Method for manufacturing a turbomachine component comprising a honeycomb structure

Abstract

The invention relates to a method for manufacturing a turbomachine component (2) comprising a wall (3) and a honeycomb structure (4) made of composite material, the honeycomb structure being located on at least a portion of a surface (30) of the wall (3), the honeycomb structure (4) comprising at least one first network of cells (42) and at least one first skin (44) covering the first network of cells (42), the method comprising the steps of: (a) providing the wall (3); and (b) manufacturing the honeycomb structure (4) on the surface, the step (b) of manufacturing the honeycomb structure (4) comprising the sub-steps of: (bl) depositing a first fold of composite material by layup to form the first skin (44); and (b2) forming the first network of cells (42) by additive manufacturing, the sub-step (bl) being performed before or after the sub-step (b2).

Description

Technical Field

[0001] This invention relates to the field of manufacturing turbine components, particularly turbine components for aircraft. More specifically, this invention relates to a method for manufacturing a turbine component comprising a wall and a honeycomb structure made of a composite material, the honeycomb structure being located on at least a portion of a surface of the wall. Background Technology

[0002] Specifically, the prior art includes documents EP-A1-4105452 and EP-A1-3725497.

[0003] A turbine, particularly a turbine for aircraft, includes components comprising walls and a honeycomb structure made of composite material, the honeycomb structure being located on at least a portion of a surface of the walls. The honeycomb structure includes one or more cell networks and one or more skins covering the cell networks. Specifically, the honeycomb structure provides mechanical, vibrational, and acoustic properties.

[0004] Some turbine components may include reinforcements. One drawback of manufacturing reinforcements is that assembling them onto turbine components (such as acoustic panels or self-reinforcing panels) can be delicate and time-consuming. One solution is to make these reinforcements in the form of a honeycomb structure to make the components lighter.

[0005] Such components can be hollow or have hollow portions containing a honeycomb structure. For example, turbine components that include (or may include) a honeycomb structure can be airflow exhaust ducts, annular casings, acoustic panels, etc.

[0006] This component can be made of metallic or composite materials.

[0007] It is known that such turbine components can be made from composite materials using RTM (Resin Transfer Molding) technology. Generally, hollow turbine components are best manufactured using RTM. This technology requires a resin injection mold, a waterproof tarpaulin for encapsulating the fiber preforms configured to form the turbine component, an autoclave for polymerizing the resin, and a core for manufacturing the hollow portions and / or unit networks of the turbine component. This technology can be cumbersome and complex to perform because it requires the use of multiple tools.

[0008] The fabrication of honeycomb structures for turbine components typically involves manufacturing the honeycomb network and one or more skins separately, assembling them using adhesives, and finally consolidating the assembly (e.g., by welding, joining, and using other assembly and consolidation tools). When fabricating honeycomb structures on the surface of a curved wall, the cell network is typically bent and then assembled onto the curved wall. One drawback of this method for fabricating honeycomb structures is that it is not suitable for turbine components that are, for example, small in size (e.g., with a small radius of curvature), cylindrical in shape, or typically have so-called non-developable surfaces (e.g., spherical, elliptical, hollow, etc.).

[0009] "Non-developable surfaces" refer to surfaces with complex curvature (especially curvature in at least two different directions). Such non-developable surfaces can be found, for example, in turbine components such as pipes, casings or external panels known as internal fixed structures (IFS), conical nacelles, etc.

[0010] Figure 1 An example of a cylindrical component 1 is shown, comprising a first cell network R1 extending around a cylindrical wall 12 of the component 1, and a second cell network R2 extending on a circular wall 14 connected to the cylindrical wall 12. The dashed arrow indicates a connection fault D between the first cell network R1 and the second cell network R2 at the cylindrical periphery 16 of the component 1. r .

[0011] Figure 2 The maximum curvature C that can be achieved on the cell network R is shown. max Examples.

[0012] Figure 3 The deformation D on the curved cell network R is shown. f Example. In particular, the walls Rp of the cellular cells Rc forming the cell network R are squeezed together.

[0013] In this context, it is worthwhile to propose a solution to address at least one of the aforementioned drawbacks, particularly by optimizing and simplifying the manufacture of the honeycomb structure on at least a portion of the turbine components. Summary of the Invention

[0014] This invention provides a simple, effective, and economical solution to the aforementioned shortcomings of the prior art.

[0015] Therefore, the present invention relates to a method for manufacturing a turbine component, particularly a turbine component for an aircraft, the turbine component comprising a wall and a honeycomb structure made of a composite material, the honeycomb structure being located on at least a portion of a surface of the wall, the honeycomb structure comprising at least one first cell network and at least one first skin covering the first cell network, the method comprising the following steps: (a) Provide walls, and (b) To form a honeycomb structure on at least a portion of the surface of the wall.

[0016] According to the present invention, step (b) of manufacturing the honeycomb structure includes the following sub-steps: (b1) Depositing a first fold of the composite material by layup to form the at least one first skin, and (b2) The at least one first cell network is formed by additive manufacturing. Sub-step (b1) is executed before or after sub-step (b2).

[0017] Therefore, this solution enables the achievement of the aforementioned objectives. Generally, the method described in this invention enables the optimization of the fabrication of honeycomb structures on at least a portion of a surface of a turbine component wall by combining techniques for depositing folded composite materials through lay-up and additive manufacturing.

[0018] In particular, the layup and additive manufacturing folded into composite materials enable the simple and efficient formation of one or more skins and one or more cell networks constituting a honeycomb structure, especially without limiting the size of turbine components. In fact, additive manufacturing allows one or more cell networks to be directly printed onto any possible dimension of the surface of the skin and / or walls of turbine components. These dimensions can be small radii of curvature, cylindrical shapes, and / or non-developable surfaces.

[0019] The combination of layup and additive manufacturing techniques also enables the enhancement of the functionality of honeycomb structures, particularly by imparting mechanical properties (such as stiffness) in addition to vibrational and acoustic characteristics, thereby increasing the stiffness and bending strength of the components. In fact, this invention enables the fabrication of simple honeycomb structures (e.g., consisting of a single skin and a cell network) or sandwich structures (e.g., consisting of a double skin and one or more cell networks) on turbine components with simple or complex shapes (i.e., including walls with unconventional curvature, hypercurvature, etc., for example, with small radii of curvature). In this way, the honeycomb structures fabricated by the method of this invention increase the local stiffness of the turbine components (especially at the walls). The vibrational characteristics of the honeycomb structures obtained by the method of this invention enhance the absorption of different resonant frequencies of the turbine during operation, preventing resonance of the turbine components. The acoustic characteristics of the honeycomb structures obtained by the method of this invention enable the attenuation of noise pollution (especially when the honeycomb structure includes at least two skins), because the cell networks can be adapted to the specific dimensions of the component.

[0020] Therefore, the advantages of this invention are based on a design that is simple to manufacture, provides very high reliability, and has low negative impacts on cost, quality, and overall size. Furthermore, this invention enables a reduction in environmental impact by improving and simplifying the manufacturing methods of turbine components.

[0021] The term "composite folding" refers to one or more fiber layers (or in other words, fabric), each of which can be manufactured, for example, by two-dimensional or three-dimensional weaving. Composite materials can include fiber preforms embedded in resin. Composite materials can have a ceramic matrix (CMC) or an organic matrix (CMO).

[0022] "Pile-up" refers to the continuous deposition of one or more skins by stacking and layering multiple folds of a composite material to form a honeycomb structure.

[0023] The term "additive manufacturing" refers to the production of an element or part of an element (such as filaments, granules, resin, etc.) by adding materials to a digital object, which in this application may be a cell network.

[0024] The manufacturing method according to the invention may include one or more of the following features, either independently or in combination: - The honeycomb structure includes at least one second skin, the at least one first cell network extending between the at least one first skin and the at least one second skin, wherein the method includes a sub-step (b3) of depositing a second fold of the composite material by layup to form the at least one second skin, the sub-step (b3) being performed before sub-step (b2) and the sub-step (b1) being performed after sub-step (b2); - Make the second skin perforated before or after the layup of sub-step (b3); - The cellular structure includes at least one second cell network, the at least one first skin covers the first cell network, and the at least one second skin is located between the first cell network and the second cell network, wherein the method includes a sub-step (b4) of forming the at least one second cell network by additive manufacturing, which is performed prior to sub-step (b3); - The turbine component includes at least one planar portion, an annular portion, a curved portion and / or a perforated portion, wherein at least one of the planar portion, annular portion, curved portion and perforated portion includes at least a portion of the surface on which a honeycomb structure is formed; The layup of sub-steps (b1) and (b3) is performed manually or automatically, and the additive manufacturing of sub-steps (b2) and (b4) is performed by laser melting (LBM) on a powder bed or by extrusion (EAM); - At least one of the first cell network and the second cell network has a thickness between 0.2 mm and 55 mm; - At least one of the first skin and the second skin has a thickness between 0.4 mm and 7 mm; - The first cell network and / or the second cell network include polygonal cells formed by additive manufacturing, such as triangular, quadrilateral, pentagonal, or hexagonal and / or circular cells; - Turbine components are selected from airflow exhaust ducts, annular casings, and acoustic panels; - Turbine components are made of metallic or composite materials; - The first fold and / or the second fold of the composite material each have a maximum fold width of approximately 20 mm or up to approximately 40 mm; this enables AFP-type layup; - The first fold and / or the second fold of the composite material each have a fold width between 0.7 mm and 6.5 mm; this enables micro-AFP type layup; - The first and / or second folds of the composite material are consolidated before being laid up.

[0025] The invention also relates to a turbine component comprising a wall and a honeycomb structure made of a composite material, the honeycomb structure being located on at least a portion of a surface of the wall, the honeycomb structure comprising at least one first cell network and at least one first skin covering the first cell network. This turbine component can be obtained by a manufacturing method according to one of the features of the invention.

[0026] Turbine components may be selected from, but are not limited to, airflow exhaust ducts, annular housings, self-reinforcing panels, and acoustic panels.

[0027] Turbine components can be made of metallic or composite materials. Attached Figure Description

[0028] The invention will be better understood from the following description, given by way of non-limiting example and with reference to the accompanying drawings, and other details, features and advantages of the invention will become more apparent, in which: Figure 1 It schematically shows a perspective view of a cylindrical component including a cellular structure with a cell network, according to the prior art; Figure 2 This is a partial perspective view showing a curved cell network of another cellular structure according to the prior art; Figure 3 This is a partial axial cross-sectional view of a deformable cell network of another honeycomb structure according to the prior art; Figure 4a It is a perspective view including the airflow discharge duct with the honeycomb structure according to the present invention; Figure 4b yes Figure 4a An enlarged perspective view of the honeycomb structure shown; Figure 5 It is a schematic perspective view of an annular shell including the honeycomb structure according to the present invention; Figure 6 This is a schematic diagram of a turbine component having a planar portion including a honeycomb structure according to the present invention; Figure 7 This is a partial schematic cross-section of a first example of a honeycomb structure according to the present invention; Figure 8 This is a partial cross-sectional view of a second example of a honeycomb structure according to the present invention; Figure 9 This is a partial schematic cross-section of a third example of a honeycomb structure according to the present invention; Figure 10 It includes Figure 7 A schematic diagram of a first example of a method for manufacturing a turbine component with a honeycomb structure; Figure 11 It includes Figure 8 A block diagram of a second example of a method for manufacturing a turbine component with a honeycomb structure; Figure 12 It includes Figure 10 A block diagram illustrating a third example of a method for manufacturing a turbine component with a honeycomb structure; Figure 13This is an enlarged axial cross-sectional view of the undeformed cell network of the honeycomb structure according to the present invention; Elements that have the same function in different embodiments have the same reference numerals in the drawings. Detailed Implementation

[0029] Figure 1 , Figure 2 and Figure 3 As described in the background section of this application, examples of turbine components including prior art honeycomb structures are shown.

[0030] This invention is applied in a general and non-limiting manner to different types of turbine components, particularly turbine components for aircraft. The turbine can be a turboprop engine or a turbojet engine.

[0031] Typically, a turbine can be composed of a fan, one or more compressors, an annular combustion chamber, one or more turbines, and possibly exhaust nozzles, from upstream to downstream (relative to the direction of airflow within the turbine).

[0032] The invention has an advantageous, but not exclusive, application in component 2, which can be an airflow discharge duct. Figure 4a and Figure 4b ), ring-shaped shell ( Figure 5 Acoustic panels or self-reinforcing panels ( Figure 6 ).

[0033] Therefore, component 2 of the present invention can be any component of a turbine having walls with complex or simple shapes.

[0034] Component 2 can be made of metallic materials (such as aluminum, steel or titanium) or composite materials.

[0035] Component 2 includes a wall 3 and a honeycomb structure 4 made of composite material, which is located on at least a portion of the surface 30 of the wall 3.

[0036] Component 2 may include at least one planar portion 2a, an annular portion 2b, a curved portion 2c, and / or a perforated portion 2d. The planar portion 2a, annular portion 2b, curved portion 2c, and / or perforated portion 2d may be formed on the wall 3. At least one of the planar portion 2a, annular portion 2b, curved portion 2c, and perforated portion 2d may include a surface 30 having a honeycomb structure 4.

[0037] The curved portion 2c may include a single curve or multiple curves. Each curvature may be unidirectional (i.e., the surface of the curved portion has curvature in a single plane), synclastique (i.e., the surface of the curved portion has curvature in a plane and on the same side), or antiticlastique (i.e., the surface of the curved portion has curvature in multiple planes and on different sides).

[0038] Figures 4a to 6 Different configurations of component 2 are shown, which may include a honeycomb structure 4, particularly manufactured using the manufacturing method based on the present invention.

[0039] Figure 4a and Figure 4b An exhaust pipe or any other component 2 of a turbine with a curved portion 2c is shown in a non-limiting manner. The curved portion 2c may include a surface 30 on which a honeycomb structure 4 is formed.

[0040] Figure 5 This is a non-limiting illustration of an annular housing or any other component 2 of a turbine having an annular portion 2b. The annular portion 2a may include a surface 30 on which a honeycomb structure 4 is formed.

[0041] Figure 6 Non-limiting illustrations are provided of acoustic panels, self-reinforcing panels, or any other turbine component 2 having a planar portion 2a. The planar portion 2a may include a surface 30 on which a honeycomb structure 4 is formed.

[0042] Figure 6 Also shown, but not limited to, is a wall 3 having a perforated portion 2d having an opening O. The perforated portion 2d may include a surface 30 on which a honeycomb structure 4 is formed. More specifically, the honeycomb structure 4 may extend around the opening O.

[0043] Figures 7 to 9 It is shown in a non-limiting manner that it can be formed in the above-described component 2 (in particular, reference 2). Figures 4a to 6 Different possible configurations of the honeycomb structure 4 of the present invention on the wall 3.

[0044] The cellular structure 4 includes at least one first cell network 42 and at least one first skin 44 covering the first cell network 42.

[0045] refer to Figure 7 The honeycomb structure 4 can form a so-called simple structure. According to the first example, this simple honeycomb structure 4 can consist of a simple first skin 44 covering the first cell network 42. Figure 7 In the example shown, the first network 42 can be located on surface 30.

[0046] refer to Figure 8 The honeycomb structure 4 can form a so-called sandwich structure. According to the second example, this sandwich structure may further include at least one second skin 48, wherein the first cell network 42 may extend between the first skin 44 and the second skin 48. Figure 8 In the example shown, the second skin 48 can be located on the surface 30. Therefore, the second skin 48 can form the upper skin of the wall 3.

[0047] refer to Figure 9 The cellular structure 4 can form a so-called 2DOF (an abbreviation for "two degrees of freedom," representing two degrees of freedom and acoustic attenuation according to two frequencies, such as low and high frequencies) structure. This 2DOF structure according to the third example may also include at least one second unit network 46, wherein a first skin 44 covers the first unit network 42, and a second skin 48 is perforated and interposed between the first unit network 42 and the second unit network 46. Figure 9 In the example shown, the second unit network 46 may be located on surface 30. The second skin 48 may include perforations 480. The honeycomb structure 4 according to the third example enhances the acoustic properties of component 2, particularly by attenuating two distinct resonant frequencies (such as the high-frequency and low-frequency ranges) through the stacking of the first unit network 42 and the second unit network 46.

[0048] The first cell network 42 and / or the second cell network 46 may include cellular cells, which may be, but are not limited to, polygonal shapes. These polygonal cells may be triangular, quadrilateral, pentagonal, hexagonal, and / or circular. Advantageously, the cellular cells of the first cell network 42 and / or the second cell network 46 may each have circular (or in other words, curved) sidewalls, such as at least one of their sidewall ends.

[0049] Advantageously, the cellular structure 4 may include at least one annular segment 40a, 40b, which may be arranged upstream and / or downstream of the skin 44, 48 and the cell network 42, 46. Figure 5 Two segments 40a and 40b are shown, which may have chamfers and may be integral (or solid). Alternatively, the annular segment or these annular segments 40a and 40b may be acoustically processed by including, for example, a third unit network, the size of which is smaller than the size of the first unit network and / or the second unit network.

[0050] The first unit network 42 may have a first thickness E between 0.2 mm and 55 mm. 42Preferably, the first thickness E 42 It can be between 5mm and 35mm.

[0051] The second unit network 46 may have a second thickness E between 0.2 mm and 55 mm. 46 Preferably, the second thickness E 46 It can be between 5mm and 35mm. Second thickness E 46 Can be used with the first thickness E 42 Same or different.

[0052] The first skin 44 may have a third thickness E between 0.4 mm and 7 mm. 44 Preferably, the third thickness E 44 It can be between 0.4mm and 2.5mm.

[0053] The second skin 48 may have a fourth thickness E between 0.4 mm and 7 mm. 48 Preferably, the fourth thickness E 48 It can be between 0.4mm and 2.5mm. Fourth thickness E 48 Can be used with a third thickness E 44 Same or different.

[0054] The honeycomb structure 4 is made of a composite material. The composite material may include fiber preforms embedded in a resin. The composite material may have a ceramic matrix (CMC) or an organic matrix (CMO). The fiber preforms may include carbon fibers, glass fibers, ceramic fibers (such as silicon carbide, glass, or aramid), polyamide fibers, metal fibers, oxide fibers, or mixtures of at least two of these fibers. The fibers of the composite material in the honeycomb structure 4 (particularly the first unit network 42 and / or the second unit network 46) may be short or long fibers.

[0055] Specifically, the first skin 44 can be formed by a first fold of the composite material. The second skin 48 can be formed by a second fold of the composite material. The first and second folds of the composite material can each comprise glass fibers, carbon fibers, aramid fibers, ceramic fibers (such as silicon carbide, glass, or aramid), or oxide fibers.

[0056] The resin of the composite material (which can form a matrix CMC or CMO) can be a thermoplastic or thermosetting resin, such as based on epoxy resin, polyepoxide, polyimide, polybismaleimide, polyurethane, polyester, polyetherimide (PEI), polyaryletherketone (PAEK) family (such as polyetheretherketone PEEK, polyetherketone PEK, polyetherketone PEKK, etc.) or vinyl ester.

[0057] This application will now describe as described above (in particular, references to...). Figures 4a to 6A method for manufacturing component 2, which includes the following (particularly referring to...) Figures 7 to 9 4. The honeycomb structure. Figures 10 to 12 Different examples of the methods of the present invention are shown in a non-limiting manner.

[0058] Figure 10 The steps in the manufacturing method of turbine component 2, particularly turbine component 2 for aircraft, are shown.

[0059] The method includes the following steps: (a) Provide wall 3, and (b) A honeycomb structure 4 is formed on at least a portion of the surface 30 of the wall 3.

[0060] A specific feature of the present invention is that step (b) of manufacturing the honeycomb structure 4 includes the following sub-steps: (b1) Depositing composite material folds by layup to form the first skin 44, and (b2) The first cell network 42 is formed by additive manufacturing.

[0061] Sub-step (b1) can be executed before or after sub-step (b2). This is determined by... Figure 10 The double arrows in the diagram represent...

[0062] As described above, the combination of layup and additive manufacturing techniques enables the direct formation of the honeycomb structure 4 on a portion of the surface 30 of the wall 3, regardless of the shape (e.g., a simple curved shape or a shape with multiple curves, a planar shape, a perforated shape, etc.) and dimensions (e.g., radius of curvature, length, etc.) of that portion of the surface 30. This enhances the vibrational and acoustic properties of the honeycomb structure 4 and also imparts mechanical properties through locally enhanced stiffness. It is not necessary to have the same reinforcing or strengthening element in the form of the honeycomb structure 4 throughout the entire component 2. In fact, referring to... Figure 4a or Figure 4b The honeycomb structure 4 can be specifically formed on the curved portion 2c of the component 2, which requires local enhancement of the mechanical, vibrational and / or acoustic properties of the component 2.

[0063] The method for manufacturing component 2 may include sub-step (b3): ​​laying down a second fold of the composite material by stacking to form a second skin 48 of the honeycomb structure 4, such as Figure 11 and Figure 12 As shown. This sub-step (b3) can be executed before sub-step (b2).

[0064] The method for manufacturing component 2 may include sub-step (b4): forming a second cell network 46 of the honeycomb structure 4 by additive manufacturing, such as Figure 12As shown. This sub-step (b4) can be executed before sub-step (b3).

[0065] The honeycomb structure 4 may include at least one of a planar portion 2a, an annular portion 2b, a curved portion 2c, and a perforated portion 2d. At least one of these planar portions 2a, annular portions 2b, curved portions 2c, and perforated portions 2d may include (or form) at least a portion of the surface 30, and the honeycomb structure 4 is manufactured on that at least portion of the surface 30 by the method according to the invention (particularly by sub-steps (b1) and (b2), and / or sub-step (b3), and possibly sub-step (b4)).

[0066] In sub-steps (b1) and / or (b3), the first and / or second folds of the composite material can be laid up manually or automatically. For example, sub-steps (b1) and / or (b3) can be performed using AFP (Automated Fiber Laying), ATL (Automated Tape Laying), or P&P (Pick & Place) techniques. AFP layup allows the first and / or second folds of the composite material to be laid down preferably in parallel and simultaneously to form a first skin 44 and possibly a second skin 48. The first and / or second folds of the deposited composite material can each have a fold width of a few millimeters to tens of millimeters. For example, the fold width of each AFP layup can be at most about 20 mm or up to about 40 mm.

[0067] Advantageously, the first and / or second folds of the composite material can be laid up using a micro AFP technique, which involves laying up the first and / or second folds of the composite material, each with a fold width between 0.7 mm and 6.5 mm.

[0068] The first and / or second folds of the composite material can be pre-consolidated (or otherwise densified) prior to layup. Specifically, the first and / or second folds of the composite material can be consolidated in suitable tools to form the final shapes of the first skin 44 and the second skin 48, respectively. Suitable tools may include ovens, autoclaves, vacuum tarpaulins, and / or molding machines.

[0069] In sub-steps (b2) and / or (b4), additive manufacturing can be performed by laser beam melting (LBM) or extrusion additive manufacturing (EAM).

[0070] Additive manufacturing in a powder bed enables the fabrication of parts with complex shapes, such as the first cell network 42 and the second cell network 46 of the honeycomb structure 4, regardless of the shape and size of that portion of the surface 30 of the part 2. Additive manufacturing also makes it easier to form and control the various possible shapes of the network of control units (especially these polygonal cells) 42, 46. Thus, polygonal cells (e.g., triangular, quadrilateral, pentagonal, or hexagonal and / or circular cells) can be formed by additive manufacturing.

[0071] LBM additive manufacturing allows for the selective consolidation of powder layers to build a three-dimensional first unit network 42 and a second unit network 46 layer by layer.

[0072] EAM additive manufacturing allows the deposition of continuous filaments of composite or thermoplastic materials to build a three-dimensional first unit network 42 and a second unit network 46 layer by layer.

[0073] Figure 7 The first example of the honeycomb structure 4 can be formed by performing sub-step (b2) to form a first cell network 42, specifically forming the first cell network 42 on the surface 30, followed by performing sub-step (b1) to form a first skin 44 covering the first cell network 42 obtained in sub-step (b2).

[0074] Figure 8 The second example of the cellular structure 4 can be formed by performing the following steps in sequence: - Perform sub-step (b3) to form the second skin 48, specifically forming the second skin 48 on surface 30. Then sub-step (b2) is performed to form the first cell network 42, specifically forming the first cell network 42 on the second skin 48 obtained in sub-step (b3). - Finally, sub-step (b1) is performed to form a first skin 42 covering the first cell network 42 obtained in sub-step (b2).

[0075] Figure 11 These steps for manufacturing the cellular structure 4 according to the second example are shown.

[0076] Figure 9 The third example of the cellular structure 4 in the diagram can be formed by performing the following steps in sequence: - Perform sub-step (b4) to form the second cell network 46, specifically forming the second cell network 46 on surface 30. -Then sub-step (b3) is performed to form a second skin 48, which specifically covers the second cell network 46 obtained in sub-step (b4). Then sub-step (b2) is performed to form the first cell network 42, specifically forming the first cell network 42 on the second skin 48 obtained in sub-step (b3). - Finally, sub-step (b1) is performed to form a first skin 44 covering the first cell network 42 obtained in sub-step (b2).

[0077] Figure 12 These steps for manufacturing the cellular structure 4 according to the second example are shown.

[0078] The second skin 48 can be perforated with perforations 480 before or after the layup of sub-step (b3).

[0079] refer to Figure 13 The first cell network 42 and / or the second cell network 46 are formed by additive manufacturing, particularly on the annular portion 2b or the curved portion 2c, enabling the sidewalls of the polygonal cells to be formed without deformation. In other words, regardless of the curvature of the wall 3, the sidewalls of the cellular cells of cell networks 42, 46 have a constant thickness. In fact, the sidewalls of these curved cellular cells (especially those with polygonal shapes) can be separated from each other by gaps J.

[0080] This application will now describe, in a non-limiting manner, two examples of tests for measuring and comparing the mechanical properties (i.e., bending strength) of a component 2 manufactured according to the method of the present invention.

[0081] In the first test, the bending force at fracture (measured in Newtons N) was measured on three different test samples EA1, EA2, and EA3. The first test sample EA1 consisted only of a first skin 44 or a second skin 48 formed by first or second folding of the composite material. More specifically, the thickness of the first sample EA1 was approximately 1 mm, representing, for example, eight folds of the composite material deposited by layup. This first sample EA1 had a bending force of approximately 45 N.

[0082] The second test sample EA2 includes a first skin 44 or a second skin 48 with a thickness of approximately 1 mm, and is tested using Ultem. ® The first unit network 42 or the second unit network 46 is formed by FFF (Fused Filament Fabrication) additive manufacturing of PEI thermoplastic resin of type 1010. The second sample EA2 has a higher flexural strength of about 65N.

[0083] The third test sample EA3 includes a first skin 44 or a second skin 48 with a thickness of approximately 1 mm, and is tested using Ultem. ®The first unit network 42 or the second unit network 46 is formed by FFF additive manufacturing of PEI thermoplastic resin of type 9085. The third sample EA3 has a greater flexural force of approximately 140N.

[0084] Based on the results of the first test, it can be concluded that component 2, including the first cell network 42 or the second cell network 46 manufactured by additive manufacturing, significantly increases the flexural strength. The choice of composite material also increases the flexural strength of component 2.

[0085] In the second test, the stiffness of three different test samples, EA4, EA5, and EA6, was measured.

[0086] The fourth sample, EA4, is made of aluminum. The fourth sample, EA4, is referred to as the reference sample; for a given weight, the bending strength of the fourth sample, EA4, is 1.

[0087] The fifth test sample EA5 consists of a first layer C1 and a second layer C2. The first layer C1 is made of PEEK material through AFP layup and has a thickness of approximately 6.35 mm. The second layer C2 partially encapsulates the first layer C1 and is made of PEI material. Compared to the fourth sample EA4, the fifth sample EA5 has twice the flexural strength and half the weight.

[0088] The sixth sample EA6 comprises the first layer C1 and the second layer C2 of the fifth test sample EA5, and a third layer C3, which extends radially from the first layer C1, has a thickness of approximately 1 mm, and is produced by additive manufacturing. Compared to the fourth sample EA4, the sixth sample EA6 has a bending strength greater than 2.5 times and a weight reduction of approximately 0.6 times.

[0089] Compared to the fourth test sample EA4, the fifth test sample EA5 and the sixth test sample EA6 exhibited greater bending strength at a lighter weight.

[0090] Therefore, the results of the second test lead to the conclusion that the sixth test sample EA6 (which substantially corresponds to component 2 formed according to the method of the present invention) shows a significant increase in stiffness.

Claims

1. A method for manufacturing a turbine component (2), particularly a turbine component for an aircraft, the turbine component (2) comprising a wall (3) and a honeycomb structure (4) made of a composite material, the honeycomb structure being located on at least a portion of a surface (30) of the wall (3), the honeycomb structure (4) comprising at least one first cell network (42) and at least one first skin (44) covering the first cell network (42), the method comprising the steps of: (a) Provide the wall (3), and (b) The honeycomb structure (4) is formed on at least a portion of the surface (30) of the wall (3). The characteristic feature is that step (b) of manufacturing the honeycomb structure (4) includes the following sub-steps: (b1) Depositing a first fold of the composite material by layup to form the at least one first skin (44), and (b2) The at least one first cell network (42) is formed by additive manufacturing, and sub-step (b1) is performed before or after sub-step (b2).

2. The manufacturing method according to claim 1, characterized in that, The honeycomb structure (4) includes at least one second skin (48), the at least one first cell network (42) extends between the at least one first skin (44) and the at least one second skin (48), wherein the method includes a sub-step (b3) of depositing a second fold of the composite material by layup to form the at least one second skin (48), the sub-step (b3) being performed before the sub-step (b2) and the sub-step (b1) being performed after the sub-step (b2).

3. The manufacturing method according to claim 2, characterized in that, Before or after the layup of the sub-step (b3), the second skin (48) is perforated (480).

4. The manufacturing method according to claim 2 or 3, characterized in that, The cellular structure (4) includes at least one second cell network (46), the at least one first skin (44) covers the first cell network (42), and the at least one second skin (48) is located between the first cell network (42) and the second cell network (46), wherein the method includes a sub-step (b4) of forming the at least one second cell network (46) by additive manufacturing, the sub-step (b4) being performed prior to the sub-step (b3).

5. The manufacturing method according to claim 4, characterized in that, The layup of sub-steps (b1) and (b3) is performed manually or automatically, and the additive manufacturing of sub-steps (b2) and (b4) is performed by laser beam melting (LBM) or by extrusion additive manufacturing (EAM).

6. The manufacturing method according to claim 4 or 5, characterized in that, At least one of the first cell network (42) and the second cell network (46) has a thickness between 0.2 mm and 55 mm (E). 42 E 44 ).

7. The manufacturing method according to any one of claims 2 to 6, characterized in that, At least one of the first skin (44) and the second skin (48) has a thickness between 0.4 mm and 7 mm (E 44 E 46 ).

8. The manufacturing method according to any one of claims 1 to 7, characterized in that, The first fold and / or the second fold of the composite material each have a maximum fold width of about 20 mm or up to about 40 mm.

9. The manufacturing method according to claim 8, characterized in that, The first fold and / or the second fold of the composite material each have a fold width between 0.7 mm and 6.5 mm.

10. The manufacturing method according to any one of the preceding claims, characterized in that, The first and / or second folds of the composite material are consolidated before being laid up.

11. The manufacturing method according to any one of claims 4 to 10, characterized in that, The first cell network (42) and / or the second cell network (46) include polygonal cells formed by additive manufacturing, such as triangular, quadrilateral, pentagonal, or hexagonal and / or circular cells.

12. The manufacturing method according to any one of the preceding claims, characterized in that, The turbine component (2) includes at least one planar portion (2a), annular portion (2b), curved portion (2c) and / or perforated portion (2d), wherein at least one of the planar portion (2a), annular portion (2b), curved portion (2c) and perforated portion (2d) includes at least a portion of the surface (30) on which the honeycomb structure (4) is manufactured.

13. The manufacturing method according to any one of the preceding claims, characterized in that, The turbine component (2) is selected from the airflow exhaust duct, the annular housing, and the acoustic panel.

14. The manufacturing method according to any one of the preceding claims, characterized in that, The turbine component (2) is made of metallic or composite materials.

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