PROCESS FOR MANUFACTURING A TURBOMACHINE DARK IN COMPOSITE MATERIAL, DAWN OBTAINED AND TURBOMACHINE

专利摘要:
The invention relates to a method for manufacturing a turbomachine blade made of composite material with fiber reinforcement densified by a matrix and comprising a blade, a platform located at a longitudinal end of the blade and at least one functional element extending from the outer face of the platform. The method comprises: - producing by multilayer weaving of a fibrous blank in one piece, - shaping the fibrous blank to obtain a one-piece fibrous preform having a first portion (302) forming a preform of the blade blade (320) and a second portion (314) forming a preform of the platform (340) and at least one functional element preform (352; 354), and - densifying the fiber preform with a matrix . The second part of the preform comprises a set of layers of son interconnected by weaving with arrangement of at least one untied zone for the deployment of the functional element preform relative to the preform of the first platform.
公开号:FR3021349A1
申请号:FR1454607
申请日:2014-05-22
公开日:2015-11-27
发明作者:Clement Roussille；Jeremy Blachier；Marie Lefebvre
申请人:SNECMA SAS；Herakles SA；
IPC主号:

专利说明:

[0001] BACKGROUND OF THE INVENTION The invention relates to turbine blades or turbomachine compressor blades, the blades being made of composite material with fiber reinforcement densified by a matrix. The targeted field is that of gas turbines for aeronautical engines or for industrial turbines. The embodiment of blades of composite material for turbomachines has already been proposed, the fiber reinforcement being obtained in particular from carbon or ceramic son and the matrix being made of ceramic material or organic material or carbon.
[0002] WO 2010/061140 A1 discloses a method for the manufacture of turbine blades of composite material with integrated heel and inner platform by: producing a fibrous blank by multilayer weaving; shaping the blank with tooling to obtain a fiber preform having foot preform and blade blade portions, blade heel preform and blade inner platform preform; and densifying the fibrous preform with a matrix. The fibrous blank is woven with a first strip-shaped portion or sheet intended to form the foot preform and blade blade and a second portion in the form of a strip or sheet intended to form the heel preforms and inner plate, the second part crossing the first at the heel locations and the inner platform. WO 2011/080443 A1 describes a similar process in which the fibrous blank is woven with a first strip-shaped portion or sheet intended to form a foot preform and blade blade, a second band-shaped portion or web for forming a preform of spoilers of blade heel cover, and a third portion in the form of a web or web intended to form a preform of dolts of blade heel and an inner platform preform of blade, the second part and the third part crossing the first at the heel locations and the inner platform. Such a method is relatively complex to implement. In addition, the production of a woven fiber blank with double penetrations induces significant stresses on the son can cause breaks in son especially when they are carbon or ceramic.
[0003] OBJECT AND SUMMARY OF THE INVENTION The purpose of the invention is to propose a simplified method making it possible to manufacture a turbomachine blade made of composite material in one piece while limiting the stresses imposed on the threads during weaving of a fibrous blank. where is obtained a preform of the dawn. In general, the invention relates to a method for manufacturing a turbomachine blade made of composite material with fiber reinforcement densified by a matrix, the blade comprising a blade, a first platform located at a longitudinal end of the blade and having a internal vein delimiting face and an outer face opposite to the inner face, and at least one functional element extending from the outer face of the first platform by connecting to said outer face in a substantially circumferential direction, the method comprising: - the production by multilayer weaving of a fibrous blank in one piece, - the shaping of the fibrous blank to obtain a one-piece fibrous preform having a first portion forming a preform of the blade of dawn and a second portion forming a preform of the first platform and at least one functional element preform, and - the densification of the fibrous die with a matrix to obtain a blade of composite material having a fiber reinforcement formed by the preform and densified by the die and forming a single piece with the blade, the first platform and said at least one integrated functional element, the method in which the second part of the preform comprises a set of son layers bonded together by weaving with provision of at least one untied area for the deployment of the or each functional element preform relative to the preform of the first platform. By functional element, is meant here a portion of a blade which connects to the outer surface of a platform to form, for example, an outer platform wiper, or heel, mobile blade, or a mounting hook s extending from the outer face of an outer platform or possibly inner platform of fixed blade, or an abradable support member extending from the outer face of an inner or possibly outer platform of blade fixed. By inner side of vein delimitation is meant here the face of an inner or outer blade platform which, in use in a compressor or a turbine, is exposed to the flow of air or gas flowing in the compressor or the turbine. The terms inner and outer are here used in relation to the situation with respect to the axis of the turbomachine in which the blade is mounted, the inner platform being for example closer to the axis than the outer platform. The term circumferential is used here with reference to the axis of the turbomachine in which the blade is mounted. With the method of the invention, thanks to the arrangement of untied zones, it is not necessary to produce the fiber blank with separate woven webs to obtain a functional element preform and a dawn platform preform. . Compared to the prior art mentioned above, the number of crossings and the complexity of the fiber blank are reduced, which limits the risk of wire breakage and simplifies the design of the forming tool of the preform. The set of layers of the second preform portion may comprise a group of common wire layers with the blade preform. The part of the fibrous blank corresponding to the second preform part may be partly in the extension of the part of the blank corresponding to the blade preform, avoiding the need for a complete traverse of the latter as in the prior art discussed above. The portion of the fibrous blank corresponding to the second preform portion may comprise one or more layers of yarns taken from the portion of the fibrous blank corresponding to the blade preform, at one or more levels in the longitudinal direction, the preform of blade having a variable thickness in the longitudinal direction. The shaping of the fibrous blank can be carried out so as to obtain a single-piece fiber preform having, in addition, a third preform portion of a second platform located at a longitudinal end of the blade opposite to that in which it is located. the first platform, and the set of son layers of the portion of the fibrous blank corresponding to the second preform portion may then comprise a group of son layers common with the portion of the fibrous blank corresponding to the preform of blade and a group of common wire layers with the portion of the blank corresponding to the second platform preform. According to a first embodiment of the method according to the invention, it aims to manufacture a mobile turbine engine blade, the blade being made of composite material with fiber reinforcement densified by a matrix and comprising a foot, a blade , an outer platform forming a heel located at one longitudinal end of the blade and having an inner vein delimiting face and an outer face opposite to the inner face, and heel wipers each extending from the outer face of the blade; heel connecting to said outer face in a substantially circumferential direction, the method comprising: - the production by multilayer weaving of a fibrous blank in one piece, - the shaping of the fibrous blank to obtain a fibrous preform in a single piece having a first portion forming a blade preform, a second portion forming a heel preform and preforms of heel wipers and a three-piece the first part lying in the extension of the first part and forming a foot preform, and - the densification of the fiber preform by a matrix to obtain a blade of composite material having a fiber reinforcement formed by the preform and densified by the matrix and forming one piece with integrated foot, blade, heel and heel taps, in which method the second part of the preform comprises a set of layers of threads linked together by weaving with the provision of untied zones allowing the deployment of the preforms of heel wipers compared to the heel preform. The set of layers of the second preform portion may comprise a group of common wire layers with the blade preform. The set of layers of the second preform portion may further comprise a group of additional wire layers not common with the blade blade preform. The shaping of the fibrous blank can be performed to provide a one-piece fibrous preform having further a fourth inner platform preform portion. In this case, the set of yarn layers of the portion of the fibrous blank corresponding to the second preform portion may comprise a group of yarn layers common with the portion of the fibrous blank corresponding to the blade preform and a group of common wire layers with the portion of the blank corresponding to the inner platform preform. Still in this case, the blade preform may comprise a set of son layers common with the foot preform and traversed by a set of son layers of the inner platform preform at the location thereof.
[0004] The foot preform may comprise a number of wire layers greater than that of the blade preform, and, in the fiber blank, the set of wire layers of the portion of the blank corresponding to the second preform portion. comprises a group of common wire layers with the portion of the blank corresponding to the blade preform and a group of common wire layers with the portion of the blank corresponding to the foot preform and not used in the blade preform . Thus, at the portion of the blank corresponding to the second preform part, a group of layers of threads used in the part of the blank corresponding to the foot preform is recovered. The set of layers of the second preform portion may further comprise a group of additional wire layers not common with the blade root preform. The portion of the fibrous blank corresponding to the second preform portion may comprise one or more layers of yarns taken from the portion of the fibrous blank corresponding to the blade preform, at one or more levels in the longitudinal direction, the preform of blade having a variable thickness in the longitudinal direction. According to a second embodiment of the method according to the invention, the latter aims at producing a fixed blade of a turbomachine, the blade being made of composite material with fiber reinforcement densified by a matrix and comprising a blade, a first platform located at a longitudinal end of the blade and having an inner vein delimiting face and an outer face opposite to the inner face, and mounting hooks extending from the outer face of the first platform by connecting to said outer face in a substantially circumferential direction, the method comprising: - producing by multilayer weaving of a fibrous blank in one piece, - shaping the fibrous blank to obtain a one-piece fibrous preform having a first part forming a blade preform, a second part forming a preform of first platform and preforms of mounting hooks, and - the densi forming the fibrous preform with a matrix to obtain a blade of composite material having a fiber reinforcement formed by the preform and densified by the die and forming a single piece with blade, first platform and integrated mounting hooks, wherein the second part the preform comprises a set of layers of son interconnected by weaving with arranging untied areas for the deployment of preforms hooks mounting relative to the preform of the first platform. The first platform preform may be an outer platform preform or an inner platform preform. The set of layers of the second preform portion may comprise a group of common wire layers with the blade preform. The portion of the fibrous blank corresponding to the second preform portion may comprise one or more layers of yarns taken from the portion of the fibrous blank corresponding to the blade preform, at one or more levels in the longitudinal direction, the preform of blade having a variable thickness in the longitudinal direction.
[0005] According to a third embodiment of the method according to the invention, the invention relates to a method of manufacturing a fixed turbomachine blade, the blade being made of a fiber-reinforced composite material densified by a matrix and comprising a blade, a first platform located at one longitudinal end of the blade and having an internal vein delimiting face and an external face opposite to the inner face, and at least one abradable supporting member extending from the outer face of the blade; the first platform being connected to said outer face in a substantially circumferential direction, the method comprising: - the production by multilayer weaving of a fibrous blank in one piece, - the shaping of the fibrous blank to obtain a preform one-piece fibrous material having a first portion forming a blade preform, a second portion forming a first platform preform and at least one preform abradable support element form, and - the densification of the fibrous preform by a matrix to obtain a composite material blade having a fibrous reinforcement formed by the preform and densified by the matrix and forming a single piece with blade, first platform and at least one integral abradable support member, wherein the second part of the preform comprises a set of layers of yarns interlinked by weaving with the provision of untied zones allowing the deployment of the or each element preform. abradable support compared to the preform of the first platform. The first platform preform may be an inner platform preform or an outer platform preform.
[0006] The set of layers of the second preform portion may comprise a group of common wire layers with the blade preform. The portion of the fibrous blank corresponding to the second preform portion may comprise one or more layers of yarns taken from the portion of the fibrous blank corresponding to the blade preform, at one or more levels in the longitudinal direction, the preform of blade having a variable thickness in the longitudinal direction. The first and second embodiments of the method according to the invention can be combined with each other to manufacture a fixed turbine engine blade with blade, outer platform, mounting hooks, inner platform and at least one support element. 'abradable integrated. In any method according to the invention, in the fibrous blank, said set of son layers may comprise layers of warp yarns extending in the longitudinal direction of the blade, and said untied zones then extend continuous in the warp direction between opposite sides of the portion of the fibrous blank corresponding to the second preform portion, over a limited distance in the weft direction. In any method according to the invention, in the fiber blank, said set of wire layers may comprise layers of weft yarns extending in the longitudinal direction of the blade, and said loosened zones then extend continuous in weft direction between opposite sides of the portion of the fibrous blank corresponding to the second preform portion, over a limited distance in the warp direction.
[0007] The invention also relates to a turbomachine blade comprising a blade, a first platform located at a longitudinal end of the blade and having an internal vein delimiting face and an external face opposite to the inner face, and at least one element. functional piece extending from the outer face of the first platform by connecting to said outer face in a substantially circumferential direction, - the blade being in one piece of composite material comprising a multi-layer woven fiber reinforcement densified by a matrix, and the fibrous reinforcement being in one piece with a first part forming a blade blade reinforcement and a second part forming a first platform reinforcement and at least one functional element reinforcement, blade in which the second reinforcing part fibrous comprises a set of layers of threads all interconnected by weaving except at a separation zone between the or each functional element reinforcement and the first platform reinforcement. In a first particular embodiment of a blade according to the invention, the latter forms a mobile turbine engine blade comprising a blade, an outer platform forming a blade root located at a longitudinal end of the blade and having a face internal vein delimiting and an outer face opposite to the inner face, and heel wipers extending from the outer face of the heel connecting to said outer face in a substantially circumferential direction, the blade being in a single piece of composite material comprising a matrix-densified multi-layer woven fibrous reinforcement, and the fibrous reinforcement being in one piece with a first blade-forming portion and a second heel-reinforcing portion and heel-wad reinforcements , blade wherein the second fibrous reinforcement portion comprises a set of layers of yarn all interconnected by weaving except at the level of separation zones between the reinforcements of bead wipers and the bead reinforcement.
[0008] In a second particular embodiment of a blade according to the invention, the latter forms a fixed turbomachine blade comprising a blade, a first platform located at a longitudinal end of the blade and having an inner face of vein delimitation and an outer face opposite to the inner face, and mounting brackets of the blade extending from the outer face of the first platform by connecting to said outer face in a substantially circumferential direction, - the blade being one-piece composite material comprising a matrix-densified multi-layered fibrous reinforcement, and the fibrous reinforcement being in one piece with a first blade-forming portion and a second portion forming a first-platform reinforcement and reinforcements of mounting hooks, vane in which the second fibrous reinforcement portion comprises a set of layers of yarns all bonded together by tis wise except at the level of separation zones between the mounting hook reinforcements and the first platform reinforcement The first platform may be an outer platform or an inner platform.
[0009] In a third particular embodiment of a blade according to the invention, the latter forms a fixed turbomachine blade comprising a blade, a first platform located at a longitudinal end of the blade and having an internal vein delimiting face and an outer face opposite to the inner face, and at least one abradable support member extending from the outer face of the first platform by connecting to said outer face in a substantially circumferential direction, - dawn being in a single piece of composite material comprising a matrix-densified multilayer woven fiber reinforcement, and - the fibrous reinforcement being in one piece with a first part forming a blade reinforcement and a second part forming a first platform reinforcement and the minus an abradable support element reinforcement, vane in which the second fibrous reinforcement portion comprises a set of wire layers all interconnected by weaving except at separation zone level between the or each abradable support element reinforcement and the first platform reinforcement. The first platform can be an indoor platform or an outdoor platform. The second and third embodiments of a blade according to the invention can be combined with each other to form a fixed blade of turbine engine made of composite material with blade, outer platform, mounting hooks, inner platform and at least one support element. 'abradable integrated.
[0010] In all embodiments of a blade according to the invention, the set of wire layers of the second reinforcing portion may comprise a group of common wire layers with the blade reinforcement. The invention also relates to a turbine wheel or turbomachine compressor comprising vanes as defined above in ceramic matrix composite material, or a turbomachine compressor wheel comprising vanes as defined above in material composite organic matrix, and a turbomachine having at least one such turbine wheel or compressor.
[0011] BRIEF DESCRIPTION OF THE DRAWINGS The invention will be better understood on reading the description given below, by way of indication but not limitation, with reference to the accompanying drawings, in which: FIG. 1 is a very schematic partial sectional view of FIG. a part of a low pressure turbine of a turbomachine; - Figure 2 is a very schematic perspective view of a moving wheel blade of the turbine of Figure 1; FIG. 3 very schematically illustrates in side elevation an example of arrangement of sets of layers of threads in a fibrous blank produced by multilayer weaving and intended to obtain a fibrous preform for a blade of the type of that of Figure 2; FIGS. 4A, 4B, 4C, and 4D are sectional views on an enlarged scale along the planes A, B, C and D of FIG. 3; FIGS. 5A, 5B, 5C and 5D are partial views corresponding to FIGS. 4A, 4B, 4C and 4D, respectively, schematically showing a mode of weaving of the fibrous blank of FIG. 3; - Figures 6 to 8 illustrate successive steps of producing a fibrous preform for a moving blade from the fiber blank of Figure 3; FIG. 9 very schematically illustrates in side elevation another example of arrangement of sets of layers of threads in a fibrous blank produced by multilayer weaving and intended to obtain a fibrous preform for a blade of the type of that of Figure 2; FIGS. 10A, 10B, 10C, 10D, and 10E are sectional views on an enlarged scale along the planes A, B, C, D and E of FIG. 9; FIG. 11 shows successive steps of an exemplary embodiment of a method for manufacturing a turbomachine moving blade in accordance with the invention; FIG. 12 very schematically illustrates in side elevation an example of arrangement of sets of layers of threads in a fibrous preform made by multilayer weaving and intended to obtain a fibrous preform for a fixed wheel vane of the following type; that of Figure 1; FIGS. 13A, 13B, 13C, and 13D are sectional views on an enlarged scale along the planes A, B, C and D of FIG. 12; FIGS. 14 to 16 illustrate successive steps for producing a fiber preform for a fixed wheel blade, starting from the blank of FIG. 12; FIG. 17 very schematically illustrates in side elevation an example of arranging sets of layers of threads in a fibrous preform made by multilayer weaving and intended to obtain a fibrous preform for a fixed wheel vane of the following type; that of Figure 1; FIGS. 18A, 18B, 18C and 18D are sectional views on an enlarged scale along the planes A, B, C and D of FIG. 17; FIGS. 19 to 21 illustrate successive steps of producing a fiber preform for a fixed wheel blade from the blank of FIG. 17; and FIG. 22 is a partial schematic view illustrating an embodiment variant of a turbine engine fixed wheel blade according to the invention. DETAILED DESCRIPTION OF EMBODIMENTS The invention is applicable to various types of turbomachine blades, in particular blades for a moving wheel or a turbine or compressor fixed wheel of different gas turbine bodies. By fixed wheel turbine or compressor, here means a set of non-rotating vanes forming a turbine distributor or compressor rectifier. 302 134 9 13 Embodiment: low pressure turbine moving wheel vane The low pressure turbine shown very schematically and partially in FIG. 1 comprises a plurality of fixed wheels 100 alternating with moving wheels 200 in the direction of the axis X of the turbine, a single pair of fixed wheel and moving wheel being shown. A fixed wheel 100 includes a plurality of blades 110 each having a blade 120 extending between an inner platform 130 and an outer platform 140. Support members 162, 164 project inwardly from the outer face. of the inner platform 130 by connecting to this outer face along connecting areas extending in a substantially circumferential direction. The support members 162 and 164 have an L-shaped profile and support a block of abradable material 166. Mounting hooks 152 and 154 protrude outwardly from the outer face of the outer platform 140 by connecting to this outer face along connecting areas extending in a substantially circumferential direction. The hooks 152 and 154 for mounting the blade in a turbine casing 10. A movable wheel 200 comprises a plurality of blades 210 (Figures 1 and 2) each having a blade 220 extending longitudinally between a inner platform 230 and an outer platform, or heel, 240. A foot 260 formed by a thicker portion, for example with a bulbous section is connected by a stag 262 to the outer face of the inner platform 230. Heel wipers 252, 254 protrude outwardly from the outer surface of the heel 240 by connecting to this outer face along connecting regions extending in a substantially circumferential direction. The outer faces of the platforms 130 and 230 and the inner faces of the platform 140 and the heel 240 delimit a stream of flow of gas in the turbine. Each blade 210 is mounted on a turbine rotor 20 by engagement of the foot 260 in a correspondingly shaped housing provided at the periphery of the rotor. In its upstream and downstream end portions (in the flow direction F of the gas flow), the platform 230 terminates in upstream and downstream spoilers 232 and 234. The blade 220 has a curved profile in cross section. of variable thickness between its leading edge 220a and its trailing edge 220b. The thickness of the blade can also vary in the longitudinal direction. The upstream 252 and downstream 254 heel licks have tooth-like profiles, the ends of which can penetrate into a layer of abradable material 14 carried by a turbine ring 18 to reduce the clearance between the blade tip and the blade ring. turbine. In its upstream and downstream end portions, the heel 240 can also end with upstream and downstream spoilers 242 and 244. The turbine rotor supports wipers 22 whose ends can penetrate into the abradable material 166 to ensure sealing of the gas flow flow vein on the inner side. A turbomachine low-pressure turbine arrangement as briefly described above is well known per se. FIGS. 3 and 4A to 4D show very schematically a fiber blank 300 from which a fibrous blade preform can be shaped in order, after densification by a matrix and possible machining, to obtain a vane made of composite material with a blade , foot, inner platform, heel and heel wipers integrated type of that illustrated in Figure 2.
[0012] In this embodiment, as in all the other embodiments described here, the fiber blank is produced by three-dimensional weaving or multilayer weaving and only the envelopes of the various woven parts of the blank are represented for the sake of clarity (except in the figures 5A to 5D). The weaving is carried out for example with the warp direction corresponding to the longitudinal direction of the blade to be produced, each part of the blank comprising a plurality of layers of warp threads linked together at least partially by weft threads. a plurality of weft son layers. The blank 300 comprises a portion 302 intended to form the blade preform of the blade to be produced. The portion 302 may have a smaller thickness in its side portions 3021, 3022 adjacent to the leading edges and the trailing edges of the vane blade to be realized than in its central portion 3023, the difference in thickness being here obtained by a different number of layers of warp yarns.
[0013] The blank 300 also includes a portion 306 having a segment 3061 for forming the blade root preform to be made and a segment 3062 for forming the blade stag preform to be made. The portion 302 is in the continuity of the segment 3062 of the portion 306 by sharing therewith layers of common warp son. However, the portion 3062 in this example has a thickness greater than that of the portion 3023, this greater thickness being obtained by a greater number of layers of warp yarns, so that a portion of the warp yarn layers of the portion 306 is not found in the part 302. The segment 3061 has a thickness greater than that of the segment 3062 to have a shape corresponding to that of the bulb 10 of the root of the blade to be produced. This greater thickness can be obtained by increasing the title and / or the texture of the weft son. Alternatively or additionally, an insert could be introduced locally during weaving. For a more detailed description of the production of a portion of fiber blank corresponding to a blade root preform, reference may be made, for example, to the aforementioned document WO 2010/061140 A1. The blank 300 further comprises a part 303 which extends along a face 306a of the portion 306, without being bonded to the portion 306. The warp son son of the warp layers of the portion 303 pass through the portion 302 at its connection to Part 306. The excess warp strands of Part 306, that is, those not included in Part 302, are joined by weaving with those of Part 303 after it has passed through portion 302, to form a portion 305. The portion 305 extends along the face 302b of the portion 302 opposite to the face 302a corresponding to the face 306a of the portion 306. The portion 305 is not bound by weaving the portion 302 along its path along it. At the end of the portion 302 opposite to that which is connected to the portion 306, a portion 304 is formed extending the portions 302 and 305 and joining them by weaving, the son layers of the portion 305 being at least part end on the side of the face 304a of the portion 304 corresponding to the face 302a of the portion 302. A segment 303A of the portion 303 extending along the face 306a of the portion 306 and a segment 305A of the portion 305 extending the segment 303A and extending along the face 302b of the portion 302 are intended to to form the inner platform preform of the dawn to achieve.
[0014] In its end portion prior to connection to the portion 304, the portion 305 has adjacent segments 305B and 305C for forming a portion of the bead preform and preforms heel darts of the blade to achieve. The segments 305B and 305C are interconnected only in their central portion to provide delimited areas 308a, 308b extending in the warp direction along their upstream and downstream edges and in the weft direction over a limited distance from these edges. (Figures 3 and 4C). The portion of the heel preforms and heel lugs of the blade to be produced, which is complementary to that formed by the segments 305B and 305C, comes from a segment 304A of the part 304 situated in the extension of the segments 305A and 305B and of the part 302. Delicate zones 309a, 309b are formed during weaving in the segment 304A all along the latter in the warp direction and for a limited distance from its upstream and downstream edges, in the weft direction ( Figure 4D). The untied zones 308a and 309a lie in continuity with one another, as well as the untied zones 308b and 309b. As described below, the function of the delta zones 308a, 308b, 309a and 309b is to allow the deployment of preforms of heel wipers of the blade to be produced.
[0015] In the sectional views 4A and 4B, arrows indicate the matches between sets of warp layers initially located in parts 303 and 306 and then in parts 302 and 305. In the fibrous blank, the number In this example, the total number of layers of warp yarns is 18. The figures with braces in FIGS. 4A to 4D show an example of distribution of the warp layers between the different parts of the fiber blank. Thus, in this example, the portion 303 comprises 4 layers, the portion 306 comprises 14 layers and the portion 302 comprises 8 layers in its side portions 3021, 3022 and 10 layers in its central portion 3023. Of course, the total number of layers warp son and their distribution may be different, the numbers given in the illustrated example simply for the purpose of facilitating understanding. Figs. 5A-5D show weave planes at different levels of the fibrous blank 300. In Figs. 5A-5D, the cross-sectional threads are the warp threads, the weft thread paths being shown. In the example illustrated, the weave is a multilayer weave, or three-dimensional weave, made with satin or multi-satin weave. Other types of multilayer weaving may be used, for example multi-layer multi-weave weave or "interlock" weave weave. "Interlock" weaving is here understood to mean a weave in which each layer of weft threads binds several layers of warp yarns with all the threads of the same weft column having the same movement in the plane of the weave. . Various multilayer weave modes are described in particular in document WO 2006/136755.
[0016] For the application envisaged here to a low-pressure turbine blade, the yarns used for weaving are made of refractory material, in particular ceramics, such as, for example, silicon carbide (SiC) -based yarns supplied under the name "Nicalon". by the Japanese company Nippon Carbon.
[0017] Fig. 5A, corresponding to Fig. 4A, shows a weave plane of weaves of portions 303 and 3062. Fig. 5B, corresponding to Fig. 4B, shows a weave armor plane of portions 302 and 305 in the vicinity of connecting the portion 302 with the portion 306, i.e., for the portion 305, at the segment 305A. FIG. 5C, corresponding to FIG. 4C, shows a weave plane of the portions 302 and 305 in the vicinity of the connection with the portion 304, that is, for the portion 305, at the segments 305B. and 305C. It is found that the segments 305B and 305C are woven in their central part while leaving the untied areas 308a and 308b in the side portions. In its lateral parts, the part 305 has a number of layers of warp threads greater than the number of warp thread layers in its central part, the difference corresponding to the difference between the number of warp thread layers in the lateral parts. of the portion 302 and the number of warp layers in the central portion of the portion 302. All the warp son layers of the portion 305 are bonded together by weaving. To avoid excessive weft floats at the thicker portions of the portions 302 and 305, in certain areas of the fibrous blank, two warp yarns of the same column may be treated in two layers of yarns. string superimposed as a single double title string thread. This is shown in FIGS. 5B and 5C in the thicker portions of portions 302 and 305. FIG. 5D, corresponding to FIG. 4D, shows a weave plane of portion 304 at the segment 304A. The presence of the untied zones 309a and 309b is noted. Advantageously, a row of fibrous blanks is woven continuously in the form of a band 3000 (FIG. 3), two adjacent blanks having their opposite longitudinal directions. Thus, the portions 303 and 306 of the blank 300 is extended by the portions 303 'and 306' of the next blank 300 '. At the other end of the blank 300, the portion 304 is extended by the portion 304 "of the previous blank 300". Areas of over-lengths are arranged between neighboring blanks (over-lengths only son of warp) to form transition zones. It should be noted that several parallel rows of blanks may be woven in the same strip, zones of extra lengths then being preferably arranged also between parallel rows (over-lengths only of weft threads). FIGS. 6 to 8 show very schematically how a fibrous preform having a shape close to that of the blade to be manufactured can be obtained from a blank 300. A blank 300 is cut in the band 3000 by cutting the ends of the parts 303 and 306 along the planes P1 and P2 and the end of the portion 304 along the plane P3. The portion 305 is cut at the end of the segment 305A along the plane P4 and at the end of the segments 305B and 305C along the plane P5, the portions of the portion 305 extending between the planes P4 and P5 being eliminated. The segment 303A is deployed along the arrow f1 of FIG. 3. The segment 305A is deployed along the arrow f2 of FIG. 3. The segments 205A and 205B deployed form a plate 313 (FIG. 6) intended, after molding, to form the inner platform preform of the dawn to manufacture. The portion 305 has, in the weft direction, a width greater than that of the portion 304, overflowing on each side thereof (see in particular FIGS. 4A and 4B), in order to be able to form preform parts corresponding to the upstream spoilers and downstream of the inner platform of the dawn to be manufactured. The segments 305B and 305C partially bonded by weaving are deployed along the arrow f3 of FIG. 3. The part 304 is folded along the arrow f4 of FIG. 3. The deployed segments 305B and 305C and the folded part 304 form a plate 314 for forming the bead preform and the heel wipe preforms of the blade to be made. We find the excess width of the portion 305 for forming upstream and downstream spoiler preforms in the bead preform of the blade to be manufactured. Then, as shown in FIG. 7, the portions adjacent to the outermost zones 308a-309a and 308b-309b can be deployed to form heel wipe preforms of the blade to be manufactured. The loosened areas 308a and 309a lie in an extension of one another to form a untied zone extending continuously in a warp direction along the upstream edge of the tray 314 between two opposite sides of the tray 314. , and over a limited distance in the weft direction from the upstream edge of the plate 314. Similarly, the untied zones 308b and 309b lie in the extension of one another to form a loosely extending zone. continuous in the warp direction along the downstream edge of the plate 314, between two opposite sides of the plate 314, and for a limited distance in the weft direction from the downstream edge of the plate 314. A fibrous preform 320 of the blade to be manufactured is then obtained by molding with deformation of the portion 302 to reproduce the curved profile of the vane blade and deformation of the trays 313, 314 to reproduce shapes similar to those of the inner platform and the heel of the blade, at and to provide the inner platform preform and heel preform with orientations corresponding to the desired orientations of the inner platform and heel relative to the longitudinal direction in the blade to be manufactured, as shown in FIG. the mold is not shown). The preform 310 is thus obtained with a blade preform 320, a 360 foot preform (with stilt preform), an inner platform preform 330, a heel preform 340 and preforms 352, 354 of bead strips. It should be noted that, advantageously, great freedom is offered for the orientation of the wafer preforms with respect to the bead preform. In the dawn to be manufactured, any desired angle between each wiper and the outer surface of the heel can be obtained. In the embodiment of FIGS. 3 to 8, it is advantageous to use, for the bead preform, layers of yarns originating from the blade root preform and not used in the blade blade preform, layers of yarns which are bifurcated between the foot preform and the blade preform part forming a heel preform and preforms of bead lugs. In another exemplary embodiment, for the portion of the fibrous blank corresponding to the bead preform, there are used layers of threads originating from the part of the blank corresponding to the blade preform, the blade preform and the resulting blade. having a variable thickness in the longitudinal direction. For this other exemplary embodiment, a woven fiber blank 370 can be used as schematically illustrated in FIGS. 9 and 10A to 10E, the weaving being in the form of a fibrous web comprising one or more rows of blanks. The blank 370 comprises a portion 372 intended to form the blade preform of the blade to be produced. In the example shown, the portion 372 has a thickness that does not vary in a transverse direction between the side portions corresponding to the leading and trailing edges. However, this thickness in the transverse direction may vary as in the case of the portion 302 of the fibrous blank of Figures 3 and 4A to 4D. The blank 370 also comprises a part 376 having a segment 3761 intended to form the preform of the blade root to be produced and a segment 3762 intended to form the stilt preform of the blade to be produced. Part 372 is in the continuity of segment 3762, the numbers of warp layers in part 372 and in segment 3762 being equal in this example. However, as in the example of FIGS. 3 and 4A to 4D, it will be possible to have a part 3762 with a thickness greater than that of part 372. The segment 3761 has a thickness greater than that of segment 3762, obtained for example by increasing the title and / or the contexture of the weft son or by introduction of an insert, as in the example of Figures 3 and 4A to 4D.
[0018] The blank further includes a portion 373 extending along a face 376a of the portion 376 without being bound thereto. The warp strands of portion 373 pass through portion 372 at its connection with portion 376 and form a portion 375 by being woven with one or more layers of warp yarns from Part 372 to one or more levels thereof longitudinally, for example, warp layers 3721 and 3722, the thickness of the portion 372 thus decreasing longitudinally from its end connected to the portion 376. The portion 375 extends along the face 372b of the portion 372 opposite the face 372a which corresponds to the face 376a of the portion 376. The portion 375 is not woven to the portion 372. At the end of the portion 372 opposed to that which is connected to the portion 376, a portion 374 is formed extending the portions 372 and 375 by weaving their layers of warp son together. A segment 373A of the portion 373 extending along the face 376a of the portion 376 and a segment 375A of the portion 375 extending the segment 373A and extending along the face 372b of the portion 372 are intended to form the inner platform preform of the dawn to achieve. In its end portion prior to connection to portion 374, portion 375 has adjacent segments 375B and 375C for forming a portion of the bead preform and bead heel preforms to be made. Segments 375B and 375C are interconnected only in their central portion to provide delimited areas 378a, 378b extending in a warp direction along their upstream and downstream edges and in a weft direction a limited distance from these edges. (FIGS. 9 and 10D). The part of the heel preforms and heel darts of the blade to be produced, which is complementary to that formed by the segments 375B and 375C, originates from a segment 374A of the part 374 situated in the extension of the segments 375A and 375B and 372. Bare zones 379a, 379b are formed during weaving in the segment 374A along the length of the segment in a warp direction and for a limited distance from its upstream and downstream edges, in a weft direction. (Figure 4D). The untied zones 378a and 379a lie in continuity with one another, as well as the untied zones 378b and 379b. The function of the slack zones 378a, 378b, 379a and 379b is to allow the deployment of preforms of heel lugs of the blade to be produced. It should be noted that FIGS. 10A, 10B, 10C, 10D and 10E are sectional views along the planes A, B, CD and E at the level of segment 373A, segment 375A, of the central portion respectively. of the part 375 after connection of the warp layers 3721, the segments 375B and 375C, and the segment 374A. After appropriate cuts, deployment of the segments 373A, 375A, 375B-375C and folding of the segment 374A, deployment of the parts adjacent to the untied zones and shaping by molding, a blade preform with a part of the blade preform is obtained. foot preform portion and stilt, an inner platform preform portion, and a bead preform portion with heel wipe preform portions, in a manner similar to that described with reference to Figures 6 to 8. As an alternative to the two examples described above, it would also be possible to bring additional layers of threads at the part of the blank corresponding to the bead preform, not necessarily from the parts of the blank corresponding to the foot preforms. of pale. Still alternatively, one could still remove layers of son at the portion of the blank corresponding to the bead preform. The three different ways described of bringing layers of warp yarns at the portion of the blank corresponding to the bead preform and wipers can be implemented separately, or combined in pairs or all together. Remarkably, a one-piece blade fiber preform with bead preform and integrated wiper preforms is obtained by limiting the feedthroughs between fibrous preform portions during weaving. This results from the production of a vane preform part forming a preform of heel and preforms of heel wipers by a set of layers of threads interconnected by weaving with the arrangement of untied zones allowing the deployment of the preforms of wipers. heel to the heel preform. On the other hand, when the blade to be manufactured comprises more than two bead wipers, the desired number of heel wipe preforms can be obtained by arranging a corresponding number of non-adjacent hairline zones between the upstream and downstream edges of the plateau corresponding to the heel, such as the plate 314 of FIG.
[0019] Note that the invention is applicable to the case where the blade inner platform preform is made separately with an opening substantially reproducing the blade profile of the blade to achieve. In this case, a fibrous blank is produced by weaving without the part corresponding to the inner platform preform, that is to say, in the embodiment of FIG. 3, without the part 303. The inner platform preform performed separately can then be engaged on the woven fiber blank to its desired position, prior to deployment of the preform part of heel preform vanes and heel wafer preforms. We could also bring the outer platform preform to a later stage of manufacture, or realize an outer platform and report it after manufacture of the blade with blade and outer platform. Successive steps of a method of manufacturing a ceramic matrix composite (CMC) blade are shown in FIG. 11. In step 381, a fibrous web is woven by three-dimensional weaving comprising a plurality of fibrous blanks. as shown in FIG. 3 or FIG. 9, optionally with several rows of fibrous blanks oriented in the warp direction. At step 382, the individual fibrous blanks are cut. In step 383, a fibrous blank is shaped in a mold, for example made of graphite for shaping the blade preform, the foot preform, the inner platform preform, the bead preform and the preforms of the mold. heel wipers, (as illustrated for example in Figures 6 to 8) to obtain a blade preform. At step 384, the blade preform is consolidated. In a manner known per se, the consolidation may be carried out by impregnation with a resin which is cross-linked and pyrolyzed, the amount of consolidation resin being chosen so that the pyrolysis residue binds the fibers of the preform sufficiently so that the latter can be manipulated while retaining its shape without the assistance of tools. It is possible to use a carbon precursor resin or a ceramic precursor resin. The impregnation with the consolidation resin may be carried out by infusion or injection into the mold or by impregnation at the stage of the fibrous blank, prior to shaping. Alternatively, also in a manner known per se, the consolidation can be carried out by partial densification with a ceramic material using a known chemical vapor infiltration (CVI) process ("Chemical Vapor Infiltration"). The consolidated preform can be extracted from the conformation tooling for densification by a ceramic matrix, for example silicon carbide SiC. The densification can be carried out by CVI. Densification can be carried out in two successive steps (steps 385 and 387) separated by a blade machining step 386 to the desired shapes and dimensions. Note that pre-machining can be performed after consolidation and before densification, including pre-machining of the inner platform and heel to eliminate excess thickness and pre-machining of the heel wipers, to be closer to the shape of the blade of FIG. 2. It will also be noted that a defrosting interphase coating may be formed between the fibers of the preform and the ceramic matrix, as is well known per se. Embodiment: compressor moving wheel vane It has been envisaged above the realization of a turbine wheel impeller of CMC material. The invention is also applicable to gas turbine compressor moving wheel vanes. In the latter case, when the temperatures encountered in service are lower, especially for the upstream stages of a compressor, it is possible not to use a CMC material, but for example an organic matrix composite material (CMO) made with fibers for example carbon or glass and a polymer matrix. Thus, after weaving a set of fibrous webs, cutting individual blanks and shaping by means of a shaping tool, a blade preform obtained, maintained in its tooling, is impregnated with a resin by injection or infusion. A heat treatment for crosslinking the resin is then carried out. Several successive cycles of impregnation with a resin and crosslinking thereof can be carried out. Machining can be performed between two cycles and / or after the end of the densification by the polymer matrix. The resin used is a polymer matrix precursor resin, such as an epoxy, bismaleimide or polyimide resin, for example. Embodiment: Turbine distributor vane FIGS. 12 and 13A to 13D show very schematically a first example of fibrous preform 400 from which a fibrous preform of blade can be shaped so that, after densification by a matrix and possible machining, to obtain a paddle composite blade, inner platform, abradable support elements, outer platform and integrated mounting brackets of the blade type 110 illustrated in FIG. the weaving of the blank 400 different weave weaves, for example a multi-satin weave similar to that of Figures 5A to 5D, or any other armor described in particular in the document WO 2006/136755 already cited. For the intended application to a turbine distributor blade, the yarns used for weaving are made of refractory material, in particular ceramic, such as, for example, silicon carbide (SIC) -based yarns supplied under the name "Nicalon". by the Japanese company Nippon Carbon. The blank 400 comprises a portion 402 intended to form the blade preform of the blade to be produced. In the illustrated example, the portion 402 has a substantially constant thickness. Alternatively, the thickness of the portion 402 could vary between its longitudinal edges similarly to the portion 302 in the embodiment of Figure 3. The blank 400 also includes a portion 403 of which a segment 403A extends along a first face 402a of the portion 402, without being bonded to the portion 402. The warp son of the warp layers of the portion 403 pass through the portion 402 to extend along the face 402b of the portion 402 opposite the face 402a. The portion 403 extends along the portion 402b 402b face without being connected to the portion 402, a distance corresponding substantially to the longitudinal dimension of the blade of the blade to manufacture. From its opposite end to that at the crossing portion 403, the portion 402 is woven together with the portion 403 to form a portion 404. The segment 403A of the portion 403 is extending along the face 402a of the portion 402 and a segment 403B of the portion 403 extending the segment 403A, after passing through the portion 402, are intended to form the inner platform preform and the support element preforms 5 d abradable from dawn to realize. Delicate zones 403a and 403b are formed substantially at mid-thickness in the segments 403A and 403B, the untied zone 403a extending in the warp direction along the upstream edges of the segments 403A and 403B and in the weft direction over a distance limited to from these upstream edges, and the untied zone 403b extending in a warp direction along the downstream edges of the segments 403A and 403B and in the weft direction over a limited distance from these downstream edges (FIGS. 12, 13A and 13B). ). As described below, the function of the delta zones 403a and 403b is to allow the deployment of preforms of abradable support elements of the blade to be produced. In its end portion prior to connection to the portion 404, the portion 403 has a segment 403C for forming a portion of the outer platform preform and preforms of the mounting brackets of the blade to be made. Delicate areas 403c and 403d are formed substantially mid-thickness in the segment 403C, the untied zone 403c extending in a warp direction along the upstream edge of the segment 403C and in a weft direction for a limited distance from it. upstream edge, and the untied area 403d extending in a warp direction along the downstream edge of the segment 403C and in a weft direction for a limited distance from this downstream edge (Figures 12 and 13C). The part of the outer platform preforms and of the mounting brackets of the blade to be produced, which is complementary to that formed by the segment 403C, originates from a segment 404A of the part 404. Delicate zones 404a, 404b are formed during weaving in the segment 404A all along the latter in the warp direction and for a limited distance from its upstream and downstream edges, in the weft direction (FIGS. 12 and 13D). The untied zones 403c and 404a lie in continuity with one another, as well as the untied zones 403d and 404b. As described below, the function of the delta zones 403c, 403d, 404a and 404b is to allow the deployment of preforms of mounting brackets for the blade to be produced. Advantageously, a row of fibrous blanks is continuously woven in the form of a band 4000 (FIG. 12), two adjacent blanks having their opposite longitudinal directions. Thus, the portions 402 and 403 of the blank 400 extend through the portions 402 'and 403' of the next blank 400 '. At the other end of the blank 400, the portion 404 is extended by the portion 404 "of the previous blank 400". Areas of over-lengths are arranged between neighboring blanks (only over-lengths of warp threads) to provide transition zones. It should be noted that several parallel rows of blanks may be woven in the same strip, areas of over-lengths then being preferably arranged also between parallel rows (only lengths of weft threads). FIGS. 12 and 14 to 16 show very schematically how a fibrous preform having a shape close to that of the blade to be manufactured can be obtained from a blank 400. A blank 400 is cut in the band 4000 by cutting the blank. part 403 at the ends of the segments 403A and 403B according to the planes P1 and P2 and cutting the portion 402 in the plane P3 located in front of the crossing location by the portion 403. The portion 404 is cut at the end of the segment 404A according to plan P4. The segment 403C is cut along the plane P5, the portions of the portion 403 extending between the planes P2 and P5 being eliminated. The segments 403A and 403B are deployed according to the arrows f1 and f2 of FIG. 12. As shown in FIG. 14, the portions of the segments 403A and 403B located on the outer side form a plate 413 intended, after molding, to form the preform of inner platform 25 while portions of the segments 403A and 403B adjacent to the inner thinned areas 403a and 403b can be deployed to form abradable support element preforms of the blade to be manufactured. The segment 403C is deployed along the arrow f3 of FIG. 12. The segment 404A is folded along the arrow f4 of FIG. 12. The deployed segment 403C and the folded segment 404 form a plate 414 intended to form the platform preform. outer and mounting hook preforms of the dawn to be manufactured. Then, as shown in Fig. 15, the portions adjacent to the outermost regions 403c, 403d, 404a and 404b may be deployed to form preforms of mounting brackets of the blade to be manufactured. The slack zones 403c and 404a lie in an extension of one another to form an untied zone extending continuously in a warp direction along the upstream edge of the plate 414, between two opposite sides of the plate 414, and a limited distance in the weft direction from the upstream edge of the tray 414. Similarly, the untied areas 403d and 404b lie in an extension of one another to form a continuously extending untied area in warp direction along the downstream edge of the plate 414, between two opposite sides of the plate 414, and over a limited distance in the weft direction from the downstream edge of the plate 414. A fiber preform 410 of the blade to be manufactured is then obtained by molding to obtain the curved profile of the blade of the blade, shapes similar to those of the inner and outer platforms of the blade, orientations of the inner platform preforms and outer preform corresponding to the x desired orientations of the inner platform and the outer platform with respect to the longitudinal direction in the blade to be produced, and shapes corresponding to those of the support members and the mounting hooks, as shown in Figure 16 (the mold not shown).
[0020] The preform 410 is thus obtained with a blade preform 420, an inner platform preform 430, preforms 462, 464 of abradable support elements, an outer platform preform 440 and preforms 452, 454 of mounting hooks. . FIGS. 17 and 18A to 18D very schematically show a second example of fibrous preform 500 from which a fibrous blade preform can be shaped in order, after densification by a matrix and possible machining, to obtain a blade in composite blade material, inner platform, abradable support members, outer platform and integrated blade-type mounting hooks 110 shown in FIG. 1. The fibrous blank 500 differs from the fiber blank 400 in that it is substantially symmetrical with respect to a median transverse plane, the part of the blank corresponding to the inner platform preform and abradable supports having a configuration similar to that of the part of the blank corresponding to the preform of outdoor platform and mounting hooks.
[0021] Thus, the blank 500 comprises a portion 502 intended to form the blade preform of the blade to be produced. In the example illustrated, the portion 502 has a substantially constant thickness. Alternatively, the thickness of the portion 502 could vary between its longitudinal edges in a similar manner to the portion 302 in the embodiment of FIG. 3. The blank 500 also includes a portion 503 that extends along its length. a face 502b of the portion 502 without being woven to it. At the longitudinal ends of portion 502, the yarn layers of portions 502 and 503 are woven together to form portions 504 and 505.
[0022] A segment 505A of the portion 505 and a segment 503A of the portion 503 which connects to the segment 505A are intended to form an inner platform preform and abradable support preforms of the blade to be produced. Delicate areas 505a, 505b and 503a, 503b are formed substantially mid-thickness in the segments 505A and 503A, the warped zones 505a and 503a extending in the warp direction along the upstream edges of the segments 505A and 503A, and direction from a distance limited from these upstream edges, and the warp-wise slack zones 505b and 503b along the downstream edges of the segments 505A and 503A and in the weft direction over a limited distance from them. downstream edges (Figures 17, 18A and 18B). The thin zones 505a, 503a, 505b and 503b have the function of allowing the deployment of preforms of abradable support elements of the blade to be produced. A segment 504A of the part 504 and a segment 503B of the part 503 which is connected to the segment 505A are intended to form an outer platform preform and preforms of the mounting brackets of the blade to be produced. Delicate zones 503c, 504a and 503d, 504b are formed substantially at mid-thickness in the segments 503B and 504A, the elongated zones 503c and 504a extending in a warp direction along the upstream edges of the segments 503B and 504A and in frame spaced a limited distance from these upstream edges, and the narrowed regions 503d and 504b extending in a warp direction along the downstream edges of the segments 503B and 504A and in the weft direction a limited distance from these edges downstream (Figures 17, 18C and 18D). Delicate areas 503c, 504a 503d and 504b have the function of allowing the deployment of preforms 35 mounting brackets of the blade to achieve.
[0023] Advantageously, at least one row of fibrous blanks 500 is continuously woven in the form of a band 5000 (FIG. 17). FIGS. 17 and 19 to 21 show very schematically how a fibrous preform having a shape close to that of the blade to be manufactured can be obtained from the blank 500. A blank 500 is cut in the band 5000 by cutting the blanks. parts 505 and 504 along the planes P1 and P4 and cutting the portion 503 at the planes P2 and P5, the portions of the portion 503 extending between the planes P2 and P5 being eliminated.
[0024] The segments 505A and 503A are deployed along the arrows f1 and f2 of FIG. 17 and form a plate 513 (FIG. 19) intended, after molding, to form the inner platform preform and the abradable support member preforms. from dawn to manufacture. The untied areas 505a and 503a lie in an extension of one another to form a untied zone extending continuously in a warp direction along the upstream edge of the tray 513 between two opposite sides of the tray 513. , and a limited distance in the weft direction from the upstream edge of the plate 513. The slender zones 505b and 503b lie in the extension of one another to form a untied zone extending continuously in the direction chain along the downstream edge of the plate 513, between two opposite sides of the plate 513, and over a limited distance in the weft direction from the downstream edge of the plate 513. The segments 503B and 504A are deployed according to the arrows f3 and f4 of 17 and form a plate 514 (FIG. 19) for forming the outer platform preform and the mounting hook preforms for the blade to be manufactured. The untied zones 503c and 504a are in the extension of one another to form a untied zone extending continuously in the warp direction along the downstream edge of the plate 514, between two opposite sides of the plate 514, and a weft-limited distance from the upstream edge of the plate 514. The untied areas 503d and 504b lie in an extension of one another to form a continuous, warp-shaped, untwisted area all along the downstream edge of the plate 514, between two opposite sides of the plate 514, and over a limited distance in the weft direction from the downstream edge of the plate 514.
[0025] Next, as shown in Fig. 20, the portions adjacent to the inner delineated areas 505a, 503a, 505b, and 503b are deployed to form abradable support member preforms of the dawn. to manufacture, while the portions adjacent to the outer zones 53c, 503d, 504a and 504b are deployed to form preforms mounting hooks of the blade to be manufactured. A fiber preform 510 of the blade to be manufactured is then obtained by molding to obtain the curved profile of the blade of the blade, 10 shapes similar to those of the inner and outer platforms of the blade, orientations of the platform preforms. inner and outer preform corresponding to the desired orientations of the inner platform and the outer platform relative to the longitudinal direction in the blade to be manufactured, as well as shapes corresponding to those of the support members and the mounting hooks, such as the shows Figure 21 (the mold is not shown). The preform 510 is thus obtained with a blade preform 520, an inner platform preform 530, preforms 562, 564 of abradable support elements, an outer platform preform 540 and preforms 552, 554 of hooks. mounting. Remarkably, in the two examples of embodiment above, one obtains a fiber preform in one piece with inner and outer platform preforms, preforms of abradable support elements and preforms of integrated mounting hooks. by limiting the crossings between fibrous preform portions during weaving. This results from the production of a platform preform preform part and preforms of support elements or mounting hooks by a set of layers of son interconnected by weaving with development of untied zones allowing the 30 deployment of support element preforms and mounting hooks relative to platform preforms. Of course, forms of abradable support elements other than those L-profile elements 162 and 164 can be realized.
[0026] Thus, Fig. 22 shows support members 162 ', 164' which protrude substantially radially from the outer face of the inner platform 130 and onto which an intermediate support 165 bearing blocks 166 may be attached. of abradable material upstream and downstream to cooperate with wagons of mobile wheels adjacent the upstream side and the downstream side of the distributor.
[0027] It is also conceivable to have a single abradable support member projecting from the central portion of the outer face of the inner platform. To obtain a CMC turbine distributor blade from a woven fiber blank, it is possible to proceed as described above with reference to FIG. 11. Embodiment: compressor stator vane It has been envisaged above that production of a turbine distributor blade made of CMC material.
[0028] The invention is also applicable in the same way to blades of CMC material for gas turbine compressor stator. When the temperatures encountered in service are lower, particularly for the upstream stages of a compressor, it is possible to use not only a CMC material but also an organic matrix composite material (CMO) produced with fibers by example of carbon or glass and a polymer matrix. To obtain a CM0 compressor straightener blade from a woven fiber blank, one can proceed as described above for a CMO compressor wheel impeller.
[0029] The method described in the last two embodiments provides blade blade, outer platform, mounting hooks, inner platform and integrated abradable support members. The method is, however, also applicable to the realization of a blade with blade, external platform, integrated mounting hooks and inner platform integrated, without integration of abradable support elements, as well as to the realization of a dawn with blade, outer platform, inner platform and at least one integrated abradable support element, without integration of mounting hooks.
[0030] Embodiments In the described exemplary embodiments of the turbine nozzle blade, the blade preform of the blade has a constant thickness in the longitudinal direction. This thickness can alternatively be varied in the same way as that described with reference to FIGS. 9 and 10A to 10E for a turbine wheel impeller blade. The same is true for a compressor impeller blade and for a compressor straightener blade. In the exemplary embodiments of FIGS. 3, 9 and 12, the longitudinal direction of the fibrous blanks in the woven strip can be reversed. In the described embodiments of turbine distributor, the mounting hooks are associated with the outer platform while the abradable support member or elements are associated with the inner platform. Alternatively, mounting hooks may be associated with the inner platform and one or more abradable support members on the outer platform. In the above, it is envisaged weaving fibrous blanks with their longitudinal direction in the warp direction. Alternatively, the weaving can be performed with the longitudinal direction of the fibrous blanks in weft, weft and warp then being reversed.

权利要求:
Claims (27)
[0001]
REVENDICATIONS1. A method of manufacturing a turbomachine blade, the blade being made of composite material with fiber reinforcement densified by a matrix and comprising a blade, a first platform located at a longitudinal end of the blade and having an inner face of vein delimitation and an external face opposite to the inner face, and at least one functional element extending from the outer face of the first platform by connecting to said outer face in a substantially circumferential direction, the method comprising: - the embodiment by weaving multilayer of a fibrous blank in one piece, - shaping the fibrous blank to obtain a one-piece fibrous preform having a first portion forming a preform of the blade blade and a second portion forming a preform of the first platform and at least one functional element preform, and - the densification of the fibrous preform by a matrix to obtain a blade made of composite material having a fiber reinforcement formed by the preform and densified by the matrix and forming a single piece with the blade, the first platform and the said at least one integrated functional element, in which process the second part of the preform comprises a set of layers of son bonded together by weaving with arrangement of at least one untied zone allowing the deployment of the or each preform of functional element relative to the preform of the first platform.
[0002]
The method of claim 1, wherein the set of layers of the second preform portion comprises a group of wire layers common with the blade preform.
[0003]
A method according to claim 1 or claim 2, wherein the portion of the fibrous blank corresponding to the second preform portion comprises one or more layers of yarns taken from the portion of the fibrous blank corresponding to the blade preform. at one or more levels in a longitudinal direction, the blade preform having a variable thickness in the longitudinal direction.
[0004]
4. A method according to any one of claims 1 to 3, wherein the shaping of the fibrous blank is performed to obtain a one-piece fiber preform having further a third preform portion of a second platform located at one longitudinal end of the blade opposite that at which the first platform is located, and the set of son layers of the portion of the fibrous blank corresponding to the second preform portion comprises a group of common wire layers with the part of the fiber blank corresponding to the blade preform and a group of wire layers common with the portion of the blank corresponding to the second platform preform.
[0005]
5. A method of manufacturing a mobile turbine engine blade, the blade being made of composite material with fiber reinforcement densified by a matrix and comprising a foot, a blade, an outer platform forming a heel located at a longitudinal end of the blade and having an internal vein-delimiting face and an opposite outer face to the inner face, and heel wipes each extending from the outer face of the heel connecting to said outer face in a substantially circumferential direction, the method comprising: - producing by multilayer weaving of a fibrous blank in one piece, - shaping the fibrous blank to obtain a one-piece fibrous preform having a first part forming a blade preform, a second part forming a preform of heel and preforms of heel wipers and a third portion lying in the extension of the first part and forming nt a foot preform, and - the densification of the fibrous preform by a matrix to obtain a composite material blade having a fibrous reinforcement formed by the preform and densified by the matrix and forming a single piece with foot, blade, heel and wipers integrated bead method, in which the second part of the preform comprises a set of layers of yarn interconnected by weaving with provision of untied areas for the deployment of preforms of bead wipers with respect to the bead preform.
[0006]
The method of claim 5, wherein the set of layers of the second preform portion comprises a group of wire layers common with the blade blade preform. 10
[0007]
The method of claim 5 or claim 6, wherein the portion of the fibrous blank corresponding to the second preform portion comprises one or more layers of yarns taken from the portion of the fibrous blank corresponding to the blade preform. at one or more levels in the longitudinal direction, the blade preform having a variable thickness in the longitudinal direction.
[0008]
8. A process according to any one of claims 5 to 7, wherein the shaping of the fibrous blank is performed to obtain a one-piece fibrous preform having further a fourth inner platform preform portion, and the set of yarn layers of the portion of the fibrous blank corresponding to the second preform portion comprises a group of yarn layers common with the portion of the fibrous blank corresponding to the blade preform and a group of layers of common son with the portion 25 of the blank corresponding to the inner platform preform.
[0009]
A method according to any one of claims 5 to 8, wherein the blade root preform comprises a number of wire layers greater than that of the blade preform, and in the fibrous blank the set of wire layers of the portion of the blank corresponding to the second preform portion comprises a group of common wire layers with the portion of the blank corresponding to the blade preform and a group of common wire layers with the part of the blank corresponding to the foot preform and not used in the blade preform. 302 134 9 37
[0010]
The method of claim 6 or 9, wherein the set of layers of the second preform portion comprises a group of additional wire layers not common with the blade preform or blade blade.
[0011]
A method according to any one of claims 5 to 9, wherein the shaping of the fibrous blank is performed to obtain a one-piece fibrous preform having further a fourth inner platform preform portion, and the The blade preform comprises a set of common wire layers with the foot preform and traversed by a set of wire layers of the inner platform preform at the location thereof. 15
[0012]
12. A method of manufacturing a fixed turbomachine blade, the blade being made of composite material with a fiber reinforcement densified by a matrix and comprising a blade, a first platform located at a longitudinal end of the blade and having an internal boundary face. and an outer face opposite to the inner face, and mounting hooks extending from the outer face of the first platform connecting to said outer face in a substantially circumferential direction, the method comprising: multilayer weaving of a single-piece fiber blank, - shaping of the fiber blank to obtain a one-piece fiber preform having a first blade preform portion, a second portion forming a preform first platform and blade mounting hook preforms; and - densifying the fiber preform by a die for 30 minutes. a blade made of composite material having a fiber reinforcement formed by the preform and densified by the die and forming a single piece with blade, first platform and integrated mounting hooks, wherein the second part of the preform comprises a set of layers of threads interconnected by weaving with the provision of untied zones enabling the preforms 302 134 9 38 to be fitted with mounting hooks relative to the first platform preform.
[0013]
The method of claim 11, wherein the set of layers of the second preform portion comprises a group of wire layers common with the blade preform.
[0014]
The method of claim 11 or claim 12, wherein the portion of the fibrous blank corresponding to the second preform portion comprises one or more layers of yarns taken from the portion of the fibrous blank corresponding to the blade preform. at one or more levels in the longitudinal direction, the blade preform having a variable thickness in the longitudinal direction.
[0015]
15. A method of manufacturing a fixed turbomachine blade, the blade being made of composite material with fiber reinforcement densified by a matrix and comprising a blade, a first platform located at a longitudinal end of the blade and having an internal boundary face. vein and an outer face opposite to the inner face, and at least one abradable support member extending from the outer face of the first platform by connecting to said outer face in a substantially circumferential direction, the method comprising: - producing by multilayer weaving of a fibrous blank in one piece, - shaping the fibrous blank to obtain a one-piece fibrous preform having a first part forming a blade preform, a second part forming a first platform preform and at least one abradable support member preform, and - densifying the fibrous preform r a matrix for obtaining a blade made of composite material having a fiber reinforcement formed by the preform and densified by the matrix and forming a single piece with a blade, a first platform and at least one integrated abradable support element, in which method the second part of the preform comprises a set of layers of son interconnected by weaving with the arrangement of untied areas for the deployment of abradable support element preform relative to the preform of the first platform. 5
[0016]
The method of claim 14, wherein the set of layers of the second preform portion comprises a group of wire layers common with the blade preform.
[0017]
17. The method of claim 14 or claim 15, wherein the portion of the fibrous blank corresponding to the second preform portion comprises one or more layers of yarns taken from the portion of the fibrous blank corresponding to the preform of the preform. at one or more levels in the longitudinal direction, the blade preform having a variable thickness in the longitudinal direction. 15
[0018]
The method of any one of claims 1 to 16, wherein, in the fibrous blank, said set of wire layers comprises layers of warp yarns extending in the longitudinal direction of the blade, and said Delicate zones extend continuously in a warp direction between opposite sides of the portion of the fibrous blank corresponding to the second preform portion, over a limited distance in the weft direction.
[0019]
19. A method according to any one of claims 1 to 16, wherein, in the fiber blank, said set of wire layers comprises weft wire layers extending in the longitudinal direction of the blade, and said thin zones extend continuously in a weft direction between opposite sides of the portion of the fibrous blank corresponding to the second preform portion, over a limited distance in the warp direction.
[0020]
20. A turbomachine blade comprising a blade, a first platform located at a longitudinal end of the blade and having an internal vein delimiting face and an external face opposite to the inner face, and at least one functional element extending to from the external face of the first platform by connecting to said outer face in a substantially circumferential direction, - the blade being a single piece of composite material comprising a multilayer woven fibrous reinforcement densified by a matrix, and - the fibrous reinforcement being in one piece with a first part forming a blade blade reinforcement and a second part forming a first blade platform reinforcement and at least one functional element reinforcement, blade in which the second fibrous reinforcement portion comprises a set of layers of yarn all interconnected by weaving except at a separation zone between the or each reinforcement functional element and the first platform reinforcement.
[0021]
21. A turbomachine mobile blade comprising a blade, an outer platform forming a blade bead located at one longitudinal end of the blade and having an internal vein delimiting face and an external face opposite to the inner face, and wipers heel extending from the outer face of the heel connecting to said outer face in a substantially circumferential direction, the blade being a single piece of composite material comprising a multilayer woven fibrous reinforcement densified by a matrix, and the fibrous reinforcement being in one piece with a first part forming a blade reinforcement and a second part forming a heel reinforcement and reinforcements of heel wipers, blade in which the second fibrous reinforcement part comprises a set of layers of threads all tied together by weaving except at the level of separation zones between the reinforcements of heel wipers and the reinforcement of tal we.
[0022]
22. Fixed turbomachine blade comprising a blade, a first platform located at a longitudinal end of the blade and having an inner vein delimiting face and an external face opposite to the inner face, and mounting brackets of the blade extending from the outer face of the first platform connecting to said outer face in a substantially circumferential direction, the blade being made of a single piece of composite material comprising a multilayer woven fiber reinforcement densified by a matrix, and - the fibrous reinforcement being in one piece with a first portion forming a blade reinforcement and a second portion forming a first platform reinforcement and mounting hook reinforcements, blade wherein the second fibrous reinforcement portion comprises 10 a set of layers of yarn all interconnected by weaving except at the level of separation zones between the reinforcements of hooks d e mounting and reinforcement of first platform.
[0023]
23. A turbomachine fixed blade comprising a blade, a first platform located at a longitudinal end of the blade and having an inner vein delimiting face and an outer face opposite to the inner face, and at least one support member of abradable extending from the outer face of the first platform by connecting to said outer face in a substantially circumferential direction, - the blade being in one piece of composite material comprising a multilayer woven fiber reinforcement densified by a matrix, and - the fibrous reinforcement being in one piece with a first blade-forming portion and a second portion forming a first-platform reinforcement and at least one abradable support element reinforcement, blade in which the second fibrous reinforcement portion comprises a set of layers of yarn all interconnected by weaving except at the level of separation zones between the or each abradable support element reinforcement and the first inner platform reinforcement.
[0024]
A blade according to any of claims 20 to 22, wherein the set of wire layers of the second reinforcing portion comprises a group of common wire layers with the blade reinforcement.
[0025]
25. Turbomachine turbine or compressor wheel comprising blades according to any one of claims 20 to 23 made of ceramic matrix composite material.
[0026]
26. A turbomachine compressor wheel comprising blades according to any one of claims 20 to 23 made of organic matrix composite material. 10
[0027]
27. A turbomachine having at least one turbine wheel or compressor according to claim 25 or claim 26.

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同族专利:

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公开号 | 公开日

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CN106687662B|2019-11-19|

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JP6563423B2|2019-08-21|

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RU2016150437A|2018-06-26|

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WO2015177473A1|2015-11-26|

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US20170198591A1|2017-07-13|

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FR3021349B1|2021-07-02|

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RU2678479C2|2019-01-29|

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CN106687662A|2017-05-17|

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US10519786B2|2019-12-31|

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RU2016150437A3|2018-11-26|

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US20200232331A1|2020-07-23|

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EP3146158A1|2017-03-29|

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JP2017530281A|2017-10-12|

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EP3146158B1|2019-08-14|

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法律状态:
2015-05-19| PLFP| Fee payment|Year of fee payment: 2 |

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2015-11-27| PLSC| Publication of the preliminary search report|Effective date: 20151127 |

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2016-05-25| PLFP| Fee payment|Year of fee payment: 3 |

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2017-04-26| PLFP| Fee payment|Year of fee payment: 4 |

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2017-08-25| CD| Change of name or company name|Owner name: HERAKLES, FR Effective date: 20170725 Owner name: SNECMA, FR Effective date: 20170725 |

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2018-02-02| CD| Change of name or company name|Owner name: SAFRAN AIRCRAFT ENGINES, FR Effective date: 20170719 Owner name: SAFRAN CERAMICS, FR Effective date: 20170719 |

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2018-04-23| PLFP| Fee payment|Year of fee payment: 5 |

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2019-04-19| PLFP| Fee payment|Year of fee payment: 6 |

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2020-04-22| PLFP| Fee payment|Year of fee payment: 7 |

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2021-04-21| PLFP| Fee payment|Year of fee payment: 8 |

优先权:

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申请号 | 申请日 | 专利标题

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FR1454607A|FR3021349B1|2014-05-22|2014-05-22|METHOD OF MANUFACTURING A TURBOMACHINE VANE FROM COMPOSITE MATERIAL, THUS OBTAINED VANE AND TURBOMACHINE INCORPORATING IT|FR1454607A| FR3021349B1|2014-05-22|2014-05-22|METHOD OF MANUFACTURING A TURBOMACHINE VANE FROM COMPOSITE MATERIAL, THUS OBTAINED VANE AND TURBOMACHINE INCORPORATING IT|

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JP2016568885A| JP6563423B2|2014-05-22|2015-05-21|Method of manufacturing a turbine engine vane formed of a composite material, the resulting vane, and a turbine engine comprising the vane|

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US15/312,944| US10519786B2|2014-05-22|2015-05-21|Method for manufacturing a turbine engine vane made of a composite material, resulting vane and turbine engine including same|

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EP15732315.5A| EP3146158B1|2014-05-22|2015-05-21|Method for manufacturing a turbine engine vane made of a composite material, resulting vane and turbine engine including same|

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PCT/FR2015/051337| WO2015177473A1|2014-05-22|2015-05-21|Method for manufacturing a turbine engine vane made of a composite material, resulting vane and turbine engine including same|

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RU2016150437A| RU2678479C2|2014-05-22|2015-05-21|Method for manufacturing a turbine engine vane made of a composite material, resulting vane and turbine engine including same|

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US16/676,551| US20200232331A1|2014-05-22|2019-11-07|Method for manufacturing a turbine engine vane made of a composite material, resulting vane and turbine engine including same|