EP4401956A1 - Leitschaufel aus verbundmaterial mit einer metallverstärkung und verfahren zur herstellung einer solchen leitschaufel - Google Patents

Leitschaufel aus verbundmaterial mit einer metallverstärkung und verfahren zur herstellung einer solchen leitschaufel

Info

Publication number
EP4401956A1
EP4401956A1 EP22785762.0A EP22785762A EP4401956A1 EP 4401956 A1 EP4401956 A1 EP 4401956A1 EP 22785762 A EP22785762 A EP 22785762A EP 4401956 A1 EP4401956 A1 EP 4401956A1
Authority
EP
European Patent Office
Prior art keywords
edge
blade
reinforcement
resin
preform
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
EP22785762.0A
Other languages
English (en)
French (fr)
Inventor
William ALBOUY
Pierre-Antoine Bossan
Justine DELOZANNE
Pierre François Robin GERAUD-GROSHENY
Jérôme OLHAGARAY
Marc WARIS
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 SA
Original Assignee
Safran 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 SA filed Critical Safran SA
Publication of EP4401956A1 publication Critical patent/EP4401956A1/de
Pending legal-status Critical Current

Links

Classifications

    • 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
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/682—Preformed parts characterised by their structure, e.g. form
    • 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
    • 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
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • 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
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • 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
    • B29C70/70—Completely encapsulating inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • F01D25/16—Arrangement of bearings; Supporting or mounting bearings in casings
    • F01D25/162—Bearing supports
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • 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
    • F01D9/00—Stators
    • F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • F01D9/04—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector
    • F01D9/041—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector using blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0077—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0094—Geometrical properties
    • B29K2995/0097—Thickness
    • 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
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2603/00—Vanes, blades, propellers, rotors with blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C27/00—Rotorcraft; Rotors peculiar thereto
    • B64C27/32—Rotors
    • B64C27/46—Blades
    • B64C27/473—Constructional features
    • B64C2027/4733—Rotor blades substantially made from particular materials
    • B64C2027/4736—Rotor blades substantially made from particular materials from composite materials
    • 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
    • F05D2230/50—Building or constructing in particular ways
    • 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
    • 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
    • F05D2300/6034—Orientation of fibres, weaving, ply angle

Definitions

  • DESCRIPTION TITLE BLADE IN COMPOSITE MATERIAL COMPRISING A METALLIC REINFORCEMENT AND METHOD FOR MANUFACTURING SUCH A BLADE the mechanical strength of such a blade made of composite material.
  • Turbomachines are known, in particular dual-flow turbomachines, comprising a fan arranged upstream of a gas generator according to the flow of gases in the turbomachine.
  • the gas generator is housed in an internal annular casing while the fan is housed in an external annular casing generally secured to a nacelle.
  • the fan generates a primary stream or hot stream circulating in a primary stream passing through the gas generator, and a secondary stream or cold stream circulating in a secondary stream around the gas generator.
  • These primary and secondary veins are separated by an annular inter-vein casing provided with a separating spout.
  • the fan comprises fan blades each with a free end facing the outer casing so as to compress an incident air flow at least in the secondary stream and, preferably, also in the primary stream.
  • the secondary stream comprises, downstream of the fan, a stage of stator vanes, also known by the term stator vanes or outlet flow guide vanes (OGV, acronym for the expression English “Outlet Guide Vane”).
  • stator vanes also known by the term stator vanes or outlet flow guide vanes (OGV, acronym for the expression English “Outlet Guide Vane”).
  • OGV blades are regularly distributed around the axis of rotation of the fan and arranged radially from the axis of rotation of the fan, downstream of the blades of blower.
  • An OGV blade has the function of straightening the flow at the outlet of a fan blade in the secondary flow of the turbomachine.
  • the OGV blades form rows of fixed blades which make it possible to guide the flow passing through the turbomachine, according to an appropriate speed and angle.
  • OGV blade 10 which comprises a blade 12 having an intrados face 18 and an extrados face 28 extending between a leading edge 14 and a trailing edge 16.
  • the longitudinal ends of an OGV blade are connected to platforms: inter-OGV platforms 20 attached to the outer radial end of the blade 12, and which are arranged between this OGV blade and the adjacent OGV blades, and a platform 22 attached to an inner radial end of the blade 12 , and connected to a hub 24 of the annular inner casing.
  • the OGV blades can be metallic or even made of a composite material, such as an organic matrix composite material (CMO), in particular to reduce their mass.
  • a composite material conventionally used comprises a fibrous preform embedded in a polymeric resin.
  • the fibrous preform can come from a three-dimensional (3D) weave or can be obtained by draping and superimposing several layers/folds (multilayer).
  • the resin can be injected into the fiber preform or the fiber preform can be pre-impregnated with the resin (also referred to as "pre-impregnated”).
  • a known manufacturing process for composite OGV blades is the liquid resin injection molding process RTM (acronym of the English expression “Resin Transfer Molding”). This involves making a fibrous preform, then placing this preform in a mold and densifying the fibrous preform with a polymer matrix which consists of impregnating the fibrous preform with a resin and polymerizing the latter to obtain the final part.
  • a protective shield or a metal reinforcement 30 In addition, in order to protect the leading edge from wear by erosion and/or degradation caused by impact with foreign bodies, it is covered with a protective shield or a metal reinforcement 30
  • a metallic foil for example made of Nickel-Cobalt or titanium alloy
  • the adhesive in strip or film, for the assembly of a metal part and a fibrous matrix creates constraints in the manufacturing operations, such as: - the adhesive has a limited to a few days at room temperature and must therefore be stored at a temperature below -18°C, - the placement of the adhesive between the edge of the fiber preform and the metal reinforcement can be complex, in particular for geometries (dimensions and shape) of the OGV blades, - a curing cycle (or heating) in stages is necessary to ensure good cohesion between the adhesive and the resin; the temperature of the first level is between 100 and 160°C and the second level, in particular to crosslink the resin, at a temperature of 180°C (figure 2b), - risk of non-compliance of the cooking cycles and therefore of setting scrap from the non-compliant assembly, and - the adhesive is an expensive
  • the performance of the adhesive depends on the chemical nature of the adhesive, the substrates used, the surface treatments and the thickness of the adhesive.
  • the resin used in the co-injection of the OGV blade manufacturing process described above is generally of the same chemical nature as the adhesive currently used.
  • bonding by the resin 50 is heterogeneous between the metal reinforcement 30 and the leading edge 14 in the absence of the adhesive.
  • different thicknesses of the resin are observed on the interface of the assembly, in particular an absence of resin on certain zones Z1 of the interface between the leading edge 14 and the metal reinforcement 30 and an excess of resin on other interface zones Z2 of the assembly.
  • the invention relates to a method for manufacturing a blade made of composite material for a turbomachine, in particular an aircraft, said blade comprising a blade having an intrados face and an extrados face extending between a leading edge and a trailing edge, the method comprising the steps of: - weaving fibers in three dimensions so as to produce a fibrous preform, - reinforcing an edge of said preform intended to form the leading edge of the blade, by integration of a metal reinforcement on said edge of the preform, - assembly of the fiber preform and the metal reinforcement in a mold, - densification of the fiber preform by a matrix to form the blade in composite material.
  • the method before the step of integrating the metal reinforcement, the method comprises a step of introducing at least one reinforcement support on the edge of the fiber preform, said reinforcement support being configured to be inserted between the metal reinforcement and said edge of the fiber preform.
  • said reinforcement support is wrapped in the matrix to bond the edge of the fiber preform and the metal reinforcement with a predefined and homogeneous minimum thickness.
  • the reinforcement support makes it possible to effectively bond the edge of the fiber preform and the metal reinforcement with a predefined minimum thickness, which can be substantially constant and homogeneous at the interface of the assembly.
  • the term “homogeneous” or “constant” thickness is understood to mean the uniform and regular distribution of the constituent elements when bonding the metal reinforcement to the leading edge of the blade blade with a minimum thickness. This minimum thickness can be predefined according to the type of constituent elements of the bonding used in the manufacturing process.
  • the constituent elements of the bonding are in particular the polymerized resin (or the densification matrix) and the reinforcing support. Indeed, the reinforcing support has a generally planar shape with a predetermined thickness.
  • the polymeric resin hardens by covering the reinforcement support, and secures the assembly (namely the metal reinforcement and the edge of the fiber preform).
  • the metal reinforcement there can be no direct contact between the metal reinforcement and the fiber preform (such as the zone Z1 of absence of resin mentioned above).
  • the bonding according to the method of the invention is therefore obtained by controlling, on the one hand, the minimum thickness necessary to secure the assembly, and on the other hand, the propagation of cracks in the bonded assembly. In this way, the bonding quality of the metal reinforcement on the leading edge of the blade blade (without adhesive), is significantly enhanced.
  • the method according to the invention also has many advantages, such as: - removal of the step of adding adhesive between the edge of the fiber preform and the metal reinforcement, - removal of a possible step of machining the edge of the fiber preform before bonding the metal reinforcement, - removal of the pairing step performed manually by an operator to bond the metal reinforcement to the edge of the densified fibrous preform, - elimination of the adhesive curing step present at each new blade assembly, this being now done at the same time as the resin curing step, - reduction of resin curing time during the densification step, and - application to any type of assembly between a composite part and a metal part .
  • the invention may comprise one or more of the following characteristics, taken separately from each other or in combination with each other: - the densification step comprises the impregnation of the fibrous preform with a resin and the transformation of the resin into a matrix by heat treatment, - the resin is injected into the fiber preform before the densification step, or the fiber preform is impregnated beforehand with the resin during the step of producing the fiber preform, - the edge of the preform comprising an intrados wall and an extrados wall interconnected by a ridge, said reinforcing support covers at least part of said intrados and extrados walls up to the edge of the edge of the fiber preform, - the reinforcing support is made in a metallic material, for example copper or aluminum, or the reinforcing support is made of a fibrous material, for example Nylon 66, Polyester or fiberglass.
  • the fibrous material is woven, non-woven or knitted
  • the reinforcing support has a minimum thickness of 50 ⁇ m, preferably the thickness is between 50 ⁇ m and 600 ⁇ m, - at the end of the densification step
  • the reinforcement support has a maximum Young's modulus of 2500 MPa, preferably the Young's modulus is between 1000 and 2000 MPa and for example 1300 MPa
  • the resin is made of a thermosetting material or thermoplastic, for example based on epoxy, polyepoxide, polyimide, polybismaleimide, polyurethane, polyester or vinyl ester, - at the densification stage, the resin envelops and passes through the reinforcing support made of fibrous material, - at the densification stage , the resin envelops the reinforcing support made of metallic material, - the densification step is carried out with a curing cycle comprising a single temperature setting stage, for example at the temperature of 180°C.
  • the invention also relates to a blade made of composite material for a turbomachine, in particular an aircraft, produced by a manufacturing method according to the invention.
  • the invention also relates to a blade made of composite material for an unducted fan (known by the English acronyms “propfan” or “open rotor”) or fanned, in particular for an aircraft, produced by a manufacturing method according to the invention.
  • the composite material blade obtained by the process of the invention can also be a stator blade of a compressor or of a turbomachine turbine, in which the metal reinforcement can be a metal part secured to any portion of the blade. (i.e. on a similar or different portion of the leading edge of the blade).
  • the present invention also relates to a turbine engine, in particular for an aircraft, comprising a blade made of composite material according to the invention.
  • the turbomachine may be an aircraft turbojet, turboprop or turbine engine.
  • FIG.1 figure 1 is a schematic representation in perspective of a blade of a fan comprising a metal reinforcement according to the prior art
  • FIG.2a figure 2a is a schematic representation in layers of a part of the assembly of the metal reinforcement and the leading edge of the blade with an adhesive of figure 1
  • FIG.2b] figure 2b is a schematic representation of a curve of cure as a function of time of the assembly of Figure 2a
  • Figure 3 is a schematic representation in layers of an assembly of the metal reinforcement on the leading edge of the blade with a polymeric resin according to the prior art
  • FIG.4 ]
  • FIG. 7b represents a tangential stress/strain curve for different thicknesses of the glue joint
  • FIG. 8 is a flowchart of a manufacturing process for the blade of Figure 4
  • Figure 9a is a schematic sectional representation along the Y plane and partial of an assembly of the metal reinforcement on the leading edge of the blade with a fibrous reinforcement support and the resin cured polymer according to one embodiment of the invention
  • Figure 9b is a schematic representation of a cooking curve as a function of time of the assembly of Figure 9a.
  • the elements having the same functions in the different implementations have the same references in the figures.
  • the invention applies generally to any part made of composite material, part of the fibrous preform of which is attached to a metal part without adhesive.
  • the invention will be described below in the context of its application to a blade made of composite material for a turbomachine, in particular an aircraft, such as an OGV blade of a turbomachine fan.
  • the blade OGV 100 extends along an axis X of elongation.
  • This axis X can be substantially perpendicular (radial) or inclined with respect to a longitudinal axis of the turbomachine (not illustrated in the figures).
  • the blade 100 comprises a blade 102 extending, on the one hand, along the X axis, and on the other hand, along a Y axis.
  • Blade 102 may have an airfoil structure to form the airfoil portion of blade 100.
  • Blade 102 includes a lower face 104 and an upper face 106 extending between a leading edge 108 and a trailing edge 110
  • Blade 102 has a curved profile of variable thickness between its leading edge 108 and its trailing edge 110.
  • the longitudinal ends of the blade 100 are connected to platforms 120, 122 attached, respectively, to the radial outer end of the blade 102 and on an inner radial end of the blade 102, as described in the foregoing with reference to FIG. 1.
  • the blade 100 also comprises a reinforcement or shield 130 for protecting the leading edge 108, in the form with a metallic tinsel.
  • This reinforcement 130 is bonded to the leading edge 108 of the blade 102 according to the method described below.
  • the metal reinforcement 130 extends in height (relative to the X axis) and over a lengthwise portion (relative to the Y axis) of an intrados wall 114 of the intrados face 104 and of an extrados wall 116 of the extrados face 106 from the leading edge 108 of the blade 102. With reference to FIG. or "U".
  • the reinforcement 130 covers the intrados 114 and extrados 116 walls of the leading edge 108 and also a ridge or nose 118 which connects the intrados 114 and extrados 116 walls to each other.
  • One of the particularities of the invention lies in the fact that at least one reinforcement support 140 is interposed between the metal reinforcement 130 and the leading edge 108 of the blade 102.
  • This reinforcement support 140 is configured to achieve bonding between the leading edge 108 of the blade 102 and the metal reinforcement 130 without adhesive.
  • the reinforcement support 140 at least partially covers the intrados 114 and extrados 116 walls of the leading edge 108 of the blade 102.
  • the reinforcement support 140 may not cover the edge 118 of the leading edge 108 of the blade 102.
  • hardened polymeric resin 150 covers the reinforcing support 140 and the edge 118 so as to secure the metal reinforcement 130 to the leading edge 108 of the blade 102 of blade 100 in composite.
  • the reinforcing support 140 can be made of a metallic material, for example copper or aluminum.
  • the metallic reinforcement support 140 can also have another secondary function, such as de-icing.
  • the reinforcing support 140 can be made of a fibrous material, for example Nylon 66, Polyester or fiberglass.
  • the fibrous reinforcing support 140 can be woven, nonwoven or knitted.
  • the reinforcing support 140 is made of fibrous material, in particular based on Nylon 66, for the following advantages of: - locally retaining a minimum of glue joint (namely the polymeric resin), - impregnating the empty spaces of the fibrous reinforcement support by the resin (figure 9a), - optimally distribute the loads in the joint, - adapt to the complex geometry of the OGV blade, - present a certain flexibility (thanks to the size of the fibers ) for easier handling for an operator, and - stabilize the propagation of cracks at the interface of the bonded assembly.
  • glue joint namely the polymeric resin
  • the resin figure 9a
  • the Applicant carried out experiments to identify the intrinsic properties of a reference seal (such as an epoxy-based resin) to be used in bonding the metal reinforcement and the leading edge of the blade blade with the reinforcement support. This identification can be made by various characterization tests of the mechanical behavior of the joint, such as modified SCARF tests, TAST (English acronym for “Thick Adherend Shear Test”), modified ARCAN, etc. In particular, tests using modified 45° SCARF test specimens were carried out by the Applicant to experimentally characterize the strength and mechanical behavior of the seal according to several modes of stress. Metal and composite parts are bonded end to end with the reference joint and the treated joints, which are inclined at an angle of 45° allowing multiaxial loading.
  • a reference seal such as an epoxy-based resin
  • the joints can be treated by sanding, laser treatment, by chemical treatment such as OAP, etc.
  • the seals are treated with an OAP, Aluminum laser or Titanium laser surface treatment.
  • the Young's modulus is measured for different thickness values of the seal from 0.20 to 1.00mm.
  • Figure 6 illustrates a linear curve representing the values of Young's modulus as a function of the thickness of the seal.
  • the Young's Modulus in Figure 6 can be measured and expressed in Megapascal (MPa). The results in Figure 6 show an increase in Young's modulus with increasing joint thickness.
  • Bulk the Young's modulus of the gasket tends towards a value B called “Bulk” (or the mass) of a conventional adhesive.
  • the Bulk value of the adhesive is approximately 2500MPa for thicknesses of 0.20 to 1.00mm. This Bulk value may be different depending on the type of adhesive used.
  • Figure 7a illustrates normal tensile (stress/strain) curves as a function of glue joint thicknesses of 200 ⁇ m, 400 ⁇ m and 600 ⁇ m
  • Figure 7b illustrates tangential tensile curves also as a function of joint thicknesses of 200 ⁇ m, 400 ⁇ m and 600 ⁇ m. In FIGS.
  • the normal and tangential stresses can be measured and expressed in Megapascals (MPa), and the (mechanical) deformations of the gasket can be determined from length measurements expressed in millimeters (mm). It is noticed that the stresses with normal and tangential rupture decrease with the increase in the thickness of the joint. Thus, the greater the thickness of the glue joint, the more fragile the glue joint.
  • the term "adhesive joint” or “joint” means the polymeric resin used to secure the metal support and the edge of the fiber preform. From the results of FIGS. 6, 7a and 7b, the mechanical properties (in particular the Young's modulus and the thickness) of the seal (or of the reinforcing support) that are optimal with respect to the conventional reference adhesive are deduced.
  • the mechanical properties of the glue joint can also be related to the thickness of the reinforcing support in the glued joint.
  • the reinforcing support 140 is preferably chosen below the threshold value corresponding to the “Bulk” value of the adhesive.
  • the reinforcing support 140 in particular in the bonded assembly (or at the end of the densification step S50 of the manufacturing process described below), can have a maximum Young's modulus of 2500 MPa.
  • the Young's modulus is advantageously between 1000 and 2000 MPa.
  • the Young's modulus of the reinforcing support 140 is of the order of 1300MPa.
  • the reinforcing support 140 may have a minimum thickness E of 50 ⁇ m, the thickness E being measured along the X axis. This value is measured experimentally and corresponds to a minimum thickness required to obtain sufficient bonding of the assembly.
  • the thickness E is preferably between 50 ⁇ m and 600 ⁇ m.
  • the method comprises the following steps of: (S10) weaving of fibers in three dimensions so as to produce a fiber preform 100' intended in particular to form the blade 102 of the blade 100, (S20) introduction of at least one reinforcing support 140 onto an edge 108' of the fiber preform 100' , the edge 108 being intended to form the leading edge 108 of the blade 102, (S30) reinforcement of the edge 108' of the fiber preform 100', by integrating a metal reinforcement 130 on the edge 108', (S40 ) assembly of the assembly (fiber preform 100', reinforcement support 140 and metal reinforcement 130) in a mould, (S50) densification of the fiber preform 100' by a matrix to form the blade 100 of composite material.
  • the fibrous preform 100' can be woven in one piece (that is to say made in one piece).
  • the fibrous preform 100' can be woven from carbon, ceramic fibers such as silicon carbide, glass, or even aramid.
  • the fibrous preform 100' can also be pre-impregnated with a polymeric resin 150.
  • This resin 150 can be made of a thermosetting or thermoplastic material, for example based on epoxy, polyepoxide, polyimide, polybismaleimide, polyurethane, polyester or vinyl ester.
  • the epoxy-based resin is an epoxy with commercial reference PR-250 or PR-2896.
  • the reinforcing support 140 is placed directly and at least partially on the intrados 114 and extrados 116 walls of the edge 108' of the fiber preform 100'.
  • the reinforcing support 140 extends from the ends of the intrados 114 and extrados 116 walls of the edge 108' as far as the edge 118 of the edge 108'.
  • This edge 118 is opposite the ends of the walls 114, 116.
  • the edge 118 of the edge 108' is not covered by the reinforcing support 140 because it plays no (or very little) role in the mechanical strength of the bonding.
  • the edge 118 are therefore sufficient to achieve bonding with only polymeric resin.
  • the reinforcing support 140 is therefore inserted between the edge 108' of the fiber preform 100' and the metal reinforcement 130.
  • the resin 150 also impregnates the empty spaces of the support reinforcement 140 made of fibrous materials.
  • the assembly placed in the mold can be sealed with a housing having the shape of the final molded part.
  • the step (S50) of densifying the fibrous preform 100' consists in particular in filling the void in the fibrous preform 100' and also in the reinforcing support 140 when it is made of fibrous material, in all or part of the volume of the preform 100' and the fibrous reinforcing support 140, by the material constituting the matrix (namely the polymeric resin).
  • the matrix can be obtained by the liquid process, such as the RTM resin transfer molding process.
  • the liquid method consists in impregnating the fibrous preform with a liquid composition containing an organic precursor of the material of the matrix.
  • the organic precursor is usually in the form of a polymer, such as polymeric resin 150, optionally diluted in a solvent.
  • the resin 150 is injected into the housing of the mold to impregnate the entire fibrous part of the preform 100' and of the reinforcing support 140 when it is made of fibrous material.
  • a pressure gradient is generally established in this internal space between the place where the resin is injected and the evacuation orifices of the latter in order to control and optimize the impregnation of the preform by the resin.
  • the transformation of the resin namely its polymerization, can be carried out by heat treatment, generally by heating or curing the mould, after removal of any solvent and crosslinking of the polymer, the preform still being maintained in the mold having a shape corresponding to that of the part to be made.
  • 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.
  • the resin 150 covers the reinforcing support 140 to harden and form an integral bond at the interface of the fibrous preform 100' and the metal reinforcement 130.
  • the resin 150 envelops the reinforcing support 140 made of metallic material or the resin 150 envelops and passes through the reinforcing support 140 made of fibrous material, so that the matrix formed bonds the edge 108' of the preform 100' and the reinforcement metal 140 of uniform thickness.
  • the method according to the invention makes it possible to co-mold (and also to co-inject when the fibrous preform is not pre-impregnated with polymeric resin) the reinforcing support 140 inserted between the metal reinforcement 130 and the edge 108' of the fibrous preform 100', in particular in a cooking cycle comprising a single temperature setting stage at 180° C. (FIG. 9b).
  • co-molding or “co-injecting” is meant a single step for molding several parts or injecting a material simultaneously in the manufacturing process.
  • the blade 100 formed can be unmolded.
  • the blade can be trimmed to remove excess resin and form the final contours of the blade.
  • the invention is however not limited to OGV blades of a turbomachine fan and can be applied to other ducted (fan) or non-ducted (propeller) blades and fixed or moving blades of the turbomachine.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Woven Fabrics (AREA)
EP22785762.0A 2021-09-13 2022-09-05 Leitschaufel aus verbundmaterial mit einer metallverstärkung und verfahren zur herstellung einer solchen leitschaufel Pending EP4401956A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR2109569A FR3126914B1 (fr) 2021-09-13 2021-09-13 Aube en matériau composite comportant un renfort métallique et procédé de fabrication d’une telle aube
PCT/FR2022/051674 WO2023037068A1 (fr) 2021-09-13 2022-09-05 Aube en matériau composite comportant un renfort métallique et procédé de fabrication d'une telle aube

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EP4401956A1 true EP4401956A1 (de) 2024-07-24

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US (1) US20240239062A1 (de)
EP (1) EP4401956A1 (de)
CN (1) CN117940273A (de)
FR (1) FR3126914B1 (de)
MX (1) MX2024002955A (de)
WO (1) WO2023037068A1 (de)

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CA3174997A1 (en) * 2020-04-01 2021-10-07 Proslide Technology Inc. Water slide segment with spacer layer and methods of manufacture therefor

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FR2892339B1 (fr) * 2005-10-21 2009-08-21 Snecma Sa Procede de fabrication d'une aube de turbomachine composite, et aube obtenue par ce procede
FR2921099B1 (fr) * 2007-09-13 2013-12-06 Snecma Dispositif d'amortissement pour aube en materiau composite
EP3486432A1 (de) * 2017-11-21 2019-05-22 Ansaldo Energia Switzerland AG Schaufel und verfahren zur herstellung davon
FR3079445B1 (fr) * 2018-03-28 2020-04-24 Safran Procede de fabrication d'une aube en materiau composite a bord d'attaque metallique rapporte pour turbine a gaz
FR3102086B1 (fr) * 2019-10-17 2022-02-18 Safran Aircraft Engines Aube en matériau composite comportant un renfort métallique, et procédés de fabrication et de réparation d’une telle aube

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US20240239062A1 (en) 2024-07-18
CN117940273A (zh) 2024-04-26
FR3126914A1 (fr) 2023-03-17
FR3126914B1 (fr) 2024-03-08
MX2024002955A (es) 2024-03-26
WO2023037068A1 (fr) 2023-03-16

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