical vapour deposition
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    • 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
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    • F05D2250/20—Three-dimensional
    • F05D2250/28—Three-dimensional patterned
    • 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
    • F05D2250/00—Geometry
    • F05D2250/30—Arrangement of components
    • F05D2250/31—Arrangement of components according to the direction of their main axis or their axis of rotation
    • F05D2250/313—Arrangement of components according to the direction of their main axis or their axis of rotation the axes being perpendicular to each other
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    • 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
    • F05D2250/00—Geometry
    • F05D2250/30—Arrangement of components
    • F05D2250/31—Arrangement of components according to the direction of their main axis or their axis of rotation
    • F05D2250/314—Arrangement of components according to the direction of their main axis or their axis of rotation the axes being inclined in relation to each other
    • 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
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    • F05D2300/21—Oxide ceramics
    • F05D2300/2112—Aluminium oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/22—Non-oxide ceramics
    • F05D2300/224—Carbon, e.g. graphite
    • 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
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/22—Non-oxide ceramics
    • F05D2300/226—Carbides
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    • 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
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/22—Non-oxide ceramics
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    • F05D2300/2282—Nitrides of boron
    • 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
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced
    • F05D2300/6033—Ceramic matrix composites [CMC]
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency
    • 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 present invention relates to the manufacture of a reinforcement in particular for a part made of composite material with a ceramic matrix (“CMC material”) by additive manufacturing technique, and more precisely by chemical vapor deposition (“Chemical Vapor Deposition”) assisted by radiation. focused energy.
  • CMC material ceramic matrix
  • Chemical Vapor Deposition chemical vapor deposition
  • CMC material parts are known to possess both good mechanical properties allowing their use for structural elements and the ability to retain these properties at high temperatures.
  • CMC parts comprise a fibrous reinforcement made of refractory fibers, typically carbon or ceramic, which is densified by a ceramic matrix, for example silicon carbide (SiC).
  • SiC silicon carbide
  • Today, ceramic matrix composite technologies are essentially based on the use of woven fibrous reinforcements. In addition to the high cost of refractory fibers, the weaving operation is also expensive and can present limitations in terms of part geometries, in particular for small parts and complex geometry, in connection with the inadequacy of the textile pitch. woven.
  • Additive manufacturing techniques are also known which make it possible to produce parts in metal or in polymer material, but these techniques do not, at the present time, give entirely satisfactory results for the deposition of refractory materials, such as ceramics.
  • the invention relates to a method for manufacturing a structure by additive manufacturing, comprising at least:
  • the formation of a reinforcement by chemical vapor deposition assisted by focused energy radiation the reinforcement being deposited along a deposition axis and comprising a plurality of interconnected ceramic or carbon reinforcing elements which define between them an interstitial volume having a tortuous shape along said deposition axis.
  • the invention proposes an additive manufacturing process in which the structure is built progressively and comprises at least one reinforcement and optionally a matrix and an interphase which are formed as the reinforcement is formed, as will be detailed below.
  • the reinforcement as well as the matrix and the interphase, when they are present, are each formed by chemical vapor deposition assisted by focused energy radiation.
  • the additive manufacturing technique proposed implements, on the one hand, a chemical vapor deposition in which there is transformation of one or more precursors under the effect of a localized and punctual heating produced by the focused energy radiation which allows, depending on the choice of the precursor, to deposit a wide variety of materials.
  • the localized heating of this (these) precursor(s) is carried out by focusing the energy radiation only at the level of the zones where the deposition of material is desired, which makes it possible to access complex geometries for the reinforcement. and in particular for the interstitial volume between the reinforcing elements.
  • a reinforcement of complex shape is thus obtained having an interstitial volume of tortuous shape at least along the deposition axis, that is to say having a sinuous and non-rectilinear shape when moving along this axis.
  • the complex shape of the reinforcement makes it possible to replace the woven textures and to lead to reinforcement properties optimized with respect to these.
  • the method according to the invention offers a great diversity in the shapes accessible without implementing a fiber weaving operation to produce the reinforcement and therefore freeing itself from the limitations associated with this technique.
  • the reinforcement is a 4D reinforcement.
  • the invention is however not limited in terms of geometry for the reinforcement. According to a variant, we can impart another shape to the reinforcement, such as a honeycomb shape for example, the shape of the reinforcement being adapted to the desired application.
  • the method comprises an alternation between the deposition of a layer of the reinforcement and the deposition of a matrix by chemical vapor deposition assisted by focused energy radiation, the matrix being present in the interstitial volume of the reinforcement obtained .
  • the matrix is deposited as the reinforcement is formed.
  • a composite material part is thus directly obtained with a matrix densifying the interstitial volume between the reinforcing elements.
  • the method comprises at least:
  • the matrix is deposited in the interstitial volume of a reinforcement layer deposited beforehand.
  • the matrix is deposited first and the reinforcing layer deposited around the previously deposited matrix.
  • the method may further comprise the formation of an interphase on the reinforcement elements of the first layer of the reinforcement before the deposition of the matrix, the interphase being able to be formed by chemical vapor deposition assisted by focused energy radiation .
  • the formation of the interphase is also carried out as the reinforcement and the matrix are formed.
  • the focal point of the energetic radiation is not in the gaseous phase but on a solid portion which can correspond to a substrate on which the structure is formed or to a part of the structure itself on which the deposit is intended to be produced, that is to say to a portion of the previously deposited structure.
  • the heating of the solid portion transmits locally energy to the gaseous precursor in order to transform it and obtain the deposit.
  • Such a characteristic also makes it possible to work in a reactor with a cold wall which makes it possible to have more flexibility on the gas pressures and the deposition temperatures while avoiding any risk of nucleation in the homogeneous phase. This makes it easier to modulate the deposition kinetics.
  • the focused energy radiation is a focused laser beam.
  • the focused laser beam wavelength can be between 1058 nm and 1068 nm, for example substantially equal to 1063 nm.
  • wavelength values in the near infrared make it possible to obtain maximum absorption of the energy by the solid portion during focusing of the laser beam on the latter.
  • the wavelengths can be lower, in the UV or the visible, in the case for example where the laser beam is focused in the gaseous phase.
  • the invention is however not limited to the use of a laser as energy radiation. As a variant, it is thus possible to use a focused electron beam.
  • gaseous precursor can form the entirety of the reinforcement or to modify the gaseous precursor as the reinforcement is deposited.
  • the gaseous precursor can also be modified between the deposition of the reinforcement and the deposition of the matrix and of the optional interphase.
  • the material forming the matrix and the possible interphase can be different from that of the reinforcement. It is possible, for example, to deposit a silicon carbide reinforcement, a pyrocarbon or boron nitride interphase and a silicon carbide matrix in the interstitial volume.
  • the structure may comprise at least one of the following materials: a carbide ceramic, for example silicon carbide, a nitride ceramic, a carbonitride ceramic, an oxide ceramic, for example alumina, or a ceramic of eutectic composition.
  • a carbide ceramic for example silicon carbide
  • a nitride ceramic for example silicon carbide
  • a carbonitride ceramic for example
  • an oxide ceramic for example alumina
  • a ceramic of eutectic composition eutectic composition.
  • the reinforcement, the matrix and the optional interphase may, independently of one another, comprise a material chosen from the list indicated above.
  • the reinforcement is a reinforcement of a turbomachine part.
  • the reinforcement can constitute the reinforcement of a turbomachine blade, of a sector of a turbine ring or of a distributor.
  • the reinforcement can constitute a reinforcement of an aircraft turbomachine part.
  • FIG. 1 shows, schematically and partially, the deposition of a first layer of the reinforcement in the context of an example of a method according to the invention.
  • FIG. 2 schematically and partially represents the deposition of the matrix in the interstitial volume of the first layer of the reinforcement of FIG. 1.
  • Figure 3 shows, schematically and partially, the deposition of a second layer of the reinforcement on the first layer densified by the matrix of Figure 2.
  • FIG. 4 schematically and partially represents the deposition of the matrix in the interstitial volume of the second layer of the reinforcement of FIG. 3.
  • FIG. 5 represents a 4D reinforcement obtained by implementing an example of a method according to the invention.
  • FIG. 6 represents a turbomachine part obtained by implementing an exemplary method according to the invention.
  • the fabricated structure comprises a reinforcement and a matrix densifying the reinforcement formed as it is deposited.
  • the structure is formed by alternating between the deposition of a reinforcement layer and the deposition of the matrix.
  • an interphase can also be formed on the elements of reinforcement after deposition of a layer of reinforcement and before deposition of the matrix.
  • the structure is formed layer by layer by additive manufacturing, a layer of the structure corresponding to a section of the latter along the deposition axis and comprising, in the example considered, the reinforcement, of the matrix and the interphase possibly present.
  • FIG. 1 illustrates the formation of a first layer 10 of the reinforcement by chemical vapor deposition assisted by focused energy radiation from a gaseous precursor G11.
  • the first layer 10 is deposited on a support S present in a hermetic reaction chamber C, for example in contact with this support S.
  • the reaction chamber C Before initiation of the deposition, the reaction chamber C was purged of traces of water and of oxygen. For this, a plurality of cycles of pumping and expansion of a gas, such as argon, can be carried out.
  • the gaseous precursor G11 is introduced into the reaction chamber C through a gas introduction channel 15 .
  • a person skilled in the art knows how to choose the gaseous precursor according to the desired material to be deposited from among the gaseous precursors known from conventional chemical vapor deposition.
  • the techniques for controlling injection and pumping of the gaseous precursor also form part of general knowledge and do not need to be detailed here. For example, methyltrichlorosilane (CHsSiCh or MTS) or monomethylsilane (MMS) can be used to deposit silicon carbide.
  • CHsSiCh or MTS methyltrichlorosilane
  • MMS monomethylsilane
  • Propane and/or methane can be used to deposit carbon.
  • the gaseous precursor can be diluted in a neutral or complementary reactive gas. It is thus possible to add hydrogen and/or nitrogen to the precursor.
  • the gaseous precursor G11 undergoes localized heating by focused energy radiation Eli in order to deposit the first layer 10 of the reinforcement with the desired geometry.
  • the first layer 10 deposited comprises a plurality of interconnected reinforcing elements 22 which between them define an interstitial volume V having a predefined and controlled shape, an example of geometry of the reinforcement will be detailed below in connection with FIG. geometry desired, the energy radiation Eli is successively focused in the areas where the deposit is desired in order to locally provide heat and locally transform the gaseous precursor Gll.
  • the focal point of the energy radiation Eli can be located at the level of a solid portion, for example at the level of the support S or of a deposit part previously produced, in order to cause its heating and cause the transformation of the nearby Gll precursor and thus achieve the deposition of the material.
  • the focal point of the energy radiation Eli can be located directly in the gaseous precursor Gll.
  • the energy radiation Eli comes from a laser.
  • the system illustrated according to this example comprises an irradiation device D which comprises a laser source 30, a collimator 33, an optical scanner 35 which makes it possible to orient the laser beam during the process as well as a focusing device 34, such as a lens, making it possible to focus the laser beam in the zone where the deposition must be carried out.
  • the laser source may be an infrared source having a wavelength of between 1058 nm and 1068 nm, for example a source of fiberable Yb photodiode type.
  • the wavelength of the laser is in the ultraviolet or the visible, in particular in the case of direct heating of the gaseous phase.
  • the laser source 30 can operate in continuous mode, preferably, or in discontinuous mode if it is sought to avoid providing too much pfd. However, it does not depart from the scope of the invention if an energy source other than a laser is used such as an electron beam. In the various cases envisaged, the focusing of the heat source is done in a manner known to those skilled in the art by using optical or electromagnetic focusing devices. Whatever the nature of the energy radiation used, the power of the focused energy radiation can be between 1 mW and 100 W, preferably between 20 mW and 5 W.
  • the focused Eli energy radiation can be moved to produce the deposition of the first reinforcement layer 10 with the desired geometry by modifying the position and/or the inclination of the optical scanner 35.
  • An irradiation control device (not shown) makes it possible to control the displacement of the Eli energy radiation. This thus makes it possible to carry out a sweep by the energetic radiation Eli focused in predefined zones where the deposition of the constituent material of the first layer 10 must be carried out.
  • the means of moving the focused energy radiation are similar to those used in selective laser molding technology (“Selective Laser Molding”; “SLM”). It will be noted that in addition to or instead of the movement of the focused energy radiation Eli, it is possible to move and/or tilt the support S during deposition.
  • a support control device makes it possible to carry out this movement or this inclination.
  • the support S can thus be movable in at least one direction in space, for example and preferably in the vertical direction Z, or even in the three directions in space.
  • the support S can be inclined around at least one of the directions in space, or even around each of them.
  • the support S remains fixed and the deposition of the first layer 10 is only obtained by a displacement of the energy radiation Eli focused in a plurality of predetermined zones.
  • the pressure in the reaction chamber C during the formation of the structure can be between 5 mbar and 3 bar, for example between 5 mbar and 15 mbar or between 1 bar and 3 bar.
  • the reaction chamber C may comprise a pressure sensor (not shown) as well as a pumping device P in order respectively to measure and adjust the pressure in the reaction chamber C as the structure is deposited.
  • the reaction chamber C comprises a gas outlet channel 17 through which the residual gaseous precursor GR11 and the reaction by-products are pumped out of the reaction chamber. It is possible, if desired, to use a separator device, such as a chromatographic system, to separate and reinject the precursor into chamber C and reject the by-products.
  • the pressure in the reaction chamber C and the surface power of the energy radiation used are determined by those skilled in the art according to the nature of the precursor used in order to adapt the deposition kinetics.
  • the reaction chamber C may further include a thermal sensor (not shown), such as a thermal camera, in order to measure the local temperature at the point of focus of the energy radiation, as well as a regulation device allowing, depending on the measurement coming from of the thermal sensor, modifying the power of the focused energy radiation in order to apply the predefined power desired to transform the precursor and carry out the deposition.
  • first layer 10 of the reinforcement has just been described in connection with FIG.
  • the deposition of the reinforcement is temporarily interrupted in order to form the matrix M in the interstitial volume of the first layer 10 previously formed as will now be described in connection with FIG. 2.
  • the irradiation by the focused energy radiation Eli is interrupted and the reaction chamber C purged.
  • a gaseous precursor G12 intended to form the matrix M in the interstitial volume of the first layer 10 by chemical vapor deposition assisted by focused energy radiation is then introduced into the reaction chamber C.
  • the precursor G12 can be different from the precursor G11 and lead the deposition of a matrix M formed of a material different from that of the first layer 10 of the reinforcement.
  • the energy radiation E12 and/or the support S are controlled in a manner similar to what has just been described above for the first layer 10.
  • the surface power of the radiation energy E12 can be different from that of the energy radiation Eli by being adapted to the precursor G12.
  • the control of the pressure in the reaction chamber and the treatment of the mixture of residual matrix precursor GR12 and of the by-products can be as described above for the case of the deposition of the first layer 10.
  • the matrix M can comprise, or even consist mainly by mass of, a carbide, nitride or oxide ceramic.
  • the matrix can for example comprise silicon carbide, or even consist mainly by weight of silicon carbide.
  • a defragilization interphase is similarly deposited on the reinforcing elements of the first layer of the reinforcement before formation of the matrix also by chemical vapor deposition assisted by focused energy radiation.
  • the interphase can be monolayer or multilayer.
  • This interphase may comprise, for example, silicon carbide, boron nitride, silicon-doped boron nitride BN(Si), or pyrocarbon PyC.
  • the interphase has a function of weakening the composite material which promotes the deflection of any cracks reaching the interphase after having propagated in the matrix, preventing or delaying the rupture of the reinforcement.
  • the deposition of the reinforcement is resumed by depositing a second layer 20 of the ceramic or carbon reinforcement on the first layer 10 densified by the matrix M, as shown in figure 3.
  • the irradiation by the focused energetic radiation E12 is interrupted and the reaction chamber C purged.
  • a gaseous precursor G21 intended to form the second layer 20 of the reinforcement by chemical vapor deposition assisted by focused energy radiation is then introduced into the reaction chamber C.
  • the focused energy radiation E21 is applied in order to deposit the second layer 20 of the reinforcement at the desired geometry on the first layer 10, similar to what was described above.
  • the characteristics described above for the deposition of the first layer 10 remain applicable to the deposition of the second layer 20.
  • the precursor G21 can be identical to or different from the precursor Gll.
  • the material of the second layer 20 of the reinforcement may be identical to or different from the material of the first layer 10 of the reinforcement.
  • the material of the second layer 20 of the reinforcement is identical to the material of the first layer 10 of the reinforcement.
  • the surface power of the energetic radiation E21 can be identical to or different from that of the energetic radiation Eli.
  • the control of the pressure in the reaction chamber and the treatment of the mixture of residual precursor GR21 and of the by-products can be as described above for the case of the deposition of the first layer 10.
  • the energetic radiation E21 can scan a set of zones defining a different pattern with respect to the pattern defined by the set of zones scanned by the energetic radiation Eli during the deposition of the first layer 10.
  • second layer 20 is superimposed on the first layer 10, here along a deposition axis materialized by the vertical direction Z.
  • the second layer 20 can be deposited in contact with the first layer 10.
  • the second layer 20 can cover substantially all of the first layer 10 , or only part of it.
  • the second layer 20 comprises a plurality of interconnected ceramic or carbon reinforcing elements which define between them an interstitial volume of different shape from the shape of the interstitial volume between the reinforcing elements of the first layer 10, so as to confer a tortuous shape to the interstitial volume of the reinforcement 1 along the deposition axis Z.
  • the shape of the interstitial volume of the second layer 20 can be substantially different from that of the interstitial volume of the first layer 10, in order to correspond to the orientation desired reinforcement.
  • the irradiation by the focused energy radiation E21 is interrupted and the reaction chamber C purged.
  • a gaseous precursor G22 intended to form the matrix M in the interstitial volume of the second layer 20 by chemical vapor deposition assisted by focused energy radiation is then introduced into the reaction chamber C (FIG. 4).
  • the method is then continued as described above to deposit the matrix M in the interstitial volume of this second layer 20 by controlling the focused energy radiation E22 and/or the support S to deposit the matrix M in the desired zones.
  • the mixture of residual precursor GR22 and by-products can be treated as described above.
  • an interphase can be deposited on the reinforcing elements of the second layer 20 before the matrix M is deposited.
  • a composite material structure 100 is then obtained comprising a reinforcement 1 and a matrix M densifying the reinforcement.
  • the reinforcement volume rate in the structure can be between 15% and 55%, for example between 25% and 35%.
  • the reinforcement rate is controlled and the reinforcement is oriented in space according to the stress directions of the part to be obtained.
  • the example illustrated has shown the manufacture of a structure 100 in which two layers 10 and 20 of the reinforcement are deposited.
  • the process can be continue by depositing, in a similar manner, a third layer of the reinforcement on the second layer 20.
  • the interstitial volume of each of the deposited layers can have a different shape in order to give the interstitial volume of the reinforcement a tortuous shape.
  • the matrix and/or the interphase can be formed after formation of the reinforcement by known techniques.
  • the reinforcement 1 illustrated in FIG. 5 corresponds to a 4D reinforcement.
  • the reinforcement 1 comprises a plurality of reinforcement elements 22, oriented along the four directions given by the diagonals of a cube, and defining between them an interstitial volume V of tortuous shape along the vertical direction Z of deposition.
  • the reinforcing elements 22 can have various shapes, such as parallelepipeds, beams having for example a circular, elliptical, square or rectangular section, spheres, ellipsoids, etc.
  • the reinforcing elements 22 can be solid or hollow.
  • the diameter of the reinforcing elements 22 can be less than or equal to 100 ⁇ m.
  • the reinforcing elements 22 can also be arranged in a mesh to form the reinforcement.
  • the reinforcement 1 has a connected interstitial volume, that is to say there is a path making it possible to pass from one space between the reinforcing elements 22 to another without crossing material of the reinforcement elements.
  • the interstitial volume is delimited by an internal surface of the ceramic or carbon material. As the interstitial volume is connected, this internal surface of the ceramic or carbon material is continuous in the structure.
  • FIG. 6 illustrates an example of a part that can be obtained by implementing the method according to the invention.
  • the invention can make it possible to form a turbomachine part, for example an aeronautical turbomachine part. It is possible, as illustrated in FIG. 6, to form a turbine blade 40. Other examples are possible, such as a turbine ring sector or a turbine nozzle sector, for example.

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EP21752074.1A 2020-08-06 2021-07-09 Verfahren zur generativen fertigung zur herstellung einer struktur Pending EP4192690A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR2008320A FR3113286B1 (fr) 2020-08-06 2020-08-06 Procédé de fabrication d’une structure par fabrication additive
PCT/FR2021/051281 WO2022029377A1 (fr) 2020-08-06 2021-07-09 Procédé de fabrication d'une structure par fabrication additive

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JPS63278835A (ja) * 1987-05-11 1988-11-16 Nippon Steel Corp セラミックス積層体の製造方法
US7402517B2 (en) * 2005-03-31 2008-07-22 Battelle Memorial Institute Method and apparatus for selective deposition of materials to surfaces and substrates
US9149988B2 (en) * 2013-03-22 2015-10-06 Markforged, Inc. Three dimensional printing
US10183330B2 (en) * 2015-12-10 2019-01-22 Vel03D, Inc. Skillful three-dimensional printing
EP3178586A1 (de) * 2015-12-10 2017-06-14 Canon Kabushiki Kaisha Verfahren und vorrichtung zur herstellung von pulver und verfahren zur herstellung eines geformten objekts
US10279578B2 (en) * 2016-06-21 2019-05-07 Washington State University Additive manufacturing of composite materials with composition gradient
CN106390198B (zh) * 2016-09-19 2019-07-23 西安交通大学 一种选区激光成形及电解还原制备个性化多孔植入物方法
FR3057864B1 (fr) * 2016-10-25 2018-11-23 Safran Ceram Procede d'infiltration ou de depot chimique en phase vapeur mettant en oeuvre le precurseur ci2bnh2 pour former du nitrure de bore
WO2018102352A1 (en) * 2016-11-29 2018-06-07 Free Form Fibers, Llc Fiber with elemental additive(s) and method of making
US11851763B2 (en) * 2017-06-23 2023-12-26 General Electric Company Chemical vapor deposition during additive manufacturing
EP4034061A4 (de) * 2019-09-25 2023-10-18 Free Form Fibers, LLC Mikro-trellis-vliesstoffe und damit verstärkte verbund- oder hybridmaterialien

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FR3113286B1 (fr) 2023-02-10
US20240254622A1 (en) 2024-08-01
CN116113534A (zh) 2023-05-12
WO2022029377A1 (fr) 2022-02-10

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