METHOD FOR MANUFACTURED A TURBOMACHINE BLADE

Abstract

The invention relates to a method for manufacturing a blade (10) for an aircraft turbomachine (1), the manufacturing method comprising the following steps: (a) providing a body made of composite material comprising a polymer matrix and fibers embedded in the matrix, (b) forming a wear-resistant protection (17) on the body, characterized in that step (b) comprises the following substeps: (b0) depositing a bonding layer (18) on the body, the bonding layer (18) comprising a tack layer (22) and an adhesion layer (21) situated between the tack layer (22) and the body, (b1) heat-treating the bonding layer (18), (b2) depositing a retention layer (19) on the bonding layer (18), and (b3) depositing a sliding layer (20) on the retention layer (19). Abstract figure: Figure 3

Description

Title of the invention: METHOD FOR MANUFACTURED A BLADE FOR A TURBOMACHINE Technical field of the invention

[0001] The invention relates to the field of manufacturing blades for aircraft turbomachinery.

[0002] The invention relates more particularly to the field of manufacturing blades comprising a body made of composite material and an anti-wear protection. Technical background

[0003] An aircraft turbomachine typically comprises, from upstream to downstream in the direction of gas flow, a movable fan rotating about a longitudinal axis, a low-pressure compressor and a high-pressure compressor, a combustion chamber, a high-pressure turbine and a low-pressure turbine, and a gas exhaust nozzle.

[0004] The blower allows the intake of an airflow which is divided, for example, into a primary flow and a secondary flow. The primary flow passes through a primary channel of the turbomachine while the secondary flow is directed towards a secondary channel surrounding the primary channel.

[0005] The primary flow is compressed within the compressors. The compressed air is then mixed with a fuel and burned within the combustion chamber. The gases from the combustion pass through the turbines and then escape through the nozzle, the cross-section of which allows these gases to be accelerated to generate propulsion.

[0006] Turbomachine components such as the blower, compressors, or turbines include blades that act on the airflow. For example, compressor blades compress the primary airflow, and blower blades compress the secondary airflow.

[0007] A blade comprises a body that is mounted in a support of the turbomachine such as a disc made of metallic material. To reduce the weight of the blade, the body is formed of a composite material that includes fibers embedded in a polymer matrix.

[0008] The body typically comprises a blade and a root. The blade has an aerodynamic shape and thus comprises an upper surface and an upper surface connected to the lower surface by a leading edge and a trailing edge. The blade root is housed in a recess in the disk in order to retain the blade on the disk when the turbomachine is in operation.

[0009] The foot, which is made of composite material, is thus in contact with the disc, which is made of metallic material. The rotation of the blade and the vibrations produced during operation generate friction at this contact point, leading to wear of the body, particularly the foot, which can cause irreversible damage to the composite material and compromise the integrity of the blade. This type of wear due to friction is also known as "fretting."

[0010] In order to limit wear damage from friction at the base of the blade, document WO-A1-2021 / 198621 proposes a blade comprising a body made of composite material and a wear protection to prevent friction. According to this document, the wear protection is a strip of fabric attached to the blade body.

[0011] According to this document, the fabric strip is attached to the body by co-molding. Thus, the body and the fabric strip are arranged in a mold, then a resin is injected to densify the blade body and bond the fabric strip to the body.

[0012] Although it makes it possible to effectively reduce premature wear of the blades by friction in particular, such a solution does not give complete satisfaction.

[0013] First, the fabric strip comprises aramid and / or polytetrafluoroethylene (PTFE) fibers. Polytetrafluoroethylene fibers generally have treatments based on perfluoroalkyl and polyfluoroalkyl (PFAS) materials. However, environmental and health regulations tend to limit the use of these perfluoroalkyl and polyfluoroalkyl materials.

[0014] Also, such strips are directly attached by molding to the blade body, and must therefore exhibit sufficient adhesion to the blade body. The types of strips that can be used are thus limited.

[0015] Moreover, the fabric strips have a high cost, which increases the cost of manufacturing a vane.

[0016] In addition, fixing the fabric strips by molding presents difficulties in positioning these fabric strips in the mold, and it is therefore difficult to ensure the repeatability of this step.

[0017] Finally, in the event of wear of these fabric strips, it is not possible to restore them without impacting the integrity of the blade due to the co-molding operation necessary for their fixing.

[0018] Therefore, there is a need to provide a blade comprising a body made of composite material including a matrix and fibers embedded in the matrix and wear protection, which complies with health and environmental regulations, is reliable, easy to manufacture and implement, can be restored without impact on the blade body and is inexpensive. Summary of the invention

[0019] To this end, the invention proposes a method for manufacturing a blade for an aircraft turbomachine, the manufacturing method comprising the following steps:

[0020] (a) provide a body made of composite material comprising a polymer matrix and fibers embedded in the matrix,

[0021] (b) form an anti-wear protection on the body,

[0022] characterized in that step (b) comprises the following substeps:

[0023] (bO) depositing a bonding layer on the body, the bonding layer comprising a tack layer and an adhesion layer located between the tack layer and the body,

[0024] (bl) heat-treat the bonding layer,

[0025] (b2) deposit a retention layer on the bonding layer, and

[0026] (b3) deposit a sliding layer on the retention layer.

[0027] Thus, according to the invention, the wear protection is multilayered. It comprises a bonding layer, a retention layer and a sliding layer.

[0028] The sliding layer, which can also be called the "anti-friction layer," reduces the coefficient of friction between the blade body and a blade support, such as a disc. The sliding layer includes, for example, a varnish.

[0029] The retention layer serves to ensure the mechanical anchoring of the sliding layer to the blade body. Specifically, the retention layer acts as a support during the deposition of the sliding layer and also forms a reservoir for the sliding layer during blade operation. Indeed, friction tends to reduce the thickness of the sliding layer during the operation of the components and the repeated movements between the blade root and the disc. Thanks to the retention layer, a minimum thickness of the sliding layer is maintained.

[0030] The bonding layer ensures the adhesion of the retention layer to the blade body. It creates a suitable surface for the deposition of the retention layer. In particular, the bonding layer anchors the retention layer. This bonding layer also allows the retention layer to be deposited by thermal spraying, for example, without damaging the blade body. Indeed, the composite material is typically incompatible with direct thermal spraying due to the temperatures involved in the thermal spraying process and the reaction of the sprayed particles with the surface of the composite material. Such a layer therefore expands the options for deposition of the bonding and retention layers.

[0031] The tack coat increases the roughness of the blade body and the chemical compatibility of the blade for the deposition of the retention layer, in particular by thermal spraying.

[0032] Thanks to such multi-layered wear protection, it is possible to avoid using materials that do not comply with environmental and health standards. Furthermore, such wear protection is easy to manufacture, inexpensive, and compatible with a body made of composite material.

[0033] Also, the restoration of such wear protection only requires the removal of the sliding or retention layer and the renewal of the deposition steps of these layers without impact on the blade body.

[0034] The invention may comprise one or more of the following features, taken individually or in combination with each other:

[0035] - at step (bl), the heat treatment is carried out at a temperature between 100°C and 200°C, preferably between 145°C and 185°C,

[0036] - at step (bl), the heat treatment is carried out for a duration between 30 minutes to 200 minutes, preferably between 45 minutes and 180 minutes.

[0037] - the adhesion layer comprises a polymer, in particular a polymer sand-cured thermosets,

[0038] - in step (b2), the retention layer (is deposited by thermal spraying,

[0039] - the thermal spraying is carried out with particles of which at least 90% of these particles have a size (d90) between 20 pm and 200 pm, preferably between 45 pm and 90 pm,

[0040] - the bonding and retention layers comprise a ceramic material or metallic selected from copper-aluminum alloys, nickel-aluminum alloys, and is for example a CoCrAlYSi-hBN alloy or a CuNiln alloy,

[0041] - step (b) further comprises after substep (b3), a subsequent substep:

[0042] (b4) heat-treat the sliding layer,

[0043] - in substep (b4), the heat treatment is carried out at a lower temperature at 250°C, preferably less than or equal to 150°C and even more preferably between 50°C and 120°C,

[0044] - the substep (bO) comprises the following substeps:

[0045] (bOO) deposit the adhesion layer onto the body, and

[0046] (b02) deposit the tack coat onto the adhesion coat,

[0047] - the substep (bO) further comprises between the substeps (bOO) and (b02) the sub- Next step:

[0048] (b01) thermally pretreat the adhesion layer. Brief description of the figures

[0049] Other features and advantages will become apparent from the following description of a non-limiting embodiment of the invention with reference to the accompanying drawings in which:

[0050] Fig. 1 is a schematic longitudinal cross-sectional view of half an aircraft turbomachine,

[0051] [Fig.2] is a schematic perspective view of a blade according to the invention and equipping the turbomachine of [Fig.1],

[0052] [Fig.3] is a very schematic view of the dawn of [Fig.2],

[0053] [Fig.4] is a very schematic view of a blade before and after it has been put into service,

[0054] [Fig. 5] is a schematic view of a manufacturing process according to the invention,

[0055] [Fig. 6] is a schematic view of the manufacturing process according to a first mode of realization, and

[0056] [Fig.7] is a schematic view of the manufacturing process according to a second embodiment. Detailed description of the invention

[0057] An example of an aircraft turbomachine 1 according to the invention is shown in [Fig. 1]. The turbomachine 1 extends around and along a longitudinal axis X.

[0058] In the present application, the terms "axial", "axially", "radial" and "radially" are defined with respect to the longitudinal axis X.

[0059] The terms "upstream", "downstream" are defined with respect to the direction of gas flow in the turbomachine 1 along the longitudinal axis X.

[0060] The terms "internal", "interior", "external", "outside", "externally" are defined with respect to the distance from the longitudinal axis X along a radial axis Z perpendicular to the longitudinal axis X.

[0061] The turbomachine 1 comprises, from upstream to downstream in the direction of gas flow F, along the longitudinal axis X, a blower 2, at least one compressor such as a low-pressure compressor 3 and a high-pressure compressor 4, a combustion chamber 5, at least one turbine such as a high-pressure turbine 6 and a low-pressure turbine 7, and a gas exhaust nozzle.

[0062] The rotor of the low-pressure turbine 7 is connected to the blower 2 and to the rotor of the low-pressure compressor 3 by a low-pressure turbine shaft (not shown). The rotor of the high-pressure turbine 6 is connected to the rotor of the high-pressure compressor 4 by a high-pressure turbine shaft (not shown).

[0063] The turbomachine 1 may also include a rectifier 8. The rectifier 8 allows the flow at the outlet of an upstream rotor to be rectified in order to provide maximum thrust at the outlet of the turbomachine 1. In the particular example of [Fig.1], the rectifier 8 is located downstream of the fan 2 and allows the secondary flow F2 to be rectified.

[0064] The turbomachine 1 may include an annular nacelle 9 centered on the longitudinal axis X surrounding the fan 2. The nacelle 9 is, for example, supported by a Fan housing (not shown). According to another example, turbomachine 1 is uncased.

[0065] The blower 2 allows the intake of an airflow which here divides into a primary flow Fl and a secondary flow F2. The primary flow Fl passes through a primary channel of the turbomachine 1 while the secondary flow F2 is directed towards a secondary channel surrounding the primary channel.

[0066] The primary flow Fl is compressed within the low-pressure compressor 3 and then the high-pressure compressor 4. The compressed air is then mixed with fuel and burned within the combustion chamber 5. The gases formed by combustion pass through the high-pressure turbine 6 and the low-pressure turbine 7. The gases finally escape through the nozzle, the cross-section of which allows the acceleration of these gases to generate propulsion. The secondary flow F2 passes through the rectifier 8, which accelerates the circulation speed of the secondary flow F2 to generate propulsion.

[0067] The blower 2, the rectifier 8, the compressors 6, 7, or the turbines 3, 4 comprise blades 10. The blades 10 equipping the rectifier 8 are known by the English term "Outlet Guide Vane" (OGV). The blades 10 are either movable or fixed in rotation about the longitudinal axis X. Typically, the blades 10 of the blower 2 are movable in rotation. The blades 10 of the rectifier 8 are fixed.

[0068] The blades 10 extend radially with respect to the longitudinal axis X. They are regularly distributed around the longitudinal axis X.

[0069] With reference to [Fig.2], the blades 10 are mounted on an annular disk 11 centered on the longitudinal axis X. The disk 11 comprises an annular body 12 having hollows 13 formed in the annular body 12. There are as many hollows 13 as there are blades 10.

[0070] Disc 11 comprises a metallic material.

[0071] Each blade 10 comprises a body which includes a blade 14 and a foot 15. Each blade 14 can be connected to foot 15 by a stilt 16.

[0072] The body is formed of a composite material comprising a matrix and reinforcing fibers embedded in this matrix.

[0073] The matrix is, for example, an organic matrix. For example, the matrix is ​​made of a polymeric material chosen from thermoplastics, for example, polypropylene, polyethylene, or thermosets, for example, an epoxy polymer, phthalonitrile, polybismaleimide, polyimide.

[0074] The fibers are, for example, carbon fibers, glass fibers, or any fiber suitable for the present application.

[0075] Each blade 14 has an aerodynamic shape. Each blade 14 thus comprises an intrados face 14a and an extrados face 14b which are connected by a leading edge and a trailing edge 14c. Preferably, the leading edge is covered with a metallic shield 14d. The shield 14d has a general trihedral shape. It has a V- or U-shaped cross-section. The shield 14d thus comprises a first fin extending over the lower surface 14a and a second fin extending over the upper surface 14b. The first and second fins are connected by a central portion covering the leading edge.

[0076] Each foot 15 has a tenon or bulb shape. It is inserted into the socket 13 of the disc 11. The stilt 16 is arranged radially between the foot 15 and the blade 14.

[0077] The blade body 10 is formed by resin transfer molding (RTM). Alternatively, the blade body 10 is formed by draping. The shield 14d is, for example, attached by co-molding onto the blade 14 during molding or by bonding after the body has been molded.

[0078] With reference to [Fig. 3], each blade 10 further comprises at least one wear guard 17. The wear guard 17 is arranged on the body of the blade 10. In particular, it is arranged on a surface of the foot 15 and / or the strut 16. Indeed, the foot 15 and the strut 16 are made of composite material and are subject to friction due to their relative movement with the disc 11, which is made of metallic material. This friction causes wear, also known as "fretting," which can considerably degrade the body of the blade 10. It is particularly advantageous to protect these areas from friction with the disc by at least one wear guard 17.

[0079] Each wear protection 17 may have an elongated shape. It extends, for example, from one end of the foot 15 and / or of the strut 16 located on the leading edge side of the blade 14 to an opposite end of the foot 15 and / or of the strut 16 located on the trailing edge side 14b.

[0080] The wear protection 17 may have a total thickness of between 0.1 millimeters (mm) and 2 mm, preferably between 0.1 mm and 1 mm, for example between 0.1 mm and 0.2 mm. Such a thickness is particularly advantageous because it protects the foot 15 and the stilt 16 from premature wear while allowing the foot 15 to be mounted in the recess 13 of the disc 11. Indeed, below this thickness, the wear protection would be insufficient, and above this thickness, the foot 15 could no longer be inserted into the recess 13 without resizing the recess 13 or even the disc 11.

[0081] As can be seen in [Fig.3], the wear protection 17 has a multi-layered structure. From the inside out, with the inside located on the side of the blade body 10, it comprises a bonding layer 18, a retention layer 19 and a sliding layer 20.

[0082] The bonding layer 18 is a hybrid layer. It comprises an adhesion sublayer 21 and a tackling sublayer 22.

[0083] The tack layer 22 has a thickness less than the adhesion layer 21. The tack layer 22 has a thickness less than the retention layer 19.

[0084] The adhesion underlayer 21 is arranged between the blade body 10 and the gripping underlayer 22. The adhesion underlayer 21 comprises a polymeric material. The polymeric material is advantageously selected from thermosetting polymers such as an epoxy, silicone, or polyurethane polymer, or from thermoplastic polymers selected, for example, from the polyaryletherketone family, such as a polyetheretherketone (PEEK) or a mixture thereof. The epoxy polymer is, for example, the commercial material Redux® 322 from HEXCEL, AF503 from 3M, or FM319.

[0085] The adhesion underlayer 21 is in the form of a film made from one of the materials mentioned. For example, the film is the commercial polymer-based film FM319, Redux® 322, or AF503. Alternatively, the adhesion underlayer 21 is in the form of a coating applied by thermal spraying. In this example, the adhesion underlayer 21 is made of a polymer material based on PEEK, for example, or any polymer compatible with the thermal spraying process.

[0086] Advantageously, the adhesion underlayer 21 has a thickness between 10 pm and 500 pm, even more advantageously between 50 pm and 500 pm and even more advantageously between 80 pm and 400 pm.

[0087] The bonding underlayer 22 is arranged between the adhesion underlayer 21 and the retention layer 19. The bonding underlayer 22 has a thickness, for example, between 40 pm and 400 pm.

[0088] The adhesion sublayer 22 comprises particles 22a embedded in the adhesion sublayer 21. By "embedded in the adhesion sublayer 21", it is understood that the particles 22a are partially embedded in the adhesion sublayer 21 and that a portion of the surface of the particles is not embedded in the adhesion sublayer 21 in order to create a surface condition favorable to the mechanical and chemical adhesion of the retention layer 19. Thus, according to the invention, the particles 22a are embedded in a depth of the adhesion sublayer 21 that is less than the thickness of the adhesion sublayer 21.

[0089] Preferably, the surface coverage of the particles 22a is greater than or equal to 70%, greater than or equal to 80%, greater than or equal to 90%, and even more preferably on the order of 100%. The surface coverage corresponds to the surface area of ​​the adhesion sublayer 21 coated by the particles 22a divided by the total surface area of ​​the adhesion sublayer 21, the surface being that opposite the blade body 10.

[0090] Advantageously, the mass ratio of particles 22a in the bonding layer 18 is between 20% and 90%, advantageously between 50% and 90%.

[0091] Advantageously, the particles 22a are metal particles. The metallic material is, for example, selected from copper-aluminum alloys, nickel-aluminum alloys, and is, for example, a CoCrAlYSi-hBN alloy or a CuNiLn alloy. The particles 22a are, for example, ceramic particles such as silicon carbide, or oxide particles such as aluminum oxide, zirconium oxide, silicon oxide, or a mixture of these particles.

[0092] Advantageously, at least 90% of the particles 22a have a size (d90) between 20 pm and 200 pm, advantageously between 45 pm and 90 pm.

[0093] Advantageously, the particles 22a have a general spherical or acicular morphology.

[0094] The adhesion underlayer 21 ensures high adhesion between the substrate, i.e. the blade body 10 and the tack underlayer 22, while also contributing to the adhesion of the sliding layer 20 to the retention layer 19. The tack underlayer 22 creates a surface favorable to the mechanical anchoring of the retention layer 19. The retention layer 19 can then be formed by thermal spraying, a process which allows the formation of coatings of complex shapes with low tolerances and in a repeatable manner.

[0095] The tack layer 22 is located between the retention layer 19 and the adhesion layer 21. The retention layer 19 has a thickness, for example, between 100 µm and 200 µm, in particular between 120 µm and 180 µm. The thickness of the retention layer 19 is notably greater than that of the tack layer 22.

[0096] The retention layer 19 comprises a material advantageously identical to the material of the bonding underlayer 22. The retention layer 19 comprises a metallic material or a ceramic material. The metallic material is, for example, selected from copper-aluminum alloys, nickel-aluminum alloys, and is, for example, a CoCrAlYSi-hBN alloy or a CuNiLn alloy. The ceramic material is, for example, silicon carbide. The material of the retention layer 19 is, for example, an oxide such as aluminum oxide, zirconium oxide, silicon oxide, or a mixture of these materials.

[0097] The retention layer 19 comprises particles 19a. Advantageously, among the particles 19a, at least 90% have a size (d90) between 20 pm and 200 pm, preferably between 45 pm and 90 pm.

[0098] With reference to [Fig.4], the retention layer 19 increases the roughness of the blade body 10. Such roughness generates an alternation of peaks PI and troughs P2 on the blade body 10. The sliding layer 20 can thus be retained inside the troughs P2 of the retention layer 19, improving the in-service performance of this sliding layer 20.

[0099] Indeed, as can be seen in [Fig.4], before the commissioning of the blade 10 as indicated by reference T1, the thickness of the sliding layer 20 is at its maximum, while after the commissioning of the blade 10 as indicated by reference T2, the thickness of the sliding layer 20 is reduced but a minimum thickness is maintained thanks to the hollows P2 created by the retention layer 19.

[0100] The sliding layer 20 has a thickness of between 15 µm and 35 µm. It comprises a lubricating material such as a varnish. The varnish may comprise an organic thermoplastic or thermosetting binder and include lubricating particles such as molybdenum disulfide (MoS2) or graphite, for example the commercial varnish Bonderite S-FN M 254 N or Everlubel 150 or MOLYKOTE® D-321R or graphite such as the commercial varnish Bonderite L-FG D 180.

[0101] The sliding layer 20 reduces the coefficient of friction between the blade body 10 and the disc 11. This reduces frictional wear on the blade 10.

[0102] A method for manufacturing the blade 10 according to the invention will now be described with reference to [Fig.5].

[0103] The process comprises the following chronological steps:

[0104] (a) provide the dawn body 10, and

[0105] (b) form the wear protection 17 on the body.

[0106] Step (a) can be carried out by molding such as resin transfer molding known by the acronym RTM for "Resin Transfer Molding" in English or by draping.

[0107] Optionally, before step (b), the blade body 10 may undergo mechanical or chemical surface preparation to improve the adhesion of the wear protection 17.

[0108] Step (b) comprises the following substeps:

[0109] (bO) deposit the bonding layer 18 on the body,

[0110] (bl) heat-treat the bonding layer 18,

[0111] (b2) deposit the retention layer 19 onto the bonding layer 18,

[0112] (b3) deposit the sliding layer 20 onto the retention layer 19, and

[0113] (b4) heat treat the sliding layer 20.

[0114] The heat treatment substep (bl) is advantageously carried out at a temperature between 100°C and 200°C, preferably between 145°C and 185°C.

[0115] The heat treatment substep (bl) is advantageously carried out for a period of between 30 min and 200 min, preferably between 45 min and 180 min. The heat treatment substep (bl) is advantageously carried out in an oven.

[0116] This substep (bl) of heat treatment allows the bonding layer 18 to be consolidated before the deposition of the retention layer 19.

[0117] After the heat treatment substep (bl), the bonding layer 18 can be mechanically treated. The mechanical treatment can be sandblasting, plasma grinding, or laser blasting.

[0118] Advantageously, substep (b2) is carried out by thermal spraying. The thermal spraying process is, for example, flame spraying, for example, high-velocity oxygen-fuel (HVOF) flame spraying, wire arc spraying, suspension spraying, plasma spraying, cold spray spraying, flame spraying, or any other applicable thermal spraying process.

[0119] Thermal projection is carried out with a powder comprising grains of which at least 90% of these grains have a size (d90) between 20 pm and 200 pm, preferably between 45 pm and 90 pm.

[0120] Advantageously, substep (b3) is carried out manually or automatically, for example by spraying with a gun or by dipping or by brushing.

[0121] Advantageously, substep (b4) is carried out at a temperature less than or equal to 250°C.

[0122] The heat treatment substep (b4) is advantageously carried out in an oven.

[0123] According to a first embodiment shown in [Fig.6], the substep (bO) comprises the following chronological substeps:

[0124] (bOO) deposit the adhesion layer 21 onto the body,

[0125] (b01) optionally heat pretreat the adhesion layer 21, and

[0126] (b02) deposit the tack layer 22 on the adhesion layer 21.

[0127] The substep (bOO) can be carried out by draping the film, or by manual application of the adhesion underlayer material 21 or by spraying.

[0128] The substep (bOl) can be carried out by heating the adhesion sublayer 21. This thermal pretreatment aims to increase tackiness, so that the particles 22a of the tack sublayer 22 adhere better to the adhesion sublayer 21. This step can be carried out by heating the adhesion sublayer 21 to a temperature below 200°C, preferably below or equal to 150°C, and even more preferably between 50°C and 120°C. The substep (bOl) is preferably carried out for a period of 1 hour or less, for example in a drying room or oven.

[0129] The substep (b02) is advantageously carried out by gravity deposition of the particles 22a, for example using a sieve manually, or automatically.

[0130] After or during the substep (b02) of depositing the tack coat 22, a mechanical treatment can be carried out. This treatment can be performed by vibration in order to remove the excess particles 22a from the bonding layer 18 and advantageously achieve a surface coverage of 100%. The blade 10 can, for example, be placed on a vibrating stand.

[0131] Substep (b02) can be carried out by sandblasting, plasma grinding or laser. This step makes it possible to release at least part of the particles of the adhesion layer 21 in order to create a surface condition favorable to the adhesion of the retention layer 19.

[0132] These mechanical treatments can be carried out in combination.

[0133] According to a second embodiment shown in [Fig.7], substep (bO) of the process comprises the following substeps:

[0134] (bOi) provide the adhesion layer 21,

[0135] (bOii) deposit the tack layer 22 onto the adhesion layer 21 to form the bonding layer 18, and

[0136] (bOiii) deposit the bonding layer 18 on the body.

[0137] Steps (bOi) and (bOii) can be carried out after or simultaneously with step (a).

[0138] Step (bOii) can be carried out by rolling on the adhesion layer 21. This makes it possible in particular to improve the homogeneity of the surface deposition of the particles 22a of the tack layer 22 on the adhesion layer 21.

[0139] A method for repairing the wear protection 17 will now be described.

[0140] The repair process comprises the following steps:

[0141] (a') removal of the retention layer 19 and the sliding layer 20, and

[0142] (b') deposition of a new retention and sliding layer on the layer of link 18.

[0143] Step (a') can be carried out by water jet blasting. Water jet blasting can be performed using grit. The grit may be smaller than 200 µm. The grit may be, for example, white corundum.

[0144] Step (b') can be carried out like steps (b2) and (b3) of the manufacturing process.

[0145] The method for repairing the wear protection 17 is simple to carry out and without impact on the blade 10. Indeed, it does not require any direct action on the blade 10.

Claims

Demands

1. A method for manufacturing a blade (10) for an aircraft turbomachine (1), the manufacturing method comprising the following steps: (a) providing a body of composite material comprising a polymer matrix and fibers embedded in the matrix, (b) forming a wear protection (17) on the body, characterized in that step (b) comprises the following substeps: (b1) depositing a bonding layer (18) on the body, the bonding layer (18) comprising a tack layer (22) and an adhesion layer (21) situated between the tack layer (22) and the body, (b1) heat treating the bonding layer (18), (b2) depositing a retention layer (19) on the bonding layer (18), and (b3) depositing a sliding layer (20) on the retention layer (19).

2. A process according to the preceding claim, characterized in that at step (bl), the heat treatment is carried out at a temperature between 100°C and 200°C, preferably between 145°C and 185°C.

3. A method according to any one of the preceding claims, characterized in that at step (bl), the heat treatment is carried out for a period of between 30 min and 200 min, preferably between 45 min and 180 min.

4. A method according to any one of the preceding claims, characterized in that the adhesion layer (21) comprises a polymer, in particular a thermosetting polymer.

5. A method according to any one of the preceding claims, characterized in that in step (b2), the retention layer (19) is deposited by thermal spraying.

6. A method according to the preceding claim, characterized in that the thermal projection is carried out with particles (19a) of which at least 90% of these particles have a size (d90) between 20 pm and 200 pm, preferably between 45 pm and 90 pm.

7. A method according to any one of the preceding claims, characterized in that the bonding (22) and retention (19) layers comprise a ceramic or metallic material selected from copper and aluminum alloys, nickel alloys and of aluminium, and is for example a CoCrAlYSi-hBN alloy or a CuNiln alloy.

8. A method according to any one of the preceding claims, characterized in that step (b) further comprises after substep (b3), a subsequent substep: (b4) heat-treating the sliding layer (20).

9. A method according to the preceding claim, characterized in that in substep (b4), the heat treatment is carried out at a temperature below 250°C, preferably less than or equal to 150°C and even more preferably between 50°C and 120°C.

10. A method according to any one of the preceding claims, characterized in that substep (b0) comprises the following substeps: (b00) depositing the adhesion layer (21) on the body, and (b02) depositing the tack layer (22) on the adhesion layer (21).

11. Method according to the preceding claim, characterized in that the substep (bO) further comprises between the substeps (bOO) and (b02) the following substep: (bOl) thermally pretreat the adhesion layer (21).

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