FR3129318A1 - METHOD FOR MANUFACTURING AND REPAIRING A PART IN COMPOSITE MATERIAL WITH A CERAMIC MATRIX - Google Patents

METHOD FOR MANUFACTURING AND REPAIRING A PART IN COMPOSITE MATERIAL WITH A CERAMIC MATRIX Download PDF

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Publication number
FR3129318A1
FR3129318A1 FR2112399A FR2112399A FR3129318A1 FR 3129318 A1 FR3129318 A1 FR 3129318A1 FR 2112399 A FR2112399 A FR 2112399A FR 2112399 A FR2112399 A FR 2112399A FR 3129318 A1 FR3129318 A1 FR 3129318A1
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Prior art keywords
ply
blade
woven fibers
ceramic matrix
fibrous structure
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FR2112399A
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French (fr)
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Mathieu LEDUC
Damien ALQUIER
Thomas TSASSIS
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Safran Aircraft Engines SAS
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Safran Aircraft Engines SAS
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Priority to FR2112399A priority Critical patent/FR3129318A1/en
Publication of FR3129318A1 publication Critical patent/FR3129318A1/en
Pending legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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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
    • 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
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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
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
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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
    • 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
    • C04B35/83—Carbon fibres in a carbon matrix
    • C—CHEMISTRY; METALLURGY
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    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/001—Joining burned ceramic articles with other burned ceramic articles or other articles by heating directly with other burned ceramic articles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/003—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts
    • C04B37/005—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts consisting of glass or ceramic material
    • 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
    • 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
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • 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
    • 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
    • F01D5/284—Selection of ceramic materials
    • 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
    • F01D9/042—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector fixing blades to stators
    • F01D9/044—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector fixing blades to stators permanently, e.g. by welding, brazing, casting or the like
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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
    • C04B2235/5216—Inorganic
    • C04B2235/524—Non-oxidic, e.g. borides, carbides, silicides or nitrides
    • C04B2235/5244—Silicon carbide
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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
    • C04B2235/5216—Inorganic
    • C04B2235/524—Non-oxidic, e.g. borides, carbides, silicides or nitrides
    • C04B2235/5248—Carbon, e.g. graphite
    • C—CHEMISTRY; METALLURGY
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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
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    • C04B2235/5252—Fibers having a specific pre-form
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
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    • C04B2235/5208—Fibers
    • C04B2235/5252—Fibers having a specific pre-form
    • C04B2235/5256—Two-dimensional, e.g. woven structures
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
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    • C04B2237/06—Oxidic interlayers
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    • C04B2237/068—Oxidic interlayers based on refractory oxides, e.g. zirconia
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    • 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
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    • C04B2237/38—Fiber or whisker reinforced
    • 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
    • F01D5/22—Blade-to-blade connections, e.g. for damping vibrations
    • F01D5/225—Blade-to-blade connections, e.g. for damping vibrations by shrouding
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    • 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
    • F01D5/30—Fixing blades to rotors; Blade roots ; Blade spacers
    • F01D5/3007—Fixing blades to rotors; Blade roots ; Blade spacers of axial insertion type
    • 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]
    • 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

Abstract

L’invention concerne un procédé de fabrication d’une pièce en matériau composite à matrice céramique, le procédé comprenant : la réalisation par tissage tridimensionnel d’une structure fibreuse (600) ;la réalisation par tissage bidimensionnel d’au moins un pli (710, 720, 730, 740) de fibres tissées ;l’intégration sur au moins une zone (610, 620, 630) de la structure fibreuse d’un pli de fibres tissées de manière à former la pièce. Figure pour l'abrégé : Figure 4The invention relates to a method of manufacturing a part made of composite material with a ceramic matrix, the method comprising: the production by three-dimensional weaving of a fibrous structure (600); the production by two-dimensional weaving of at least one ply (710 , 720, 730, 740) of woven fibers;the integration on at least one zone (610, 620, 630) of the fibrous structure of a ply of woven fibers so as to form the part. Figure for abstract: Figure 4

Description

PROCÉDÉ DE FABRICATION ET DE RÉPARATION D’UNE PIÈCE EN MATÉRIAU COMPOSITE À MATRICE CÉRAMIQUEMETHOD FOR MANUFACTURING AND REPAIRING A PART IN COMPOSITE MATERIAL WITH A CERAMIC MATRIX

La présente invention concerne la fabrication de pièces en matériau composite à matrice au moins majoritairement en céramique, matériau ci- après désigné par CMC.The present invention relates to the manufacture of parts made of composite material with a matrix at least predominantly made of ceramic, material hereinafter referred to as CMC.

L’invention concerne plus particulièrement le domaine des turbines à gaz et notamment celui des turbomoteurs pour des aéronefs.The invention relates more particularly to the field of gas turbines and in particular that of turbine engines for aircraft.

Dans les moteurs aéronautiques et en particulier dans les turbines à gaz ou turbomachines de tels moteurs, les pièces soumises à de hautes températures sont depuis longtemps réalisées en alliages métalliques. Les exigences actuelles et futures en matière de réduction de consommation spécifique, diminution de pollution, etc… dans les moteurs aéronautiques engendrent un accroissement de masse significative pour ces derniers.In aeronautical engines and in particular in gas turbines or turbomachines of such engines, the parts subjected to high temperatures have long been made of metal alloys. Current and future requirements in terms of reduction of specific consumption, reduction of pollution, etc. in aeronautical engines generate a significant increase in mass for the latter.

Afin de réduire de façon significative la masse et admettre des températures de fonctionnement plus élevées que celles autorisées avec les alliages métalliques actuels, on utilise de plus en plus des matériaux composites à matrice céramique.In order to significantly reduce the mass and allow higher operating temperatures than those permitted with current metal alloys, ceramic matrix composite materials are increasingly being used.

En effet, les matériaux composites à matrice céramique, ci- après désigné par CMC, font partie des matériaux composites dits thermostructuraux, c'est-à-dire des matériaux composites ayant des bonnes propriétés mécaniques et une capacité à conserver ces propriétés à température élevée. En outre, des pièces, telles que des aubes, réalisées en CMC présentent un gain de masse significatif par rapport à de mêmes pièces réalisées avec les alliages métalliques habituels.Indeed, ceramic matrix composite materials, hereinafter referred to as CMC, are part of the so-called thermostructural composite materials, that is to say composite materials having good mechanical properties and an ability to retain these properties at high temperature. . In addition, parts, such as blades, made of CMC have a significant weight saving compared to the same parts made with the usual metal alloys.

De façon bien connue, les pièces en CMC sont formées par un renfort fibreux en fibres réfractaires (carbone ou céramique) obtenu par tissage tridimensionnel ou multicouche qui est densifié par une matrice céramique, notamment carbure, nitrure, oxyde réfractaire.... Des exemples typiques de matériaux CMC sont les matériaux C-SiC (renfort en fibres de carbone et matrice en carbure de silicium), les matériaux SiC-SiC et les matériaux C-C/SiC (matrice mixte carbone/carbure de silicium). La fabrication de pièces en composite CMC est bien connue. La densification du renfort fibreux par une matrice céramique est en général réalisée par voie gazeuse (infiltration chimique en phase vapeur) ou par voie liquide (imprégnation avec un précurseur liquide de céramique et traitement thermique de pyrolyse pour transformer le précurseur en céramique). Des procédés de fabrication d'une aube de turbomachine en CMC sont notamment décrits dans les documents FR 3021349-A1 et FR 3032648-A1.In a well-known way, CMC parts are formed by a fibrous reinforcement in refractory fibers (carbon or ceramic) obtained by three-dimensional or multilayer weaving which is densified by a ceramic matrix, in particular carbide, nitride, refractory oxide, etc. Examples typical CMC materials are C-SiC materials (carbon fiber reinforcement and silicon carbide matrix), SiC-SiC materials and C-C/SiC materials (mixed carbon/silicon carbide matrix). The manufacture of CMC composite parts is well known. The densification of the fibrous reinforcement by a ceramic matrix is generally carried out by a gaseous route (chemical infiltration in the vapor phase) or by a liquid route (impregnation with a liquid ceramic precursor and thermal pyrolysis treatment to transform the precursor into ceramic). Methods for manufacturing a CMC turbomachine blade are described in particular in documents FR 3021349-A1 and FR 3032648-A1.

Le document FR 3021349-A1 décrit un procédé de fabrication d’une aube en CMC tissé en trois dimensions et le document FR 3032648-A1 décrit un procédé de fabrication d’une aube en CMC comme assemblage de deux structures tissées en trois dimensions.Document FR 3021349-A1 describes a method for manufacturing a three-dimensional woven CMC blade and document FR 3032648-A1 describes a method for manufacturing a CMC blade as an assembly of two three-dimensional woven structures.

Toutefois, dans le cas d’une aube obtenue par tissage tridimensionnel de fibres, la rupture d’une fibre dans les deux directions principales de tissage peuvent engendrer une altération locale des propriétés mécaniques et de l’intégrité de la pièce. Ces ruptures ne peuvent être réparées, par exemple par remplacement de la fibre concernée, du fait de la structure en trois dimensions du tissage. Or, en fonctionnement, certaines surfaces de l’aube peuvent présenter des usures liées à des contacts avec leur environnement ou des déchirures liées à des impacts. En effet, de telles usures sont connues sur les aubes en base Nickel et engendrent des altérations dimensionnelles des surfaces. Par conséquent, il est donc probable que des usures similaires engendrent des ruptures de fibres dans le réseau tridimensionnel en surface pour des aubes en matériau CMC.However, in the case of a blade obtained by three-dimensional fiber weaving, the breakage of a fiber in the two main weaving directions can cause a local alteration of the mechanical properties and the integrity of the part. These breaks cannot be repaired, for example by replacing the fiber concerned, due to the three-dimensional structure of the weaving. However, in operation, certain surfaces of the blade may show wear related to contact with their environment or tears related to impacts. Indeed, such wear is known on Nickel-based blades and generates dimensional alterations of the surfaces. Consequently, it is therefore probable that similar wear generates fiber breaks in the three-dimensional surface network for blades made of CMC material.

L’invention a pour but de proposer un procédé de fabrication d’une pièce, notamment une aube de turbomachine en matériau CMC, permettant de réparer des zones de contact ou d’impact de la pièce.The aim of the invention is to propose a method for manufacturing a part, in particular a turbomachine blade made of CMC material, making it possible to repair areas of contact or impact of the part.

À cet effet, l’invention concerne un procédé de fabrication d’une pièce en matériau composite à matrice céramique, le procédé comprenant :To this end, the invention relates to a method for manufacturing a part made of composite material with a ceramic matrix, the method comprising:

  • la réalisation par tissage tridimensionnel d’une structure fibreuse ;the production by three-dimensional weaving of a fibrous structure;
  • la réalisation par tissage bidimensionnel d’au moins un pli de fibres tissées ;the production by two-dimensional weaving of at least one ply of woven fibers;
  • l’intégration sur au moins une zone de la structure fibreuse d’un pli de fibres tissées de manière à former la pièce.the integration on at least one zone of the fibrous structure of a ply of woven fibers so as to form the part.

L’invention permet ainsi d’atteindre l’objectif susmentionné. En particulier, l’invention permet de fabriquer une pièce, notamment une aube de turbomachine, en matériau CMC comprenant une structure obtenue par « tissage tridimensionnel » et un ou des plis superficiels obtenus par « tissage bidimensionnel » superposés localement à la structure sur des zones de contact ou d’impact de la pièce. En d’autres termes, l’aube ainsi fabriquée est constituée d’un cœur tissé 3D et de plis superficiels 2D sur des zones de contacts ou d’impacts de l’aube.The invention thus makes it possible to achieve the aforementioned objective. In particular, the invention makes it possible to manufacture a part, in particular a turbomachine blade, in CMC material comprising a structure obtained by "three-dimensional weaving" and one or more surface folds obtained by "two-dimensional weaving" locally superimposed on the structure on areas part contact or impact. In other words, the blade thus manufactured consists of a woven 3D core and 2D surface folds on contact or impact zones of the blade.

Après fonctionnement, ces plis superficiels, si usés, peuvent être réparés, par exemple retirés et remplacés, sans que la structure de la pièce ne soit endommagée, afin de permettre la poursuite d’exploitation du produit et éviter une couteuse mise au rebut et un remplacement par une pièce neuve, ce qui est impossible avec une structure intégralement tridimensionnelle.After operation, these surface folds, if worn, can be repaired, for example removed and replaced, without the structure of the part being damaged, in order to allow the continuation of exploitation of the product and to avoid an expensive scrapping and a replacement with a new part, which is impossible with a fully three-dimensional structure.

Ainsi, ce procédé de fabrication selon l’invention permet de bénéficier des avantages d’un tissage tridimensionnel permettant de disposer de propriétés mécaniques non négligeables dans les trois directions de la matière, ce qui est particulièrement intéressant pour les aubes de turbine, par rapport à un procédé de fabrication classique par assemblage de structures pré-imprégnées tissées en deux dimensions, ne permettant que peu de tenue dans la direction normale aux plis.Thus, this manufacturing method according to the invention makes it possible to benefit from the advantages of a three-dimensional weave making it possible to have non-negligible mechanical properties in the three directions of the material, which is particularly advantageous for turbine blades, compared to a conventional manufacturing process by assembling pre-impregnated structures woven in two dimensions, allowing little hold in the direction normal to the folds.

L’invention s’applique ainsi également de manière générale à toute pièce en matériau CMC sujet à contact et impacts, telle que les aubes fixes ou mobiles mais également des anneaux de turbine.The invention thus also applies generally to any part made of CMC material subject to contact and impact, such as fixed or moving blades but also turbine rings.

Ce procédé de fabrication permet avantageusement de rendre réparable les zones de contact ou d’impact de l’aube et plus généralement les couches superficielles à condition qu’elles ne soient pas sollicitées par des contraintes fortement tri-directionnelles.This manufacturing process advantageously makes it possible to make the contact or impact zones of the blade and more generally the surface layers repairable, provided that they are not stressed by highly tri-directional stresses.

L’invention permet ainsi d’améliorer la réparabilité après fonctionnement d’une telle pièce, notamment d’une aube, et donc d’augmenter la rentabilité économique de celle-ci.The invention thus makes it possible to improve the repairability after operation of such a part, in particular of a blade, and therefore to increase the economic profitability of the latter.

Le procédé de fabrication selon l’invention peut comprendre une ou plusieurs des caractéristiques suivantes, prises isolément les unes des autres ou en combinaison les unes avec les autres :The manufacturing process according to the invention may comprise one or more of the following characteristics, taken separately from each other or in combination with each other:

  • le pli de fibres tissées est pré-imprégné d’une matrice en céramique et la structure fibreuse et le pli de fibres tissées sont densifiés simultanément par diffusion de matrice céramique de manière à former la pièce ;the ply of woven fibers is pre-impregnated with a ceramic matrix and the fibrous structure and the ply of woven fibers are densified simultaneously by diffusion of the ceramic matrix so as to form the part;
  • l’intégration du pli de fibres tissées comporte le collage du pli de fibres sur la structure fibreuse avec une colle céramique ;the integration of the woven fiber ply involves gluing the fiber ply to the fibrous structure with a ceramic glue;
  • le collage comporte le dépôt d’un film de colle de manière continue sur le pli de fibres tissées ;gluing involves depositing a film of glue continuously on the ply of woven fibers;
  • le film de colle est déposé sur le pli de fibres tissées de manière à définir une zone dépourvue de colle à une extrémité du pli de fibres tissées.the glue film is deposited on the ply of woven fibers so as to define a zone devoid of glue at one end of the ply of woven fibers.
  • la réalisation de la structure fibreuse comporte le tissage tridimensionnel d’une préforme fibreuse, le conformage de la préforme fibreuse dans un moule, et la densification de la préforme fibreuse par diffusion d’une matrice céramique dans le moule de manière à former la structure fibreuse ;the production of the fibrous structure comprises the three-dimensional weaving of a fibrous preform, the shaping of the fibrous preform in a mold, and the densification of the fibrous preform by diffusion of a ceramic matrix in the mold so as to form the fibrous structure ;
  • la pièce en matériau composite à matrice céramique est une aube mobile ou une aube fixe ou un anneau de turbine.the ceramic matrix composite material part is a moving vane or a fixed vane or a turbine ring.

L’invention concerne également une aube en matériau composite à matrice céramique pour une turbomachine, notamment d’aéronef, réalisée par un procédé de fabrication selon l’invention, et comprenant un pied et une pale s'étendant longitudinalement à partir du pied jusqu’à une plateforme extérieure formant talon, et dans laquelle au moins un pli de fibres tissées en deux dimensions est agencé sur une zone d’une structure fibreuse de l’aube parmi une zone de portée du pied, une zone du talon ou une zone de pale, la structure fibreuse étant tissée en trois dimensions.The invention also relates to a blade made of composite material with a ceramic matrix for a turbomachine, in particular an aircraft, produced by a manufacturing method according to the invention, and comprising a root and a blade extending longitudinally from the root to to an outer platform forming a heel, and in which at least one ply of two-dimensional woven fibers is arranged on one zone of a fibrous structure of the blade among a foot bearing zone, a heel zone or a blade, the fibrous structure being woven in three dimensions.

Avantageusement, une telle aube est réparable par retrait du ou des plis de fibres tissées usé(s) ou abimé(s). Lors de l’opération de retrait, les fibres tissées en trois dimensions ne sont pas endommagées.Advantageously, such a blade can be repaired by removing the worn or damaged plies of woven fibers. During the removal operation, the three-dimensionally woven fibers are not damaged.

De préférence, l’aube est une aube fixe ou mobile pour turbine de la turbomachine.Preferably, the blade is a fixed or mobile blade for the turbine of the turbomachine.

L’invention concerne également une roue de turbine de turbomachine comprenant de telles aubes fabriquées par un procédé de fabrication selon l’invention.The invention also relates to a turbomachine turbine wheel comprising such blades manufactured by a manufacturing method according to the invention.

L'invention concerne également un anneau de turbine de turbomachine comprenant de telles aubes fabriquées par un procédé de fabrication selon l’invention.The invention also relates to a turbomachine turbine ring comprising such blades manufactured by a manufacturing method according to the invention.

Un autre objet de l’invention concerne une turbomachine comprenant au moins une roue ou anneau de turbine selon l’invention.Another object of the invention relates to a turbomachine comprising at least one turbine wheel or ring according to the invention.

L’invention concerne également un procédé de réparation d’une pièce en matériau composite à matrice céramique pour une turbomachine, la pièce étant une aube en matériau composite à matrice céramique pour une turbomachine selon l’invention et telle que décrite précédemment ou un anneau de turbine selon l’invention et tel que décrit précédemment, le procédé comprenant :The invention also relates to a method for repairing a part made of composite material with a ceramic matrix for a turbomachine, the part being a vane made of composite material with a ceramic matrix for a turbomachine according to the invention and as described previously or a turbine according to the invention and as described above, the method comprising:

  • le retrait d’un pli de fibres tissées sur une zone de l’aube ;the removal of a ply of woven fibers from an area of the blade;
  • l’intégration d’un autre pli de fibres tissées non densifié sur la zone de l’aube.the integration of another ply of non-densified woven fibers on the blade area.

Selon un mode de réalisation, le retrait comporte l’arrachement du pli de fibres tissées.According to one embodiment, the shrinkage comprises the tearing of the woven fiber ply.

Alternativement, dans le cas où le pli de fibres tissées et la structure fibreuse sont en matériaux différents, le retrait du pli de fibres tissées est réalisé par attaque chimique sélective du pli de fibres tissées.Alternatively, in the case where the ply of woven fibers and the fibrous structure are made of different materials, the removal of the ply of woven fibers is carried out by selective chemical attack of the ply of woven fibers.

La présente invention sera mieux comprise et d’autres détails, caractéristiques et avantages de la présente invention apparaîtront plus clairement à la lecture de la description d’un exemple non limitatif qui suit, en référence aux dessins annexés sur lesquels :The present invention will be better understood and other details, characteristics and advantages of the present invention will appear more clearly on reading the description of a non-limiting example which follows, with reference to the appended drawings in which:

  • la est un ordinogramme d’un mode de réalisation d’un procédé de fabrication d’une pièce en matériau composite à matrice céramique selon l’invention ;there is a flowchart of one embodiment of a method of manufacturing a part made of composite material with a ceramic matrix according to the invention;
  • la est un ordinogramme d’un autre mode de réalisation d’un procédé de fabrication d’une pièce en matériau CMC selon l’invention ;there is a flowchart of another embodiment of a method of manufacturing a CMC material part according to the invention;
  • la représente une aube selon l’invention,there represents a blade according to the invention,
  • la illustre schématiquement une structure fibreuse et des plis de fibres tissées en deux dimensions avant assemblage pour former l’aube de la ;there schematically illustrates a fibrous structure and plies of fibers woven in two dimensions before assembly to form the blade of the ;
  • la illustre une vue tridimensionnelle et partiellement en coupe d’un pied de l’aube de la ;there illustrates a three-dimensional view and partially in section of a foot of the blade of the ;
  • la illustre une vue de dessus d’un talon de l’aube de la ; etthere illustrates a top view of a heel of the dawn of the ; And
  • la est un ordinogramme d’un procédé de réparation selon l’invention d’une pièce en matériau CMC fabriqué selon un procédé de fabrication selon l’invention.there is a flowchart of a repair method according to the invention of a part made of CMC material manufactured according to a manufacturing method according to the invention.

Les éléments ayant les mêmes fonctions dans les différentes mises en œuvre ont les mêmes références dans les figures.The elements having the same functions in the different implementations have the same references in the figures.

Claims (14)

Procédé de fabrication d’une pièce en matériau composite à matrice céramique, le procédé comprenant :
  • la réalisation (100) par tissage tridimensionnel d’une structure fibreuse (600) ;
  • la réalisation (200) par tissage bidimensionnel d’au moins un pli (710, 720, 730, 740) de fibres tissées ;
  • l’intégration (300 ; 400) sur au moins une zone (610, 620, 630) de la structure fibreuse (600) d’un pli de fibres tissées de manière à former la pièce.
Process for manufacturing a part made of composite material with a ceramic matrix, the process comprising:
  • the production (100) by three-dimensional weaving of a fibrous structure (600);
  • the production (200) by two-dimensional weaving of at least one ply (710, 720, 730, 740) of woven fibers;
  • the integration (300; 400) on at least one zone (610, 620, 630) of the fibrous structure (600) of a ply of woven fibers so as to form the part.
Procédé de fabrication selon la revendication 1, dans lequel le pli de fibres tissées (710, 720, 730, 740) est pré-imprégné d’une matrice en céramique et la structure fibreuse (600) et le pli de fibres tissées sont densifiés (340) simultanément par diffusion de matrice céramique de manière à former la pièce.A manufacturing method according to claim 1, wherein the ply of woven fibers (710, 720, 730, 740) is pre-impregnated with a ceramic matrix and the fibrous structure (600) and the ply of woven fibers are densified ( 340) simultaneously by ceramic matrix diffusion so as to form the part. Procédé de fabrication selon la revendication 1, dans lequel l’intégration (400) du pli de fibres tissées comporte le collage du pli de fibres sur la structure fibreuse avec une colle céramique.A manufacturing method according to claim 1, wherein the embedding (400) of the woven fiber ply includes bonding the fiber ply to the fibrous structure with a ceramic glue. Procédé de fabrication selon la revendication 3, dans lequel le collage comporte le dépôt (410) d’un film de colle de manière continue sur le pli de fibres tissées.Manufacturing method according to claim 3, in which the gluing comprises depositing (410) a film of glue continuously on the ply of woven fibers. Procédé de fabrication selon la revendication 3, dans lequel le collage comporte le dépôt (410) d’un film de colle de manière discontinue, en une pluralité de portions, sur le pli de fibres tissées.Manufacturing process according to claim 3, in which the gluing comprises depositing (410) a film of glue in a discontinuous manner, in a plurality of portions, on the ply of woven fibers. Procédé de fabrication selon l’une des revendications 4 ou 5, dans lequel le film de colle est déposé sur le pli de fibres tissées de manière à définir une zone dépourvue de colle à une extrémité du pli de fibres tissées.Manufacturing process according to one of Claims 4 or 5, in which the film of glue is deposited on the ply of woven fibers so as to define a zone devoid of glue at one end of the ply of woven fibers. Procédé de fabrication selon l’une des revendications précédentes, dans lequel la réalisation (100) de la structure fibreuse (600) comporte :
  • le tissage tridimensionnel (110) d’une préforme fibreuse ;
  • le conformage (120) de la préforme fibreuse dans un moule ;
  • la densification (130) de la préforme fibreuse par diffusion d’une matrice céramique dans le moule de manière à former la structure fibreuse (600).
Manufacturing process according to one of the preceding claims, in which the production (100) of the fibrous structure (600) comprises:
  • three-dimensional weaving (110) of a fiber preform;
  • shaping (120) the fiber preform in a mold;
  • the densification (130) of the fibrous preform by diffusion of a ceramic matrix in the mold so as to form the fibrous structure (600).
Procédé de fabrication selon l’une des revendications précédentes, dans lequel la pièce en matériau composite à matrice céramique est une aube mobile ou une aube fixe ou un anneau de turbine.Manufacturing process according to one of the preceding claims, in which the part made of composite material with a ceramic matrix is a moving blade or a fixed blade or a turbine ring. Aube (500) en matériau composite à matrice céramique pour une turbomachine, notamment d’aéronef, réalisée par un procédé de fabrication selon l’une des revendications précédentes, et comprenant un pied (510) et une pale (502) s'étendant longitudinalement à partir du pied (510) jusqu’à une plateforme extérieure formant talon (516), et dans laquelle au moins un pli de fibres tissées en deux dimensions (710, 720, 730, 740) est agencé sur une zone d’une structure fibreuse (600) de l’aube parmi une zone (610) de portée du pied, une zone (630) du talon ou une zone (620) de pale, la structure fibreuse (600) étant tissée en trois dimensions.Blade (500) made of composite material with a ceramic matrix for a turbine engine, in particular for an aircraft, produced by a manufacturing method according to one of the preceding claims, and comprising a root (510) and a blade (502) extending longitudinally from the foot (510) to an outer heel platform (516), and wherein at least one ply of two-dimensional woven fibers (710, 720, 730, 740) is arranged over an area of a structure fibrous structure (600) of the blade from among a foot bearing zone (610), a heel zone (630) or a blade zone (620), the fibrous structure (600) being woven in three dimensions. Aube selon la revendication précédente, dans laquelle l’aube est une aube pour turbine de la turbomachine.Blade according to the preceding claim, in which the blade is a turbine blade of the turbomachine. Anneau de turbine pour turbomachine comprenant au moins une aube en matériau composite à matrice céramique selon la revendication 9 ou 10.Turbine ring for a turbomachine comprising at least one blade made of composite material with a ceramic matrix according to claim 9 or 10. Procédé de réparation d’une pièce en matériau composite à matrice céramique pour une turbomachine, la pièce étant une aube en matériau composite à matrice céramique pour une turbomachine selon l’une des revendications précédentes 9 ou 10 ou un anneau de turbine selon la revendication 11, le procédé comprenant :
  • le retrait (710) d’un pli de fibres tissées sur une zone de l’aube ;
  • l’intégration (720) d’un autre pli de fibres tissées non densifié sur la zone de l’aube.
Method for repairing a part made of composite material with a ceramic matrix for a turbomachine, the part being a vane made of composite material with a ceramic matrix for a turbomachine according to one of the preceding claims 9 or 10 or a turbine ring according to Claim 11 , the method comprising:
  • removing (710) a ply of woven fibers from an area of the blade;
  • integrating (720) another ply of non-densified woven fibers over the blade area.
Procédé de réparation selon la revendication précédente 12, dans lequel le retrait (710) comporte l’arrachement du pli de fibres tissées.Repair method according to the preceding claim 12, in which the removal (710) comprises the tearing of the woven fiber ply. Procédé de réparation selon la revendication précédente 12, dans lequel le pli de fibres tissées et la structure fibreuse sont en matériaux différents et le retrait du pli de fibres tissées est réalisé par attaque chimique sélective du pli de fibres tissées.Repair process according to the preceding claim 12, in which the ply of woven fibers and the fibrous structure are made of different materials and the removal of the ply of woven fibers is carried out by selective chemical attack of the ply of woven fibers.
FR2112399A 2021-11-23 2021-11-23 METHOD FOR MANUFACTURING AND REPAIRING A PART IN COMPOSITE MATERIAL WITH A CERAMIC MATRIX Pending FR3129318A1 (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3021349A1 (en) 2014-05-22 2015-11-27 Herakles PROCESS FOR MANUFACTURING A TURBOMACHINE DARK IN COMPOSITE MATERIAL, DAWN OBTAINED AND TURBOMACHINE INCORPORATING IT
FR3032648A1 (en) 2015-02-16 2016-08-19 Herakles PROCESS FOR MANUFACTURING A TURBOMACHINE BLADE OF COMPOSITE MATERIAL
US20180119549A1 (en) * 2016-11-01 2018-05-03 Rolls-Royce Corporation Turbine blade with three-dimensional cmc construction elements
WO2020025878A1 (en) * 2018-08-03 2020-02-06 Safran Ceramics Method for manufacturing a part made from cmc
FR3092787A1 (en) * 2019-02-18 2020-08-21 Safran Aircraft Engines Repair or resumption of manufacture of a composite material part with three-dimensional woven fiber reinforcement

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3021349A1 (en) 2014-05-22 2015-11-27 Herakles PROCESS FOR MANUFACTURING A TURBOMACHINE DARK IN COMPOSITE MATERIAL, DAWN OBTAINED AND TURBOMACHINE INCORPORATING IT
FR3032648A1 (en) 2015-02-16 2016-08-19 Herakles PROCESS FOR MANUFACTURING A TURBOMACHINE BLADE OF COMPOSITE MATERIAL
US20180119549A1 (en) * 2016-11-01 2018-05-03 Rolls-Royce Corporation Turbine blade with three-dimensional cmc construction elements
WO2020025878A1 (en) * 2018-08-03 2020-02-06 Safran Ceramics Method for manufacturing a part made from cmc
FR3092787A1 (en) * 2019-02-18 2020-08-21 Safran Aircraft Engines Repair or resumption of manufacture of a composite material part with three-dimensional woven fiber reinforcement

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