WO2019097147A1 - Structure fibreuse et piece en materiau composite incorporant une telle structure - Google Patents
Structure fibreuse et piece en materiau composite incorporant une telle structure Download PDFInfo
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- WO2019097147A1 WO2019097147A1 PCT/FR2018/052803 FR2018052803W WO2019097147A1 WO 2019097147 A1 WO2019097147 A1 WO 2019097147A1 FR 2018052803 W FR2018052803 W FR 2018052803W WO 2019097147 A1 WO2019097147 A1 WO 2019097147A1
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- Prior art keywords
- warp
- weft
- layers
- fibrous structure
- threads
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Classifications
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D25/00—Woven fabrics not otherwise provided for
- D03D25/005—Three-dimensional woven fabrics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
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- 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
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D41/00—Looms not otherwise provided for, e.g. for weaving chenille yarn; Details peculiar to these looms
- D03D41/004—Looms for three-dimensional fabrics
-
- 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
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- 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
- B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
-
- 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0809—Fabrics
- B29K2105/0845—Woven fabrics
-
- 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
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
-
- 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
- B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
- B29K2309/02—Ceramics
-
- 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
- B29L2031/082—Blades, e.g. for helicopters
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2101/00—Inorganic fibres
- D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
- D10B2101/08—Ceramic
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2101/00—Inorganic fibres
- D10B2101/10—Inorganic fibres based on non-oxides other than metals
- D10B2101/12—Carbon; Pitch
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Definitions
- the present invention relates to the production of composite material parts and more particularly the realization by three-dimensional weaving (3D) or multilayer fiber reinforcement structures for such parts.
- One field of application of the invention is the production of parts made of structural composite material, that is to say parts of structure with fiber reinforcement and densified by a matrix.
- the composite materials make it possible to produce parts having a lower overall mass than these same parts when they are made of metallic material.
- the invention more particularly relates to composite material parts locally comprising one or more parts of extra thickness as is the case for example of the foot of an aeronautical engine blade which corresponds to a zone of large variation in thickness in the piece made of composite material.
- the thickness change is controlled at the level of the fibrous structure intended to form the reinforcement of the part.
- the textile of the preform mechanically interacts with the insert and can lead in particular to shearing of the textile, rotations of the insert, delimitations between the insert and the textile, etc.
- the molding and densification of the part of the preform intended to form the blade root prove to be delicate, in particular because the tolerances on the profile of the bulbous foot are very small (on the order of tenth of a millimeter) and the requirements in terms of mechanical properties of this part of the dawn are important, the foot of the dawn concentrating the majority of efforts applied on the dawn.
- the invention proposes, according to a first aspect, a fibrous structure comprising a plurality of weft and interleaved chain layers in a multilayer three-dimensional weave, the fibrous structure comprising at least first and second adjacent portions in the warp direction, the first portion having, in a direction perpendicular to the warp and weft directions, a thickness greater than thickness of the second part,
- the first portion comprises at least one fibrous texture obtained by three-dimensional weaving of the warp and weft layers in the form of a Mock Leno weave mesh, said at least one texture being present between skins present on the surface of the first part and being bound to the skins by warp threads belonging to said skins which are deflected locally in said texture.
- the use of the fibrous structure of the Mock Leno weave fiber texture allows for a large variation in thickness between the first and second parts while controlling the core fiber content in the first part.
- this Mock Leno weave texture allows very good infiltration of the fibrous structure of the matrix constituents due to its airy grid structure and is compatible with the use of high titre strands.
- the fibrous structure of the invention is entirely textile (i.e. without inserting insert) and son of the latter are linked together by 3D weaving or multilayer which allows the structure to be indelaminable.
- a first group of warp yarns comprising at least one inter-layer bonding warp yarn binding the weft yarns of a first layer of the texture to the weft yarns of a second layer of the texture adjacent to the first layer;
- a second group of warp threads distinct from the first group of warp threads and adjacent to the latter in the weft direction, said second group comprising at least one inter-layer link warp thread binding the weft threads of the first group of warp threads; layer to those of the second layer and having a sense of interlacing with the weft yarns inverted with respect to the interleaving direction exhibited by the inter-layer link warp yarn of the first group with the weft yarns.
- inter-layer link warp yarns of each of the first and second groups are interlaced with the weft yarns in reverse interleaving directions avoids contact between these two bonding yarns.
- This characteristic makes it possible to maintain a non-zero spacing along the weft direction between the first and second groups of warp yarns and thus to give the texture a grid shape which has channels formed in its thickness, each of these channels being delimited in the weft direction by two groups of adjacent warp yarns and in the warp direction by two groups of adjacent weft yarns.
- the presence of these channels makes it possible to confer on the Mock Leno texture an aerated structure, thus allowing in particular good infiltration of the constituents of the matrix.
- each of the first and second groups of warp yarns comprises at least two side warp yarns located on each side of the inter-ply binder warp yarn, each of these side warp yarns being interwoven with the weft yarns of the first layer.
- the side warp yarns of the first group have an interweaving direction with the weft yarns which is inverted with respect to the interlacing direction exhibited by the side warp yarns of the second group with the weft yarns.
- the Mock Leno weave fiber texture has, in a direction perpendicular to the warp and weft directions, a decreasing thickness in the direction of the second portion.
- Such a characteristic is advantageous in order to control the geometry of the first part and to ensure the thickness transition with the second part.
- the first and second parts comprise the same number of warp yarns continuously woven between said first and second parts and the first part comprises a number of layers of warp thread greater than the number of layers of warp threads. chain present at the heart of the second part.
- the first part may for example include at heart a number of layers of warp son equal to twice the number of warp son layers present in the heart of the second part.
- the structure comprises carbon son or son ceramic material.
- the ceramic material of the wires may for example be an oxide material, such as alumina, or a non-oxide material, such as silicon carbide.
- the present invention also relates to a composite material part comprising a fiber reinforcement densified by a matrix, said fibrous reinforcement consisting of a fibrous structure as described above.
- the part corresponds to a turbine blade, the first part of the fibrous structure constituting the blade root portion of the fibrous reinforcement.
- the present invention is also directed to a method of manufacturing a multilayer three-dimensional woven fiber structure between a plurality of weft and warp layers, the fibrous structure comprising at least first and second adjacent portions in the warp direction, the first part having, in a direction perpendicular to the warp and weft directions, a thickness greater than the thickness of the second part,
- the making of the first part comprises a step of three-dimensional weaving of the warp layers and of weft in which a fibrous texture is formed in the form of a Mock Leno weave mesh at the heart of the first part as well as skins on the surface of the first part, the weave of the skins being modified locally by in order to deflect certain warp threads from said skins and to weave them with the Mock Leno weave texture.
- the Mock Leno weave texture has, in a direction perpendicular to the warp and weft directions, a decreasing thickness in the direction of the second part.
- the first and second parts comprise the same number of warp yarns continuously woven between said first and second parts and the first part comprises at heart a number of layers of warp threads greater than the number layers of warp son present in the heart of the second part.
- the first part comprises at heart a number of layers of warp son equal to twice the number of strings of warp son present in the heart of the second part.
- the fibrous structure comprises carbon son or son of ceramic material.
- the ceramic material of the wires may for example be an oxide material, such as alumina, or a non-oxide material, such as silicon carbide.
- FIG. 1 is a schematic view illustrating the multilayer weaving of a fibrous structure for the manufacture of an aircraft engine blade in accordance with one embodiment of the invention
- FIGS. 2 to 17 are enlarged scale sectional views partially representing 16 successive planes of a weave of a portion of extra thickness of the fibrous structure of FIG. 1,
- FIG. 18 is a schematic perspective view of a fibrous preform of blade derived from the fibrous structure of FIG. 1;
- FIG. 19 is a schematic perspective view of a blade made of composite material obtained by densification by a matrix of the preform of FIG. 18, and
- Fig. 20 is a photograph showing a woven Mock-Leno weave texture.
- the invention is generally applicable to the production of fibrous structures capable of constituting fibrous reinforcements, or preforms, for the manufacture of composite material parts, in particular aeronautical engine blades, the parts being obtained by densification fibrous structures by a matrix.
- the matrix is typically a resin, in the case of composite materials used at relatively low temperature, typically up to 300 ° C, or a refractory material such as carbon or ceramic, for example silicon carbide, in the case of thermostructural composites.
- the fibrous structure of the invention is obtained by three-dimensional weaving or by multilayer weaving.
- three-dimensional weaving or “3D weaving” is meant here a weaving mode whereby at least some of the warp son bind weft son on several weft layers.
- multilayer weaving is meant here a 3D weave with several weft layers whose basic armor of each layer is equivalent to a conventional 2D fabric weave, such as a linen, satin or twill type armor, but with some points of the weave that bind the weft layers between them.
- the production of the fibrous structure by 3D or multilayer weaving makes it possible to obtain a bond between the layers, and thus to have good mechanical strength of the fibrous structure and of the composite material part obtained, in a single textile operation. It is advantageous to favor obtaining, after densification, a surface state free of major irregularities, that is to say a good state of completion to avoid or limit finishing operations by machining or to avoid resin cluster formation in the case of resin matrix composites.
- the skin is preferably made by weaving with a type of armor canvas, satin or twill to limit surface irregularities, a satin-like weave providing a smooth surface appearance.
- a variation of skin weave armor can be made on the outer surface of the fibrous structure to impart particular properties desired for example by passing from a linen-type armor favoring a tight connection to a satin-type armor favoring a state smooth surface.
- a fibrous Mock-Leno type texture is used for the weaving heart of the fibrous structure.
- Yarns or strands of different titles between heart and skin and / or between warp and weft can also be used to achieve a ratio within desired limits between the volume ratio of warp fibers and the fiber density by weft.
- the title i.e. the cross-section
- the yarns or strands used for weaving the fibrous structure may be desirable to vary the title, i.e. the cross-section, of the yarns or strands used for weaving the fibrous structure, in particular by using yarns or strands of different titles between heart and skin and / or between warp and weft.
- a descending title between heart and skin promotes access to the heart of the gas through the skin in the case of CVI densification.
- Titles may also be selected to achieve a ratio within the desired limits between the volume density of the warp fibers and the fiber density by weft.
- yarns of different chemical natures between different parts of the fibrous structure in particular between the core and the skin, in order to confer particular properties on the piece of composite material obtained, in particular in terms of resistance to oxidation. or wear.
- FIG. 1 shows very schematically a fibrous structure 200 intended to form the fibrous reinforcement of an aeronautical engine blade.
- the fibrous structure 200 is obtained by three-dimensional weaving, or 3D weaving, or by multilayer weaving made in a known manner by means of a Jacquard weaving loom on which a bundle of strand wires or strands 201 in a plurality is arranged. of layers, the warp yarns binding weft yarns 202 also arranged in a plurality of layers.
- a detailed example of embodiment of a fiber preform intended to form the fiber reinforcement of a blade for an aeronautical engine is described in particular in US Pat. No. 7,101,154, US Pat. No. 7,241,112 and WO 2010/061140.
- the fibrous structure 200 is woven in the form of a strip extending generally in a direction X corresponding to the longitudinal direction of the blade to be produced.
- the fibrous structure has a variable thickness determined according to the longitudinal thickness and the profile of the blade of the blade to achieve.
- the fibrous structure 200 In its part intended to form a foot preform, the fibrous structure 200 has a portion of extra thickness 203 determined according to the thickness of the root of the blade to be produced.
- the fibrous structure 200 is extended by a part of decreasing thickness 204 for forming the stilt of the blade and then a portion 205 for forming the blade of the blade.
- the portion 205 has in a direction perpendicular to the X direction a variable thickness profile between its edge 205a for forming the leading edge of the blade and its edge 205b intended to form the trailing edge of the blade to be realized .
- the fibrous structure 200 is woven in one piece and must have, after cutting nonwoven son, the shape and the almost final dimensions of the dawn ("net shape").
- the decrease in thickness of the preform is achieved by progressively removing weft layers during weaving.
- the same number of warp yarns are used in the thickening portion 203 as in the decreasing thickness portion 204.
- the warp yarn layers present in the thickening portion 203 are exploded so as to have a number of layers of warp son higher in the thickening portion 203 than in the decreasing thickness portion 204.
- the warp son layers present in the heart of the thickened portion 203 then have a lower contexture that the layers of warp son present in the decreasing thickness portion 204.
- contexture means here the number of son per unit length in the warp and weft directions.
- FIGS. 2 to 17 partially represent 16 successive planes of a weave of the thickening portion 203 of the fibrous structure 200 obtained by 3D weaving, the weft layers being visible in section.
- the fibrous structure 200 comprises, in its thickening portion 203, 22 weft layers, ie 44 half-weft layers t1 to t44.
- the first skin 2032 comprises the weft half-layers t1 to t10, the second skin 2033 the weft half-layers t35 to t44 and the core the weft half-layers t11 to t34.
- the 3D weave is Mock Leno type (ML texture).
- the weaving is three-dimensional.
- the half-frame layers t1 and t2 are connected by an armor of the irregular satin type.
- the half-frame layers t43 and t44 are connected by an irregular satin-type weave.
- a plurality of chain yarns C1, C2, C3, C16, C17 and C18 bind weft yarns 20 at the skins 2032 and 2033.
- the Mock Leno ML texture of the core 2031 is bonded to the skins 2032 and 2033 by yarn deflection.
- chain of skins in this ML texture (see for example the C3 and C16 son in Figure 3). The deflection of these warp yarns forms bonding points PL linking the Mock Leno ML texture to the skins 2032 and 2033.
- weft layers are gradually removed until a number of weft layers compatible with the portion 205 to form the blade of the blade.
- the Mock Leno ML texture having heart 2031 of the first portion 203 comprises a plurality of CT1-CT12 layers of weft son (see Figure 2 in particular).
- the Mock Leno texture comprises twelve layers of weft threads, but it is not beyond the scope of the invention if it comprises a number of layers of different weft threads.
- String threads such as C51, C71, C91, C1 11, C131 and C151 shown in FIG. 2 are interwoven with the weft threads
- the texture Mock Leno ML also has, in a direction perpendicular to the warp and weft directions, a decreasing thickness in the direction of the second part 204.
- the fact of progressively decreasing the thickness of this texture ML makes it possible to control the level of fibers in a zone 203a corresponding to the passage between the end of the thickening portion 203 and the beginning of the decreasing thickness portion 204, that is to say the area where the thickness of the fibrous structure begins to decrease.
- weft threads of the texture Mock Leno ML are progressively replaced in the warp direction by weft threads 24 having the same title as the weft threads 20 present in the decreasing thickness portion 204 and in the skins 2032 and 2033 of the fibrous structure.
- each layer of CT1-CT12 weft threads comprises a plurality of weft thread groups noted in FIG. 2 GT1 for the weft groups of the first CTI layer ML and GT4 texture for groups of weft son of the fourth layer of this ML texture for example.
- the adjacent weft son columns of the Mock Leno texture ML are spaced apart by nonzero spacing along the warp direction.
- the groups of adjacent weft yarns of the same layer CTi, with i varying from 1 to 12 in the example illustrated are spaced from the spacing er.
- the spacing er can be substantially constant along the chain direction as illustrated or, alternatively, be variable along this direction.
- the Mock Leno ML texture is in the form of a grid having through channels along its thickness. As will be detailed hereinafter, the presence of each of these through-channels results from the non-zero spacing existing, on the one hand, between the groups of adjacent weft threads and, on the other hand, between the groups of threads adjacent chain.
- each of the groups of weft threads comprises at least two lateral threads 21 between which is present at least one central thread 30.
- Each group of weft threads therefore comprises at least three threads.
- the central wire 30 is a strand of diameter greater than that of the two lateral son 21.
- the illustrated example relates to groups of weft son each comprising three weft son. However, it is not beyond the scope of the invention when the groups of weft son each comprise more than three weft son.
- the texture ML comprises in the example illustrated a plurality of groups of warp son each comprising eight warp son. It is not beyond the scope of the invention if the Mock Leno texture comprises groups of warp son each having a number of warp son different from eight. Thus, more generally, each of the groups of warp threads may comprise at least three warp threads. Furthermore, in the illustrated example, the number of warp threads in each of the warp thread groups is different from the number of weft threads in each of the weft thread groups, but it is not beyond the scope of the invention when these numbers of threads are equal.
- the inter-layer bonding warp thread C83 of the first group of warp threads binds the weft threads of the CT4 layer of the Mock Leno texture to the weft threads of the CT5 layer of this texture. More precisely, the warp thread C83 passes alternately over each of the threads of a group of weft threads GT4 from a first layer CT4 and beneath each of the threads of a group of weft threads GT5. a second layer CT5.
- the C83 wire passes over each son of a first group GT4 weft son of the first layer CT4, then below each of the son of a second group of GT5 weft son of the second layer CT5 then again above each of the threads of a third group GT4 of weft threads of the first layer CT4 and so on.
- the interlocking warp yarn C811 of the second group of warp yarns binds the weft yarns of the CT4 layer of the Mock Leno texture to the weft threads of the CT5 layer of this texture. More precisely, the warp thread C811 passes alternately above each of the threads of a group GT4 of weft threads of the first layer CT4 and below each of the threads of a group GT5 of weft threads of the second layer CT5.
- the wire C811 passes over each of the son of a first group GT4 of weft son of the first layer CT4, then below each of the threads of a second group GT5 of weft threads of the second layer CT5 and then again above each of the threads of a third group GT4 of weft threads of the first layer CT4 and so on.
- the warp C811 has a direction of interlacing with the weft yarns reversed with respect to the direction of interlacing presented by the warp thread C85 with the weft threads.
- the warp thread C85 passes below each of the threads of a group of weft threads of the second layer CT5.
- the warp thread C85 passes over of each of the threads of a weft thread group of the first layer CT4.
- the connecting wire C83 of the first group also has an interleaving direction with the weft yarns inverted with respect to the interleaving direction presented by the C813 binding yarn with the weft yarns.
- this inverted direction of interleaving between the inter-layer connection wires of the first and second groups of warp yarns contributes to obtaining a non-zero spacing between the first and second groups of warp yarns and therefore to the formation of a fibrous texture in the form of a grid whose porosity channels have improved accessibility.
- the connecting threads of the same group of warp threads have the same direction of interlacing with the weft threads makes it possible to allow the connection between the threads of the same group of threads to be aligned. chain and therefore also participates in the formation of porosity channels (compact grouping of son of the same group).
- the texture Mock Leno ML when moving in the weft direction, the texture Mock Leno ML exhibits an alternation between first groups of warp threads and second groups of warp threads with an inverted interweaving direction.
- the texture Mock Leno ML when moving in the weft direction, the texture Mock Leno ML successively presents a first group of warp threads then a second group of warp threads and then again a first group of warp threads then again a second group of warp threads and so on.
- Each of the first groups of warp yarns is adjacent to a second group of warp yarns.
- the first group of warp threads further comprises at least one first side warp thread C71 located on a first side of the interlocking thread C83 and at least one a second side chain wire C77 located on a second side of the connecting wire C83, the second side being opposite to the first side in the weft direction.
- the inter-layer bonding thread C83 is present between the side warp threads C71 and C77. More precisely in the illustrated example, the inter-layer bonding threads C83 and C85 of the first group of warp threads are both present between the lateral threads C71 and C77 of the first group of warp threads.
- Each of the side warp threads C71 and C77 is interlaced with a plurality of weft thread groups GT4 of the first layer CT4.
- the warp thread C71 passes beneath a first lateral thread 21 of a first group of weft threads GT4 and then above the central thread 30 of this first group and then below a second lateral thread 21 of this thread. first group.
- the warp thread C71 then passes over a first lateral thread 21 of a second group of weft threads GT4 adjacent to the first group in the warp direction, then below the central thread 30 of this second group and then to above a second lateral wire 21 of this second group and so on.
- the warp thread C71 passes alternately below the lateral threads 21 of a group GT4 of weft threads and above the lateral threads 21 of the group GT4 of weft threads adjacent in the warp direction.
- the warp thread C71 passes alternately over the central thread 30 of a group GT4 of threads frame and below the core wire GT4 of the group of weft yarns adjacent in the warp direction.
- each of the groups of weft yarns comprise two lateral weft yarns between which are present at least two central weft yarns
- This warp yarn could then pass over a first side yarn of a second group of weft yarns adjacent to the first group in the warp direction, then below each of the central yarns of this second group and then above a second side wire of this second group and so on. This is valid for the first and second groups of warp threads present in the Mock Leno texture according to such a variant.
- the second group of warp yarns further comprises at least one first C79 side chain yarn located on a first side of the inter-thread yarn.
- the inter-layer bonding thread C811 is present between the side warp threads C79 and C715.
- the inter-layer connection son C811 and C813 of the second group of warp son are both present between the lateral son C79 and C715 of the second group of warp son.
- Each of the C79 and C715 side chain son is interlaced with several groups of weft yarns of the first layer CT4.
- the warp thread C79 passes over a first lateral thread 21 of a first group of weft threads GT4, then below the central thread 30 of this first group and then over a second lateral thread 21. of this first group.
- the warp thread C79 then passes below a first lateral thread 21 of a second group of weft threads GT4 adjacent to the first group in the warp direction, then above the central thread 30 of this second group and then below a second lateral wire 21 of this second group and so on.
- the warp thread C79 passes alternately over the lateral threads 21 of a group GT4 of weft threads and below the side threads 21 of the group GT4 of adjacent weft threads in the warp direction.
- the warp yarn C79 passes alternately below the center yarn 30 of a group GT4 of weft yarns and above the center yarn 30 of the group GT4 of weft yarns adjacent in the warp direction.
- the warp C79 has a direction of interlacing with the weft son inverted with respect to the direction of interlacing presented by the warp C77 with the weft son.
- the warp thread C79 passes over each of the side threads 21 of a given group of weft threads
- the warp thread C77 passes below each of the side threads 21. of this same group.
- the warp thread 77 passes over the center thread 30 of the same group.
- the warp yarn C71 also has a direction of interlacing with the weft yarns reversed with respect to the interleaving direction presented by the C715 warp yarn with the weft yarns.
- this inverted direction of interlacing between the side wires of the first and second groups of warp yarns contributes to obtaining a non-zero spacing between the first and second groups of warp yarns.
- second groups of warp son and thus the formation of a fibrous texture in the form of a grid whose porosity channels are particularly accessible.
- the fact that the lateral threads of the same group of warp threads have the same direction of interlacing with the weft threads makes it possible to allow the connection between lateral threads of the same group of warp threads and therefore also participates in the formation of porosity channels (compact grouping of son of the same group).
- the use of a Mock Leno texture at the heart of the first part of the fibrous structure makes it possible to significantly increase the thickness of the fibrous structure while controlling the average rate of fibers at the core, which is not the case when only high-titre wires are used. Indeed, by using son having a high title in the heart of the structure, it is certainly possible to increase the thickness of the structure locally, but this results in an increase in the average rate of core fibers incompatible with the required mechanical properties. When the average level of core fibers is too high, it is not possible to have a network of porosities sufficient to allow good access of the constituents of the matrix to the heart of the fibrous structure.
- the amount of matrix present at heart is then insufficient, which does not make it possible to obtain a piece of composite material which has, in a homogeneous manner, the required mechanical properties.
- This problem is solved by the use of the Mock Leno texture which, thanks to its through channels formed in its thickness, makes it possible to locally increase the thickness of the structure while limiting the increase in the average rate of fibers.
- a fibrous structure is thus obtained which, in its thickening portions, offers very good access to the core for the constituents of the matrix during its densification.
- FIG. 20 shows an example of a Mock Leno ML texture that can be used in the core of the first part of the fibrous structure. It can be noted the presence of CA through channels formed in the thickness of the texture and giving it an airy structure, easily infiltrable by the matrix.
- the fibrous structure according to the invention may be woven in particular, but not exclusively, from carbon fiber threads, ceramic fibers such as silicon carbide, or oxide fibers such as alumina.
- the non-woven threads are cut.
- the fiber preform 100 illustrated in FIG. 18 is then obtained and woven in one piece.
- the fiber preform 100 is then densified to form a composite material blade 10 illustrated in FIG. 19.
- the densification of the fibrous preform intended to form the fibrous reinforcement of the part to be manufactured consists in filling the porosity of the preform, in all or part of the volume thereof, by the material constituting the matrix. This densification can be carried out in a manner known per se according to the liquid method (CVL) or the gaseous process (CVI), or alternatively in a sequence of these two processes.
- CVL liquid method
- CVI gaseous process
- the liquid process consists of impregnating the preform with a liquid composition containing a precursor of the matrix material.
- the precursor is usually in the form of a polymer, such as a high performance epoxy resin, optionally diluted in a solvent.
- the preform is placed in a mold that can be sealed with a housing having the shape of the molded final blade. Then, the mold is closed and the liquid matrix precursor (for example a resin) is injected throughout the housing to impregnate the entire fibrous portion of the preform.
- the conversion of the precursor into a matrix is carried out by heat treatment, generally by heating the mold, after removal of the optional solvent and crosslinking of the polymer, the preform being always maintained in the mold having a shape corresponding to that of the piece to realize.
- the heat treatment consists in pyrolyzing the precursor to transform the matrix into a carbon or ceramic matrix according to the precursor used and the pyrolysis conditions.
- liquid precursors of ceramics in particular of SiC, may be polycarbosilane (PCS) or polytitanocarbosilane (PTCS) or polysilazane (PSZ) type resins, whereas liquid carbon precursors may be rate resins.
- PCS polycarbosilane
- PTCS polytitanocarbosilane
- PSZ polysilazane
- relatively high coke such as phenolic resins.
- the densification of the fiber preform can be carried out by the well-known method of transfer molding known as RTM ("Resin Transfer Molding").
- RTM Resin Transfer Molding
- the fiber preform is placed in a mold having the external shape of the part to be produced.
- a thermosetting resin is injected into the inner space of the mold which comprises the fibrous preform.
- a pressure gradient is generally established in this internal space between the place where the resin is injected and the evacuation ports of the latter in order to control and optimize the impregnation of the preform with the resin.
- the densification of the fiber preform may also be carried out, in a known manner, by gaseous method by chemical vapor infiltration of the matrix (CVI).
- CVI chemical vapor infiltration of the matrix
- the fibrous preform corresponding to the fibrous reinforcement of the blade to be produced is placed in an oven in which a gaseous reaction phase is admitted.
- the pressure and the temperature prevailing in the furnace and the composition of the gas phase are chosen so as to allow the diffusion of the gas phase within the porosity of the preform to form the matrix by deposition, at the heart of the material on contact.
- an SiC matrix can be obtained with methyltrichlorosilane (MTS) giving SiC by decomposition of the MTS while a carbon matrix can be obtained with hydrocarbon gases such as methane and / or propane giving the carbon by cracking.
- MTS methyltrichlorosilane
- hydrocarbon gases such as methane and / or propane giving the carbon by cracking.
- a densification combining liquid route and gaseous route can also be used to facilitate implementation, limit costs and production cycles while obtaining satisfactory characteristics for the intended use. It is also possible to use a melt infiltration process (“Melt-Infiltration”) to form the matrix in the porosity of the fibrous preform.
- Melt-Infiltration a melt infiltration process
- the matrix is formed by infiltration with silicon or with a silicon alloy in the molten state.
- the ceramic particles may for example be silicon carbide particles. When carbon particles are introduced, the latter react with the molten silicon introduced to form silicon carbide.
- the ceramic particles or carbon can be introduced by slip way.
- the densification processes described above make it possible to produce, from the fibrous structure of the invention, mainly parts made of composite material having an organic matrix (CMO), a carbon matrix (C / C) and a ceramic matrix matrix (CMC). ).
- CMO organic matrix
- C / C carbon matrix
- CMC ceramic matrix matrix
- the fibrous structure is impregnated with a slip loaded with refractory oxide particles. After removal of the liquid phase from the slip, the preform thus obtained is subjected to a heat treatment to sinter the particles and obtain a refractory oxide matrix.
- the impregnation of the structure can be carried out with processes using a pressure gradient, such as injection molding processes known as "RTM” or submicron powder suction called "APS".
- a blade 10 of composite material which, as illustrated in FIG. 19, comprises in its lower part a root 103 formed by the thickening portion 203 of the fibrous structure 200 which is prolonged by a stitch 104 formed by the part of decreasing thickness 204 of the structure 200 and a blade 105 formed by the portion 205 of the fibrous structure 200.
- the fibrous structure and its manufacturing method according to the present invention may in particular be used to produce turbomachine blades having a more complex geometry than the blade shown in FIG. 19, such as blades comprising, in addition to that of FIG. 19 , one or more platforms for performing functions such as vein sealing, anti-tip, etc.
Abstract
Description
Claims
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
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CN201880072931.9A CN111448346A (zh) | 2017-11-14 | 2018-11-09 | 一种纤维结构和包含该结构的复合材料部件 |
RU2020119181A RU2774531C2 (ru) | 2017-11-14 | 2018-11-09 | Волокнистая структура и часть из композитного материала, содержащая такую структуру |
EP18819180.3A EP3710626B1 (fr) | 2017-11-14 | 2018-11-09 | Structure fibreuse et piece en materiau composite incorporant une telle structure |
US16/763,900 US10995431B2 (en) | 2017-11-14 | 2018-11-09 | Fiber structure and a composite material part incorporating such a structure |
BR112020009347-5A BR112020009347B1 (pt) | 2017-11-14 | 2018-11-09 | Estrutura fibrosa, peça de material compósito, e, método de fabricar uma estrutura fibrosa |
JP2020538119A JP6801148B1 (ja) | 2017-11-14 | 2018-11-09 | 繊維構造体およびその構造体を組み込んだ複合材料部品 |
CA3079919A CA3079919A1 (fr) | 2017-11-14 | 2018-11-09 | Structure fibreuse et piece en materiau composite incorporant une telle structure |
US17/221,439 US11560650B2 (en) | 2017-11-14 | 2021-04-02 | Fiber structure and a composite material part incorporating such a structure |
Applications Claiming Priority (4)
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US201762585953P | 2017-11-14 | 2017-11-14 | |
US62/585,953 | 2017-11-14 | ||
FR1855627 | 2018-06-25 | ||
FR1855627A FR3082854B1 (fr) | 2018-06-25 | 2018-06-25 | Structure fibreuse et piece en materiau composite incorporant une telle structure |
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US16/763,900 A-371-Of-International US10995431B2 (en) | 2017-11-14 | 2018-11-09 | Fiber structure and a composite material part incorporating such a structure |
US17/221,439 Division US11560650B2 (en) | 2017-11-14 | 2021-04-02 | Fiber structure and a composite material part incorporating such a structure |
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WO2019097147A1 true WO2019097147A1 (fr) | 2019-05-23 |
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FR3102390A1 (fr) * | 2019-10-29 | 2021-04-30 | Safran | Préforme fibreuse tissée pour réaliser une plateforme rapportée de soufflante en matériau composite |
FR3102392A1 (fr) * | 2019-10-29 | 2021-04-30 | Safran | Préforme fibreuse tissée pour réaliser une aube de soufflante en matériau composite |
FR3102391A1 (fr) * | 2019-10-29 | 2021-04-30 | Safran | Préforme fibreuse tissée pour réaliser une pièce en matériau composite, notamment une aube de turbomachine |
FR3106519A1 (fr) * | 2020-01-28 | 2021-07-30 | Safran | Préforme fibreuse tissée pour réaliser une pièce en matériau composite, notamment une aube de turbomachine |
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