METHOD FOR MANUFACTURED A COMPOSITE PART WITH INTEGRATED MARKING AND THE RESULTING COMPOSITE PART

Abstract

The invention relates to a method for manufacturing a part (120) made of organic matrix composite material for a turbomachine (100), particularly for aircraft, comprising: - producing a preform (125) woven from fibers, placing the woven preform in a mold, and impregnating the woven preform with a resin (126); and - before impregnating the woven preform with the resin, placing an identification support (140) formed by a superposition of at least one ply (142) of pre-impregnated glass fibers and a label (144) bearing information relating to the organic matrix composite part in an area of ​​the woven preform. Figure 4

Description

Title of the invention: METHOD FOR MANUFACTURING A COMPOSITE MATERIAL PART WITH INTEGRATED MARKING AND COMPOSITE PART THUS OBTAINED Technical field of the invention

[0001] The invention relates to a method for manufacturing a part made of composite material and in particular to the marking of such a part. It relates more particularly to the marking of a composite part comprising a woven preform impregnated and coated with hardened resin. Technical background

[0002] In the aeronautical industry, it is necessary to mark certain parts, at least to ensure and facilitate their identification and traceability.

[0003] In the past, "barcode" type marking was widely used, for example by means of a simple self-adhesive label applied directly to the part. Such a rudimentary system has the disadvantage that the label can peel off or be damaged, compromising at least medium-term or long-term traceability. Furthermore, the amount of information that can be associated with the part is quite limited.

[0004] Currently, the identification of composite parts for turbomachines, particularly aircraft, such as blades and casing parts, is carried out by cotton labeling.

[0005] [Fig.l] represents an exploded view of such a labeled part 10. After manufacturing the part 2 in organic matrix composite (OMC) material, a cotton label 14 is stuck on said part by applying a first layer of varnish 12 on the part then a second layer of varnish on the cotton label 14.

[0006] Labeling is done manually and adds an additional step to the production of the part and therefore an additional cost to the final part.

[0007] On the one hand, some of the varnishes used present a certain danger / toxicity and will be banned from use in the coming years, in particular due to the introduction of the REACH regulation (European regulation no. 1907 / 2006) to secure the manufacture and use of chemical substances in European industry.

[0008] On the other hand, this labeling technique can present some drawbacks in engine operation, either by premature wear of the varnish layer, then leading to illegibility of the label and therefore the loss of all or part of the information on the part, or by flaking of the varnish, causing particles that may be unmanageable by the engine and will wear out other parts.

[0009] Furthermore, the labeling of a part made of organic matrix composite (OMC) material is subject to various design difficulties such as the durability of the label, its resistance to chemicals and its environment (UV, dust, etc.), its compatibility with the different materials of the part and / or the assembly of the parts, its compatibilities with respect to the manufacturing process of the part (thermal cycle, pressure, workability, etc.) and its printability, its readability, its lightness, its thickness. In addition, the labeling is also linked to the constraints related to the surface condition of the part, in particular the location in or out of cold / hot air flow, external constraints (saline air, polluted air, etc.).

[0010] Thus, there is a need for a new, efficient labeling method that can ensure the traceability of labeled parts to certification authorities throughout the part's operation. Labeling is all the more important since engraving is impossible on a part made of composite material since there is no question of damaging, notching, cracking, etc. the part to be labeled.

[0011] The invention aims to propose a solution making it possible to remedy at least some of these drawbacks.

[0012] In particular, the present invention provides a method for manufacturing a part made of organic matrix composite (OMC) material, in particular in a 3D woven composite material having an integrated identification support. Summary of the invention

[0013] The invention relates to a method for manufacturing a part made of organic matrix composite material for a turbomachine, in particular an aircraft turbomachine, comprising: - the production of a woven preform of fibers, the placement of the woven preform in a mold and the impregnation of the woven preform with a resin; and - before impregnation of the woven preform with the resin, the placement in an area of ​​the woven preform of an identification support formed by a superposition of at least one ply of pre-impregnated glass fibers and a label containing information relating to the organic matrix composite part.

[0014] Thus, the invention proposes a new method for integrating a label into the part to be labeled during the manufacture thereof.

[0015] The invention thus makes it possible to integrate a label into the part without requiring an additional specific step to install the label since its integration is planned during the manufacture of the part, before the injection of the resin into the part manufacturing mold.

[0016] Since the label is covered by the resin in the finished part, there is no risk of it coming off during operation of the turbomachine.

[0017] The materials of the identification support are adapted so as not to affect the resin and the polymerization thereof, be thermally stable during the possible cooking of the resin-impregnated preform and / or the exothermic polymerization reaction of the resin, not disturb the weaving, not hinder the closing of the blade manufacturing mold, and not be too bulky.

[0018] For example, the method is advantageously applicable for the manufacture of a blade of a turbomachine, in particular a fan blade, or a casing of a turbomachine, in particular a fan casing.

[0019] The manufacturing method according to the invention may comprise one or more of the following characteristics, taken individually or in combination with each other, in all technically possible combinations: - at least one ply of pre-impregnated glass fibers is placed directly on the woven preform; - the assembly comprises at least two plies of pre-impregnated glass fibers, the label being arranged between at least two plies of pre-impregnated glass fibers; - the woven preform is pre-impregnated and formed from a glass fiber fabric and an epoxy resin; - the label is made of cotton fabric with a weight between 80 and 120 g.m2; - the information relating to the piece is printed on the cotton fabric, for example in the form of alphanumeric characters and / or QR code and / or bar code; - the label includes an RFID chip comprising a memory storing information relating to the organic matrix composite part; - the manufacturing process comprising, after injection of the resin, a step of polymerization of the resin by heating or by baking or by thermal stripping; - the part made of organic matrix composite material is a turbomachine blade, in particular a turbomachine fan blade, or a turbomachine casing part, in particular a turbomachine fan casing.

[0020] The invention also relates to a part made of organic matrix composite material for a turbomachine, in particular an aircraft, comprising an assembly formed from a woven preform of fibers and a superposition in an area of ​​the preform of at least one ply of glass fibers and a label comprising information relating to the part, the assembly being densified by a resin.

[0021] The invention also relates to a method for repairing such an organic matrix composite part, comprising: - removal of the label from the preform area of ​​the part; - the application of another non-densified label on the preform area of ​​the part; - impregnation with a resin then densification of the preform of the part and the other label.

[0022] Advantageously, the removal involves tearing off the label. Brief description of the figures

[0023] The invention will be better understood and other characteristics and advantages will become apparent upon reading the detailed description which follows, comprising embodiments, given for illustrative purposes with reference to the appended figures and presented as non-limiting examples, which may serve to complete the understanding of the present invention and the description of its embodiment and, where appropriate, contribute to its definition, in which: - [Fig.l], already described, is a schematic sectional representation of a part labeled according to the prior art; - [Fig.2] is a schematic representation in longitudinal section of a turbomachine comprising parts to which the invention applies; - [Fig.3] is a schematic representation of a blade, in particular a fan blade, with an identification support according to the invention; - [Fig.4] is a schematic cross-sectional representation of a labeled part according to the invention; - [Fig.5] is a schematic sectional representation of a labeled part according to another embodiment of the invention; - [Fig.6] is a schematic representation of the identification support of [Fig.2]; - [Fig.7] is a schematic representation of a step of reading the label of an identification support of a fan casing of a turbomachine; - [Fig.8] represents a flowchart of a method for manufacturing a composite part according to the invention; and - [Fig.9] is a schematic representation of a piece of woven fibrous structure of a preform on which an identification support is positioned.

[0024] Elements having the same functions in different implementations have the same references in the figures. Detailed description of the invention

[0025] With reference to [Fig. 2], a turbomachine 100 is shown extending along a turbomachine axis X and making it possible to move the aircraft from an air flow entering the turbomachine 100 and circulating from upstream to downstream. Subsequently, the terms “upstream” and “downstream” are defined with respect to the turbomachine axis X oriented from upstream to downstream. Similarly, the terms “inside” and “outside” are defined according to a radial direction R defined relative to the axis X. In a known manner, the turbomachine 100 comprises at least one compressor, a combustion chamber and a turbine for rotating the compressor. The turbomachine 100 comprises upstream a fan 110 which makes it possible to accelerate the air flow from upstream to downstream in the turbomachine 100.

[0026] The fan 110 comprises a disk 111, integral in rotation with a shaft of the compressor, comprising housings, distributed around the periphery of the disk 111, in which blades 120 are respectively mounted by axial insertion along the turbomachine axis X from upstream to downstream. The blades 120 extend in the same plane transverse to the turbomachine axis X. For the sake of clarity and conciseness, a single blade 120 will now be presented. In this example, the turbomachine 100 comprises a cone 112 which is mounted upstream of the disk 111. The blades are surrounded by an annular casing 130. Each blade 120 extends along a radial axis R.

[0027] [Fig. 3] represents an exemplary embodiment of a fan blade 120 according to the invention. Each blade 120 successively comprises a mounting foot 121 configured to be mounted axially along a turbomachine axis X in a housing of the disk 111 of the fan 110, an air deflection blade 123 extending radially along the radial axis R relative to the turbomachine axis X. The blade 120 extends radially in the mounted position. The mounting foot 121 is thus described as radially inner while the air deflection blade 123 is described as radially outer.

[0028] The invention applies to any “composite” part of such a turbomachine, i.e. made of organic matrix composite material (OMC), requiring labeling and in particular to the casing 130 and the blades 120 of such a turbomachine.

[0029] In the remainder of the description, the invention is applied for example to a blade 120 made from a composite material comprising a plurality of fibers impregnated with a polymeric resin 126.

[0030] The fibers, preferably carbon fibers or even glass fibers, are woven together so as to form at least one preform 125 which is intended to be embedded in the resin 126. In this example, the resin is thermosetting of the epoxy, bismaleimide, polyimide type.

[0031] Such a preform is described in detail below.

[0032] Furthermore, the blade 120 comprises an identification support 140 formed by a superposition of at least one pre-impregnated glass fiber ply 142 and a label 144 comprising information relating to the organic matrix composite part, the blade 120 in the present example. Thus, at least one pre-impregnated glass fiber ply 142 is placed directly on the woven preform 125 during the manufacture of the blade as described below.

[0033] Preferably, the identification support 140 comprises at least one other ply 142 of pre-impregnated glass fibers so that the label 144 is arranged between at least two plies 142 of glass fibers. In other words, the identification support 140 comprises at least two plies 142 arranged on either side of the label 144, such as in the example shown in [Fig. 4]. Of course, the identification support 140 may contain more than two plies 142 of glass fibers. In addition, there may be a different number of plies 142 of glass fibers arranged above the label and below the label (between the label 144 and the preform 125).

[0034] [Fig. 5] illustrates another exemplary embodiment of the invention in which the identification support 140 comprises two plies 142 of glass fibers arranged between the label 144 and the preform 125.

[0035] Such folds are described in detail below.

[0036] Preferably, the label 144 is made of a cotton fabric whose weight is between 80 and 120 g.m2.

[0037] Advantageously, the information relating to the part is printed on the cotton fabric, for example in the form of alphanumeric characters and / or QR code and / or bar code. [Fig. 6] schematically represents a label 144 on which are printed for example a serial number 146, a version number 147 and a QR code 148.

[0038] According to these examples, the resin is advantageously optically transparent in order to allow direct optical reading by a reading device 150, in this case an optical reading device, of the label 144 of the identification support 140. Furthermore, the identification support 140 is preferably placed in a visible (optically) zone of the part to be labeled, in particular in the case of a blade, on the blade thereof or in the case of a casing 130 on its visible external surface as illustrated in [Fig.7].

[0039] Printing information on cotton fabric can be done manually or by a printer. The ink is chosen to withstand the manufacturing characteristics of the piece (time, pressure, temperature).

[0040] Alternatively, the tag 144 may comprise an RFID chip (not shown) comprising a memory storing information relating to the organic matrix composite part. Such an RFID chip advantageously allows the wireless transmission of the information it contains to a reading device 150, in particular in this case an RFID reader which can recover the transmitted data. In one embodiment, the tag 144 is an RFID chip and it is positioned in a location of the component rich in glass fibers. Positioning such a tag 144 in a location rich in glass fibers makes it possible to reduce the dissipation of the signal transmitted by the tag induced by the carbon fiber, and to increase the detection distance. from 10 centimeters, or even 20 centimeters up to 10 meters. The invention thus allows detection without removing the engine, that is to say detection directly under the aircraft or the engine alone as illustrated in [Fig.7].

[0041] The RFID chip comprises in particular for this purpose an antenna and one or more electronic components. The English acronym “RFID”, or “Radio Frequency Identification”, designates a support of the radio-identification type. A label according to RFID technology is known to those skilled in the art. The RFID chip is, preferably, a passive device, that is to say without a battery, but powered by a radio wave generated by the reading device 150, in particular the RFID reader. Alternatively, the RFID chip could comprise a battery.

[0042] Preferably, the RFID chip is configured to operate on the UHF band, the English acronym for “Ultra High Frequency”, for example at a frequency in particular between 860 and 960 MHz.

[0043] The glass fiber folds allow the RFID chip to be electrically insulated in order to maximize the detection distance of the RFID chip by the appropriate reading device 150.

[0044] According to this embodiment, the identification support can be arranged in a non-visible area of ​​the part when the turbomachine is assembled, in particular at the level of the root of the blade 120.

[0045] Thus, during a method of reading the data of the part according to the invention, and as illustrated in [Fig.7], the antenna of the RFID chip is configured to receive a reading request from the reading device 150 and to transmit in return data relating to the part bearing the label.

[0046] The information of the identification medium 140 may be definitive or modifiable in order to be updated according to the type of label. They may thus report on the weaving, shaping, injection, machining, repair or other operations of the part and may thus retain knowledge of possible incidents occurring during one or more operations of this type.

[0047] The invention also proposes a method for manufacturing a part, for example a blade 120 as described above or a casing 130. [Fig.8] illustrates a flowchart of such a method comprising a step S12 of producing a preform 125 woven from fibers.

[0048] The preform 125 is formed from a fabric of fibers injected with resin, that is to say that the preform is obtained from a fiber structure 127 made by weaving fibers. Preferably, the fiber structure 127 is obtained by three-dimensional weaving. By “three-dimensional weaving” or “3D weaving” is meant here a weaving method by which certain warp threads 128 bind weft threads 129 of several distinct weft layers such as for example an “interlock weave”. By "Interlock weave" here means a 3D weave in which each warp column links several layers of wefts, all the threads of the same warp column having the same movement in the plane of the weave.

[0049] Such a fibrous structure 127 obtained by 3D weaving makes it possible to obtain a connection between the layers of weft threads, therefore to have good mechanical strength of the fibrous structure and of the composite material part obtained, in a single textile operation. Such a fibrous structure 127 is shown diagrammatically in [Fig.9].

[0050] The fibrous structure 127 can be produced in a known manner by means of a Jacquard type loom on which a bundle of warp threads 128 or strands has been arranged in a plurality of layers, the warp threads 128 being linked by layers of weft threads 129 or strands also arranged in a plurality of layers. The threads or strands used to weave the fibrous structure 127 can preferably consist of carbon fibers and / or glass fibers. Other fibers are also possible such as natural fibers, aramid, polyester, etc.

[0051] Alternatively, the fibrous structure may be the result of the superposition of plies of woven fibers obtained by laminated two-dimensional weaving. By "two-dimensional weaving" or "2D weaving" is meant here a weaving method by which the interlacing of warp threads and weft threads is carried out on a single weft layer forming a ply of fibers or 2D woven fiber ply.

[0052] The fibrous structure 127 is then placed in a mold (not shown) and impregnated with a resin to form the preform 125 during a step S14.

[0053] The impregnation process as such is known, and may for example be an LCM type process (for the English abbreviation “Liquid Composite Molding”), a resin injection molding process assisted or not by vacuum (also called “RTM” or “VARTM” for the English acronyms “Resin Transfer Molding” or “Vacuum-assisted Resin Transfer Molding”) or even by autoclave, or in an oven.

[0054] The ply 142 of [Fig.4] is a fibrous structure 127 made of Hexcel® HexForce M26T material: 2*2 205g / m2 and formed by a 2*2 twill type weave, E-type glass fibers, and the resin is an epoxy resin.

[0055] Such a fibrous structure is particularly advantageously used on the fan casing of turbomachines for its fire-resistant properties.

[0056] The method continues with a step S16 of placing the identification support 140 in an area of ​​the part. For this, at least one ply 142 of pre-impregnated glass fibers is placed directly on the preform 125.

[0057] Such a ply 142 of pre-impregnated glass fibers is obtained from a fiber structure made by two-dimensional weaving and then impregnated with the same resin as the preform. By "two-dimensional weaving" or "2D weaving" is meant here a method of weaving by which the interlacing of warp threads and weft threads is carried out on a single weft layer forming a ply of fibers or 2D woven fiber ply. The plies 142 of woven fibers or 2D plies can also be produced using a Jacquard type loom on which a bundle of warp threads has been arranged in a single layer and a bundle of weft threads in a single layer. In one embodiment, the threads or strands used to weave the fiber preform are made of carbon fibers, or even glass fibers.

[0058] For example, each fiberglass ply is made of material commercially available under the reference Hexcel® HexForce M26T: 2*2 205g / m2 and formed by a 2*2 twill type weave, type E glass fibers. The average thickness of an insulating ply is substantially equal to approximately 0.16 mm.

[0059] The label 144 is then superimposed on the glass fiber ply(ies) placed on the preform in the mold.

[0060] Advantageously, at least one other ply 142 of pre-impregnated glass fibers is placed on the label 144 so as to have at least one ply 142 of glass fibers on either side of the label 144.

[0061] The method then comprises a step S18 of injecting resin into the mold so as to simultaneously impregnate the preform 125 and the identification support 140.

[0062] Then, during a step S20, the resin is polymerized. In the case of a thermosetting resin, the resin is polymerized by a heating means.

[0063] The invention also proposes a method for repairing a part manufactured according to such a manufacturing method, and in particular a method for replacing the identification support, more particularly for replacing the label, when the latter is damaged or needs to be renewed.

[0064] Such a method comprising a step of removing the label from the area of ​​the preform of the part, during which the damaged label to be replaced and at least any fiberglass folds arranged above said label are removed. The removal of the label to be removed can be carried out by tearing, for example by mechanical tearing using a manual hook-type tool or by an automated tool.

[0065] The repair / replacement process continues by placing a new identification support containing a new non-densified label on the area of ​​the preform of the part. In particular, at least one new pre-impregnated glass fiber ply is placed directly on the preform in the same area of ​​the part as the identification support that was removed. Then the new label is superimposed on the glass fiber ply(ies). In a similar manner to the manufacturing process, at least one other pre-impregnated glass fiber ply can advantageously be placed on the new label.

[0066] The assembly formed by the part from which the label has been removed and the new identification support is impregnated with a resin, then densified by polymerization of the resin, for example by heating.

[0067] Obviously, the invention is not limited to the embodiments described above and provided solely by way of example. It encompasses various modifications, alternative forms and other variants that may be envisaged by those skilled in the art within the scope of the invention and in particular all combinations of the different operating modes described above, which may be taken separately or in association.

Claims

Claims

1. Method for manufacturing a part (120; 130) made of organic matrix composite material for a turbomachine (100), in particular an aircraft, comprising: - producing a preform (125) woven from fibers, placing the woven preform in a mold and impregnating the woven preform with a resin (126); and - before impregnating the woven preform with the resin, placing in a zone of the woven preform an identification support (140) formed by a superposition of at least one ply (142) of pre-impregnated glass fibers and a label (144) comprising information relating to the organic matrix composite part.

2. A manufacturing method according to claim 1, wherein at least one ply (142) of pre-impregnated glass fibers is laid directly on the woven preform (125).

3. Manufacturing method according to claim 1 or 2, wherein the identification support (140) comprises at least two plies (142) of pre-impregnated glass fibers, the label (144) being arranged between at least two plies of pre-impregnated glass fibers.

4. A manufacturing method according to any preceding claim, wherein the woven preform (125) is pre-impregnated and formed from a fabric (127) of glass fibers and an epoxy resin.

5. A manufacturing method according to any one of the preceding claims, wherein the label (144) is made of a cotton fabric having a weight between 80 and 120 g.m2.

6. Manufacturing method according to the preceding claim, in which the information relating to the part (120, 130) is printed on the cotton fabric, for example in the form of alphanumeric characters and / or QR code (148) and / or bar code.

7. Manufacturing method according to one of claims 1 to 5, in which the label (144) comprises an RFID chip comprising a memory storing information relating to the organic matrix composite part.

8. Manufacturing method according to any one of the preceding claims, comprising after the injection of the resin, a step of polymerizing the resin by heating or by baking or by thermal stripping.

9. Manufacturing method according to any one of the preceding claims, in which the part made of organic matrix composite material is a turbomachine blade (120), in particular a turbomachine fan blade, or a turbomachine casing part (130), in particular a turbomachine fan casing.

10. Method for repairing an organic matrix composite part for a turbomachine, in particular an aircraft, comprising an assembly formed from a woven preform of fibers and a superposition in an area of the preform of at least one ply of glass fibers and a label comprising information relating to the part, the assembly being densified by a resin, the method comprising: - removing the label from the area of the preform of the part; - placing another non-densified label on the area of the preform of the part; - impregnating with a resin then densifying another assembly formed from the preform of the part and the other non-densified label.

11. A repair method according to claim 10, wherein the removal comprises tearing off the label.

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