Method for manufacturing a part made of reinforced composite material

Abstract

A manufacturing process for a part (10) made of reinforced composite material comprises: - the production of a preform of a structural part impregnated with a first matrix precursor having a Young's modulus greater than or equal to 2 GPa, - the transformation of the first precursor into a first matrix to obtain a densified structural part (11) with a first matrix having a Young's modulus greater than or equal to 2 GPa, - the production of a preform of a reinforcing part impregnated with a second matrix precursor having a Young's modulus less than or equal to 0.5 GPa, - the bonding of the reinforcing part preform onto the structural part.- the transformation of the second matrix precursor of the preform of the reinforcing part so as to obtain a reinforced composite material part comprising a reinforcing part (12) densified with a second matrix having a Young's modulus less than or equal to 0.5 GPa and said structural part. Figure for the abbreviation: Fig. 2.,

Description

Title of the invention: Method for manufacturing a part made of reinforced composite material technical field

[0001] The present invention relates to the general field of manufacturing parts made of composite material that are exposed to impacts. Previous technique

[0002] In an aircraft gas turbine engine, certain parts are susceptible to impacts from objects, such as the turbine casing surrounding a rotating blade wheel. This type of casing performs several functions. In particular, it defines an air intake or flow path in the engine and incorporates a debris trap. The debris trap retains fragments of damaged blades, propelled by centrifugal force, to prevent them from passing through the casing and reaching other parts of the aircraft.

[0003] Previously made of metallic material, housings, such as blower housings, are now made of composite material, that is to say from a fibrous preform densified by an organic matrix, which makes it possible to produce parts with a lower overall mass than the same parts when made of metallic material while having at least equivalent or even greater mechanical resistance.

[0004] The manufacture of a blower housing from an organic matrix composite material is described in particular in US patent 8,322,971. In the housing disclosed in US patent 8,322,971, the retention shield is formed by an excess thickness obtained in the housing's fibrous reinforcement, which has a progressively increasing thickness. The fibrous reinforcement is obtained by winding a 3D woven fibrous texture, which has an excess thickness suitable for forming a retention shield. The housing thus obtained exhibits good mechanical properties at the retention shield, both in terms of puncture resistance (retention) and dynamic behavior.

[0005] However, the solution of forming a portion of extra thickness in the fibrous reinforcement of the housing is not always suitable because, even if it locally reinforces the impact resistance of the housing, it also modifies its structural behavior as well as the sensitivity of the housing to vibrational stresses.

[0006] Furthermore, in the new generation of unfaired engines (known as "open fan" or "open rotor" engines), it is planned to design casings made of composite material. capable of containing titanium blades. These housings must, therefore, have very good impact resistance against blade debris with a mass of up to 800 grams, which corresponds to an impact energy of between 20,000 and 60,000 joules.

[0007] Other parts or components made of composite material of an aircraft engine are also likely to receive impacts with a high amount of energy.

[0008] There is, therefore, a need for a solution that strengthens the retention capacity of a part made of composite material while preserving good structural properties over the whole of the part. Description of the invention

[0009] To this end, the invention proposes a method for manufacturing a part made of reinforced composite material comprising:

[0010] - the production of a fibrous preform of a structural part impregnated with a first matrix precursor having a Young's modulus greater than or equal to 2 GPa, - the transformation of the first precursor into a first matrix so as to obtain a densified structural part with a first matrix having a Young's modulus greater than or equal to 2 GPa, - the production of a fibrous preform of a reinforcement part impregnated with a second matrix precursor having a Young's modulus less than or equal to 0.5 GPa, - the bonding of the fibrous preform of the reinforcement part onto the structural part, - the transformation of the second matrix precursor of the fibrous preform of the reinforcement part so as to obtain a densified reinforcement part with a second matrix having a Young's modulus less than or equal to 0.5 GPa and a reinforced composite material part comprising said structural part and said reinforcement part, or - the production of a fibrous preform of a structural part impregnated with a first precursor of a first matrix having a Young's modulus greater than or equal to 2 GPa, - the formation on the fibrous preform of the structural part of a fibrous preform of a reinforcing part, - impregnation, before or after the formation of the fibrous preform of the reinforcing part, of said fibrous preform of the reinforcing part with a second precursor of a second matrix having a Young's modulus less than or equal to 0.5 GPa, - the transformation of the first and second precursors respectively into a first matrix and a second matrix in order to obtain a part made of material reinforced composite comprising a structural part densified by a first matrix having a Young's modulus greater than or equal to 2 GPa and a reinforcing part densified by a second matrix having a Young's modulus less than or equal to 0.5 GPa.

[0011] The process according to the invention makes it possible to strengthen the retention capacity of the part without modifying the structural properties of the whole of it.

[0012] Indeed, since the structural part of the component is manufactured independently, it can be produced by focusing on the mechanical properties necessary to perform a structural function. It is thus possible to give the structural part of the component sufficient stiffness for its structural function, in particular by densifying the structural part with a matrix having a Young's modulus greater than or equal to 2 GPa.

[0013] Since the rigidity required for the part is ensured by the structural component, it is then possible to produce a reinforcement section in composite material whose matrix is ​​described as "flexible," that is, having a Young's modulus less than or equal to 0.5 GPa, which does not allow the composite material to have sufficient rigidity to perform a structural function. However, such a reinforcement section, combined with a structural component, makes it possible to obtain a composite material part with a significantly higher energy dissipation gain relative to its surface mass than the same part made of a metallic material, for example titanium, or of a single structural composite material.

[0014] According to a particular feature of the process of the invention, the fibrous preform of the reinforcing part is impregnated with the second matrix precursor after its formation on the fibrous preform of the structural part impregnated with the first matrix precursor.

[0015] According to another particular feature of the process of the invention, the fibrous preform of the reinforcing part is formed from one or more fibrous layers pre-impregnated with the second matrix precursor.

[0016] According to another particular feature of the process of the invention, the fibrous preform of the reinforcement part is made by three-dimensional weaving between a plurality of warp yarns or strands and a plurality of weft yarns or strands.

[0017] According to another particular feature of the process of the invention, the fibrous preform of the reinforcement part is made by layering a plurality of unidirectional fibrous layers.

[0018] According to one embodiment of the method of the invention, the reinforced composite material part corresponds to a part of revolution or a sector of a part of revolution for a gas turbine, the structural part of the reinforced composite material part corresponding to a structural shell or a sector of a shell structural consisting of the fibrous preform of the structural part densified by the first matrix, the reinforcement part of said part in reinforced composite material corresponding to a reinforcement belt consisting of the fibrous preform of the reinforcement part densified by the first matrix.

[0019] As explained above, the structural ferrule or the sector thereof can be manufactured taking into account the structural properties that one wishes to give to the part, while the reinforcing belt can be manufactured taking into account the energy dissipation capacities that one wishes to give to the part.

[0020] The fibrous preform of the structural ferrule or structural ferrule sector is preferably made by depositing a plurality of unidirectional fibrous layers on a mold in order to obtain a fibrous preform of structural ferrule or a fibrous preform of structural ferrule sector extending in width along an axial direction and in thickness along a radial direction between an inner face and an outer face.

[0021] According to a particular feature of the process of the invention, the layers of the plurality of unidirectional fibrous layers deposited on the mold have fibers oriented in different directions from one layer to another. This makes it possible to reinforce the mechanical properties of the part along predefined stress directions, particularly in the fiber orientation directions of the unidirectional layers composing the preform of the structural shell or structural shell sector. The layers of the plurality of unidirectional fibrous layers deposited on the mold may, in particular, have fibers oriented at any angle between 0° and ± 90°, such as, for example, an angle of ± 45° or ± 60° with respect to the direction of the warp and / or weft yarns or strands of the fibrous texture.

[0022] The invention also relates to a part made of reinforced composite material manufactured in accordance with the manufacturing process of a part made of reinforced composite material of the invention.

[0023] The invention further relates to a part of revolution or a sector of a part of revolution made of a composite material manufactured according to the method for manufacturing a part of a composite material of the invention. The part of revolution may, in particular, correspond to a gas turbine blower housing or a low-pressure gas turbine compressor. The sector of the part of revolution may, in particular, correspond to a blower housing sector or a low-pressure gas turbine compressor housing sector.

[0024] The invention further relates to an aeronautical gas turbine engine having a part of revolution or one or more sectors of a part of revolution of the invention (blower casing, low pressure compressor according to the invention, blower casing sector(s), or low pressure compression casing sector(s). Brief description of the drawings

[0025] [Fig-1] [Fig. 1] is a perspective and partial cross-sectional view of an aircraft engine equipped with a fan casing made of composite material according to an embodiment of the invention,

[0026] [Fig.2] The [Fig.2] is a cross-sectional view along plane ILII of the housing of the [Fig.l],

[0027] [Fig.3] Fig.3 schematically shows an example of a stratified structure of a fibrous preform of a structural ferrule,

[0028] [Fig.4] Fig.4 is a perspective view showing the shaping of a fibrous preform of a structural ferrule,

[0029] [Fig.5] Fig.5 is a schematic perspective view of a loom showing the weaving of a fibrous texture used for forming the fibrous reinforcement of a reinforcing belt of the casing of Figures 1 and 2,

[0030] [Fig.6] Fig.6 shows an interlock weave,

[0031] [Fig.7] Fig.7 is a perspective view showing the shaping of a texture fibrous materials intended to form the fibrous reinforcement of a reinforcement belt for the blower housing shown in Figures 1 and 2,

[0032] [Fig.8] Fig.8 is a cross-sectional view showing the profile of a fibrous preform of the housing of Figures 1 and 2 as well as a tooling allowing densification with a matrix of the fibrous preform. Description of the implementation methods

[0033] The invention applies generally to any part made of composite material exposed to impacts from objects. The invention applies more particularly, but not exclusively, to parts of revolution or sectors of parts of revolution made of composite material for gas turbines.

[0034] A method for manufacturing a part made of composite material according to the invention is described below, applied, according to a first example, to a blower housing for an aeronautical gas turbine engine.

[0035] Such an engine, as shown very schematically by [Fig.1], comprises, from upstream to downstream in the direction of the gas flow E, a blower 1 disposed at the inlet of the engine, a compressor 2, a combustion chamber 3, a high-pressure turbine 4 and a low-pressure turbine 5.

[0036] The motor is housed inside a casing comprising several parts corresponding to different elements of the motor. Thus, the blower 1 is surrounded by a blower casing 10 having a shape of revolution.

[0037] Fig. 2 shows the profile (axial section) of the blower housing 10.

[0038] The housing 10 extends in width along an axial direction DA between its ends upstream and downstream (from left to right in [Fig.2]) which are here fitted with external flanges 14, 15 to allow its assembly and connection with other elements. The housing 10 extends lengthwise along a circumferential direction Dc.

[0039] According to the invention, the casing 10 comprises a structural ferrule 11 made of a first composite material having on its inner or outer surface a reinforcing band made of a second composite material. In the example described here, the structural ferrule has on its outer surface 11b a reinforcing band 12 made of a second composite material. The reinforcing band 12 defines a retention zone of the casing 10 capable of retaining debris from damage to the fan blades, and projected radially by the rotation of the fan, to prevent it from passing through the casing and damaging other parts of the aircraft. The inner surface 1la of the structural ferrule 11 here defines the engine air intake duct.

[0040] According to the invention, the structural ferrule 11 is made from a fibrous reinforcement densified by a first matrix having a Young's modulus greater than or equal to 2 GPa, preferably between 2 GPa and 4.5 GPa, while the reinforcing belt 12 is made from a fibrous reinforcement densified by a second matrix having a Young's modulus less than or equal to 0.5 GPa, preferably between 0.002 GPa and 0.5 GPa. The housing 10 thus has a structural character suitable for its integration into an aircraft engine while having very good retention capacity in an area delimited by the reinforcing belt 12.Indeed, the flexibility of the second matrix present in the reinforcement belt significantly increases the energy dissipation capacity of the housing compared to the same housing made of composite material, even with an extra thickness at the retention shield but without a flexible matrix reinforcement section.

[0041] Impact resistance tests were carried out at moderate speeds on, firstly, composite material specimens densified with a matrix having a Young's modulus greater than or equal to 2 GPa and, secondly, on composite material specimens densified with a matrix having a Young's modulus less than or equal to 0.5 GPa. The specimens densified with the matrix having a Young's modulus greater than or equal to 2 GPa were perforated from an impact energy threshold of approximately 470 joules, while the specimens densified with the matrix having a Young's modulus less than or equal to 0.5 GPa withstood impacts without perforation having an impact energy of at least 820 joules.

[0042] The composite material part of the invention is, therefore, remarkable in that it comprises a structural part intended to ensure the structural functions of the part and a densified reinforcement part with a so-called "flexible" matrix giving the final composite material part a significant gain in impact resistance without perforation.

[0043] As explained in detail below, in the example described here, the fibrous reinforcement of the structural ferrule 11 is formed by a plurality of unidirectional layers superimposed on one another, while the fibrous reinforcement of the reinforcing belt 12 is formed by a fibrous texture made in the form of a strip by three-dimensional weaving.

[0044] A method for manufacturing the blower housing 10 according to an embodiment of the invention is now described. In the method described below, the part is directly manufactured with its final geometry of revolution. However, the invention also applies to the unitary manufacturing of sectors of the part of revolution, the latter being obtained by assembling several of these sectors of revolution, for example by tightening flanges located at the ends of each sector.

[0045] As shown in Figures 3 and 4, a fibrous preform 100 of the structural collar is formed by successive deposits of unidirectional layers onto a mold, in this case a mandrel 200. The deposition of the unidirectional layers onto the mandrel is preferably carried out using the known technology of automatic fiber placement, known as AFP (for "Automatic Fiber Placement"). The unidirectional layers deposited on the mandrel may be pre-impregnated with a first liquid matrix precursor or be "dry," that is, without being pre-impregnated, the fibrous preform of the structural collar being impregnated with a first liquid matrix precursor subsequently. In the latter case, the fibrous preform of the structural collar is impregnated with the first matrix precursor before the formation of the fibrous preform of the reinforcing belt.In all cases, the first precursor used here is an organic matrix precursor having a Young's modulus greater than or equal to 2 GPa, preferably between 2 GPa and 4.5 GPa. The structural part of the component to be manufactured, here the structural ferrule 11 of the housing 10, can be made from a fiber reinforcement, for example of carbon, glass, or aramid, densified by a polymer matrix, obtained, for example, from an epoxy or polyimide resin giving a first matrix with a Young's modulus greater than or equal to 2 GPa. The manufacture of such a housing is described in particular in US document 8,322,971.

[0046] In the case of manufacturing a sector of a part of revolution, a preform of a structural ferrule sector is formed by successive deposits of unidirectional layers on a mold corresponding to the shape of the structural ferrule sector to be manufactured.

[0047] The mandrel 200 ([Fig.4]) (or sector mold) has an external surface 201 whose profile corresponds to the internal surface of the structural shell to be produced. By being deposited on the mandrel 200, the unidirectional layers conform to its profile. The mandrel 200 also includes two flanges 220 and 230 to form parts of fibrous preform corresponding to the flanges 14 and 15 of the housing 10.

[0048] The fibrous preform 100 of the structural ferrule (or structural ferrule sector) comprises a plurality of unidirectional layers, i.e., layers each having fibers or wires extending in the same direction. The unidirectional layers are preferably deposited one on top of the other with different orientations so as to have fibers or wires in the fibrous preform oriented in different directions, which makes it possible to strengthen the mechanical properties of the part along predefined stress directions, particularly in the orientation directions of the fibers of the unidirectional layers composing the structural ferrule preform (or structural ferrule sector).

[0049] An example of a fibrous preform 100 composed of a stratification of unidirectional layers is illustrated in [Fig.3]. In this example, it has a stratification of unidirectional layers 101, 102, 103, 104 and 105 oriented at different angles with respect to a longitudinal direction L, namely 0° (101), 90° (102), +45° (103), 90° (104), and -45° (105).

[0050] It should be noted that the fibrous preform of the structural ferrule (or structural ferrule sector) may have different layers in their orientation and / or number than those illustrated in [Fig. 3]. For example, when it is desired to reinforce the shear mechanical properties of the structural ferrule, the fibrous preform may comprise at least one first unidirectional layer oriented at +45° and at least one second unidirectional layer oriented at -45°.

[0051] As illustrated in [Fig.5], the process according to the invention also includes the production of a fibrous texture 90 by weaving using a jacquard type loom 60 on which a bundle of warp yarns or strands 70 has been arranged in a plurality of layers, the warp yarns being linked by weft yarns or strands 80. The fibrous texture is produced by three-dimensional weaving.

[0052] The term “three-dimensional weave” or “3D weave” refers to a weaving method in which at least some of the weft yarns interlock with warp yarns over several layers of warp yarns, or vice versa. An example of a three-dimensional weave is the so-called “interlock” weave. “Interlock” refers to a weave structure in which each layer of warp yarns interlocks with several layers of weft yarns, with all the yarns in the same warp column having the same movement within the plane of the weave.

[0053] Figure 6 shows an example of an interlock weave for creating the fibrous texture 90. In Figure 6, the weft yarns 80 are shown in cross-section. A three-dimensional weave with an interlock weave is a weave in which each warp yarn 70 connects several layers of weft yarns 80, the paths of the warp yarns 70 being identical. Other three-dimensional weaving methods are possible, such as multi-layered weaves with multi-satin or multi-plain weaves. Weaves of this type are described in document WO2006136755.

[0054] The realization of the fibrous texture 90 by 3D weaving makes it possible to obtain a bond between the layers, therefore to have good mechanical strength of the fibrous texture and of the reinforcement belt in composite material obtained, in a single textile operation.

[0055] The fibrous texture 90 has a band shape which extends lengthwise in a direction X ([Fig.5]) corresponding to the direction of scrolling of the warp yarns or strands 70 and widthwise or transversely in a direction Y ([Fig.5]) corresponding to the direction of the weft yarns or strands 80.

[0056] In the example described here, the structural shell (or structural shell sector) fibrous preform 100 is formed on the mandrel 200 from unidirectional fibrous layers pre-impregnated with the first matrix precursor, or formed on said mandrel from dry unidirectional fibrous layers. The fibrous preform is then impregnated with the first matrix precursor after its formation on the mandrel and before the formation of the reinforcing belt preform. The first precursor is usually in the form of a polymer, such as a resin, possibly diluted in a solvent. The fibrous preform 100 is placed in a mold that can be hermetically sealed in order to impregnate it with the first matrix precursor.

[0057] As illustrated in [Fig. 7], the fibrous texture 90 is then wound one or more times onto the external surface 100b of the fibrous preform 100 of the structural ferrule impregnated with the first matrix precursor at a predetermined location on the ferrule along the axial direction DA, corresponding to a debris retention zone of the final housing. Consequently, in the fibrous reinforcement of the final reinforcing belt, the warp yarns or strands extend along the circumferential direction Dc ([Fig. 2]) while the weft yarns or strands extend along the axial direction DA ([Fig. 2]). In the case of manufacturing a sector of a part of revolution, one or more layers of the fibrous texture are draped over the fibrous preform of the structural ferrule sector.

[0058] The fibrous texture 90 can be pre-impregnated with a second liquid matrix precursor, different from the first matrix precursor described above, before being wound onto the external surface 100b of the fibrous preform 100 of the structural ferrule impregnated with the first matrix precursor. According to one embodiment, the fibrous texture 90 can be wound onto the fibrous preform 100 of the structural ferrule impregnated with the first matrix precursor in a dry state, i.e., without being pre-impregnated, the fibrous texture being impregnated with a second liquid precursor. of the matrix after shaping. In all cases and in accordance with the invention, the second precursor is a precursor that allows the formation of a matrix having a Young's modulus less than or equal to 0.5 GPa, preferably between 0.002 GPa and 0.5 GPa. Such a precursor may, in particular, consist of: - the Resoltech 1600 / 1606 epoxy system marketed by the company Resoltech, which allows the formation of a matrix with a Young's modulus of 2.6 MPa, - EPOXONIC® 361 resin, marketed by EPOXONIC®, which allows the formation of a matrix with a Young's modulus of 2.8 MPa, or - Sikadur®-22 Lo-Mod resin, marketed by Sika®, allows the formation of a matrix with a Young's modulus of 455 MPa.

[0059] The fibrous texture 90 has a width l90 that is less than the width l100 of the fibrous preform 100 of the structural shell (or structural shell sector) along the axial direction DA ([Fig. 7]). The width l90 of the fibrous texture determines the axial area or extent over which the structural shell of the housing is to be locally reinforced. Generally, the width l90 of the fibrous texture 90 is between 10% and 80% of the width hoo of the fibrous preform 100.

[0060] Once wound on a determined number of turns on the external surface 100b of the fibrous preform 100, the fibrous texture 90 forms a fibrous preform of a reinforcing belt.

[0061] The fibrous preform 100 of the structural ferrule (or structural ferrule sector) and the fibrous texture 90 may comprise fibers, for example, of carbon, glass, or aramid. The fibrous preform 100 of the structural ferrule (or structural ferrule sector) and the fibrous texture 90 may be made with fibers of the same or different types.

[0062] Figure 8 shows a cross-sectional view of a fibrous preform 300 of a part of revolution, here of the housing 10 to be produced, consisting, from the center outwards, of the unidirectional layers 101 to 105 of the fibrous preform 100 of the structural ferrule and the fibrous texture 90 (wound in a single turn on Figure 8). The number of turns or spirals of the fibrous texture 90 depends on the desired thickness of the reinforcing band and the desired local reinforcing properties.

[0063] As illustrated in [Fig. 8], the fibrous preform 300 is placed between a plurality of sectors 240 forming a counter-mold and the mandrel 200 forming a support, these elements respectively having the external and internal shapes of the housing to be produced. Then, if the fibrous texture 90 is not pre-impregnated, the second liquid matrix precursor is injected into the reinforcing belt preform.

[0064] The transformation of the first and second precursors into first and second matrices respectively, namely their polymerization, is carried out by heat treatment, generally by heating the mold, after removal of any solvent and crosslinking of the polymer, the preform always being kept in the mold having a shape corresponding to that of the part to be produced.

[0065] In the case of manufacturing a sector of a part of revolution, only the shapes of the mold and the counter-mold are modified to adapt to the geometry of the sector to be manufactured. All other characteristics of the densification step described above also apply to the densification of a fibrous preform of a sector of a part of revolution.

[0066] After polymerization, the part is demolded. Finally, the part is trimmed to remove excess resin and the chamfers are machined to obtain the housing 10 illustrated in figures 1 and 2, namely comprising the structural ferrule 11 (or the structural ferrule sector) comprising a fibrous reinforcement corresponding to the fibrous preform of the structural ferrule (or ferrule sector) densified by a first matrix having a Young's modulus greater than or equal to 2 GPa and comprising on an external surface 11b a reinforcement belt of composite material 12 comprising a fibrous reinforcement corresponding to the fibrous preform of the belt densified by a second matrix having a Young's modulus less than or equal to 0.5 GPa.

[0067] According to another embodiment of the process of the invention, the part of revolution (or the sector of the part of revolution), here the housing 10, can be manufactured in the following way:

[0068] - formation of a fibrous preform of structural collar (like the fibrous preform 100) (or a fibrous preform of a structural ferrule sector) by depositing a plurality of unidirectional fibrous layers pre-impregnated with the first matrix precursor or dry onto a mandrel (or sector mold) as already described above,

[0069] - possible impregnation of the structural ferrule preform with the first - matrix precursor if it has been formed with dry fibrous layers, - densification (heat treatment) of the fibrous preform of the structural ferrule (or structural ferrule sector) by the first matrix so as to obtain a structural ferrule (or structural ferrule sector) in composite material (like the structural ferrule 11) comprising a fibrous reinforcement corresponding to the fibrous preform of the structural ferrule (or structural ferrule sector) densified by the first matrix having a Young's modulus greater than or equal to 2 GPa, - realization by three-dimensional weaving of a fibrous texture in the form of a strip (like the fibrous texture 90), - shaping of the fibrous texture and possible impregnation of the fibrous preform of the reinforcing belt by the second matrix precursor if it is not already pre-impregnated,

[0070] - densification (heat treatment) of the fibrous preform of the belt reinforcement by the second matrix so as to obtain a reinforcement belt in composite material comprising a fibrous reinforcement corresponding to the fibrous preform of the reinforcement belt densified by the second matrix having a Young's modulus less than or equal to 0.5 GPa,

[0071] - bonding the reinforcing belt to the structural shell (or to a sector of structural ferrule).

[0072] In the case of a structural ring of revolution, the reinforcing belt is made in two parts which are then attached and glued onto the structural ring.

[0073] According to one embodiment, after the production by three-dimensional weaving of a fibrous texture in the form of a strip, the process may include the following steps: - winding on one or more turns of the pre-impregnated or second matrix precursor fibrous texture on an external surface of the structural shell made of composite material (or draping of one or more layers of 3D fibrous texture on an external surface of the structural shell sector made of composite material) in order to form a fibrous preform of the reinforcing belt, - densification (heat treatment) of the fibrous preform of the belt by a matrix.

[0074] A part of revolution (or sector of part of revolution) is thus obtained in composite material which can correspond to the housing 10 of figures 1 and 2, namely comprising the structural ferrule 11 comprising a fibrous reinforcement corresponding to the fibrous preform of the structural ferrule densified by a first matrix having a Young's modulus greater than or equal to 2 GPa and comprising on an external surface 11b a reinforcement belt in composite material 12 comprising a fibrous reinforcement corresponding to the fibrous preform of the belt densified by a second matrix having a Young's modulus less than or equal to 0.5 GPa.

[0075] According to yet another embodiment, the fibrous preform of the reinforcing part, here the fibrous preform of the reinforcing belt, can be produced by draping or layering unidirectional fibrous layers that can be either pre-impregnated with the first and second matrix precursors, or impregnated together after their layering. The fibrous preform of the structural part, here the preform of the structural ferrule or structural ferrule sector, pre-impregnated or impregnated with the first matrix precursor, and the fibrous preform of the reinforcing part, here the fibrous preform of the reinforcing belt, pre-impregnated or impregnated with the second matrix precursor, are co-cured so as to obtain a part made of composite material, here a structural part of revolution (or sector of part of revolution) made of composite material comprising a structural ferrule (or sector of structural ferrule) comprising a fibrous reinforcement corresponding to the fibrous preform of structural ferrule (or sector of structural ferrule) densified by a first matrix having a Young's modulus greater than or equal to 2 GPa and comprising on an external surface a reinforcement belt made of composite material comprising a fibrous reinforcement corresponding to the fibrous preform of the belt densified by a second matrix having a Young's modulus less than or equal to 0.5 GPa.

[0076] The invention is particularly applicable to the manufacture of fan housings or housing sections and / or low-pressure compressor housings for various types of gas turbine engines, such as conventional enclosed engines or new-generation unenclosed engines known as "open rotor" engines. According to another embodiment, a part of revolution or a sector of a part of revolution is manufactured from a composite material as described above, but in which the reinforcing band is present on the inner surface of the structural shell or the structural shell sector.

[0077] The invention is also applicable to the manufacture of half-rings or half-shells connected together by axial flanges.

Claims

1. Demands Method for manufacturing a part (10) made of reinforced composite material comprising: - the production of a fibrous preform of a structural part (100) impregnated with a first matrix precursor having a Young's modulus greater than or equal to 2 GPa, - the transformation of the first precursor into a first matrix so as to obtain a densified structural part (11) with a first matrix having a Young's modulus greater than or equal to 2 GPa, - the production of a fibrous preform of a reinforcement part impregnated with a second matrix precursor having a Young's modulus less than or equal to 0.5 GPa, - the bonding of the fibrous preform of the reinforcing part onto the structural part (11), - the transformation of the second matrix precursor of the fibrous preform of the reinforcing part so as to obtain a densified reinforcing part (12) with a second matrix having a Young's modulus less than or equal to 0.5 GPa and a reinforced composite material part comprising said structural part and said reinforcing part, or - the production of a fibrous preform of a structural part (100) impregnated with a first precursor of a first matrix having a Young's modulus greater than or equal to 2 GPa, - the formation on the fibrous preform of the structural part of a fibrous preform of a reinforcing part, - impregnation, before or after the formation of the fibrous preform of the reinforcing part, of said fibrous preform of the reinforcing part with a second precursor of a second matrix having a Young's modulus less than or equal to 0.5 GPa, - the transformation of the first and second precursors respectively into a first matrix and a second matrix so as to obtain a part (10) of reinforced composite material comprising a structural part (11) densified by a first matrix having a Young's modulus greater than or equal to 2 GPa and a reinforcing part (12) densified by a second matrix having a Young's modulus less than or equal to 0.5 GPa.

2. A method according to claim 1, wherein the fibrous preform of the reinforcing part is impregnated with the second matrix precursor after its formation on the fibrous preform of the structural part impregnated with the first matrix precursor.

3. A method according to claim 1, wherein the fibrous preform of the reinforcing part is formed from one or more fibrous layers pre-impregnated with the second matrix precursor.

4. A method according to any one of claims 1 to 3, wherein the fibrous preform of the reinforcing part is made by three-dimensional weaving between a plurality of warp yarns or strands and a plurality of weft yarns or strands.

5. A method according to any one of claims 1 to 3, wherein the fibrous preform of the reinforcing part is made by layering a plurality of unidirectional fibrous layers.

6. A method according to any one of claims 1 to 5, wherein the reinforced composite material part (10) corresponds to a part of revolution or a sector of a part of revolution for a gas turbine, the structural part (11) of the reinforced composite material part corresponding to a structural shell or a sector of a structural shell made up of the fibrous preform of the structural part densified by the first matrix, the reinforcing part (12) of said reinforced composite material part corresponding to a reinforcing belt made up of the fibrous preform of the reinforcing part densified by the first matrix.

7. A method according to claim 6, wherein the fibrous preform of the structural shell or structural shell sector is produced by depositing a plurality of unidirectional fibrous layers (101, 102, 103, 104, 105) onto a mold (200) in order to obtain a fibrous preform of structural shell (100) or a fibrous preform of structural shell sector extending in width along an axial direction (DA) and in thickness along a radial direction (Dr) between an inner face and an outer face.

8. A method according to claim 7, wherein the layers (101, 102, 103, 104, 105) of the plurality of unidirectional fibrous layers deposited on the mold (200) have fibers oriented in different directions from one layer to another.

9. A method according to claim 8, wherein the layers (101, 102, 103, 104, 105) of the plurality of unidirectional fibrous layers deposited on the mold (200) have fibers oriented at an angle between 0° and ± 90° relative to the direction of the warp and / or weft yarns or strands of the fibrous texture.

10. Part made of reinforced composite material manufactured according to the process according to any one of claims 1 to 9.

11. Part of revolution or sector of part of revolution manufactured in accordance with the process according to any one of claims 6 to 9.

12. Part of revolution or sector of part of revolution according to claim 11, the part (10) of revolution or sector of part of revolution corresponding to a housing or sector of housing of gas turbine blower.

13. Part of revolution or sector of part of revolution according to claim 11, the part (10) of revolution or sector of part of revolution corresponding to a housing or sector of housing of low pressure gas turbine compressor.

14. Aeronautical gas turbine engine comprising at least one part of revolution or one or more sectors of part of revolution made of composite material according to any one of claims 11 to 13.

Images