Method for manufacturing a turbomachine part from composite material

Abstract

Method for manufacturing a turbomachine part from composite material. The invention relates to a method comprising: - shaping a 3D woven blank (1) comprising one or more deployable fibrous portions (3), including: the deployment (E1a) of each deployable fibrous portion by a gripper device (61) mounted on a robotic arm (6), the positioning (E2) of a first conformation part (5) opposite a face (F2) of each deployed fibrous portion, the release of each deployed fibrous portion by deactivating the gripper device once it is in contact with the first conformation part, and the shaping of each deployed and released fibrous portion by holding it between the first conformation part and a second conformation part, and - densification by forming a matrix in a porosity of the blank thus shaped. Figure for the abstract: Fig. 1.

Description

Title of the invention: Method for manufacturing a turbomachine part from composite material. Technical field

[0001] The present description relates to a method for manufacturing a turbomachine part from composite material in which the shaping is assisted by the use of a gripper device mounted on a robotic arm. A particular area of ​​application of the invention is the manufacture of parts from ceramic matrix composite material (“Ceramic Matrix Composite”; “CMC”), for example with a silicon carbide matrix. Previous technique

[0002] Ceramic matrix composite materials (CMCs) withstand temperatures ranging from 600°C to 1400°C. Due to their superior high-temperature resistance, CMCs require less cooling. Since this cooling is traditionally obtained from the compressor, which impacts the turbomachine's efficiency, CMCs improve engine efficiency, thereby reducing fuel consumption. Furthermore, their use helps optimize turbomachine performance, notably by reducing the overall mass of the turbomachine, which further contributes to lower fuel consumption and thus a significant reduction in pollutant emissions.

[0003] The manufacture of such parts may include obtaining a reinforcing texture, notably by three-dimensional weaving, which is then shaped in a forming tool to obtain a preform of the part to be produced. This shaping may be followed, in a manner known per se, by a step, called consolidation, during which material is deposited into a porosity of the texture formed in the forming tool from a gaseous phase introduced through perforations in the tool. The thickness of the material thus deposited is sufficient to bind the fibers of the preform together so that it can be manipulated while retaining its shape without assistance from the forming tool.The manufacturing of the part can then continue after demolding of the consolidated preform by pre-densification by gaseous means of the residual porosity of the consolidated preform, then by densification by injection of slip followed by infiltration with molten silicon.

[0004] Three-dimensional weaving makes it possible to form textures in a single weaving step, which are then manually shaped in the former by unfolding fibrous portions formed by one or more unbinding zones of the fabric. Manual molding limits the production rate and the repeatability of shaping can be improved.

[0005] It is desirable to address these drawbacks. Description of the invention

[0006] The present description relates to a method for manufacturing a turbomachine part made of composite material, comprising: - the shaping of a fibrous blank obtained by three-dimensional weaving comprising one or more deployable fibrous portions, including: • the deployment of each deployable fibrous portion, achieved by activating and moving a gripping device mounted on a robotic arm, • the positioning of a first conformation part opposite a face of each deployed fibrous portion, each deployed fibrous portion resting on the first conformation part thus positioned, • the release of each deployed fibrous portion by deactivating the grasping device once it is in contact with the first conforming part, and • the shaping of each deployed and released fibrous portion by maintaining it between the first conformation part and a second conformation part, and - densification by formation of a matrix in a porosity of the rough thus shaped.

[0007] The invention proposes an automated solution for shaping the draft without manual manipulation, which improves repeatability and significantly increases production capacity.

[0008] In one embodiment, the gripping device performs an electrostatic gripping of each fibrous portion.

[0009] Such a feature advantageously makes it possible to avoid any risk of damage to the blank.

[0010] In one embodiment, each fibrous portion is moistened and the gripping device performs a thermoelectric gripping of each fibrous portion.

[0011] Such a feature advantageously makes it possible to avoid any risk of damage to the blank.

[0012] In this case, the gripping device freezes the water present by thermoelectric cooling so as to adhere to each fibrous portion, and the gripping device then melts the previously frozen water by thermoelectric heating so as to release each fibrous portion.

[0013] In one embodiment, the gripping device performs a gripping of each fibrous portion by suction.

[0014] In one embodiment, the gripping device performs a gripping of each fibrous portion over an area of ​​excess length, and the shaping of the blank further includes an elimination of said area of ​​excess length after the release of each deployed fibrous portion.

[0015] Such a feature advantageously avoids any risk of damage to the blank due to gripping on an area of ​​excess length intended to be eliminated and which is not part of the useful area of ​​the blank.

[0016] In one embodiment, the fibrous blank is a turbine ring sector reinforcement comprising, on each of its lateral edges, a deployable fibrous portion intended to form a reinforcement of an attachment part of the ring sector and formed by a debonding of the fabric.

[0017] In one embodiment, the part is made of a ceramic matrix composite material and the matrix is ​​formed in whole or in part by chemical vapor deposition. In particular, a first part of the matrix may be formed by chemical vapor deposition, and a second part of the matrix may then be formed by deposition of molten silicon or a silicon alloy.

[0018] Alternatively, the part is made of organic matrix composite material and the densification includes the introduction of a resin into the porosity of the shaped blank followed by the hardening of this resin. Brief description of the drawings

[0019] [Fig.1] Fig.1 represents, schematically and partially, the deployment of a fibrous portion and the positioning of a first conformation part in the context of an example of a process according to the invention.

[0020] [Fig.2] Fig.2 represents, schematically and partially, the release of the fibrous portion deployed in Fig.1.

[0021] [Fig.3] Fig.3 represents, schematically and partially, a succession of steps according to the example of figures 1 and 2.

[0022] [Fig.4] Fig.4 represents, schematically and partially, the deployment of a fibrous portion in the context of another example of a method according to the invention implementing a variant of a gripping device.

[0023] [Fig.5] Fig.5 represents, schematically and partially, the positioning of a first conformation part and the release of the deployed portion in the context of the example illustrated in Fig.4.

[0024] [Fig.6] Fig.6 represents, schematically and partially, the deployment of a fibrous portion in the context of another example of a method according to the invention implementing another variant of a gripping device.

[0025] [Fig.7] Fig.7 represents, schematically and partially, the positioning of a first conformation part and the release of the deployed portion in the context of an embodiment variant.

[0026] [Fig.8] The [Fig.8] represents, schematically and partially, the cutting of an overlength area on which the gripping took place to carry out the deployment within the framework of the [Fig.7]. Description of the implementation methods

[0027] The invention is now described by means of figures, which are provided for descriptive purposes to illustrate certain embodiments of the invention and which should not be interpreted as limiting the latter.

[0028] The fibrous blank 1, illustrated in particular in [Fig. 1], is intended to form the fibrous reinforcement of a turbine ring sector. Those skilled in the art will recognize that the invention is not limited to the manufacture of this type of part. The figures show only half the width of the blank 1, it being understood that a similar shaping is carried out on the other half.

[0029] The blank 1 is first obtained by three-dimensional weaving. By "three-dimensional weaving" or "3D weaving," we mean here a weaving method in which at least some of the warp yarns interlock with weft yarns over several weft layers, such as an "interlock weave." By "interlock weaving," we mean here a 3D weave structure in which each warp layer interlocks with several weft layers, with all the yarns in the same warp column having the same movement in the plane of the weave. It should be noted that a reversal of roles between warp and weft is possible and should be considered as also covered by the claims.

[0030] The blank 1 can be made in a known way by means of a Jacquard type loom on which a bundle of warp yarns or strands has been arranged in a plurality of layers, the warp yarns being linked by layers of weft yarns or strands also arranged in a plurality of layers.

[0031] The wires or strands used for the blank 1 may be made of ceramic fibers, for example, fibers formed essentially of silicon carbide SiC (hereinafter referred to as SiC fibers) or silicon nitride Si3N4. Wires supplied by the Japanese company Nippon Carbon under the reference "Hi-Nicalon" or "Hi-Nicalon Type-S" may be used. The wires or strands used may also be made of carbon fibers or glass fibers, among other possible materials.

[0032] The blank 1 is positioned on a support S and includes, on each of its lateral edges BL, a debonding 2 which allows the formation of a deployable fibrous portion 3 that can be separated from a base portion 4. Each debonding 2 extends from a base 2a to an edge BL. The blank 1 has a central portion 10 from which each debonding 2 extends. The central portion 10 is located between two bases 2a of debonding 2. In a manner known per se, a debonding is made between two layers of warp yarns by not passing weft yarns through the debonding zone so as not to bind yarns of warp layers located on either side of the debonding. Portion 3, for example, is intended here to form a reinforcement of a part of the ring sector attachment allowing the connection to a turbine casing, and portion 4, for example, is intended to define its annular base delimiting the hot gas flow vein.Portion 3 is entirely woven here, but this does not depart from the scope of the invention when it is not, as will be detailed in relation to figures 7 and 8 described below.

[0033] In the example illustrated in Figures 1 and 2, portion 3 is deployed using an electrostatic gripper device 61 mounted on a robotic arm 6. In the illustrated example, the device 61 is positioned opposite a first face Fl of portion 3. Upon activation, the device 61 generates an electrostatic force that creates adhesion to portion 3. Portion 3 is then deployed following the movement of the arm 6, which is fixed to the device 61. This deployment and movement are respectively represented by the arrows "Ela" and "Elb" in [Fig. 1]. The deployed portion 3 is moved away from the base 4 so as to straighten it and position it transversely to the mid-section 10. The electrostatic force is adjusted according to the thickness of the portion 3 to be gripped.

[0034] A first conformation part 5 is then positioned opposite a second face F2 of the unfolded portion 3. This positioning is indicated by the arrow "E2" in [Fig. 1]. In the example considered, the second face F2 is opposite the first face FL. The first part 5 is positioned within the detachment between portion 3 and base 4. The first part 5 is positioned above base 4. Base 4 is located between support S and the first part 5.

[0035] As can be seen in [Fig. 2], the deployed portion 3 rests on the first part 5 thus positioned and is then released (arrow "E3a") by deactivation of the device 61, which is then moved away from portion 3 (arrow "E3b"). The electrostatic force generated by the device 61 is stopped to produce the release.

[0036] A simplified view of these steps is illustrated in [Fig. 3]. In this figure, the gripper device and the robotic arm are not shown. The deployed and released portion 3 is held in shape between the first part 5 and a second Part 7 is shaped to give it the desired form (arrows "E4"). The second part 7 may have been positioned before the release of portion 3, or after this release once portion 3 is resting on the first part 5. In the case illustrated in [Fig. 3], the second part 7 was positioned before the deployment of portion 3 and forms, in particular, a stop for it.

[0037] This gives us the rough 1 shaped in the conforming tooling which is ready to be densified by a matrix.

[0038] Figures 4 and 5 relate to a variant in which the gripper device 62 performs thermoelectric gripping of each portion 3. The elements identical to those previously described bear the same reference symbols. It should be noted, however, that each portion 3 is moistened to enable thermoelectric gripping. The device 62 comprises a plurality of Peltier cells 622 located between two surfaces 621 and 623. To achieve the deployment Ela illustrated in [Fig. 4], the electric current applied to the cells 622 produces thermoelectric cooling of the surface 623 relative to the surface 621. Thus, the device 62 locally freezes the water in the adhesion zone 31 to create adhesion to the portion 3 and allow its deployment.The first part 5 is then positioned as described above and then thermoelectric heating of the surface 623 relative to the surface 621 is carried out in order to defrost the water, in the adhesion zone 31, and release the portion 3 ([Fig.5]). .

[0039] Figure 6 illustrates another variant where the gripper device 63 performs a suction gripping. In this other variant, the device 63 can include several suction cups 631 that can be individually activated / deactivated.

[0040] Figure 7 illustrates another variant incorporating the grasping device 63 of the [Fig. 6]. The same reference symbols designate the same elements as described above. In this variant, the device 63 grips portion 3 on an extra length 32. This extra length is a part intended for removal and is not part of the usable volume of the blank. Here, zone 32 corresponds to a non-woven area, the fibers of which may be held in place by a retaining element or a binding composition, extending from the 3D woven portion of part 3. According to a variant not shown, the extra length corresponds to a woven portion.

[0041] Following the release (“E3a”) of the deployed portion 3, the area 32 is eliminated (“E3c”) for example by cutting as illustrated in [Fig. 8]. This elimination can be carried out before the shaping of portion 3 between the first 5 and the second 7 parts.

[0042] We have just described the formatting of the draft. The following section focuses on describing its densification. Densification is achieved through the implementation of techniques known in themselves. A possible range will be described below as an example, but a person skilled in the art will recognize that other solutions are possible while remaining within the scope of the invention.

[0043] At least part of the matrix can be formed by chemical vapor infiltration (CVI) in a porosity of the blank 1 being shaped in the forming tool. For example, a first silicon carbide (SiC) matrix phase can be formed to consolidate the shaped blank 1. The consolidation thus achieved incompletely densifies the shaped blank 1 but is sufficient to allow it to maintain its shape without the assistance of a holding tool. The shaped and consolidated blank is then removed from the forming tool, and densification is continued by forming a second matrix phase, for example of silicon carbide, by chemical vapor infiltration, so as to obtain a partially densified preform of the part to be produced.Densification can be furthered by introducing a suspension of silicon carbide particles, possibly with added carbon particles, into the residual porosity of the partially densified preform, followed by infiltration of molten silicon or a silicon alloy (a technique known as "Melt-Infiltration"; "MI"). This allows for the production of a part made of a ceramic matrix composite material, for example, silicon carbide, possibly including a Si-SiC matrix portion.

[0044] Examples of manufacturing a part from a ceramic matrix composite material have just been described, but those skilled in the art will recognize that the invention is also applicable to the manufacture of parts from an organic matrix composite material. In this case, densification is achieved by introducing a resin into the porosity of the shaped blank, followed by solidification of the resin by crosslinking (in the case of a thermosetting resin) or cooling (in the case of a thermoplastic resin) in order to form the organic matrix.

[0045] The application of the invention to the shaping of a turbine ring sector reinforcement has just been described, but those skilled in the art will recognize that the invention can be applied to other parts. According to an unillustrated embodiment, a turbomachine blade reinforcement can be shaped by deploying streamlined portions designed to form a reinforcement of a functional part of the blade, such as a platform, spoiler, or heel reinforcement. The invention is also applicable to the manufacture of a distributor, angle bracket, or any other composite part.

Claims

Demands

1. A method for manufacturing a turbomachine part from composite material, comprising: - shaping a fibrous blank (1) obtained by three-dimensional weaving comprising one or more deployable fibrous portions (3), comprising: • the deployment (Ela) of each deployable fibrous portion, carried out by activation and displacement (Elb) of a device (61; 62;63) gripper mounted on a robotic arm (6), • the positioning (E2) of a first conformation part (5) opposite a face (F2) of each deployed fibrous portion, each deployed fibrous portion bearing on the first conformation part thus positioned, • the release (E3a) of each deployed fibrous portion by deactivation of the gripper device once in contact with the first conformation part, and • the shaping (E4) of each deployed and released fibrous portion by holding it between the first conformation part and a second conformation part (7), and - the densification by formation of a matrix in a porosity of the blank thus shaped.;

2. A method according to claim 1, wherein the gripping device (61) performs an electrostatic gripping of each fibrous portion (3).

3. Method according to claim 1, wherein each fibrous portion (3) is moistened and wherein the gripper device (62) performs a thermoelectric gripping of each fibrous portion (3).

4. Method according to claim 1, wherein the grasping device (63) performs a grasping of each fibrous portion (3) by aspiration.

5. A method according to any one of claims 1 to 4, wherein the gripping device grips each fibrous portion (3) over an area (32) of excess length, and wherein the the form of the draft further includes an elimination (E3c) of said overlength zone after the release of each deployed fibrous portion.

6. A method according to any one of claims 1 to 5, wherein the fibrous blank is a turbine ring sector reinforcement comprising, on each of its lateral edges, a deployable fibrous portion intended to form a reinforcement of a hooking part of the ring sector and formed by a unbinding of the fabric.

7. A method according to any one of claims 1 to 6, wherein the part is made of ceramic matrix composite material and the matrix is ​​formed in whole or in part by chemical vapor phase infiltration.

8. A method according to claim 7, wherein a first part of the matrix is ​​formed by chemical vapor infiltration, and wherein a second part of the matrix is ​​subsequently formed by infiltration of silicon or a silicon alloy in the molten state.

9. A method according to any one of claims 1 to 6, wherein the part is made of organic matrix composite material and the densification comprises an introduction of a resin into the porosity of the shaped blank followed by a hardening of this resin.

Images