Turbine bucket with electrically de-iced conductor and related manufacturing method

Abstract

The invention proposes a turbine bucket (9; 109); 209), where the turbine bucket comprises an electrical conductor (32) completely covered by a metal material formed by cold gas dynamic spraying of a metal powder. The invention also relates to a method for manufacturing a turbomachine bucket, the method comprising: manufacturing a body by forging, casting, machining and / or additive manufacturing; arranging or depositing an electrical conductor on the body; and covering the electrical conductor by cold gas dynamic spraying of the metal powder. The invention also provides a turbomachine compressor comprising a vane, the vane being manufactured by a vane according to the invention or a method according to the invention.

Description

Technical Field

[0001] The present invention relates to a de-icing system for turbine blades. Background Art

[0002] Climate change is a major concern for many legislative and regulatory bodies around the world. Indeed, countries have already adopted, are currently adopting, or will soon adopt various carbon emission limits. In particular, stringent standards apply to both new aircraft and already-in-service aircraft, which will need to implement technical solutions to ensure compliance with existing regulations. Civil aviation has been mobilizing for years to contribute to the fight against climate change.

[0003] Technological research has significantly improved the environmental performance of aircraft. Applicants have considered influencing factors at all stages of design and development to obtain aviation components and products with lower energy consumption and greater environmental protection. The integration and use of these components and aviation products in civil aviation have a moderate environmental impact, with the goal of improving the energy efficiency of aircraft.

[0004] Therefore, the applicant is continuously working to reduce the negative climate impact of greenhouse gases by using methods, operating benign development and manufacturing processes and reducing greenhouse gas emissions to the lowest possible level in order to reduce the environmental footprint of activities that emit greenhouse gases.

[0005] This ongoing research and development work focuses on new generation aircraft engines, aircraft weight reduction (particularly through the materials used and lighter onboard equipment), the development of electrical technologies to ensure propulsion, and aviation biofuels as a necessary complement to technological progress.

[0006] In this context, the present invention relates more specifically to aspects related to the efficiency and safety of aircraft turbomachine compressors. In practice, within the main flow channel and at the inlet of the low-pressure compressor (often also called a "booster"), there is a set of straightening stator vanes (also called "inlet guide vanes (IGV)").

[0007] During certain phases of flight and while on the ground, atmospheric conditions can be encountered that favor the formation of frost or ice on the straightening blades. When this occurs, it can lead to partial or complete obstruction of the main flow path and the ingestion of detached ice chunks into the main flow path. This obstruction can effectively lead to insufficient supply to the combustion chamber, which can stall or prevent the turbine from accelerating.

[0008] Published patent document EP 3 228 834 A1 discloses an aircraft turbine including a compressor blade equipped with an electric deicing device having a thermistor. The solution proposed in this document has room for improvement in manufacturing process and heat transfer efficiency to achieve more effective deicing. Summary of the Invention

[0009] Technical issues

[0010] The object of the present invention is to propose a simple and economical manufacturing method for obtaining an effective de-icing blade.

[0011] Technical Solution

[0012] The present invention is the result of technical research aimed at significantly improving the performance of aircraft and, in this sense, contributing to reducing the environmental impact of aircraft. To this end, the present invention relates to a blade for a turbine, wherein the blade includes an electrical conductor that is completely covered with a metallic material formed by cold gas dynamic spraying of metal powder.

[0013] This approach has many advantages: this approach ensures good thermal conductivity within the blade; this approach provides surface conditions that are compatible with the manufacturing constraints of the blade; and this approach ensures good fatigue durability and / or corrosion resistance.

[0014] According to an advantageous embodiment of the invention, the metal material comprises aluminum and / or aluminum oxide loaded with silicon carbide and / or contains other fillers (e.g., mineral fillers). These materials are suitable for manufacturing processes by spraying, are good thermal conductors and are lightweight. Preferably, the metal material consists mainly of aluminum from the 1xxx series (with at least 99% aluminum), the 2xxx series (with copper as the main alloying element), or the 6xxx series (with magnesium and silicon as the main alloying elements).

[0015] According to an advantageous embodiment of the invention, in addition to the electrical conductors and the metallic material, the blade is primarily composed of a metal matrix composite material based on aluminum. Preferably, the metal matrix is reinforced with 10% to 30% silicon carbide (SiC) particles. Preferably, the aluminum constituting the metal matrix corresponds to the 2xxx or 6xxx series.

[0016] According to an advantageous embodiment of the invention, the electrical conductors describe a pattern with free ends.The cold gas dynamic spraying process does enable certain design limitations on the pattern described by the electrical conductors to be overcome, unlike other manufacturing techniques which may be more restrictive.

[0017] According to an advantageous embodiment of the invention, the metal material extends at most to half the thickness of the blade.Thus, the amount of metal material remains small over the entire blade.

[0018] The invention also relates to a method for manufacturing a blade of a turbine, comprising: manufacturing a body by forging, casting, machining and / or additive manufacturing; arranging or depositing an electrical conductor on the body; and covering the electrical conductor by cold gas dynamic spraying of metal powder.

[0019] According to an advantageous embodiment of the invention, the production of the body comprises: forming a recess in the body, the arranging or depositing step being such that the electrical conductor is arranged or deposited in the recess.

[0020] According to an advantageous embodiment of the invention, the groove comprises a U-shaped or V-shaped profile, or a funnel-shaped Y-shaped profile. Such a profile is easy to implement and helps to hold the conductor in place before and during covering the conductor with material.

[0021] According to an advantageous embodiment of the invention, the covering is such that the metal material produced by cold gas dynamic spraying of metal powder fills the groove and is flush with the surface of the blade, or alternatively overflows from the groove.

[0022] According to an advantageous embodiment of the invention, the covering is carried out at low pressure, preferably the gas reaches a pressure between 3 and 10 bar. In addition, the jet speed can be about 300 to 800 m / s. This helps to avoid damage to the electrical conductors.

[0023] According to an advantageous embodiment of the invention, the electrical conductor comprises two wires enclosed in an insulating sheath.The two wires can be joined at the ends of the conductor to close the electrical circuit.

[0024] According to an advantageous embodiment of the invention, the electrical conductors are made from layers of copper powder sprayed using cold gas dynamic spraying. This method allows for complete freedom in the patterning of the electrical conductors and the creation of conductive "surface" areas of greater or lesser width and density, depending on the local deicing requirements.

[0025] According to an advantageous embodiment of the invention, the method comprises the step of holding the electrical conductor in place on the body and possibly in the groove, said holding being ensured by at least one of the following means: gluing, soldering, cladding, arranging bridges, filling the grooves, using a wheel in combination with a cold air dynamic spraying tool, and micro welding.

[0026] According to an advantageous embodiment of the invention, the covering is such that the metal material produced by cold gas dynamic spraying of metal powder constitutes at most 50% of the total volume of the blade.

[0027] The present invention further relates to a compressor of a turbomachine, the compressor comprising a blade, wherein the blade is a blade according to one of the above embodiments or is manufactured at least partially by a method according to one of the above embodiments.

[0028] It should be understood that every detail of one embodiment described above can be combined with every other detail of other embodiments.

[0029] Benefits provided

[0030] The coating of the metallic material of the electrical conductor by means of a dynamic injection of cold gas ensures improved heat conduction between the conductor and the body of the blade, thanks to the absence of porosity and the judicious choice of the materials present. The choice of the injected metallic material and of the material forming the body of the blade according to the invention also ensures subsequent mechanical and metallurgical compatibility, as well as favorable durability of the electrical conductor, thereby making it resistant to fatigue and possible impacts by foreign bodies during operation. Furthermore, the risks associated with corrosion (e.g., electrochemical corrosion) and erosion are avoided.

[0031] The heat conductor of the invention enables efficient defrosting of the blades by enabling them to obtain a temperature of approximately 5°C on the surface, despite the fact that the outside temperature may reach -40°C and the air velocity is approximately 800 km / h.

[0032] The blades of the present invention can minimize the amount of accumulated ice that could detach and damage other components of the turbine, thereby making it possible to avoid blockage of the flow passages and maintain the operability of the turbine.

[0033] The invention thus makes it possible to improve the performance of the aircraft compressor and the overall efficiency of the turbine, which translates into a reduction in fuel consumption and greenhouse gas emissions, thereby reducing the environmental impact of the aircraft.

[0034] The cold gas jet process enables the deposition of material without damaging the electrical conductors or the blades.

[0035] According to an advantageous embodiment, the surface condition obtained can be re-machined in order to ensure the aerodynamic function of the blade.

[0036] Cold spraying also makes the material have good uniformity and continuity.

[0037] Cold spraying enables good mechanical adhesion (no cavities, strong plastic deformation when the material is deposited) and physicochemical (metallurgical) adhesion to "compatible" materials (eg aluminum or aluminum alloys) arranged in relation to each other.

[0038] Therefore, there is a specific synergy between the blade material, the electrical conductor material (or the jacket) and the cold sprayed material, which together ensure good mechanical strength and good thermal conductivity. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] [ Figure 1 ] shows a cross-sectional view of a compressor of a turbine including a blade according to the present invention;

[0040] [ Figure 2 ] shows the manufacturing method according to the present invention [ Figure 1 ] of the vane method;

[0041] [ Figure 3 ] shows one embodiment of the present invention [ Figure 1 ] a front view of a blade including an electrical conductor;

[0042] [ Figure 4 ] shows the difference with [ Figure 3 ] a partial perspective view of the cables corresponding to the electrical conductors of the blades;

[0043] [ Figure 5 ] is a first embodiment of the present invention [ Figure 3 ] a cross-sectional view of the blade taken along the axis AA;

[0044] [ Figure 6 ] schematically illustrates the formation of a metallic material by dynamic jetting of cold gas of a metal powder;

[0045] [ Figure 7 ] shows [ Figure 4 ] is set in [ Figure 5 ] an enlarged cross-sectional view of a cable in a groove of a blade;

[0046] [ Figure 8 ] is a second embodiment of the present invention [ Figure 3 ] a cross-sectional view of the blade taken along the axis AA;

[0047] [ Figure 9 ] is a third embodiment of the present invention [ Figure 1 ] is a cross-sectional view of the blade taken along the axis AA. DETAILED DESCRIPTION

[0048] In the following description, the terms "inboard" and "outboard" refer to positions relative to the axis of rotation of an axial turbine. The axial direction corresponds to the direction along the turbine's axis of rotation, with length measured axially. Width is measured circumferentially. The radial direction is perpendicular to the axis of rotation. Upstream and downstream refer to the prevailing direction of flow in the turbine.

[0049] The dimensions of the drawings are not drawn to scale, and particularly the thickness or radial dimensions are exaggerated to facilitate reading of the drawings.

[0050] Figure 1 A sectional view of a compressor 2 of an axial turbine 4 is shown.

[0051] The turbine 4 may correspond to a turbojet, a turbofan, a turboprop, a turboshaft, or any other type of two-flow turbine. Alternatively, the turbine 4 may correspond to a multi-flow turbine, such as an unducted three-flow turbojet ("Counter-Rotating Open Rotor (CROR)" or "Unducted Single Fan (USF)") or any other three-flow turbine.

[0052] Preferably, the compressor 2 corresponds to a low-pressure compressor or a high-pressure compressor (not shown). The turbine 4 also includes Figure 1 Other components not shown in the drawing include a high-pressure compressor, a combustion chamber, and one or more turbine stages. The one or more turbines drive a rotating rotor 6. The rotor supports a plurality of rows of rotor blades 8 associated with a plurality of rows of stator vanes 10. Thus, the rotation of the rotor 6 about its axis of rotation X allows the air flow to be progressively compressed as it reaches the inlet of the combustion chamber.

[0053] A fan 12 (partially shown) is coupled to the rotor 6 and generates an air flow that is divided into a radially inner flow F1 (commonly referred to as the primary flow F1) and a radially outer flow F', which may correspond to the secondary flow F' in a two-flow turbine or the tertiary flow F' in a three-flow turbine 4.

[0054] The main flow F1 and the outer flow F′ are separated by a separation nozzle 14 .

[0055] The rotor buckets 8 may extend radially from a rotor support 16 , which may be of the drum type (an integrated bucket drum or any other type of rotor support).

[0056] The stator vanes 10 extend substantially radially from the outer casing 18. The stator vanes 10 can be fixed and stationary there using fixing pins 20. The stator vanes 10 pass radially through the main flow F1.

[0057] The low-pressure compressor 2 includes a row of rectifier stator vanes 9, 109, 209 at the inlet of the main flow F1 flow passage 22. These rectifier stator vanes 9, 109, 209 can be fixed or have variable pitch, commonly referred to as variable stator vanes (VSV). The variable pitch of the vanes 9, 109, 209 can be ensured by an actuation system (not shown) that adjusts the angle formed by the vanes 9, 109, 209 around the axis 24.

[0058] Each bucket 9, 109, 209 comprises a blade 11 and two platforms 26 arranged at the two ends of the blade 11. Each platform 26 is provided with a journal 28 providing a pivot connection with a housing 18, 30, the platform 26 being housed in a housing 31 of these housings 18, 30. The outer surface 18.1 and the lower guide surface 30.1 delimit the flow channel 22.

[0059] In this upstream part of the turbine, certain elements are subject to the effects of frost. Therefore, the blades 9, 109, 209 of the invention comprise defrosting means.

[0060] The present invention is not limited to variable stator vanes (VSV) 9 , 109 , 209 , but can also be applied to other vanes, whether they are variable stator vanes (VSV) or not, stators or not.

[0061] Figure 2 Shown Figure 1 1. Partial manufacturing process 100 of a bucket 9, 109, 209. The process is "partial" because other steps may occur before or after those described herein.

[0062] Method 100 includes a first step 102 corresponding to manufacturing a bucket body by at least one of the following manufacturing techniques: forging, casting, molding, machining, fiber braiding, and / or additive manufacturing. For example, a forged or molded bucket may be machined to achieve appropriate manufacturing tolerances. Alternatively, the bucket may be manufactured entirely by additive manufacturing, with or without further machining.

[0063] The blades of the present invention may be made primarily of a metal matrix composite material.

[0064] Preferably, the metal matrix composite material constituting the bucket comprises an aluminum substrate reinforced with silicon carbide (SiC) particles (10 to 30% SiC by volume).

[0065] The aluminum constituting the metal matrix may be from the 2xxx series (with copper as the main alloying element) or from the 6xxx series (with magnesium and silicon as the main alloying elements).

[0066] The composite material constituting the blade of the present invention may correspond to one or more elements of 2009 / SiC / 15p-T4, 6092 / SiC / 17.5p-T6, 6092 / SiC / 25p-T6, 2124 / SiC / 25p-T4, etc.

[0067] Alternatively, the blades may be made of a composite material with a titanium base, more precisely of a titanium alloy of the TA6V type.

[0068] The high cycle fatigue strength (HCF) of composites is much higher than that of aluminum, while the density of composites is close to that of aluminum. As a result, the stiffness of the blades can approach that of titanium (commonly used to make turbine blades) while having better inherent properties, such as better thermal conductivity, which facilitates de-icing of the blades.

[0069] The step 102 of manufacturing the body of the blade may comprise producing an optional groove in the body of the blade, the groove extending in particular along the blade 11 , the groove opening onto the outer camber side or the inner camber side of the blade 11 .

[0070] The method 100 then comprises a step 104 of arranging or depositing an electrical conductor on the body of the bucket manufactured in step 102 .

[0071] for Figure 3 In the blades 9 and 109 according to the first and second embodiments of the invention shown, the electrical conductors correspond to electrical cables, and step 104 consists in arranging the electrical conductors on the blades, or even in grooves created in the body of the blades. Figure 9 In the illustrated blade 209 according to the third embodiment, step 104 comprises depositing the electrical conductor by spraying a copper layer.

[0072] Step 106 involves covering the conductor with the sprayed metal, and optional step 108 involves holding the cable before and partially during the covering with the metal. These steps will be discussed later.

[0073] refer to Figure 3 The blade 11 of the bucket 9, 109 includes a leading edge 11.1 and a trailing edge 11.2, as well as a lower surface 11.3 and an upper surface 11.4 extending from the leading edge 11.1 to the trailing edge 11.2.

[0074] The blade 9, 109 comprises an electrical cable 32 constituting an electrical de-icing conductor. Preferably, the cable 32 extends on the inner camber side 11.3 and follows a curved path substantially corresponding to a spiral and / or serpentine pattern, the curved path comprising a proximal portion 32.1 adjacent to the platform 26 at the blade head and a distal portion 32.2 close to the platform 26 at the blade root.

[0075] The cable 32 may extend over the entire surface of the blade 11 or, as shown, be restricted to the upstream half of the blade 11. The cable may extend to approximately 80% (±10%) of the height H of the blade 11.

[0076] Preferably, the blades 9, 109 are elongated in profile, with a H / C (height to chord) ratio greater than 5 and a thickness greater than 2 mm and less than 4 mm. For example, the height H may be equal to 200 mm and the chord C may vary from 20 mm to 40 mm.

[0077] Preferably, the cable 32 passes through the upper platform 26 only once to reach a power source (not shown). In this regard, the aperture through the inner arc side 11.3 and the platform 26 may be arranged at right angles to the proximal portion 32.1.

[0078] Alternatively, as Figure 3 As shown, a section of the cable may extend along the pivot axis 24 of the bucket 9, 109 or the median axis 11.5 of the blade 11. The cable 32 further comprises a non-linear portion 32.3 adjacent to the proximal portion 32.1.

[0079] Thus, the pattern described by the cable 32 may include a first section 33 along the axis 11.5 and extending to the distal portion 32.2, and a second section 33.1 parallel and proximate to the leading edge 11.1.

[0080] A third section 33.2 connected to the second section 33.1 by a circular portion 32.4 may be inserted between the first section 33 and the second section 33.1. Other configurations are possible and the "spiral" configuration may be supplemented by additional sections.

[0081] Preferably, the third section 33.2 of the cable 32 extends centrally between the first section 33 and the second section 33.1, maintaining the same distance transversely (along the axial direction of the turbine). Advantageously, this allows for uniform de-icing of the entire half of the blade 9, 109, with each surface element "seeing" the same density of cables and, therefore, the same energy. However, the other (much thinner) portion of the blade without the cables will be de-iced by heat conduction.

[0082] Preferably, the “spiral” pattern of the cables 32 ends with a free end 32.5. Advantageously, the free end 32.5 is arranged at about one third of the height H measured from the lower platform 26 at the bottom of the blade 9, 109. Advantageously, this makes it possible to maintain a surface density covered by the cables 32 that is uniformly distributed along the radial extent of the blade 9, 109, so as to de-ice the entire height H of the blade uniformly.

[0083] The free end 32 . 5 is achievable when the cable 32 comprises two wires 34 that can be connected together at the distal end 32 . 5 .

[0084] to this end, Figure 4 These wires 34 are shown, Figure 4 yes Figure 3 A partial perspective view of the cable 32 of the blade.

[0085] It can be seen that the two electric wires 34 correspond to the two heating metal wires 34, which are covered by an insulating layer 36. Preferably, the insulating layer 36 is made of magnesium oxide powder, so that the two electric wires 34 can be electrically insulated so that the heat energy is diffused only toward the blades of the wheel bucket of the present invention.

[0086] The wires 34 and insulation 36 are covered by a protective metal sheath 38 which can be made of stainless steel or an aluminum alloy or (superalloy containing mainly nickel). For this reason, advantageously, the cable 32 is a shielded resistance cable. The diameter of the sheath 38 can be about 0.5mm to 2mm.

[0087] Figure 5 According to the first embodiment of the present invention Figure 3 A sectional view of the blade 9 taken along the axis AA.

[0088] exist Figure 5 As can be seen in FIG, the blade 9 comprises a groove 40 for receiving the cable 32. In this respect, reference is made to Figure 2 In the method 100 , the step 104 of arranging the electrical conductor in the body of the blade 9 comprises arranging the cable 32 in the groove 40 , and the step 102 of manufacturing the body comprises forming the groove 40 in the body.

[0089] Advantageously, the groove 40 makes it easier to install the bucket 9, to increase thermal conductivity (because the cable 32 is embedded in the bucket 9, between the inner and outer camber sides 11.3, 11.4), and to maintain a smooth outer or inner camber side surface without roughening (after remachining).

[0090] Preferably, the depth of the groove 40 is constant across the bucket.

[0091] The groove 40 is covered by a filling material 42 , advantageously corresponding to a metal powder flush with the inner arc side 11 . 3 .

[0092] In practice, the method 100 for manufacturing the blade 9 comprises a step 108 of coating the electrical conductor 32 with a metallic material. The metallic coating is obtained by dynamic spraying of a cold gas of metal powder.

[0093] Cold gas dynamic spraying (also known as "cold spraying") is a method of producing coatings from powders that are suspended in a high-velocity jet of gas and deform upon impact.

[0094] Figure 6 The principle of forming a metal material by a cold spray process is shown.

[0095] Figure 6The left part of the drawing shows the ejection of solid metal powder particles 44, which have a size of 10 μm to 100 μm and are ejected at a speed between 300 m / s and 1400 m / s. A supersonic impact S is expected on the substrate 46. In the context of the present invention, the substrate 46 is the body of the blade 9, 109, 209 and the electrical conductor.

[0096] exist Figure 6 As can be seen in the central portion of FIG, the supersonic impact causes plastic deformation 47 of the particles 44 and substrate 46, which is followed by heat transfer through the substrate 46. In this configuration, the continuous ejection of particles 44 causes continuous deformation of said particles 44, which is followed by isotropic heat transfer, thereby forming a layer 48 comprising particles 44 connected by plastic deformation.

[0097] The continuous powder elements are agglomerated without cavities between the powder elements. The continuous powder elements are mechanically and metallurgically bonded by plastic deformation of the powder elements.

[0098] This manufacturing process can therefore be detected on the finished component by observing deformed grains and the absence of cavities between consecutive layers due to plastic deformation upon impact.

[0099] Figure 7 Shown Figure 5 , particularly showing the cable 32 in its groove 40.

[0100] The electrical conductors 32 are covered by a metal material 42 sprayed by a cold spray process. Preferably, the metal powder of the material 42 covering the cable 32 is mainly made of aluminum, preferably aluminum from the 1xxx series (with at least 99% aluminum) or from the 2xxx or 6xxx series, with or without a load of silicon carbide (SiC) balls and / or aluminum oxide (Al2O3) balls and / or other fillers.

[0101] The loading of SiC and / or Al2O3 and / or other fillers can be selected depending on the pressure used during cold spraying. In fact, cold spraying is carried out using inert gas (nitrogen and / or helium) or pressurized air heated to 500°C to 1000°C between 4 and 60 bar. When the gas is between 10 and 60 bar, we call it high pressure, then the loading of the balls becomes optional, preferably aluminum from the 6xxx series.

[0102] For the present invention, preferably low-pressure cold spraying is used, in particular between 3 and 10 bar, with the powder propelled at a speed of about 300 to 800 m / s. This advantageously makes it possible to avoid damage to the jacket 38 of the cable 32 and to have a narrow bead of material deposited.

[0103] Cold spraying ensures good bonding of the material 42 to the bucket, the sprayed material 42 being compact and dense (porosity typically less than 1%), thereby enabling effective retention and protection of the electrical conductors.

[0104] The material 42 is capable of undergoing surface treatment of the bucket, such as anodizing.

[0105] The material 42 may be flush with the surface of the blade. Alternatively, the material 42 may extend beyond the groove 40 to cover part or all of the surface 11 . 3 of the blade 9 .

[0106] The intended filling of the groove 40 is completed, ie the blade is free of any cavities. The cable 32 and the filling material 42 may be the only two elements in the groove.

[0107] Figure 7 A groove 40 is shown having a hemispherical bottom, the diameter of the groove 40 being slightly larger than the outer diameter of the cable 32. Alternatively, the bottom may be straight.

[0108] Optionally, the cable 32 may have an outer jacket to further protect the cable 32 during the cold spray phase, or to facilitate maintenance of the cable by deformation of the jacket, or to limit the amount of material that comes into contact.

[0109] The sides of the groove 40 may be straight so that the profile of the groove 40 is U-shaped. Alternatively (see Figure 7 The profile of the groove (denoted as 41) may be V-shaped or Y-shaped (funnel-shaped).

[0110] The V-shape enables greater flexibility in selecting the spray direction during cold spraying.

[0111] Preferably, the sidewall of the V-shaped groove 41 has an inclination of 10° to 60° relative to a direction perpendicular to the inner arc side 11 . 3 .

[0112] The cable 32 is kept as close to the bottom as possible. Figure 2 The method 100 includes, after the step 104 of placing the cable in the groove and parallel to the cold spray jet, a step 108 of holding the cable 32 in place. The holding step 108 begins before the cold spraying 106 and can be completed before the cold spraying step 106 is completed. The holding step 108 can include holding the cable 32 in the groove 40. Different techniques can be used, such as gluing, welding, cladding, placing bridges, caulking the grooves, using a wheel in combination with a cold gas jet tool, and micro welding.

[0113] For example, several dots of glue or solder may be made to hold the cable in the groove, followed by a cold spray step.

[0114] Alternatively, several bridges may be arranged at regular intervals on the cable tray 32 and then, during cold spraying, the bridges that have become redundant are gradually removed.

[0115] In one variation, the outer jacket wedges the cable jacket into the bottom of the groove.

[0116] In another variation, the sides of the groove are partially adapted (plastically deformed) to reduce the opening of the groove and prevent the cable from coming out.

[0117] Another possible technique is to place wires on top of the cable 32. The wires can be aluminum or nickel (or any other ductile material). The wires are paired to hold the cable 32 in the bottom of the groove. Cold spraying is then performed, and the wires are embedded in the material along with the cable 32.

[0118] Other alternatives for retaining the cable 32 include performing laser micro-welding or soft soldering joints, or performing soldering joints via ball capacitors (micro-welding adhesive).

[0119] Finally, any combination of at least two of these techniques may be considered.

[0120] Figure 8 yes Figure 3 A sectional view of the blade taken along the axis AA; in this second embodiment of the present invention, the reference numeral plus 100 represents Figure 5 A unique element or elements that are different compared to the first embodiment.

[0121] The blade 109 includes a groove 140 for receiving the cable 32. Figure 5 Unlike the example of FIG, the groove 140 does not follow the path of the cable 32 because the groove 40 is wide enough to accommodate the entire serpentine pattern (or other shape).

[0122] Advantageously, the groove 140 can be quickly filled with the metallic material 42 , for example by means of a spray nozzle of the tool producing a cold spray, which is larger than the spray nozzle producing the spray on the blade 9 .

[0123] In this configuration, the volume of powder injected to form material 42 may be as much as 50% of the total volume of bucket 109 .

[0124] In this respect, similarly to the blade 9 according to the first embodiment, it is possible to Figure 2 The bucket 109 is obtained by following the successive steps 102 , 104 , 106 and 108 of the method 100 shown in FIG.

[0125] It can be seen that the bottom 140.1 of the groove 140 is flat and the cable 32 is deposited directly on the flat bottom 140.1. Figure 5In comparison, a larger groove allows for greater manufacturing tolerances on the groove and makes it easier to insert the cable into the groove.

[0126] Figure 9 According to the third embodiment of the present invention Figure 1 sectional view of the blade 209 taken along the axis AA.

[0127] Like the vane 109, the vane 209 may include grooves 140. In this configuration, the electrical conductor 232 of the vane 209 corresponds to a layer of copper powder sprayed by dynamic cold gas spraying. Advantageously, due to the copper constituting the conductor 232, the conductor 232 has excellent thermal conductivity.

[0128] To this end, for the blade 209, step 104 comprises depositing the electrical conductor 232. In this case, Figure 2 Step 106 of the illustrated method 100 includes covering the copper layer with metal powder sprayed by cold gas. In this configuration, the sprayed electrical conductors 232 do not need to be held in place before being covered with the metal material 42 (step 108).

[0129] Electrical conductors 232 can reach a power source (not shown) through apertures through the inner arc side and the platform in a manner similar to the first and second embodiments of the present invention.

[0130] Electrical insulation (not shown) may be provided between electrical conductor 232 and material 42 to electrically insulate material 42. This insulation may correspond to a layer of magnesium oxide powder.

[0131] Although Figure 9 A wide outline of the copper layer is shown (thus a strip rather than a linear path), but the copper layer could alternatively be narrower and depict something like Figure 3 path.

[0132] As an alternative to cold spraying metal materials, the electrical conductors can be covered by brazing. Brazing ensures good heat transfer between the de-icing conductors and the blades. Optional reworking (e.g. polishing) may be required.

[0133] Another alternative to cold spraying of metallic materials could be resin injection to ensure coverage of the electrical conductors.

[0134] It should be noted that the present invention is presented for de-icing blades, but a person skilled in the art will be able to adapt the same teachings to de-icing any other part of a turbine (casing, housing, structural arms, flow separation nozzles, etc.) by depositing an electrical conductor and then covering it by a cold gas jet.

Claims

1. A turbine blade (9; 109; 209) of a turbine (4), characterized in that The blade comprises an electrical conductor (32; 232) which is completely covered with a metallic material (42) formed by cold gas dynamic spraying of metal powder.

2. The blade (9; 109; 209) according to claim 1, characterized in that The metal material (42) includes aluminum loaded with silicon carbide and / or aluminum oxide, and / or contains other fillers.

3. The blade (9; 109; 209) according to claim 1 or 2, characterized in that Apart from the electrical conductor (32; 232) and the metallic material (42), the blade (9; 109; 209) consists mainly of a metal matrix composite material based on aluminum.

4. The blade (9; 109; 209) according to any one of claims 1 to 3, characterized in that The electrical conductor (32; 232) describes a pattern having a free end (32.5).

5. The blade (9; 109; 209) according to any one of claims 1 to 4, characterized in that The metal material (42) extends over at most half the thickness of the blade.

6. Used for manufacturing a blade (9) of a turbine (4); 109； 209), the method (100) comprising: - manufacturing (102) the body by forging, casting, machining and / or additive manufacturing; - arranging (104) or depositing an electrical conductor (32; 232) on said body; and - Covering (108) the electrical conductor (32; 232) by cold gas dynamic spraying of metal powder.

7. The method (100) according to claim 6, characterized in that The manufacture of the body comprises: forming a groove (40; 41; 140) in the body, and an arrangement (104) or deposition step such that the electrical conductor (32) is arranged or deposited in the groove (40; 41; 140).

8. The method (100) according to claim 7, characterized in that The groove (40; 41; 140) comprises a U-shaped or V-shaped profile, or a funnel-shaped Y-shaped profile.

9. The method (100) according to claim 7 or 8, characterized in that The covering (108) is such that the metal material (42) produced by cold gas dynamic spraying of metal powder fills the groove (40; 41; 140) and is flush with the surface (11.3) of the blade (9; 109; 209), or alternatively overflows from the groove (40; 41; 140).

10. The method (100) according to any one of claims 6 to 9, characterized in that Said covering (108) is carried out at low pressure, preferably the gas reaches a pressure comprised between 3 and 10 bars.

11. The method (100) according to any one of claims 6 to 10, characterized in that The electrical conductor (32) includes two wires (34) enclosed in an insulating sheath (38).

12. The method (100) according to any one of claims 6 to 10, characterized in that The electrical conductor (232) is made of a copper powder layer sprayed by cold gas dynamic spraying.

13. The method (100) according to any one of claims 6 to 11, characterized in that The method comprises a step (106) of holding the electrical conductor (32) in place on the body and capable of being held in the groove (40; 41; 140), said holding (106) being ensured by at least one of the following means: gluing, soldering, cladding, arranging bridges, filling the groove (40; 41; 140), using a wheel combined with a cold air dynamic spraying tool, micro welding.

14. The method (100) according to any one of claims 6 to 13, characterized in that The covering is such that the metal material (42) produced by cold gas dynamic spraying of metal powder constitutes at most 50% of the total volume of the blade (9; 109; 209).

15. A compressor (2) of a turbomachine (4), comprising a blade (9; 109; 209), characterized in that the blade (9; 109; 209) is a blade according to any one of claims 1 to 5 or is manufactured at least partially by a method according to any one of claims 6 to 14.

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