Rotationally symmetrical component made of composite material with improved holding capacity

Abstract

A method for manufacturing a composite rotating part (100) for a propulsion assembly, the method comprising:-making a fibrous preform on a mandrel (200), the mandrel having a profile corresponding to the profile of the part to be manufactured, and-densifying the fibrous preform by means of a matrix. Fabricating a fibrous preform includes forming a strip-shaped fibrous blank (140) including at least one continuous layer of fibers and at least one discontinuous layer of fibers, the fibrous blank being shaped on a mandrel, the continuous layer of fibers of the fibrous blank extending around the mandrel (200) at least one full circle.

Description

Technical Field

[0001] The present invention relates to the general field of manufacturing composite rotating parts for propulsion components, such as gas turbine fan cases, air inlets or nacelle covers for aircraft engines. Background Art

[0002] In an aircraft gas turbine engine, the fan casing performs multiple functions. It defines the air inlet flow path into the engine, supports the abradable material facing the fan blade tips, supports possible sound wave absorbing structures for acoustic treatment at the engine inlet, and incorporates or supports a protective cover. The protective cover constitutes a debris collector that retains debris that is splashed out by centrifugal action (e.g., fragments of ingested objects or damaged blades) in order to prevent them from passing through the casing and reaching other parts of the aircraft.

[0003] Casings that were previously made of metal material (e.g. fan housings) are now made of composite materials, i.e. fiber preforms densified by an organic matrix, which makes it possible to produce a component whose overall mass is lower than the mass of these same components when they were made of metal material, while having at least the same mechanical strength (if not greater).

[0004] The manufacture of a fan housing made of an organic matrix composite material is described in particular in document US 8 322 971. In the housing disclosed in document US 8 322 971, the shield is composed of an excess thickness portion (having a variable thickness) obtained at the level of the fiber reinforcement of the housing. The fiber reinforcement is obtained by winding a 3D woven fiber fabric having an excess thickness portion capable of forming the shield.

[0005] However, in order to be able to contain the fragments that fly with very high energy in the event of a blade loss, the excess thickness must always have a significant dimension in the radial direction, which significantly increases the overall mass of the composite component. The same applies to the air inlet of the propulsion assembly or the nacelle cover. Summary of the invention

[0006] It would therefore be desirable to have a solution to provide a composite rotating component for a propulsion assembly having a lower overall mass than prior art composite housings while having at least equal, if not greater, retention capabilities.

[0007] To this end, according to the invention, a method for manufacturing a composite rotating part for a propulsion assembly is proposed, the method comprising:

[0008] - making a fiber preform on a mandrel having a profile corresponding to the profile of the part to be manufactured, and - densifying the fiber preform by means of a matrix,

[0009] It is characterized in that making the fiber preform includes: forming a strip-shaped fiber blank, the strip-shaped fiber blank includes at least one continuous fiber layer and at least one discontinuous fiber layer, the fiber blank is formed on the core shaft, and the at least one continuous fiber layer of the fiber blank extends at least one full circle around the core shaft.

[0010] The method of the invention thus makes it possible to obtain a composite material component with improved holding capacity due to the presence of one or several discontinuous fiber layers in its fiber reinforcement. In the event of a collision with a protruding object such as a blade in an aerospace engine casing (FBO: Fan Blade Out), this discontinuous fiber layer can indeed be damaged in order to dissipate the energy. The continuous fiber layer of the component ensures the mechanical cohesion and strength of the component.

[0011] It is thus possible to produce composite material rotational components with very good holding capacity without requiring a significant increase in thickness, these components having a lower overall mass than the overall mass of prior art composite material components.

[0012] According to one aspect of the method of the present invention, the discontinuous fiber layer is a non-woven fabric or a random fiber mat having discontinuous long fibers.

[0013] According to another aspect of the method of the present invention, the continuous fiber layer is selected from at least one of the following fiber structures: a three-dimensional woven structure, a unidirectional layer stack, a two-dimensional woven layer stack, and a woven fabric. The fiber blank may include a single continuous fiber layer, which corresponds to a strip fiber structure, and the strip fiber structure has a three-dimensional weaving between a plurality of warp yarns and a plurality of weft yarns. In this case, making the fiber preform includes: winding the fiber blank as a whole on the mandrel one or several turns. The fiber blank may include: a single continuous fiber layer, which also corresponds to a strip fiber structure with a three-dimensional weaving, and the strip fiber structure includes a first part and a second part in the length direction, in which the warp yarns are interconnected by weft yarns throughout the thickness of the fiber structure, and the second part includes a non-interconnected area, which exists in the middle of the thickness of the fiber structure and extends in the fiber structure along a plane parallel to the surface of the fiber structure, and the non-interconnected area divides the fiber structure into a first skin and a second skin; the discontinuous fiber layer, which is arranged between the first skin and the second skin. In this case, making the fiber structure comprises winding the fiber blank around the mandrel one or more times.

[0014] The invention also relates to a composite rotating part for a propulsion assembly, comprising a fiber reinforcement densified by a matrix, characterized in that the fiber reinforcement comprises at least one continuous fiber layer and at least one discontinuous fiber layer in thickness direction.

[0015] As described above, the composite component of the present invention provides very good holding capacity while having a controlled thickness and, therefore, a reduced overall mass compared to prior art composite components.

[0016] According to one aspect of the present invention, the discontinuous fiber layer is a non-woven fabric or a random fiber mat having discontinuous long fibers.

[0017] According to another aspect of the present invention, the continuous fiber layer is selected from at least one of the following fiber structures: a three-dimensional woven structure, a unidirectional layer stack, a two-dimensional woven layer stack, and a woven fabric. The fiber reinforcement may include: a single continuous fiber layer, which is composed of a strip fiber structure with three-dimensional weaving or multi-layer weaving, the strip fiber structure including a first part and a second part, in which the warp yarns are interconnected by weft yarns throughout the thickness of the fiber structure, and the second part includes a non-interconnected area, which exists in the middle of the thickness of the fiber structure, and the non-interconnected area divides the fiber structure into a first skin and a second skin; the discontinuous fiber layer, which exists between the first skin and the second skin.

[0018] According to another aspect of the component according to the invention, the latter corresponds to a housing comprising a shield including: an extra thick portion forming a retaining zone, the shield also comprising: a clamp located at its axial end. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a perspective view and a partial cross-sectional view of an aircraft engine equipped with a fan case made of a composite material according to one embodiment of the present invention,

[0020] Figure 2 is along Figure 1 A cross-sectional view of the plane II-II of the housing,

[0021] Figure 3 is a schematic perspective view of a loom, which shows a method for forming Figure 1 and Figure 2 Weaving of fiber fabrics of fiber reinforcements of the shell,

[0022] Figure 4 is a schematic perspective view of a layer with continuous fibers,

[0023] Figure 5 is a schematic perspective view of a layer with discontinuous fibers,

[0024] Figure 6 According to one embodiment of the present invention, there is formed Figure 4 and Figure 5 A schematic perspective view of a fiber blank of layers,

[0025] Figure 7 It shows Figure 6 A schematic three-dimensional diagram of the fiber blank forming process,

[0026] Figure 8 is from Figure 6 A cross-sectional view of a fiber preform obtained from a fiber blank,

[0027] Fig. 9 is shown for densification Figure 8 Schematic diagram of the prefabricated tool,

[0028] Fig.10 is a schematic perspective view showing a fiber blank formed according to another embodiment of the present invention,

[0029] Fig.11 Is Fig.10 Cross-sectional view of a housing made of a fiber blank. DETAILED DESCRIPTION

[0030] The present invention is generally applicable to any composite rotating part for a propulsion assembly which may be subject to impact. In particular, such parts for propulsion assemblies relate to, but are not limited to, gas turbine fan cases, cabin air inlets and nacelle covers found in aircraft engines.

[0031] The present invention will be described below in conjunction with its application in a fan casing of an aircraft gas turbine engine.

[0032] like Figure 1 As shown very schematically in FIG. 1 , such an engine comprises, from upstream to downstream in the airflow direction: a fan 1 arranged at the engine inlet, a compressor 2, a combustion chamber 3, a high-pressure turbine 4 and a low-pressure turbine 5.

[0033] The engine is housed in a casing comprising several parts corresponding to the different elements of the engine. Thus, the fan 1 is surrounded by a fan casing 100 .

[0034] Figure 2The profile of a fan casing 100 made of composite material is shown, as it can be obtained by the method according to the invention. The inner surface 101 of the casing defines an air inlet flow channel. It can be provided with an abradable coating 102 in line with the trajectory of the fan blade tips, the blades 13 being partially shown very schematically. Therefore, the abradable coating is only arranged on a part of the casing length (in the axial direction). An acoustic treatment coating (not shown) can also be arranged on the inner surface 101, in particular upstream of the abradable coating 102.

[0035] The housing 100 may be provided with external clamps 104 , 105 at its upstream and downstream ends in order to allow its mounting and its connection to other elements.

[0036] The housing 100 is made of a composite material with fiber reinforcements densified by a matrix made of fibers (e.g., carbon fibers, glass fibers, aramid fibers, or ceramic fibers) and a matrix made of polymers (e.g., epoxy resins, bismaleimide, or polyimide), carbon, or ceramics.

[0037] In the example described here, the fiber reinforcement is formed by winding a fiber blank on a mandrel whose profile corresponds to the profile of the shell to be manufactured. Advantageously, the fiber reinforcement constitutes a complete tubular fiber preform of the shell 100, which is formed in one piece with the reinforcement portions corresponding to the clamps 104,105.

[0038] According to the invention, the fiber blank is made of at least one continuous fiber layer and at least one discontinuous fiber layer assembled together as described below. In the example described here, the continuous fiber layer is made of a strip fiber structure with a three-dimensional weave. More specifically and as Figure 3 As illustrated in FIG. 1 , the fiber structure 50 is produced in a known manner by three-dimensional weaving using a jacquard-type loom 10, on which a bundle of warp yarns or strands 20 has been arranged in multiple layers, the warp yarns being interconnected by weft yarns or strands 30. For example, the yarn used for weaving the fiber structure 50 is a yarn made of carbon fibers, such as IM7, AS4 or AS7 fibers, or ceramic fibers such as silicon carbide, glass fibers or aramid fibers. The yarn count is typically 12k, 24k or 48k. Different types of yarns can be used in the same preform. The fiber structure is made by three-dimensional weaving. Here, "three-dimensional weaving" or "3D weaving" refers to a weaving pattern by which at least some of the weft yarns are interconnected over several layers of warp yarns, and vice versa. An example of three-dimensional weaving is a weaving known as "interlocking" weaving. Here, "interlocking" weaving refers to a weaving in which each layer of warp yarns interconnects several layers of weft yarns, wherein all yarns of the same warp yarn column have the same movement within the weaving plane.

[0039] like Figure 3 and Figure 4 As illustrated in FIG, the fiber structure 50 has a strip shape extending in length along a direction X corresponding to the direction of travel of the warp yarns or strands 20 and extending in width or transversely along a Y direction corresponding to the direction of the weft yarns or strands 30.

[0040] like Figure 4 As shown in the example, the fiber structure 50 has a thickness of E 50 The fiber structure 50 has a strip shape of (e.g., 5 mm) which corresponds to a 3D weave using weft yarns to weave three to five warp yarn layers together in a plane and over the thickness of the strip. 50 Upper and Length L 50 The width l 50 is defined as a function of the width of the housing to be manufactured, the width l 50 For example, it can be 2m, and the length L 50 is defined as a function of the diameter of the shell to be manufactured and the number of turns required in the fiber reinforcement. For example, in order to manufacture a similar cylindrical shell with a diameter of 4 m by performing two blank turns, the length of the fiber structure to be woven is about 25 meters. This length can be extended to prevent the start and end of the fiber structure from being at the same angular position, which could create a weak point in the component.

[0041] In the example described here, the discontinuous fiber layer consists of a fiber mat. "Fiber mat" refers to a fiber fabric corresponding to a discontinuous fiber aggregate, the fibers being generally arranged randomly or in bulk so as to obtain isotropy in a plane. In the present invention, the production of the fiber mat can be adjusted so as to obtain a mat with orthogonal anisotropy so that the modules are as close as possible in the plane to the modules along the warp direction and / or weft direction of the 3D woven fiber structure, which modules can be different. In this case, the percentage of fibers in the sheet direction and in the transverse direction is affected by the travel speed of the conveying system. The faster it travels, the more the fibers are oriented in the direction of the roller. It is also possible to define a dropshaft that more or less redirects the fibers.

[0042] Figure 5 The strip fiber mat 60 is exemplified, and the strip fiber mat comprises: 60 The thickness E of the fiber 61 is 60 Preferably between 1 mm and 5 mm. In the example described here, the fiber mat 60 has a width l equal to that of the fiber structure 50. 50 Width l 60 and less than the length L of the fiber structure 50 50 Length L 60 , so that: the fiber structure 50 is present only in the last winding of the fiber blank. Preferably, the fiber mat 60 comprises: the same type of fibers as the fiber structure 50. Even if a higher grammage can be used, the grammage of the fiber mat is usually 200g / m 2 Up to 1000g / m 2 between.

[0043] like Figure 6 , a fiber blank 140 is then made by arranging the fiber mat 60 on the 3D woven fiber structure 50. A step of stitching the fitting edges between the fiber mat 60 and the fiber structure 50 may also be performed to hold them in place in the fiber blank 140. The fiber blank 140 may be compacted before it is wound in order to reduce expansion.

[0044] like Figure 7 As shown in the example, then, by moving the fiber blank 140 along the direction S R The fiber preform is formed by winding on a mandrel 200, wherein the fiber structure 50 is arranged against the mandrel 200, the profile of which corresponds to the profile of the shell to be manufactured. The mandrel 200 has an outer surface 201, the profile of which corresponds to the inner surface of the shell to be manufactured. By winding on the mandrel 200, the fiber blank 140 matches its profile. The mandrel 200 also includes two flanges 220 and 230 to form a fiber preform portion corresponding to the clamps 104 and 105 of the shell 100.

[0045] Figure 8 A cross-sectional view of a fiber preform 300 is shown, which is obtained after winding a fiber blank 140 on a mandrel 200 in several layers. The number of turns or coils is a function of the desired thickness and the thickness of the fiber fabric. Preferably, it is at least equal to 2. In the example described here, the preform 300 comprises, along its thickness direction: two layers 51 and 52 of the fiber structure 50 and two layers 62 and 63 of the fiber mat 60, the layer 62 being interposed between adjacent layers 51 and 52, and the layer 63 being present on the outer periphery of the preform 300. The fiber preform 300 also comprises: ends 320, 330 corresponding to the clamps 104, 105 of the shell.

[0046] The fiber preform 300 is then densified by means of a matrix.

[0047] The densification of the fiber preform consists in filling all or part of the volume of the pores of the preform with the material constituting the matrix.

[0048] The matrix can be obtained in a manner known per se according to liquid technology.

[0049] The liquid process consists in impregnating the preform with a liquid composition containing an organic precursor of the matrix material. The organic precursor is usually in the form of a polymer such as a resin, which is optionally diluted in a solvent. The fiber preform is placed in a mold, which can be closed in a sealed manner with a housing having the shape of the final molded part. Fig. 9 , here, a fiber preform 300 is placed between a plurality of sectors 240 forming a counter-mold and a mandrel 200 forming a support, these elements respectively having the external shape and the internal shape of the shell to be manufactured. A liquid matrix precursor (such as a resin) is then injected into the entire shell to impregnate the entire fiber portion of the preform.

[0050] The conversion of this precursor into an organic matrix (i.e. its polymerization) is carried out by thermal treatment (generally by heating a mould), the preform remaining in the mould, after removal of any solvent and crosslinking of the polymer, the shape of which corresponds to the shape of the part to be manufactured. In particular, the organic matrix can be obtained from an epoxy resin (for example a high performance epoxy resin sold as Epoxy) or from a liquid precursor of a carbon matrix or a ceramic matrix.

[0051] In the case of forming a carbon matrix or a ceramic matrix, the thermal treatment comprises: pyrolyzing an organic precursor to convert the organic matrix into a carbon matrix or a ceramic matrix, depending on the precursor used and the pyrolysis conditions. For example, the liquid carbon precursor may be a resin with a relatively high char content (e.g. a phenolic resin), while the liquid ceramic precursor (particularly SiC) may be a resin of the polycarbosilane (PCS) or polytitanium carbosilane (PTCS) or polysilazane (PSZ) type. Several consecutive cycles from impregnation to thermal treatment may be performed to achieve the desired degree of densification.

[0052] According to one aspect of the present invention, the densification of the fiber preform can be carried out by a known transfer molding process called RTM (resin transfer molding). According to the RTM process, the fiber preform is placed in a mold having the shape of the shell to be manufactured. Thermosetting resin is injected into the internal space defined between the mandrel 200 and the counter-mold 240.

[0053] For example, the resin used may be an epoxy resin. Resins suitable for the RTM process are well known. Preferably, they have a low viscosity to facilitate their infusion into the fibers. The choice of temperature grade and / or chemical nature of the resin is determined according to the thermomechanical loads that the component must withstand. Once the resin has been infused throughout the reinforcement, it is polymerized by a heat treatment according to the RTM process.

[0054] After injection and polymerization, the part is demoulded. Finally, the part is trimmed to remove excess resin and chamfers are machined to obtain Figure 1 and Figure 2 100 as illustrated in the example. Thus, the shell 100 made of composite material comprises a fiber reinforcement, which consists of two layers 51 and 52 of a fiber structure 50 and two layers 62 and 63 of a fiber mat 60 in the thickness direction thereof, the layer 62 being between adjacent layers 51 and 52, and the layer 63 being present at the outer periphery of the shell 100. The number of turns or coils of the continuous fiber layer (here the fiber structure 50) is a function of the required thickness and the layer thickness. Preferably, it is at least equal to 2. The number of turns or coils of the discontinuous fiber layer (here the fiber mat 60) is a function of the required holding capacity. Thus, the shell 100 has a holding area or shield over its entire width, which is capable of holding: fragments, particles or objects taken in at the engine inlet or fragments, particles or objects originating from damage of the fan blades, and radially protruding through the rotation of the fan, thereby preventing them from passing through the shell and damaging other parts of the aircraft. Here, the discontinuous fiber layer consisting of the fiber mat 60 can have a smaller width than the width of the continuous fiber layer consisting of the fiber structure 50. In this case, the discontinuous fiber layer forms an excess thickness in the shell, which corresponds to the holding area or shield of the shell as described below.

[0055] Fig.10 4 illustrates the formation of a fiber blank 440 according to another embodiment of the present invention. The fiber blank 440 is formed by assembling a continuous fiber layer with a discontinuous fiber layer. Fig.10 As illustrated in FIG. 1 , the fiber structure 70 is made in a known manner by 3D weaving using yarns, for example, made of carbon fibers (e.g., IM7, AS4 or AS7 fiber) or ceramic fiber such as silicon carbide, glass fiber or aramid fiber. The yarn count is usually 12k, 24k or 48k. Different types of yarns can be used in the same preform.

[0056] like Fig.10As illustrated in FIG. 1 , the fiber structure 70 has a strip shape, which extends in length along a direction X corresponding to the direction of travel of the warp yarns or strands, and which extends in width or transversely along a direction Y corresponding to the direction of the weft yarns or strands. The fiber structure 70 has a thickness E 70 The fiber structure 70 has a strip shape (e.g. 10 mm) and a thickness corresponding to a 3D weave in which six to ten layers of warp yarns are woven together in the strip plane and thickness using weft yarns. 70 and length L 70 Upper extension, width l 70 is defined as a function of the width of the housing to be manufactured, for example, the width l 70 It can be 2m, and the length L 70 is defined as a function of the diameter of the shell to be manufactured and the number of turns required in the fiber reinforcement. For example, in order to manufacture a similar cylindrical shell with a diameter of 4 m by turning the preform 2 times, the length of the fiber structure to be woven is about 25 m. This length can be extended to prevent the start and end of the fiber structure from being in the same angular position, which could create a weak point in the component.

[0057] The fiber blank 440 also includes a discontinuous fiber layer. In the example described here, the discontinuous fiber layer is composed of a non-woven fabric 80 with discontinuous long fibers (DLF). The discontinuous long fibers have a length included between 8mm and 100mm (e.g., 12.5mm, 25mm or 50mm).

[0058] In the example described here, the nonwoven fabric 80 having discontinuous long fibers has a smaller size than the fiber structure 70 so as to form an extra thickness portion in the final shell as described below. Therefore, the fabric 80 has a strip shape with a width l 80 Less than the width l of the fiber structure 70 70 , and its corresponding length L 80 Less than or equal to the length L of the fiber structure 70 70 half, so that: depending on the winding arrangement of the blank on the mandrel, the fiber structure 70 only exists in the first or last winding of the fiber blank. The fabric 80 has a thickness E preferably between 1 mm and 5 mm. 80 Preferably, the fabric 80 comprises: the same type of fibers as the fiber structure 70. Preferably, the fiber fabric 80 is compacted before it is inserted into the structure 70. The fiber structure 70 may also be compacted to facilitate the insertion of the fabric 80.

[0059] The fiber blank 440 also differs from the fiber blank 140 described above in that a non-woven fabric 80 with discontinuous long fibers is inserted into the non-interconnected parts of the fiber structure 70. More specifically, the fiber structure 70 comprises a first portion 75 comprising an inner non-interconnected region 71 and a second portion 76 having no non-interconnected regions. The first portion 75 may, for example, have a length of 12 m, while the second portion may have a length of 13 m. In this case, the non-woven fabric 80 with discontinuous long fibers has a length less than or equal to 12 m. The non-interconnected regions 71 locally form a first superimposed skin 73 and a second superimposed skin 74 in the fiber structure 70 and are separated from each other along a plane parallel to the surface of the fiber structure 70 so as to define an inner shell 72 therebetween. In a known manner, the non-interconnected regions 71 are obtained by defining a plane parallel to the surface of the fiber structure 70 and are generally located in the thickness E of the structure 70. 70 In the example described here, the weft yarns present in the first skin 73 do not extend into the warp yarn layers of the second skin 74, and the weft yarns present in the second skin 74 do not extend into the warp yarn layers of the first skin 73, so as to form non-interconnected areas 71. For example, the skins 73 and 74 each include three to five warp yarn layers, which are woven together in the plane and thickness of the strip using weft yarns. Of course, the skins can include a different number of warp yarn layers.

[0060] Still in the example described here, the non-interconnected area does not extend to the side edges of the fiber structure, thereby forming a "sock" shaped shell. However, the non-interconnected area can extend to the side edges of the fiber structure, thereby dividing the fiber structure into two skins over its entire width.

[0061] like Fig.10 As illustrated in FIG. 4 , the fiber blank 440 is formed by inserting a non-woven fabric 80 having discontinuous long fibers into the shell 72 of the fiber structure 70 .

[0062] Then, if Figure 7 As shown in FIG. 1 , the fiber preform is formed by winding the fiber blank 440 onto a mandrel.

[0063] Depending on the stacking sequence desired to be obtained in the thickness direction (i.e., first skin 73, fabric 80, second skin 74 and second portion 76 or second portion 76, first skin 73, fabric 80 and second skin 74), the winding on the mandrel can start from the first portion 75 or the second portion 76 of the fiber structure 70. In the example described here, the first portion 75 of the fiber structure 70 is first wound on the mandrel.

[0064] The fiber preform is then densified by means of the matrix according to the conditions already described above for the fiber preform 300 .

[0065] After injection and polymerization, the part is demoulded. Finally, the part is trimmed to remove excess resin and chamfers are machined to obtain Fig.11 The housing 600 is shown in FIG. The inner surface 601 of the housing defines an air inlet flow channel. It may be provided with a wearable coating and / or an acoustic treatment coating ( Fig.11 Here, the housing 600 has external clamps 604, 605 at its upstream and downstream ends to allow its installation and connection with other elements.

[0066] Thus, the composite shell 600 comprises a fiber reinforcement, which is composed between its inner and outer peripheries of a first skin 73 of a first portion 75 of a fiber structure 70, a nonwoven fabric 80 with discontinuous long fibers, a second skin 74 of the first portion 75 of the fiber structure 70, and a second portion 76 of the fiber structure 70. The number of turns or coils of the continuous fiber layer (here the fiber structure 70) is a function of the desired thickness and the layer thickness. Preferably, it is at least equal to 2. The number of turns or coils of the discontinuous fiber layer (here the nonwoven fabric 80 with discontinuous long fibers) is a function of the desired holding capacity.

[0067] In the example described here, the outer shell 600 also includes an extra thick portion 610 formed by inserting a non-woven fabric 80 having discontinuous long fibers into the fiber structure 70. This extra thick portion forms a retaining area or shield capable of retaining debris, particles or objects ingested at the engine inlet or debris, particles or objects originating from damage to the fan blades and protruding radially by the rotation of the fan to prevent them from passing through the casing and damaging other parts of the aircraft.

[0068] The presence of a discontinuous fiber layer over the entire width of the component (housing 100) or over a portion of the width of the component (housing 600) provides the component with very good retention capabilities.

[0069] In the above examples, the continuous fiber layer is a strip with a 3D weave. The continuous fiber layer can also be a unidirectional layer stack, a two-dimensional woven layer stack, or a braid.

[0070] In particular, the discontinuous fiber layer may be a non-woven fabric or a random fiber mat having discontinuous long fibers.

[0071] The method of manufacturing a fan case for an aircraft gas turbine engine described above is also applicable to manufacturing other composite rotating parts for propulsion components such as a nacelle or a nacelle cowl air inlet.

Claims

1. A method for manufacturing a composite rotating component (100) for a propulsion assembly, the method comprising: making a fiber preform (300) on a mandrel (200) having a profile corresponding to the profile of the part to be manufactured, and densifying the fiber preform (300) by means of a matrix, It is characterized in that making the fiber preform includes: forming a strip-shaped fiber blank (140), the strip-shaped fiber blank includes at least one continuous fiber layer and at least one discontinuous fiber layer, the fiber blank is formed on the core shaft, and the at least one continuous fiber layer of the fiber blank extends at least one full circle around the core shaft (200).

2. The method according to claim 1, wherein: The at least one discontinuous fiber layer is a non-woven fabric (80) or a random fiber mat (60) having discontinuous long fibers.

3. The method according to claim 1 or 2, wherein: The at least one continuous fiber layer is selected from at least one of the following fiber structures: a three-dimensional woven structure, a unidirectional layer stack, a two-dimensional woven layer stack, a braid.

4. The method according to claim 3, wherein: The fiber blank (140) comprises: a continuous fiber layer corresponding to the strip fiber structure (50), the strip fiber structure having a three-dimensional weaving between a plurality of warp yarns (20) and a plurality of weft yarns (30), and wherein making the fiber preform comprises: winding the fiber blank around the core shaft for one or several turns.

5. The method according to claim 3, wherein: The fiber blank comprises: a continuous fiber layer corresponding to a strip fiber structure (70) having a three-dimensional weave, wherein the strip fiber structure (70) comprises a first part (76) and a second part (75) in the length direction, wherein in the first part, the warp yarns are interconnected through the weft yarns throughout the thickness of the fiber structure, and the second part comprises a non-interconnected area (71), wherein the non-interconnected area exists at a middle position of the thickness of the fiber structure and extends in the fiber structure along a plane parallel to the surface of the fiber structure, and the non-interconnected area (71) divides the fiber structure into a first skin (73) and a second skin (74); a discontinuous fiber layer arranged between the first skin and the second skin, and wherein the production of the fiber structure comprises: winding the fiber blank around the core shaft for one or several turns.

6. A composite rotating component (100) for a propulsion assembly, the composite rotating component comprising a fiber reinforcement, the fiber reinforcement being densified by a matrix, characterized in that The fiber reinforcement comprises at least one continuous fiber layer and at least one discontinuous fiber layer in the thickness direction.

7. The component according to claim 6, wherein The at least one discontinuous fiber layer is a non-woven fabric (80) or a random fiber mat (60) having discontinuous long fibers.

8. A component according to claim 6 or 7, wherein: The at least one continuous fiber layer is selected from at least one of the following fiber structures: a three-dimensional woven structure, a unidirectional layer stack, a two-dimensional woven layer stack, a braid.

9. The component according to claim 8, wherein The fiber reinforcement comprises: a continuous fiber layer corresponding to a strip fiber structure (70) having three-dimensional weaving or multi-layer weaving, the strip fiber structure comprising a first part (76) and a second part (75), wherein the first part has warp yarns interconnected by weft yarns throughout the thickness of the fiber structure, the second part comprises a non-interconnected area (71), the non-interconnected area exists at a middle position of the thickness of the fiber structure, the non-interconnected area (71) divides the fiber structure into a first skin (73) and a second skin (74); the discontinuous fiber layer exists between the first skin and the second skin.

10. A component according to any one of claims 6 to 9, corresponding to a housing (600) comprising a shield, the shield comprising: An extra thick portion (610) is formed to form a retaining area, and the shield further comprises: clamps (604, 605) located at the axial ends thereof.

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