WO2019068987A1 - Procede pour la realisation d'une piece creuse en materiau composite a matrice ceramique - Google Patents
Procede pour la realisation d'une piece creuse en materiau composite a matrice ceramique Download PDFInfo
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- WO2019068987A1 WO2019068987A1 PCT/FR2018/052347 FR2018052347W WO2019068987A1 WO 2019068987 A1 WO2019068987 A1 WO 2019068987A1 FR 2018052347 W FR2018052347 W FR 2018052347W WO 2019068987 A1 WO2019068987 A1 WO 2019068987A1
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- preform
- core
- heating
- hollow
- oxidation
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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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- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
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- C04B35/58—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 borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
- C04B35/584—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 borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
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- 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
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- 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
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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
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/603—Composites; e.g. fibre-reinforced
- F05D2300/6033—Ceramic matrix composites [CMC]
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- 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 a method for producing a hollow part made of ceramic matrix or CMC composite material.
- a field of application of the invention is the manufacture of structural parts used in hot parts of a turbomachine, for example parts of turbine, rear body or secondary nozzles of the turbomachine. More specifically, the invention can be used for producing dispensers or hollow turbine blades.
- a turbine stage consists of a fixed blade or distributor belonging to a stator, followed by a mobile blade belonging to a rotor.
- the first distributor stages are generally hollow in order to convey air radially from the outside to the inside of the turbine, so as to feed the hub with air to ensure the pressurization and purging and its possible cooling . Part of this air may be intended for cooling the dispenser.
- the blades may also be hollow in order to be traversed by cooling air.
- the use of hollow parts also reduces the mass of the turbomachine.
- a method for producing hollow parts in CMC is known from US 2014/0048978. This method comprises the steps of:
- the first disadvantage is related to the fact that the core and the mold (or shaper) are made of different materials. Indeed, the core, made of silicon, has a thermal expansion different from the mold, made of carbon or metal, which can induce a variability of the finished part. Compensation is thus necessary to ensure the right fiber content and the good sizing of the part.
- the second disadvantage is related to having to correctly size the volume of the silicon core so that the whole of the porous preform is infiltrated by the silicon of the core.
- drainage means are provided to evacuate this excess out of the cavity.
- a crucible must be provided to bring into the cavity of the complementary silicon. This makes the infiltration step of the preform more complex.
- the invention aims to overcome these disadvantages by providing a simple alternative, effective and inexpensive.
- the invention proposes a method for producing a hollow part made of ceramic matrix composite material comprising the steps of:
- the core can be easily removed, without risk of degradation of the preform. Indeed, the latter having been consolidated before removal of the core, said preform retains its size and shape after removal of the core.
- oxidation is meant the chemical reaction of the nucleus with an oxidizing agent or oxidation agent transforming it into an oxide. Furthermore, the removal of the core by oxidation can easily be achieved within the current range of CMC parts manufacturing, without requiring significant adaptations of the manufacturing process.
- the core can be pierced through or can be perforated.
- the step of extracting the ring by oxidation may comprise the substeps consisting of:
- Said heating can be carried out in the presence of a catalyst, such as for example potassium acetate.
- Said heating can be carried out at a temperature between 400 ° C and 800 ° C.
- Said heating may comprise:
- the first and second heating cycles may vary depending on the volume of the core and the section of the core which is in direct contact with the air.
- a mechanical removal operation of the core for example a scraping operation, can be performed after each heating cycle.
- the oxidizable core may be made of carbon, graphite or other material derived from carbon.
- Such materials are particularly resistant to the consolidation step.
- the hollow fiber preform can be made by draping or assembling fibrous textures around the core, or by weaving a preform having a hollow zone for insertion of the core.
- Said consolidation of the preform may comprise the substeps consisting of:
- Said consolidation of the son may comprise the substeps consisting of:
- the hollow preform can then be shaped, a core of oxidizable material being housed or inserted into the preform.
- the hollow fiber preform can then be woven with these consolidated yarns or can then result from the assembly around an oxidizable core of one-dimensional fabrics made from these consolidated yarns.
- the step of extraction of the nucleus by oxidation may be followed by a step of densification of the preform consisting at least in part of:
- a metal powder for example a silicon powder
- molten metal for example molten silicon
- the step of extracting the nucleus by oxidation may be followed by the steps of:
- FIG. 1 is a diagram illustrating the various successive steps of the method according to the invention.
- FIG. 2 is a schematic view of the preform in which is inserted the core
- FIG. 3 is a schematic view of the preform after removal of the core by oxidation.
- FIG. 1 shows schematically the various steps of a method of producing a hollow part made of ceramic matrix composite material (CMC) according to one embodiment of the invention.
- CMC ceramic matrix composite material
- This method comprises a first step E1 in which a hollow fiber preform is shaped, a core of oxidizable material being housed or inserted into the preform.
- the core is for example made of carbon, graphite or other material derived from carbon.
- the fibrous preform intended to form the fibrous reinforcement of the part according to the invention can be obtained by multilayer weaving between a plurality of layers of warp threads and a plurality of weft layers.
- the multilayer weave produced can be in particular an "interlock" weave weave, that is to say a weave weave in which each layer of weft yarn binds several layers of warp yarns with all the yarns of a weave. same column of weft having the same movement in the plane of the armor.
- the weaving can be performed with warp son extending in the longitudinal direction of the preform, being noted that weaving with weft yarns in this direction is also possible. .
- the son used may be silicon carbide (SiC) son provided under the name "Nicalon”, “Hi-Nicalon” or “Hi-Nicalon-S” by the Japanese company Nippon Carbon or “Tyranno SA3" by the company UBE and having a titre (number of filaments) of 0.5K (500 filaments).
- SiC silicon carbide
- the fibrous reinforcement of the piece according to the invention can also be formed from a fibrous preform obtained by assembling two fibrous textures.
- the two fibrous textures may be bonded together, for example by sewing or needling, or simply juxtaposed.
- the two fibrous textures can in particular be each obtained from a layer or a stack of several layers of:
- unidirectional sheet of son or cables or multidirectional layers obtained by superimposition of several unidirectional sheets in different directions and by unidirectional webs connection between them, for example by sewing, by chemical bonding agent or by needling.
- the fibrous reinforcement of the piece according to the invention can also be formed by draping unidirectional folds, fabrics or bands, around the core.
- the hollow zone in the preform is made directly by constructing the preform around the core.
- step E2 The assembly comprising the preform and the core inserted in the hollow zone of the preform is then placed in a conformation tool (step E2) so as to maintain the preform in a shape close to that of the part to be manufactured.
- a boron nitride (BN) interphase coating is then formed by chemical vapor infiltration or CVI ("Chemical Vapor Infiltration" - step E3), the preform remaining in the desired shape by means of the conformation tooling, said tool being placed in an oven.
- the tool may be made of graphite and may have holes for the passage of the gas phase.
- This gaseous phase can comprise boron trichloride BCb, ammonia NH3 and hydrogen gas H2.
- a ceramic matrix layer is formed by CVI on the BN interphase for consolidation of the preform (Step E4), that is to say to bind the fibers of the preform sufficiently between them so that the preform can retain its shape without the assistance of the conformation tooling.
- This matrix layer is for example made of silicon carbide SiC.
- steps E3 and E4 the preform and the core are subjected to a temperature of between 700 and 1100 ° C.
- the core 2 (visible in dashed lines in Figure 2) and the preform 1 are then removed from the conformation mold and are placed in an oven under an oxidizing atmosphere, that is to say in the presence of a catalyst , such as for example potassium acetate, to carry out the extraction of the nucleus by oxidation (E5).
- oxidation is meant the reaction of a body with oxygen, giving an oxide.
- the core is thus removed by means of a chemical reaction transforming it into oxide.
- the core and the preform undergo a first heating cycle in which the temperature in the oven is maintained between 400 ° C and 800 ° C, for example of the order of 600 ° C, for a period of between 20 and 30 hours, for example from the order of 25 hours.
- Part of the core is then removed by mechanical action, for example by scraping. At the end of the first cycle of heating and scraping, between 30 and 50% of the mass of the core can be removed.
- the core and the preform then undergo a second heating cycle in which the temperature in the oven is maintained between 400 ° C and 800 ° C, for example of the order of 600 ° C, for a period of between 10 and 15 hours, for example of the order of 12 hours.
- the remainder of the core is then removed by mechanical action, for example by scraping.
- a preform 1 having a hollow zone 3 is obtained, said hollow zone 3 being illustrated in dashed lines in FIG.
- a ceramic matrix is then formed in the preform by impregnating said preform with a slip containing one or more carbon or ceramic powders, for example SiC, Si 3 N 4 , C, B and their mixtures, in aqueous suspension, or SC ("Slurry Casting" - step E6).
- This densification step is performed in a mold at room temperature.
- the preform is then removed from the mold and dried, and the formation of the ceramic matrix is continued in an oven by infiltration with molten silicon or a molten alloy containing predominantly silicon, or Ml (“Melt Infiltration" - step E7).
- the constituent (s) present within said molten silicon alloy may be chosen from B, Al, Mo, Ti, and mixtures thereof.
- This densification step is carried out at a temperature of, for example, between 1400 ° C. and 1450 ° C.
- step E7 The piece from step E7 is then removed from the oven and functional surfaces are optionally machined (step E8), for example by milling.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Ceramic Products (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Moulds, Cores, Or Mandrels (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
Abstract
Description
Claims
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
RU2020115056A RU2770493C2 (ru) | 2017-10-02 | 2018-09-25 | Способ получения полой детали из композиционного материала с керамической матрицей |
BR112020006473-4A BR112020006473B1 (pt) | 2017-10-02 | 2018-09-25 | Método para produzir uma peça oca feita de um material compósito com matriz cerâmica |
JP2020539147A JP7197595B2 (ja) | 2017-10-02 | 2018-09-25 | セラミックマトリクス複合材料からなる中空部品の製造方法 |
US16/652,481 US11608299B2 (en) | 2017-10-02 | 2018-09-25 | Method for producing a hollow part made of a ceramic matrix composite material |
EP18792425.3A EP3856698A1 (fr) | 2017-10-02 | 2018-09-25 | Procede pour la realisation d'une piece creuse en materiau composite a matrice ceramique |
CN201880064163.2A CN111164061A (zh) | 2017-10-02 | 2018-09-25 | 用于制造由陶瓷基复合材料制成的中空部件的方法 |
CA3077612A CA3077612A1 (fr) | 2017-10-02 | 2018-09-25 | Procede pour la realisation d'une piece creuse en materiau composite a matrice ceramique |
Applications Claiming Priority (2)
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FR1759189 | 2017-10-02 | ||
FR1759189A FR3071830B1 (fr) | 2017-10-02 | 2017-10-02 | Procede pour la realisation d'une piece creuse en materiau composite a matrice ceramique |
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WO2019068987A1 true WO2019068987A1 (fr) | 2019-04-11 |
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PCT/FR2018/052347 WO2019068987A1 (fr) | 2017-10-02 | 2018-09-25 | Procede pour la realisation d'une piece creuse en materiau composite a matrice ceramique |
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US (1) | US11608299B2 (fr) |
EP (1) | EP3856698A1 (fr) |
JP (1) | JP7197595B2 (fr) |
CN (1) | CN111164061A (fr) |
BR (1) | BR112020006473B1 (fr) |
CA (1) | CA3077612A1 (fr) |
FR (1) | FR3071830B1 (fr) |
RU (1) | RU2770493C2 (fr) |
WO (1) | WO2019068987A1 (fr) |
Cited By (2)
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FR3114532A1 (fr) * | 2020-09-29 | 2022-04-01 | Safran | Procédé de fabrication d’une pièce creuse en CMC |
WO2023094782A1 (fr) | 2021-11-26 | 2023-06-01 | Safran Ceramics | Noyau pour la réalisation de distributeur en composite à matrice céramique |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
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FR3112142B1 (fr) * | 2020-07-03 | 2022-09-09 | Safran Ceram | Procédé de fabrication d’une aube de distributeur en matériau composite à matrice céramique |
FR3115280B1 (fr) | 2020-10-20 | 2023-07-21 | Safran Ceram | Procédé de fabrication d’une pièce creuse en matériau composite à matrice métallique ou céramique renforcée avec des fibres courtes |
FR3121678B1 (fr) * | 2021-04-08 | 2023-04-14 | Safran Ceram | Procédé de fabrication d’une pièce creuse utilisant un noyau à composition optimisée pour faciliter son extraction |
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- 2018-09-25 JP JP2020539147A patent/JP7197595B2/ja active Active
- 2018-09-25 EP EP18792425.3A patent/EP3856698A1/fr active Pending
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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FR3114532A1 (fr) * | 2020-09-29 | 2022-04-01 | Safran | Procédé de fabrication d’une pièce creuse en CMC |
WO2022069814A1 (fr) * | 2020-09-29 | 2022-04-07 | Safran | Procede de fabrication d'une piece creuse en cmc |
WO2023094782A1 (fr) | 2021-11-26 | 2023-06-01 | Safran Ceramics | Noyau pour la réalisation de distributeur en composite à matrice céramique |
FR3129615A1 (fr) | 2021-11-26 | 2023-06-02 | Safran Ceramics | Noyau pour la réalisation de distributeur en Composite à Matrice Céramique |
Also Published As
Publication number | Publication date |
---|---|
JP7197595B2 (ja) | 2022-12-27 |
FR3071830A1 (fr) | 2019-04-05 |
RU2020115056A3 (fr) | 2021-11-16 |
RU2020115056A (ru) | 2021-11-08 |
US11608299B2 (en) | 2023-03-21 |
BR112020006473B1 (pt) | 2024-02-20 |
EP3856698A1 (fr) | 2021-08-04 |
FR3071830B1 (fr) | 2021-03-12 |
JP2020536042A (ja) | 2020-12-10 |
US20200270180A1 (en) | 2020-08-27 |
CN111164061A (zh) | 2020-05-15 |
RU2770493C2 (ru) | 2022-04-18 |
BR112020006473A2 (pt) | 2020-10-06 |
CA3077612A1 (fr) | 2019-04-11 |
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