Method for manufacturing ducts for a heat exchanger

Abstract

This method for manufacturing a plate comprising ducts for a heat exchanger is characterized in that it comprises the following steps: - applying an anti-diffusion material (step 30) to a first metal sheet at places on the first metal sheet that are intended to form duct portions; - placing the first metal sheet in contact with a second metal sheet between a male tool and a female tool forming a mould (step 34); - diffusion welding (step 46) of the first metal sheet to the second metal sheet within the mould in such a way as to form the plate; - injecting a pressurized inert gas (step 48) between the first metal sheet and the second metal sheet, at the places where the anti-diffusion material has been applied, in order to effect the shaping of the ducts.

Description

[0001] DESCRIPTION

[0002] TITLE: Process for manufacturing pipes for a heat exchanger

[0003] Technical field

[0004] The present invention relates to the manufacture of heat exchangers.

[0005] In particular, the present invention relates to the production of a plate in which are housed pipes allowing an exchange of heat between a heat transfer fluid circulating in the pipes and an external environment.

[0006] In general, the invention applies to any type of heat exchanger but is particularly relevant in the context of the manufacture of a heat exchanger arranged on a surface of revolution, and more particularly for the exhaust system of a turbomachine of an aircraft, the heat exchanger allowing the recovery of heat in the exhaust flow so as to heat fuel and / or air intended to enter a combustion chamber of the turbomachine.

[0007] Previous techniques

[0008] The manufacture of parts in the aeronautical field is generally subject to constraints of mass and size of said parts. In the context of the integration of heat exchangers in an aircraft, and in particular in a turbomachine of an aircraft, said integration is difficult to carry out after the manufacture of the parts of the turbomachine and is therefore preferentially carried out during the manufacture of said parts.

[0009] With a view to improving the performance of turbomachines, it is possible to heat air and / or fuel before they enter a combustion chamber of the turbomachine. A heat source located nearby is preferred in order to increase the thermal efficiency of the turbomachine and thus contribute to reducing the environmental footprint of the turbomachine. A heat source is, for example, the gases exiting through the exhaust system of the turbomachine.

[0010] However, the positioning of a heat exchanger in the primary exhaust flow of the turbomachine induces pressure losses of the turbomachine and negatively impacts the thrust of the aircraft. The positioning of a heat exchanger in the turbomachine must therefore be perfectly integrated so as not to harm the efficiency and compactness of said turbomachine.

[0011] Statement of the invention

[0012] The present invention therefore aims to manufacture pipes for a compact and integrated heat exchanger. To this end, the invention is the result of technological research aimed at significantly improving the performance of aircraft and, in this sense, contributes to reducing the environmental impact of aircraft.

[0013] The present invention relates to a method of manufacturing a plate comprising pipes for a heat exchanger, the method comprising the following steps:

[0014] - Application of an anti-diffusing material to a first sheet at locations of the first sheet intended to form portions of pipes;

[0015] - Placement of the first sheet in contact with a second sheet between a male tool and a female tool forming a mold;

[0016] - Diffusion welding of the first sheet with the second sheet within the mold so as to form the plate;

[0017] - Injection of an inert gas under pressure between the first sheet and the second sheet at the locations where the anti-diffusing material has been applied in order to form the pipes.

[0018] Advantageously, the method comprises a step of injecting an inert gas under pressure into a cavity between one of the first and second sheets and one of the male tool and the female tool after the diffusion welding step and so as to form the first and second sheets according to the shape of the desired plate. In one embodiment, following the step of injecting a gas into the cavity, and before the step of injecting a gas at the locations to which the anti-diffusion material has been applied, the welded first and second sheets are positioned in a mold comprising a second male tool and a second female tool.

[0019] In another embodiment, the first welded sheet and the second welded sheet are positioned in a mold comprising the male tool and a second female tool, the step of injecting into the cavity being extended and / or repeated so as to be carried out simultaneously with the step of injecting an inert gas under pressure between the first sheet and the second sheet at the locations to which an anti-diffusing material has been applied, so that the pressure during the injection of inert gas is similar in the formed pipes and in the cavity.

[0020] Advantageously, the first sheet is placed in a constriction of the male tool during the placement step, the constriction having a depth between the thickness of the first sheet and the sum of the thicknesses of the first and second sheets, and in which a step of injecting an inert gas under pressure is carried out between the second sheet and the female tool so that the second sheet is partially pushed into the constriction and allows a diffusion welding step without movement of the second sheet relative to the first sheet.

[0021] In a particular embodiment, the method further comprises a step of forming a distributor and / or a collector between the first sheet and the second sheet, or between the first sheet and a third sheet.

[0022] Advantageously, the process includes a final step of cooling the sheets and a step of sandblasting the sheets after forming the pipes.

[0023] Advantageously, the anti-diffusing material comprises boron nitride.

[0024] Advantageously, the inert gas comprises argon. In one embodiment, the formed pipes have a cross-section of semi-circular, rectangular, bell-shaped, semi-elliptical, or triangular shape.

[0025] Advantageously, the sheets are made from a material comprising a titanium alloy and / or a nickel alloy.

[0026] In a particular mode of implementation, the male tooling and the female tooling are made so that their expansion coefficients are different.

[0027] The invention also relates to an exhaust system comprising a heat exchanger comprising a plate obtained by the method as defined above.

[0028] Brief description of the drawings

[0029] Other aims, characteristics and advantages of the invention will appear on reading the following description, given solely by way of non-limiting example, and made with reference to the appended drawings in which:

[0030] [Fig 1] is a schematic sectional view of a turbomachine of an aircraft; and

[0031] [Fig 2] is a view of an embodiment of an exhaust system of a turbomachine; and

[0032] [Fig 3] is a representation of the different stages of a first mode of implementation of the manufacturing method according to the invention; and

[0033] [Fig 4] is a schematic representation of the manufacturing environment for the manufacturing process of Figure 3; and

[0034] [Fig 5A]

[0035] And

[0036] [Fig 5B] are schematic cross-sectional representations of first and second welded sheets during the manufacturing process of Figure 3; and

[0037] [Fig 6] is a representation of the different stages of a second mode of implementation of the manufacturing method according to the invention; and

[0038] [Fig 7A]

[0039] And [Fig 7B]

[0040] And

[0041] [Fig 7C] are schematic cross-sectional representations of a first and a second sheet during the manufacturing process of Fig. 6; and

[0042] [Fig 8] is a representation of the different stages of a third mode of implementation of the manufacturing method according to the invention; and

[0043] [Fig 9A]

[0044] And

[0045] [Fig 9B] are schematic cross-sectional representations of a first and a second sheet during the manufacturing process of Figure 8; and

[0046] [Fig 10] is a representation of the first steps of the method according to the invention integrating a variant of implementation of said method; and

[0047] [Fig 1 1 A]

[0048] And

[0049] [Fig 1 1 B] are schematic cross-sectional representations of a first and a second sheet during the manufacturing process of Figure 10; and

[0050] [Fig 12] is a representation of a male and female annular tooling allowing the fabrication of heat exchanger pipes in a single sector.

[0051] Detailed description of at least one embodiment

[0052] Figure 1 schematically shows a turbomachine 2 of an aircraft. The turbomachine 2 comprises a fan 4 for recovering air from the atmosphere outside the turbomachine 2, a compressor 6, a combustion chamber 8, a turbine 10, and an exhaust system 12.

[0053] In particular, the exhaust system 12 comprises a nozzle 14 and a central body 16 forming an exhaust stream 18 of gas of annular section. The exhaust system 12 comprises a heat exchanger 20 configured to heat fuel at the inlet of the combustion chamber 8 and / or air at the outlet of the compressor 6 and before entry into the combustion chamber 8 from heat exchanges between the exhaust stream 18 of gas and the pipes 26 via the wall of the nozzle 14.

[0054] Figure 2 schematically shows an embodiment of the exhaust system in which the heat exchanger 20 is positioned on the nozzle 14. Alternatively, by analogy, the heat exchanger 20 can be positioned on the central body (not shown in Figure 2) of the exhaust system.

[0055] The heat exchanger 20 comprises at least one distributor 22, at least one collector 24 and pipes 26.

[0056] The distributor 22 is configured to inject a heat transfer fluid into the pipes 26 themselves configured to circulate said heat transfer fluid in said pipes 26 to a collector 24 configured to recover the heated heat transfer fluid.

[0057] The pipes 26 are formed in a plate 28 forming the nozzle 14. In the embodiment shown, the nozzle 14 comprises an internal surface in contact with which the exhaust gases are expelled.

[0058] In particular, the plate 28 comprising the pipes 26 of the heat exchanger 20 is produced using the manufacturing method according to the invention described below.

[0059] Figure 3 shows the different steps of an embodiment of the method for manufacturing a plate 28 comprising pipes 26 according to the invention. By way of example, reference will be made to the pipes 26 and more broadly to the heat exchanger 20 illustrated in Figure 2. Nevertheless, other plates 28 of pipes 26 for other uses can also be produced with the implementation of the method below.

[0060] Figure 4 shows a schematic representation of the manufacturing environment of said plate 28.

[0061] In a first step, a step 30 of applying an anti-diffusing material (not shown) is carried out on a first sheet 32 ​​at locations of the first sheet 32 ​​intended to form portions of pipes 26. The first sheet 32 ​​is for example a flat or curved fold of material and the thickness of which is significantly thinner than its other dimensions.

[0062] An anti-diffusing material is understood to mean a material which, once applied to the first sheet 32, prevents the first sheet 32 ​​from being welded to a second sheet during diffusion welding. The anti-diffusing material comprises, for example, boron nitride.

[0063] In other words, the anti-diffusing material is applied, for example periodically to the first sheet 32, so as to form an alternation of sheet covered with anti-diffusing material and bare sheet. By bare sheet is meant a portion of sheet without a coating of anti-diffusing material.

[0064] Next, a step 34 is carried out of placing the first sheet 32 ​​in contact with a second sheet 36. The contact must be established so that the anti-diffusing material is caught between the first sheet 32 ​​and the second sheet 36.

[0065] In addition, the first sheet 32 ​​and the second sheet 36 superimposed are placed in a mold 38 comprising a male tool 40 and a female tool 42 forming said mold 38, the sheets 32 and 36 being in particular positioned between the male tool 40 and the female tool 42 illustrated in FIG. 4.

[0066] Advantageously, the male 40 and female 42 tools each comprise a seal 43 positioned at the periphery of said tools 40 and 42 at the junction of the male 40 tool and the female 42 tool, in order to ensure fluid tightness between the interior and the exterior of the mold 38.

[0067] The mold 38 makes it possible to combine specific temperature and pressure conditions, for example conditions necessary for carrying out diffusion welding. The mold 38 is, for example, included in a superplastic forming press. The female tool 42 comprises grooves 44 configured to give their shape to the pipes 26. The male and female tool 40 and 42 have a shape similar to the shape of the sheets 32 and 36 so that the placement of the sheets 32 and 36 in the mold 38 does not deform said sheets 32 and 36. Step 46 of diffusion welding of the first sheet 32 ​​with the second sheet 36 is then carried out in the mold 38, the two sheets 32 and 36 thus becoming integral and forming the plate 28 intended to comprise the pipes 26. Only the locations on which the anti-diffusing material has been applied do not comprise a weld between the first sheet 32 ​​and the second sheet 36.

[0068] Figure 5A schematically shows the first and second sheets 32 and 36 welded in the mold 38.

[0069] A step 48 is then carried out of injecting an inert gas under pressure between the first sheet 32 ​​and the second sheet 36. The injection is carried out for example from openings 50 made in the mold 38, for example in the female tool 42, and illustrated in FIG. 4. The openings 50 are for example configured to form the collectors 24 and / or the distributors 22. The injected gas is directed in particular to the locations 51 to which the anti-diffusing material has been applied. The pressure of the injected gas is configured to deform the second sheet 36 and press it against the grooves 44 of the female tool 42 so as to form the pipes 26. The injected inert gas is maintained in the mold 38 using the sealing of said mold 38 provided by the seals 43.

[0070] Figure 5B schematically shows the pipes 26 formed at the end of this step 48 of injecting inert gas under pressure.

[0071] Furthermore, the inert gas is, for example, argon or a mixture comprising argon.

[0072] In addition, the formed pipes 26 take the form of the grooves 44 which may have different shapes. For example, the cross-section of the formed pipes is semi-circular, as illustrated, or rectangular, or bell-shaped, or semi-elliptical, or triangular.

[0073] In one embodiment, for example for an aeronautical application, the first and second sheets 32 and 36 are made of a material resistant to high temperatures compared to most metals, for example in a material comprising a titanium alloy and / or a nickel alloy. In a particular embodiment, for example for the manufacture of a heat exchanger 20 as illustrated in FIG. 2, it is optionally possible to carry out a step (not shown) of forming a distributor 22 and / or a collector 24 by injecting an inert gas between the two sheets 32 and 36 in a suitable mold. As a variant, the pipes are formed between the first sheet 32 ​​and the second sheet 36 and a distributor and / or a collector is formed between the first sheet 32 ​​and a third sheet (not shown).This latter mode of implementation makes it possible to form a plate 28 comprising the pipes on one side of the plate, and the distributors and collectors on the other side of the plate.

[0074] Optionally, a step 52 of cooling the sheets 32 and 36, and more generally the plate 28 comprising the pipes 26 and formed by welding the sheets 32 and 36, is also carried out at the end of the manufacturing process. Additionally, a step 54 of stripping the sheets 32 and 36 is carried out, for example by sandblasting, so as to clean the areas oxidized and / or soiled during the manufacturing process.

[0075] In the previously described embodiment, a step 56 of forming the first sheet and the second sheet is optionally carried out prior to step 30 of applying the anti-diffusing material. Step 56 makes it possible, in the case where the sheets 32 and 36 do not have the appropriate shape to carry out their placement in the mold 38, to give them the shape of the desired plate 28, the mold 38 having a shape also adapted to the shape of the desired plate 28.

[0076] Figure 6 shows schematically the steps of another mode of implementation of the method according to the invention.

[0077] In this embodiment, the forming of the first sheet 32 ​​and the second sheet 36 is carried out during the manufacturing method according to the invention.

[0078] Thus, firstly, step 30 is carried out of applying an anti-diffusing material (not shown) to the first sheet 32 ​​at locations of the first sheet 32 ​​intended to form portions of pipes 26. This step is carried out in the same way as the previous embodiment illustrated in FIG. 3. Then, step 34 is carried out of placing the first sheet 32 ​​in contact with the second sheet 36 as described previously. In this embodiment, since the sheets 32 and 36 are not previously formed, they are placed in the mold 38 comprising a male tool 58 of neutral shape and a female tool 60 whose surface does not include grooves 44 and corresponding to the final shape of the desired plate 28. Figure 7A schematically shows the first and second sheets 32 and 36 between the male tool 58 and the female tool 60.

[0079] In a manner similar to the embodiment illustrated in FIG. 3, step 46 of diffusion welding of the first sheet 32 ​​with the second sheet 36 is then carried out in the mold 38, the two sheets 32 and 36 thus becoming integral and forming the plate 28 intended to comprise the pipes 26. Inert gas is injected into the cavity 61 via the tool 60 to press the first sheet 32 ​​and the second sheet 36 against the male tool 58 during diffusion welding. Only the locations on which the anti-diffusion material has been applied do not comprise a weld between the first sheet 32 ​​and the second sheet 36.

[0080] Then, a step 62 is carried out of injecting an inert gas under pressure into a cavity 64 via the tool 58, for example between the male tool 58 and the first sheet 32, so as to give the sheets 32 and 36 the shape of the desired plate 28. Figure 7B shows the sheets 32 and 36 at the end of this step 62.

[0081] A step 66 of changing tools in the mold 38 is then carried out. The welded sheets 32 and 36 are thus positioned between a second male tool 40 and a second female tool 42 identical to the male tool and the female tool of the embodiment illustrated in FIG. 3, the welded sheets 32 and 36 having the desired final shape. In particular, the second female tool 42 comprises grooves 44 configured to give their shape to the pipes 26. FIG. 7C shows the sheets 32 and 36 at the end of this step 66.

[0082] Step 48 of injecting an inert gas under pressure between the first sheet 32 ​​and the second sheet 36 is then carried out as described previously, and so as to form the pipes, as illustrated in FIG. 5B.

[0083] Steps 62 and 48 of injecting an inert gas are preferably carried out separately, step 62 of injection into the cavity 64 preferably being implemented before step 48 of injecting gas between the sheets 32 and 36. Furthermore, the injected inert gas may be of the same composition during the implementation of steps 62 and 48, or of a different composition.

[0084] Optionally, the cooling steps 52 and / or stripping steps 54 are finally carried out.

[0085] Figure 8 shows schematically the steps of another mode of implementation of the method according to the invention.

[0086] In this embodiment, the steps of applying an anti-diffusing material 30, placing the sheets 34, diffusion welding 46 and injecting an inert gas under pressure 62 are carried out as described in the embodiment previously described and illustrated in FIG. 6.

[0087] In this embodiment, however, a step 68 is carried out for changing a single tool in the mold 38. In particular, the welded sheets 32 and 36 are thus positioned between the male tool 58 and the second female tool 42 identical to the female tool of the embodiment illustrated in FIG. 3. FIG. 9A shows the sheets 32 and 36 at the end of this step 68.

[0088] Then, steps 48 and 62 of injecting inert gas under pressure into the cavity 64 are carried out simultaneously, so that the pressure during the injection of inert gas is similar in the formed pipes 26 and in the cavity 64 once the plate 28 and the pipes 26 are formed. 9B shows the sheets 32 and 36 at the end of these steps 48 and 62.

[0089] Optionally, the cooling steps 52 and / or stripping steps 54 are finally carried out.

[0090] Figure 10 schematically shows the first steps of the method according to the invention integrating a variant of implementation of said method. In this variant, applicable to all modes of implementation, step 30 described above of applying an anti-diffusing material is carried out, as well as step 34 of placing the first sheet 32 ​​in contact with the second sheet 36 as described above.

[0091] However, the sheets 32 and 36 are positioned between a male tool 70 comprising a constriction 72 and the female tool 60 or 42. More precisely, the first sheet 32 ​​is positioned in the constriction 72, the dimensions of the constriction 72 being substantially identical to the dimensions of the first sheet 32, as well as smaller than the dimensions of the second sheet 36, the constriction 72 having a depth of dimension comprised between the thickness of the first sheet 32 ​​and the sum of the thicknesses of the first and second sheets 32 and 36.

[0092] The movements of the first sheet 32 ​​are thus limited for the following steps of the method. Figure 1 1A shows the sheets 32 and 36 at the end of this step 34.

[0093] Then, a step 74 is carried out of injecting an inert gas under pressure between the second sheet 36 and the female tool 60 or 42 so that the second sheet 36 is partially pushed into the constriction, also limiting the movements of the second sheet 36. FIG. 1 1B shows the sheets 32 and 36 at the end of this step 34.

[0094] The welding step 46 described above is then carried out, this step 46 being facilitated by the absence of movement and friction of the second sheet 36 relative to the first sheet 32.

[0095] The steps following step 46 of the embodiments previously described and illustrated in Figures 3, 6 and 8 can then be carried out.

[0096] The different implementation methods described can be implemented for different uses and different forms of heat exchanger.

[0097] For the manufacture of pipes for a heat exchanger 20 as illustrated in FIG. 2, it is possible to manufacture different sectors 76, then to assemble them, for example by TIG welding, in other words Tungsten Inert Gas in Anglo-Saxon terms, TIG welding being known to those skilled in the art.

[0098] Figure 12 schematically shows a male tool 40 and a female tool 42 which are annular and allow the manufacture of pipes 26 of a heat exchanger 20 in a single sector according to the method of implementing the process illustrated in Figure 3.

[0099] Advantageously, the male tool 40 comprises a key tool.

[0100] Advantageously, the female tool 42 and the male tool are made from materials comprising different expansion coefficients, for example the male tool 40 having a higher expansion coefficient than the female tool 42 so as to more easily apply a force to the sheets 32 and 36 during heating for diffusion welding.

Claims

CLAIMS 1. Method for manufacturing a plate (28) comprising pipes (26) for a heat exchanger (20), characterized in that it comprises the following steps: Application of an anti-diffusing material (step 30) on a first sheet (32) at locations (51) of the first sheet (32) intended to form portions of pipes (26) Placing the first sheet (32) in contact with a second sheet (36) between a male tool (40; 58; 70) and a female tool (42; 60) forming a mold (38) (step 34); Diffusion welding (step 46) of the first sheet (32) with the second sheet (36) within the mold (38) so as to form the plate (28); Injecting an inert gas under pressure into a cavity (64) between one of the first and second sheets (32; 36) and one of the male tool (58) and the female tool (60) after the diffusion welding step (46) and so as to form the first and second sheets according to the shape of the desired plate (28) (step 62); Injection of an inert gas under pressure (step 48) between the first sheet (32) and the second sheet (36) at the locations (51) to which the anti-diffusing material has been applied so as to form the pipes (26).

2. Method according to claim 1, in which, following the step (62) of injecting a gas into the cavity, and before the step (48) of injecting a gas into the locations (51) to which the anti-diffusing material has been applied, the first sheet and the second welded sheet are positioned (step 66) in a mold (38) comprising a second male tool (40) and a second female tool (42), or in which the first sheet (32) and the second welded sheet (36) are positioned in a mold comprising the male tool (58) and a second female tool (42), the step (62) of injection into the cavity (64) being extended and / or repeated so as to be carried out simultaneously with the step (48) of injecting an inert gas under pressure between the first sheet (32) and the second sheet (36) at the locations (51) to which an anti-diffusing material has been applied, so that the pressure during the injection of inert gas is similar in the formed pipes (26) and in the cavity (64).

3. Method according to one of claims 1 and 2, in which the first sheet (32) is placed in a constriction (72) of the male tool (70) during the step (34) of placing, the constriction (72) having a depth between the thickness of the first sheet (32) and the sum of the thicknesses of the first and second sheets, and in which a step (74) of injecting an inert gas under pressure between the second sheet (36) and the female tool (60) is carried out so that the second sheet (36) is partially pushed into the constriction (72) and allows a step (46) of diffusion welding without movement of the second sheet (36) relative to the first sheet (32).

4. Method according to any one of claims 1 to 3, further comprising a step of forming a distributor and / or a collector between the first sheet (32) and the second sheet (36), or between the first sheet and a third sheet.

5. Method according to any one of claims 1 to 4, comprising a final step (52) of cooling the sheets (32; 36) and a step (54) of sandblasting the sheets (32; 36) after forming the pipes (26).

6. A method according to any one of claims 1 to 5, wherein the anti-diffusing material comprises boron nitride, and / or wherein the inert gas comprises argon.

7. Method according to any one of claims 1 to 6, in which the formed pipes (26) have a cross-section of semi-circular, or rectangular, or bell-shaped, or semi-elliptical, or triangular shape.

8. Method according to any one of claims 1 to 7, in which the male tool (40) and the female tool (42) are made from materials with different expansion coefficients.

9. Exhaust system (12) comprising a heat exchanger (20) comprising a plate (28) obtained by the method according to any one of claims 1 to 8.

Images