Process for manufacturing a blade by chemical vapor infiltration

Abstract

Method for manufacturing a blade by chemical vapor infiltration The invention relates to a method for manufacturing a blade (300) made of a ceramic matrix composite material comprising at least one chemical vapor infiltration of a fiber preform of the blade (200), the fiber preform of the blade (200) comprising at least one root preform (210), the method being characterized in that the root preform (210) comprises an internal housing (106a) opening onto the exterior of the preform of the blade (200) and in that an insert (50) is inserted into the housing (106a) of the root preform (210) before the chemical vapor infiltration. Figure for abstract: Fig. 2

Description

Title of the invention: Method for manufacturing a blade by chemical vapor infiltration Technical field

[0001] The present invention relates to the manufacture of a blade made of ceramic matrix composite material by chemical vapor infiltration. Prior art

[0002] The production of turbomachine blades from ceramic matrix composite (CMC) material is well known. Ceramic matrix composite materials withstand temperatures ranging from 600°C to 1400°C, thus requiring less cooling, and are lighter while retaining good mechanical properties. The efficiency of the turbomachine is improved, which allows a reduction in fuel consumption.

[0003] The fiber reinforcement of the turbomachine blades is formed by a fiber preform which can be produced by weaving, for example by three-dimensional weaving. In a well-known manner, a fiber blank is produced by weaving, for example by three-dimensional weaving. The fiber blank is then shaped so as to obtain a fiber preform. Then, chemical vapor infiltration, or "CVI" for "Chemical Vapor Infiltration" in English, can be carried out on the fiber preform.

[0004] However, carrying out chemical vapor infiltration at the blade root is particularly delicate, since the root portion is formed by a thick and dense fiber reinforcement. Indeed, the circulation of gases at the core of the root is not carried out satisfactorily during chemical vapor infiltration. Thus, the quality of the composite material at the blade root may be insufficient. Statement of the invention

[0005] In order to overcome the aforementioned drawbacks, the invention proposes a manufacturing method making it possible to obtain a blade made of ceramic matrix composite material by chemical vapor infiltration having sufficient material quality at the root of the blade.

[0006] For this purpose, the invention proposes a method for manufacturing a blade made of ceramic matrix composite material comprising a root, the method comprising chemical vapor infiltration of a fiber preform of the blade, the fiber preform of the blade comprising at least one root preform,

[0007] the method being characterized in that the foot preform comprises an internal housing opening onto the exterior of the fiber preform of the blade and separating a first skin of the foot preform of a second skin of the foot preform, an insert being inserted into the housing of the foot preform before the chemical vapor infiltration, the insert opening onto the exterior of the fiber preform and keeping the first skin spaced from the second skin.

[0008] Thus, the presence of an internal housing inside the root preform filled by an insert makes it possible to reduce the thickness of the fiber reinforcement. The circulation of gases inside the entire root preform is thus facilitated, making it possible to obtain a better material quality at the root of the final blade.

[0009] According to a particular embodiment of the invention, the foot preform is produced in a single piece by three-dimensional weaving. The fiber blade preform can be produced in a single piece by three-dimensional weaving.

[0010] According to a first embodiment of the invention, the insert is made from a material among a carbide, a nitride or carbon.

[0011] Such an insert is intended to remain in the final blade.

[0012] According to a particular aspect of this first embodiment of the invention, the method may further comprise a second chemical vapor infiltration. The second chemical vapor infiltration is carried out after the first chemical vapor infiltration. The second chemical vapor infiltration may be considered as a consolidation step of the fiber blade preform.

[0013] According to a particular aspect of this first embodiment of the invention, the first chemical vapor infiltration can make it possible to deposit an interphase layer on the fibers of the fiber preform of the blade and the second chemical vapor infiltration can make it possible to form at least a first matrix phase in the porosities of the fiber preform of the blade.

[0014] According to a particular aspect of this first embodiment of the invention, the fiber preform of the blade can be arranged in a former for the first chemical vapor infiltration. The fiber preform of the blade can be maintained in the former for the second chemical vapor infiltration. Thus, the fiber preform of the blade is not removed from the former between the first chemical vapor infiltration and the second chemical vapor infiltration.

[0015] According to a particular aspect of this first embodiment of the invention, the method may further comprise a third chemical vapor infiltration after the first and second chemical vapor infiltration, the third chemical vapor infiltration making it possible to form at least a second matrix phase in the porosities of the fiber preform of the blade.

[0016] The second matrix phase deposited during the third chemical infiltration in vapor phase may be identical to the first matrix phase deposited during the second chemical vapor infiltration.

[0017] According to a particular aspect of this first embodiment of the invention, the fiber preform of the blade can be removed from the former between the second chemical vapor infiltration and the third chemical vapor infiltration.

[0018] According to a second embodiment of the invention, the chemical vapor infiltration corresponds to a first chemical vapor infiltration carried out at a first temperature, the method further comprising a second chemical vapor infiltration carried out at a second temperature higher than the first temperature, the insert being made of oxide so that said insert is partially eliminated during the second chemical vapor infiltration so as to reduce the volume of said insert.

[0019] The second chemical vapor infiltration is carried out after the first chemical vapor infiltration. The second chemical vapor infiltration can be considered as a consolidation step of the fiber blade preform.

[0020] Thus, during the first chemical vapor infiltration, while the fiber preform is not yet self-supporting, the insert is stable and contributes to maintaining its shape. At the end of the first chemical vapor infiltration, the fiber preform is sufficiently set to remain in the required shape and the insert is then no longer necessary to maintain its shape. During the second chemical vapor infiltration, the insert is degraded, in particular at its surface in contact with the foot preform. This degradation leads to a reduction in the volume of the insert and to the formation of an intercalary space between the insert and the foot preform. This intercalary space promotes the circulation of reactive gases in the internal housing. Thus, the gases have access to the internal housing of the fiber preform, which makes it possible to accelerate and facilitate the second chemical vapor infiltration.

[0021] According to a particular aspect of this second embodiment of the invention, the partially removed insert can be removed from the internal housing after the second chemical vapor infiltration. The partially removed insert can also be removed during the second chemical vapor infiltration. The removal of the insert can in particular be carried out mechanically, for example by means of shocks and / or vibrations.

[0022] According to a particular aspect of this second embodiment of the invention, the insert may comprise one or more materials from silicon dioxide, aluminum oxide, zirconium dioxide.

[0023] According to a particular aspect of this second embodiment of the invention, the first chemical vapor infiltration can make it possible to deposit an interphase layer on the fibers of the fiber preform of the blade and the second chemical vapor infiltration can make it possible to form at least a first matrix phase in the porosities of the fiber preform of the blade.

[0024] According to a particular aspect of this second embodiment of the invention, the fiber preform of the blade can be arranged in a former for the first chemical vapor infiltration. The fiber preform of the blade can be maintained in the former for the second chemical vapor infiltration. Thus, the fiber preform of the blade is not removed from the former between the first chemical vapor infiltration and the second chemical vapor infiltration.

[0025] According to a particular aspect of this second embodiment of the invention, the method may further comprise a third chemical vapor infiltration after the first and second chemical vapor infiltration, the third chemical vapor infiltration making it possible to form at least a second matrix phase in the porosities of the fiber preform of the blade.

[0026] The second matrix phase deposited during the third chemical vapor infiltration may be identical to the first matrix phase deposited during the second chemical vapor infiltration.

[0027] According to a particular aspect of this second embodiment of the invention, the fiber preform of the blade can be removed from the former between the second chemical vapor infiltration and the third chemical vapor infiltration.

[0028] According to a particular aspect of the invention, the insert may comprise one or more discontinuous external surfaces such that said one or more external surfaces are in contact with the fiber preform in a discontinuous manner during the chemical vapor infiltration. In particular, said one or more external surfaces may be in contact with the fiber preform in a discontinuous manner during the first chemical vapor infiltration.

[0029] The presence of such discontinuous external surfaces makes it possible to facilitate the circulation of reactive gases on the surface of the insert during chemical vapor infiltration. In particular, in the context of the second embodiment of the invention, such surfaces are particularly easy and quick to remove during the second chemical vapor infiltration so that the volume reduction of the insert can be carried out more quickly after the start of said second chemical vapor infiltration. These discontinuous external surfaces may be in the form of external surfaces having relief patterns or grooves. These external surfaces discontinuous can also be obtained with an insert having a lattice or mesh structure.

[0030] According to a particular aspect of the invention, the insert may comprise one or more external surfaces having relief patterns or grooves.

[0031] According to a particular aspect of the invention, the insert may have a lattice or mesh structure.

[0032] Such an insert allows particularly easy circulation of reactive gases, including from the lower edge of the fiber preform.

[0033] According to a particular aspect of the invention, the method may further comprise an infiltration of ceramic powder after the chemical vapor infiltration(s).

[0034] According to a particular aspect of the invention, the method may further comprise liquid infiltration after the chemical vapor infiltration(s). Brief description of the drawings

[0035] [Fig-1] [Fig.l] is a perspective representation of a fiber blank.

[0036] [Fig.2] [Fig.2] is a cross-sectional representation of a fiber preform obtained by shaping the fibrous blank of [Fig.l] and placed in a former for the first chemical vapor infiltration.

[0037] [Fig.3] [Fig.3] is a graph representing a cycle comprising the first and second chemical vapor infiltration.

[0038] [Fig.4] [Fig.4] is a cross-sectional representation of the fiber preform of the [Fig.2] during the second chemical vapor infiltration, illustrating the decrease in volume of the insert.

[0039] [Fig.5] [Fig.5] is a perspective representation of a first variant of the insert.

[0040] [Fig.6] [Fig.6] is a perspective representation of a second variant of the insert.

[0041] [Fig.7] [Fig.7] is a cross-sectional representation of the fiber preform of FIGS. 2 and 4 during a third chemical vapor infiltration, after removal of the insert.

[0042] [Fig.8] [Fig.8] is a cross-sectional representation of the blade obtained according to the second embodiment of the invention. Description of the embodiments

[0043] The invention applies generally to the production of blades made of ceramic matrix composite material comprising a root.

[0044] The fiber reinforcement of the blade is formed at least in part by a fiber preform. The fiber preform is obtained by shaping a fiber blank 100. The fiber blank 100 comprises a foot blank 110, as illustrated in [Fig.l]. The foot blank 110 is intended to be shaped to obtain the foot preform.

[0045] The fibrous blank 100 can be obtained by three-dimensional weaving carried out in a known manner using a jacquard-type loom on which a bundle of warp threads or strands has been arranged in a plurality of layers of several hundred threads each, the warp threads being linked by weft threads. The fibrous blank 100 is preferably woven in a single piece, in order to improve its mechanical characteristics.

[0046] By "three-dimensional weaving" is meant here a weaving method by which at least some of the warp threads bind weft threads over several weft layers. A reversal of roles between warp and weft is possible. It is considered that a fiber blank produced by three-dimensional weaving may comprise another type of weaving on its surface, for example two-dimensional weaving, in order to improve its surface condition.

[0047] Preferably, the three-dimensional weave used is an "interlock" weave. By "interlock" we mean here a weave weave in which each layer of weft threads binds several layers of warp threads with all the threads of the same weft column having the same movement in the plane of the weave.

[0048] Other known types of three-dimensional weaving may be used, such as those described in document WO 2006 / 136755. This document describes in particular the production by weaving in a single piece of fiber reinforcement structures for parts such as blades having a first type of core armor and a second type of skin armor which make it possible to confer both the mechanical and aerodynamic properties expected for this type of part.

[0049] The fiber blank 100 extends in a radial direction DR, corresponding to the span direction of the blade to be manufactured, between a lower edge 100a and an upper edge. The fiber blank 100 extends in an axial direction DA, corresponding to the chord direction of the blade to be manufactured, between a first lateral edge 100c and a second lateral edge 100d.

[0050] During weaving, a separation 106 may be produced in a well-known manner inside the foot blank 110 of the fiber blank 100. The separation 106 extends between two successive layers of warp threads. Thus, the separation 106 extends along a plane parallel to the surface of the fiber blank 100. The separation 106 thus locally separates a first skin 111 and a second skin 112 of the foot blank 110. The separation 106 does not extend beyond the foot blank 110. The separation 106 opens onto the lower edge 100a of the fiber blank 100.

[0051] Once the weaving is finished, the non-woven threads present around the fibrous blank 100 are cut to extract said blank.

[0052] The fiber blank 100 is shaped so as to obtain a fiber preform 200, as illustrated in section in [Fig.2]. The fiber preform 200 comprises a root preform 210. The root preform 210 is intended to form the fiber reinforcement of the root of the blade. The root preform 210 is obtained by shaping the root blank 110. The fiber preform 200 extends in the radial direction DR, corresponding to the span direction of the blade to be manufactured, between a lower edge 200a and an upper edge.

[0053] The shaping of the fiber blank 100 into a fiber preform 200 is carried out by opening the uncoupling 106 of the fiber blank 100 so as to form a single internal housing 106a. The internal housing 106a is present inside the foot preform 210. The internal housing 106a is accessible via the lower edge 200a of the fiber preform 200. The lower edge 200a of the fiber preform 200 corresponds to the lower edge 100a of the fiber blank 100. Preferably, the internal housing 106a opens only onto the lower edge 200a of the fiber preform 200. The internal housing 106a does not extend beyond the foot preform 210. The internal housing 106a separates a first skin 211 and a second skin 212 of the foot preform 210. The first skin 211 and the second skin 212 of the foot preform 210 correspond respectively to the first skin 111 and the second skin 112 of the fiber blank 100. foot 110.

[0054] According to the invention, an insert 50 is arranged in the internal housing 106a. The insert 50 fills the internal housing 106a. The insert 50 keeps the first and second skins 211 and 212 spaced apart from each other. The insert 50 may be flush with the lower edge 200a of the fiber preform 200. The insert 50 opens out at the lower edge 200a of the fiber preform 200. The insert 50 may be a single piece.

[0055] According to a first embodiment of the invention, the insert 50 is made of a material among a carbide, a nitride or carbon. For example, the insert 50 can be made of silicon carbide. In this first embodiment, the insert 50 is intended to remain in the final blade.

[0056] According to a second preferred embodiment of the invention, the insert 50 comprises one or more oxide-type materials. For example, the insert 50 may comprise one or more materials from silicon dioxide, or silica, aluminum oxide, or alumina, and zirconium dioxide, or zirconia. In the second embodiment, the insert 50 is not intended to remain in the final blade. The insert 50 will thus be removed during the second chemical vapor infiltration or after the second chemical vapor infiltration, as explained below.

[0057] The fiber preform 200 is subjected to a first chemical vapor infiltration, as illustrated in [Fig.2]. For this purpose, the fiber preform 200 is arranged in a conformer 6. [Fig.2] illustrates a conformer 6 comprising a plurality of holding elements which define gas flow channels between them. An example of a conformer of this type is described in particular in document FR 3130852 A1. It is of course not outside the scope of the invention if another type of conformer is used.

[0058] In a well-known manner, the fiber preform 200 arranged in the former 6 can be placed in a chemical vapor infiltration installation. The chemical vapor infiltration installation can comprise an enclosure delimiting a reaction chamber provided with a gas inlet pipe which can open into a homogenization zone making it possible to homogenize the gas(es) before their diffusion into the reaction chamber. The reaction chamber can comprise a support on which the fiber preform 200 loaded in the former 6 is intended to be deposited. The residual gases can be extracted at the top of the installation by an evacuation pipe which is connected to suction means. The heating is for example produced by an assembly comprising an inductor and a susceptor.

[0059] In order to carry out the first chemical vapor infiltration, one or more reactive gases Gi are introduced into the reaction chamber. The first chemical vapor infiltration may make it possible to deposit an interphase layer on the fibers of the fiber preform 200. The first chemical vapor infiltration thus makes it possible to obtain a self-supporting fiber preform 200, i.e. a fixed fiber preform 200. The reactive gas(es) Gi may contain one or more interphase material precursors. The interphase material is intended to cover the fibers of the fiber preform 200. For example, the reactive gas(es) Gi may contain one or more boron nitride BN precursors.The consolidation of the preform 200 is ensured, in a manner well known per se, by depositing within it the material produced by decomposition of the precursor(s) contained in the reactive gas(es) Gi diffusing inside the accessible internal porosity of the preform 200.

[0060] The first chemical vapor infiltration is carried out at a first temperature. If the material deposited by the first chemical vapor infiltration is boron nitride, the first temperature will be about 700°C, as illustrated in [Fig.3].

[0061] [Fig. 3] illustrates an example of a cycle comprising a first chemical vapor infiltration and a second chemical vapor infiltration. The first chemical vapor infiltration makes it possible to deposit an interphase layer on the fibers of the fiber preform 200. The second chemical vapor infiltration makes it possible to deposit a matrix phase in the porosities of the fiber preform 200. In the example illustrated in [Fig. 3], the first in chemical vapor filtration allows boron nitride to be deposited on the fibers of the fiber preform 200. The second chemical vapor infiltration allows silicon carbide to be deposited in the porosities of the fiber preform 200.

[0062] As illustrated in [Fig.4], the second chemical vapor infiltration is preferably carried out by maintaining the fiber preform 200 in the former 6 used for the first chemical vapor infiltration.

[0063] The second chemical vapor infiltration is carried out at a second temperature higher than the first temperature of the first chemical vapor infiltration. In the example illustrated in [Fig.3], the first temperature is about 700°C and the second temperature is between 1000°C and 1400°C. Preferably, the second temperature is variable but always higher than the first temperature. Thus, the second temperature can be variable between 1000°C and 1400°C. The second temperature is preferably decreasing during the second chemical vapor infiltration.

[0064] In order to carry out the second chemical vapor infiltration, one or more reactive gases G2 are introduced into the reaction chamber, as illustrated in [Fig. 4]. The second chemical vapor infiltration allows at least partial densification of the fiber preform 200. The second chemical vapor infiltration thus makes it possible to form at least a first matrix phase in the porosities of the fiber preform 200. The reactive gas(es) G2 may contain one or more ceramic matrix precursors. For example, the reactive gas(es) G2 may contain one or more silicon carbide SiC precursors. Methyltrichlorosilane MTS may be used, in a manner well known per se, as a precursor of silicon carbide SiC.The at least partial densification of the preform 200 is ensured, in a manner well known per se, by depositing within it the material produced by decomposition of the precursor(s) contained in the reactive gas(es) G2 diffusing inside the accessible internal porosity of the preform 200.

[0065] The second chemical vapor infiltration is carried out at the second temperature. If the material deposited by the second chemical vapor infiltration is silicon carbide, the second temperature will be between 1000°C and 1400°C, as illustrated in [Fig.3].

[0066] More generally, the first and second chemical vapor infiltrations can allow, in a well-known manner, the deposition of interphase or ceramic matrix phase materials such as pyrolytic carbon PyC, boron-doped carbon BC, boron carbide B4C, boron nitride BN, silicon nitride Si3N4, and silicon carbide SiC. Reference may in particular be made to documents US 5,246,736, US 5,738,951, US 5,965,266, US 6,068,930 and US 6,284,358.

[0067] In the first embodiment of the invention (not shown), the insert remains stable during chemical vapor infiltration. The insert therefore remains present in the foot preform 210.

[0068] In the second embodiment of the invention, illustrated in Figures 4 and 7, the insert 50 decomposes during the second chemical vapor infiltration. Indeed, during the second chemical vapor infiltration, the high temperature and the environment loaded with H2 gas cause the reduction of the insert 50 made of oxide. Thus, the surfaces of the insert 50 in contact with the gases decompose by reduction. The progressive reduction of the insert 50 leads to the formation of an interposed space between the insert 50 and the foot preform 210, which allows better access to the internal part of the foot preform 210 for the reactive gas(es) G2.

[0069] At the end of the first and second chemical vapor infiltrations, the fiber preform 200 is self-supporting. The fiber preform 200 can thus be removed from the shaper 6. In the context of the second embodiment of the invention, the partially removed insert 50 can be completely removed during the second chemical vapor infiltration or after the chemical vapor infiltration.

[0070] The partially removed insert 50 may be removed mechanically, for example by subjecting it to shocks and / or vibrations.

[0071] In the example illustrated in the preceding figures, the insert has a solid geometry with flat surfaces. It is of course not outside the scope of the invention if the insert has a hollow geometry, and / or if the insert has non-flat or complex surfaces. In particular, the insert may comprise one or more discontinuous external surfaces so that said external surface(s) are in contact with the fiber preform in a discontinuous manner during the first chemical vapor infiltration, and at the start of the second chemical vapor infiltration. For example, Figures 5 and 6 illustrate geometry variants for the insert.

[0072] According to a first variant illustrated schematically in [Fig. 5], the insert 50bis may have raised patterns or grooves on one or more outer surfaces of the insert 50bis intended to be in contact with the fiber preform 200. The raised patterns or grooves may be organized in the form of a network. The raised patterns or grooves may have a honeycomb geometry, as illustrated in [Fig. 5]. Thus, the insert 50bis is in contact with the fiber preform 200 in a discontinuous manner. This first variant is particularly interesting in the context of the second embodiment of the invention, according to which the insert is removed from the fiber preform. Such a geometry of the insert makes it possible to accelerate and facilitate the reduction of the volume of the insert.Indeed, the reduction of the relief patterns of the insert, which represent a very limited volume, is sufficient to allow the removal of the insert 50bis from the fiber preform 200 or the creation of a significant intercalary space. with the fiber preform. Thus, to obtain the same spacing distance between the insert and the fiber preform 200 during the second chemical vapor infiltration, and thus allow the removal of the insert, the smooth and flat insert 50 requires the removal of a larger volume of material than the insert 50bis with raised patterns or grooves on its surface.

[0073] According to a second variant illustrated schematically in [Fig.6], the insert 50ter may have a hollow lattice or hollow mesh structure. Thus, the insert 50ter is in contact with the fiber preform 200 in a discontinuous manner. The insert 50ter also allows the circulation of gases through said insert 50ter. The insert 50ter having a lattice or mesh structure is configured to be traversed right through by the reactive gases. In the context of the first embodiment of the invention, such an insert 50ter makes it possible to facilitate the circulation of gases during the first chemical vapor infiltration, and where appropriate during subsequent chemical vapor infiltrations. This advantage is all the more appreciable since, in the first embodiment of the invention, the insert is not reduced during the second chemical vapor infiltration.In the context of the second embodiment of the invention, such an insert 50ter is easy and quick to remove from the fiber preform 200 during the second chemical vapor infiltration, for reasons similar to those set out in the first variant above.

[0074] The second chemical vapor infiltration may allow the formation of a satisfactory matrix phase in the porosities of the fiber preform 200, making it possible to obtain the final blade made of composite material. However, generally, the second chemical vapor infiltration is followed by other matrix formation steps, making it possible to obtain the final composite material.

[0075] Thus, when the second chemical vapor infiltration is completed, the method may further comprise a third chemical vapor infiltration, as illustrated in [Fig.7]. This third chemical vapor infiltration is preferably carried out outside a former, in order to allow better circulation of the reactive gases. In the context of the second embodiment of the invention, the insert 50 has preferably been removed from the fiber preform 200 when the third chemical vapor infiltration begins. The chemical vapor infiltration installation used for the third chemical vapor infiltration may be the same as that used for the first and second chemical vapor infiltrations.

[0076] In order to carry out the third chemical vapor infiltration, one or more reactive gases G3 are introduced into the reaction chamber, as illustrated in [Fig.7]. The third chemical vapor infiltration allows at least partial densification of the fiber preform 200. The third chemical vapor infiltration vapor phase thus makes it possible to form at least a second matrix phase in the porosities of the fiber preform 200. The reactive gas(es) G3 may be identical to the reactive gas(es) G2 used during the second chemical vapor infiltration. The reactive gas(es) G3 may contain one or more ceramic matrix precursors. For example, the reactive gas(es) G3 may contain one or more silicon carbide SiC precursors. Methyltrichlorosilane MTS may be used, in a manner well known per se, as a precursor of silicon carbide SiC. The at least partial densification of the preform 200 is ensured, in a manner well known per se, by depositing within it the material produced by decomposition of the precursor(s) contained in the reactive gas(es) G3 diffusing inside the accessible internal porosity of the preform 200.

[0077] When the chemical vapor infiltration(s) are complete, an additional step of ceramic powder infiltration can be carried out in a well-known manner. The infiltration of ceramic powder can be carried out in a well-known manner using a slip, for example according to the so-called “STM” process for “Slurry Transfer Molding”. This additional step makes it possible to quickly form a part of the matrix in the porosities of the fiber preform 200. In the context of the second embodiment of the invention, this additional step makes it possible to at least partially fill the internal housing 106a left free by the insert 50.

[0078] An additional liquid infiltration step, called “MI” for “Melt Infiltration”, can also be carried out. This additional liquid infiltration step is preferably carried out after the ceramic powder infiltration step. This additional step is conventionally carried out by introducing a composition comprising molten silicon into the remaining porosities of the fiber preform 200 to obtain the final matrix. In the context of the second embodiment of the invention, this additional step makes it possible to finish filling the internal housing 106a left free by the insert 50.

[0079] In the first embodiment, a blade is ultimately obtained made of ceramic matrix composite material comprising the insert at its root.

[0080] In the second embodiment, as illustrated in [Fig.8], a blade 300 is ultimately obtained in ceramic matrix composite material comprising a portion 306 devoid of fibers in the root 310 of the blade 300. The portion 306 devoid of fibers separates a first skin 311 of the root 310 from a second skin 312 of the root 310. The portion 306 devoid of fibers corresponds to the volume of the fiber preform 200 which was occupied by the insert 50. The portion 306 devoid of fibers can be made of matrix material.

Claims

Claims

1. A method of manufacturing a blade (300) made of a ceramic matrix composite material having a root (310), the method comprising chemical vapor infiltration of a fiber preform of the blade (200), the fiber preform of the blade (200) comprising at least one root preform (210), the method being characterized in that the root preform (210) comprises an internal housing (106a) opening onto the exterior of the fiber preform of the blade (200) and separating a first skin (211) of the root preform (210) from a second skin (212) of the root preform (210), an insert (50) being inserted into the housing (106a) of the root preform (210) before the chemical vapor infiltration, the insert (50) opening onto the exterior of the fiber preform (200) and now the first skin (210) separated from the second skin (220).

2. A manufacturing method according to claim 1, wherein the chemical vapor infiltration corresponds to a first chemical vapor infiltration carried out at a first temperature, the method further comprising a second chemical vapor infiltration carried out at a second temperature higher than the first temperature, the insert (50) being made of oxide so that said insert (50) is partially eliminated during the second chemical vapor infiltration so as to reduce the volume of said insert (50).

3. The manufacturing method of claim 2, wherein the partially removed insert is removed from the inner housing (106a) after the second chemical vapor infiltration.

4. A manufacturing method according to claim 2 or 3, wherein the insert (50) comprises one or more materials from silicon dioxide, aluminum oxide, zirconium dioxide.

5. A manufacturing method according to any one of claims 2 to 4, wherein the first chemical vapor infiltration makes it possible to deposit an interphase layer on the fibers of the fiber preform of the blade (200) and wherein the second chemical vapor infiltration makes it possible to form at least a first matrix phase in the porosities of the fiber preform of the blade (200).

6. A manufacturing method according to claim 1, wherein the insert is made of a material among a carbide, a nitride or carbon.

7. A manufacturing method according to any one of claims 1 to 6, wherein the insert (50bis; 50ter) comprises one or more discontinuous external surfaces such that said one or more external surfaces are in contact with the fiber blade preform (200) in a discontinuous manner during chemical vapor infiltration.

8. A manufacturing method according to any one of claims 1 to 7, wherein the insert (50bis) comprises one or more external surfaces having relief patterns or grooves.

9. A manufacturing method according to any one of claims 1 to 7, wherein the insert (50ter) has a lattice or mesh structure.

10. A manufacturing method according to any one of claims 1 to 9, the method further comprising ceramic powder infiltration after the chemical vapor infiltration(s).

11. A manufacturing method according to any one of claims 1 to 10, the method further comprising liquid infiltration after the chemical vapor infiltration(s).

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