• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a manufacturing method (S) of a workpiece (1) in a metal matrix composite material comprising the following steps: - opening (S1) a tool (10) comprising a support part (14) and a part molding (14), - placing (S2) a fibrous reinforcement in the tooling (10), - closing (S3) sealingly the tool (10), leaving a space between the fibrous reinforcement (2) and the parts of the tooling, - introducing (S5) the molten metal matrix (3) into the tool (10) so as to fill the space between the fibrous reinforcement (2) and the parts (13, 14) of the tooling - Apply (S5) a force on the tool (10) to impregnate the fibrous reinforcement (2) with the metal matrix (3).
    公开号:FR3021669A1
    申请号:FR1455038
    申请日:2014-06-03
    公开日:2015-12-04
    发明作者:Muriel Sabah；Nicolas Maisonnave
    申请人:Sagem Defense Securite SA；Safran SA；
    IPC主号:
    专利说明:

    [0001] FIELD OF THE INVENTION The invention relates to a method for manufacturing a part in a composite material comprising a fiber reinforcement densified by a metal matrix, particularly in the field of aeronautics.
    [0002] TECHNOLOGICAL BACKGROUND Today, it is necessary to comply with very high environmental requirements that are difficult to reconcile with safety requirements, which often involves a significant increase in the mass and cost of manufacturing the parts concerned. . However, it is difficult to envisage making parts at a high cost, even if they have the mechanical, thermal and electrical properties required. For example, in the field of aeronautics, avionics boxes containing power electronics are subjected to very severe environments in temperature and vibration that require good energy transmissions (mechanical, thermal and electrical). These housings are therefore generally made of aluminum because this material has both low density and good thermal conductivity. However, aluminum is not enough to remove all the calories generated by the power electronics, so it is necessary to equip the housing with additional cooling systems including cooling plates, heatsinks and / or heat pipes, which increase the overall weight of the housing and drastically reduce its performance in the face of environmental constraints. It has already been proposed to use composite materials in order to combine the advantageous properties of several different materials and to improve the mass and / or the manufacturing cost of the different parts made in these materials.
    [0003] For example, in the field of aeronautics, it has been proposed to produce fan casings in a composite material with fiber reinforcement densified by a polymer matrix. The parts thus obtained are both light and mechanically resistant. However, this type of material is non-conductive and hardly resistant to severe temperature environments due to the polymeric composition of the matrix. This type of composite material can therefore be envisaged for the manufacture of parts requiring good thermal and electrical conductivity such as avionic housings.
    [0004] In the space field, it has been proposed to make composite materials comprising a metal matrix densified reinforcement (known by the acronym C3M for metal matrix composite materials). The metal matrix may then comprise a pure metal or an alloy, while the reinforcement may comprise fibers or foams with open porosity. In order to obtain these composite materials with a metal matrix, it is known to infiltrate the metal matrix under pressure in liquid form (molten) in the reinforcement in a hyperclave enclosure. According to this technique, a mold comprising a fibrous preform zo and a crucible containing blocks of the metal intended to form the matrix of the part is placed in the enclosure. Vacuum is then created inside the enclosure and the mold, the crucible containing the metal blocks is heated and the mold is preheated. When the alloy contained in the crucible is completely melted, it is transferred inside the mold. This transfer is performed automatically by pressurizing the chamber at a pressure level generally between about 30 bar and about 100 bar. As soon as the mold is filled, the cooling of the part is accelerated by bringing a cooling member into contact with a wall of the mold. As long as the temperature has not fallen below the solidification temperature of the alloy, the pressure is maintained in the vessel to compensate for the natural shrinkage of the metal.
    [0005] This process then makes it possible to obtain a composite material having a high dimensional stability and excellent mechanical, thermal and electrical properties (depending on the materials chosen for the fibrous reinforcement and the metal matrix). However, it is extremely complex to implement and very consumer in terms of energy, manufacturing time and cost, which makes it difficult to industrialize on a large scale outside the space domain. In EP 0 164 536, it has been proposed to manufacture an elongated object comprising a composite material formed of carbon fibers and a magnesium metal matrix. For this purpose, a bundle of high-strength carbon parallel fibers is introduced into an elongated stainless steel enclosure, preheated to about 700 ° C and placed in the cavity of a preheated casting mold preheated to about 200 ° C, such that the opening of the enclosure is oriented upwards. The molten magnesium alloy is then poured into the cavity at about 700 ° C and a piston, also preheated to about 200 ° C, is pressed into the top of the mold to compress the molten alloy and force it to penetrate the fiber bundle when cooling the device. After raising the piston, the solidified part is extracted upwards by a pusher. The final piece is obtained by machining during which the enclosure is eliminated. However, in this document, the parts obtained necessarily have a main direction extending along the axis of compression of the piston. Furthermore, the shape of the parts is limited to an elongated shape and it is necessary to apply a very large force on the piston (of the order of 1500 bars) in order to infiltrate the metal alloy in the fibers. of carbon. Finally, this method requires a long and tedious machining step to remove the metal alloy and the steel enclosure around the composite material thus obtained.
    [0006] SUMMARY OF THE INVENTION An object of the invention is to propose a new metal matrix composite material that can be used in particular in the field of aeronautics, which has better electrical and thermal performance and a higher density than aluminum or monolithic magnesium while having equivalent mechanical performance, and for a reasonable cost. Another object of the invention is to provide a part in a new metal matrix composite material, which combines the mechanical, thermal and electrical characteristics of several materials, which can be achieved easily and quickly for a reasonable cost, and which can if necessary, undergo subsequent finishing operations such as machining and other assemblies such as welding, riveting etc.
    [0007] For this purpose, the invention proposes a manufacturing method for manufacturing a part in a composite material comprising a fibrous reinforcement densified by a metal matrix, for example a part of an aeronautical engine, the manufacturing method comprising the following steps zo: - open a tool comprising a support part and a molding part, by spreading the molding part of the support part in order to delimit with the support part a housing, - place a fibrous reinforcement in the housing of the tool, 25 sealing the tooling, fixing the molding part on the support part and providing a space between the fibrous reinforcement and the parts of the tooling, melting the metal matrix, introducing the metal matrix into the tooling so as to fill the space between the fibrous reinforcement and the tooling parts, - apply a force on the molding part and / or on the support part in such a way as to rock the molding part and the support part and reduce the space between the fibrous reinforcement and the parts of the tool, to impregnate the fibrous reinforcement with the metal matrix. Some preferred but nonlimiting features of the manufacturing method described above are as follows: the support part and / or the molding part are preheated to a preheating temperature less than or equal to the melting temperature of the metal matrix; the support part and / or the molding part are preheated to a temperature between about 200 ° C. and 600 ° C., the support part and / or the molding part are preheated, the molding part being preheated to a temperature greater than temperature of the support part, - the method further comprises a step during a wire mesh is placed between the support portion and the fibrous reinforcement and / or between the molding portion and the fibrous reinforcement, prior to closing the tooling the method further comprises a step of treating the fibrous reinforcement adapted to increase the permeability of the fibers forming the ren the pre-treatment stage comprises a step of desensitizing the fibers forming the fibrous reinforcement and a chemical treatment step with a fluoride salt, by deposition of carbide or by deposition of nickel, and - the filling step of the space between the fibrous reinforcement and the parts of the tooling and / or the step of impregnating the fibrous reinforcement with the metal matrix are carried out under vacuum. According to a second aspect, the invention also proposes a part made of a composite material comprising a fiber reinforcement densified by a metal matrix, for example for an aeronautical engine, characterized in that it is obtained according to a manufacturing method such as described above.
    [0008] Some preferred but non-limiting features of the part are as follows: the part comprises an elongated piece, for example a plate or a rod, an avionics box for a motor or a metal reinforcement of an edge of attack, the part comprises a fiber volume content of between 30% and 70%, preferably between 40% and 65%, the fiber reinforcement comprises synthetic fibers, the fiber reinforcement comprises carbon fibers, fibers of glass, aramid fibers, boron fibers, and / or kevlar fibers, for example carbon fibers with a high modulus of thermal conductivity, the fiber reinforcement comprises between one and ten folds of superposed fibers, preferably between two and eight plies, typically between four and eight plies, the metal matrix comprises an aluminum alloy and / or a magnesium alloy, and the fibrous reinforcement is woven in two dimensions, woven in three dimensions, tress two-dimensional, woven in three dimensions and / or laminate.
    [0009] According to a third aspect, the invention also provides tooling for the manufacture of a workpiece as described above, comprising: - a mold, the mold comprising: * a support part, 25 * a molding part, movable relative at the support part in order to delimit with the support part a housing adapted to receive a fibrous reinforcement, * a sealing member, arranged between the support part and the molding part, adapted to seal the mold when the molding part 30 is fixed on the support portion while providing a space between the fibrous reinforcement and the tooling portions, and a through hole formed in the molding portion or in the mold support portion and opening into the housing, said through hole being adapted to allow the introduction of a metal matrix in the housing, and 5 - an actuator, configured to apply a force on the molding part and / or the support part of the mo ule so as to bring the molding part and the support part and reduce the space between the fibrous reinforcement and parts of the tool, to impregnate the fibrous reinforcement with the metal matrix.
    [0010] According to a fourth aspect, the invention finally proposes a mold for a tooling as described above characterized in that it comprises: a support part, a molding part, movable relative to the support part in order to delimit with the support part a housing adapted to receive a fibrous reinforcement, - a sealing member, arranged between the support part and the molding part, adapted to seal the tooling when the molding part is fixed on the support part while providing a space between the fibrous reinforcement and the parts of the tooling, and - a through orifice, formed in the molding part or in the support part and opening into the housing, said through orifice being adapted to allow the introduction of a matrix metallic in the housing. According to a preferred but nonlimiting characteristic, the mold 25 may further comprise a vent opening into the housing and configured to be in fluid communication with a vacuum pump. BRIEF DESCRIPTION OF THE DRAWINGS Other features, objects and advantages of the present invention will become more apparent upon reading the following detailed description and with reference to the accompanying drawings given by way of non-limiting examples and in which: FIG. 1 illustrates an exemplary tooling according to one embodiment of the invention, and FIG. 2 is a flowchart representing various steps of an exemplary embodiment of the manufacturing method according to the invention.
    [0011] DETAILED DESCRIPTION OF AN EMBODIMENT In what follows, the invention will be more particularly described in its application for the manufacture of a turbomachine part 1, typically an avionics housing, a dissipation plate can be used in such a housing to improve the heat exchange and cooling of the housing, or a metal reinforcement for a leading edge of a turbomachine blade, configured to protect the leading edge of this blade against the mechanical and thermal stresses it undergoes during the operation of the turbomachine.
    [0012] This is however not limitative, insofar as the invention applies to any part 1 obtainable in a mold 12 by a foundry, whatever its shape (plane, convex, concave, etc.) or its use, insofar as said part 1 comprises a composite material comprising a fibrous reinforcement 2 densified by a metal matrix 3. By composite material, here will be understood a material comprising a fibrous reinforcement 2 densified by a metal matrix 3. The fibrous reinforcement 2 may comprise any type of fiber suitable for the intended use for the part 1. For example, in the case of a part 1 intended to undergo a severe temperature environment, the fibers are preferably chosen so as to support such temperatures. In this example, it may especially be all types of fibers excluding natural fibers.
    [0013] For example, in the case of a turbomachine part 1, the fibers may comprise synthetic fibers such as carbon fibers (for example high modulus thermal conductivity carbon fibers such as pitch fibers). (precursor), glass fibers, aramid fibers, boron fibers, kevlar fibers Fiber reinforcement 2 can be woven in two dimensions, woven in three dimensions, plaited in two dimensions, braided in three dimensions and / or laminate (stack of fiber plies) In order to improve the mechanical strength of the part 1, the fibers of the fibrous reinforcement 2 preferably have sufficient permeability to guarantee good impregnation of the metal alloy 3. This In one embodiment, the wetting angle is close to 0 °, for example between 0 ° and 60 °, for example an angle wetting of the order of 40 ° to 50 ° already allows to ensure good impregnation of the fibers. If appropriate, when the fibers do not have sufficient permeability to ensure good infiltration of the metal alloy 3 in the fibrous reinforcement 2, it is possible to subject them to prior treatment in order to increase their permeability. This treatment may firstly comprise a step during which the fibers are desensitated by heating them to a temperature of the order of 500 ° C. Depending on the type of fiber, the permeability may remain insufficient, despite this step of desizing. For example, the fibers may still have a wetting angle of the order of 150 °. In this case, to further increase the permeability level of the fibers and achieve suitable wetting angles, typically 40 ° to 50 °, chemical treatments with fluoride salt or carbide or nickel deposition can be added to previously desensitized fibers. Furthermore, the metal matrix 3 can comprise any type of alloy adapted to the use envisaged for the part 1. Thus, for a part 1 requiring both excellent temperature resistance in a severe environment, good mechanical strength and a good electrical conductivity for a small footprint, reduced weight and moderate cost, the metal matrix 3 may comprise an aluminum-based alloy and / or a magnesium-based alloy. This type of alloy may in particular be suitable for a dissipation plate or for an avionics box as described above.
    [0014] Other types of metal alloys that can be used. These alloys may include metals suitable for sand casting, foundry metals (such as cast iron and steel), metals that may be used for shell molding (by gravity, pressure, or lost wax) having a melting point of less than 900 ° C (cuprous alloys, aluminum, zinc, etc.). Tooling 10 The method S can be implemented using a suitable tooling 10, comprising a mold 12 having a support part - or matrix 14 15 - and a molding part - or punch 13. The punch 13 is movable by relative to the matrix 14 so as to define therewith a housing 15 adapted to receive a fibrous reinforcement 2. In one embodiment, the facing faces of the die 14 and the punch 13 form the housing 15 and cooperate to conform the piece 1 in the mold 12.
    [0015] The mold 12 further comprises a through orifice 11, formed in the punch 13 or die 14 and opening into the housing 15, to allow the introduction of a molten metal alloy 3 into the housing 15. In the example of embodiment shown in FIG. 1, the through orifice 11 is formed in the punch 13.
    [0016] In order to allow the manufacture of a composite material part 1, the mold 12 has: - an initial configuration, in which the punch 13 is separated from the die 14 so as to allow access to the housing 15. - a wetting configuration, wherein the punch 13 is positioned on the matrix 14. In this wetting configuration, the punch 13 and the die 14 delimit the housing 15, intended to receive the fibrous reinforcement 2. The housing 15 then has a initial internal volume, which corresponds to the volume of the fibrous reinforcement 2 used to form the part 1 to which is added a volume of air, between the fibrous reinforcement 2 and the mold 12, intended to be filled by the metal alloy 3. In the embodiment 5 illustrated in the figures, the air volume extends for example between the fibrous reinforcement 2 and the punch 13. - an impregnation configuration, in which the punch 13 and the die 14 are brought together s in order to reduce the internal volume of the housing 15. In this impregnation configuration, the internal volume of the housing 15 substantially corresponds to the final volume of the part 1. The mold 12 may further comprise a sealing member 17, disposed between the die 14 and the punch 13. The sealing member 17 is configured to seal the housing 15 of the mold 12 when it is in its wetting configuration or in its impregnation configuration. For this purpose, the sealing member 17 is chosen to seal the housing 15 of the mold 12 in its wetting configuration and maintain this seal when the punch 13 and the die 14 are brought into the impregnation configuration, for example by elastic deformation of the sealing member 17. In this way, a space between the fibrous reinforcement 2 and the punch 13, intended to receive the metal alloy 3 in the wetting configuration, can be arranged while guaranteeing the sealing of the mold 12. In an exemplary embodiment, the sealing member 17 may comprise a seal attached to a peripheral zone of the punch 13 (or the die 14, respectively) intended to come into contact with the die 14 (respectively the punch 13) when the mold 12 is closed. The seal 17 may in particular comprise a relatively ductile metal seal so as to allow the closure of the mold 12, which expands when the temperature of the mold 12 increases and thus makes it possible to seal the mold 12. In a variant, the seal Sealing ring 17 may be an O-ring fastened to die 14 (respectively punch 13) such that, when punch 13 is attached to die 14 to close mold 12, punch 13 (respectively die 14) comes into contact with the o-ring and compresses it, thereby sealing the housing 15 of the mold 12.
    [0017] Optionally, the mold 12 may also include a preheating member configured to preheat the mold 12 to a defined temperature depending on the melting temperature of the metal alloy 3 to avoid thermal gradients with the alloy. metal 3 10 when introduced into the mold 12. This preheating member can then be independent of the tool 10 to make the mold 12 independent in terms of thermal regulation. Finally, the tooling 10 may comprise an actuator 16 configured to apply a force on the punch 13 and / or on the die 14 so as to bring the punch 13 and the die 14 together and reduce the space between the fibrous reinforcement 2 and the mold 12, for impregnating the fibrous reinforcement 2 with the metal alloy 3. The actuator 16 may form an integral part of the mold 12 or be separated therefrom. The embodiment variant in which the mold 12 is distinct from the actuator 16 has the advantage of allowing the manufacture of several parts 1 in series with the same actuator 16 by using several different molds 12, regardless of the cooling time of the parts. 1 in the mold 12.
    [0018] In an exemplary embodiment, the actuator 16 may in particular comprise a press capable of applying a pressure of up to 2000 tons. The pressure applied will of course be adapted to the size and dimensioning of the tooling.
    [0019] The invention will be illustrated here in the case of the production of a part 1 comprising a thermal dissipation plate of composite material comprising a fiber reinforcement 2 densified with a metal alloy 3021669 13 3. The skilled person will then adapt without excessive effort the steps of the method S for the production of other parts 1 of composite material. In this example, the thermal dissipation plate of composite material comprises a first face and a second face parallel and interconnected by side edges. Here, the first face and the second face correspond to the faces of the parallelepiped whose surface is the largest. The housing 15 defined by the die 14 and the punch 13 is then of generally parallelepipedal shape. Therefore, the die 14 and the punch 13 each have an open cavity whose contour is generally parallelepipedic, said cavities together forming the housing 15 of the mold 12 when the die 14 and the punch 13 are assembled. As a variant, only the die 14 (or the punch 13) 15 can comprise such a cavity, the punch 13 (or the die 14) then being flat. In one embodiment, the cavity of the matrix 14 comprises a first wall corresponding to the first surface of the plate to be made, the cavity of the punch 13 comprises a second wall 20 corresponding to the second surface, the first wall and the second wall. extending opposite and parallel when the mold 12 is closed. In other words, the cavities each have a main direction of extension substantially perpendicular to the direction of movement of the punch 13 with respect to the die 14, which makes it possible to optimize the distribution of the metal alloy 3 in the fibrous reinforcement 2 and to homogenize the forces applied to the largest surfaces of the part 1. In the case of a part 1 having a shape different from that of a plate, it will be understood that the shape of the matrix 14 and the punch form 13 must be adapted. Thus, for comparison, for a generally rectangular housing, the matrix 14 may for example comprise a cavity whose contour is generally parallelepipedic, while the punch 13 comprises a complementary projecting shape configured to penetrate into the cavity of the matrix 14. Manufacturing method 5 In order to manufacture a composite material part 1, the method S of the invention comprises a first step S1 during which the mold 12 is opened to be brought into its initial configuration, by moving the die 14 of the punch 13 so as to disengage the housing 15.
    [0020] During a second step S2, the fibrous reinforcement 2 intended to form the part 1 is placed in the housing 15 of the mold 12, on the matrix 14. If necessary, the fibrous reinforcement 2 can be treated beforehand (step S20 ) in order to modify its permeability and improve the impregnation of the metal alloy 3. In the example of a heat dissipation plate, the fibrous reinforcement 2 may have a generally parallelepiped shape. On the other hand, the fibrous reinforcement 2 may comprise several superposed fiber plies, typically between one and ten plies of fibers, preferably between two and eight plies of fibers, typically four to eight plies of fibers. In addition, in order to make the plate thermally and electrically conductive, the folds may comprise carbon fibers. In one embodiment, a wire mesh may be placed between the punch 13 and the fiber reinforcement 2 (step S21), and optionally between the die 14 and the fiber reinforcement 2. The objective of this wire mesh is homogenizing the distribution of the metal alloy 3 on and in the fibrous reinforcement 2, creating a perforated surface which limits the stresses likely to hinder the flow of the molten alloy, which facilitates the progression of the molten alloy around fibrous reinforcement 2.
    [0021] In a third step S3, the tooling 10 can be brought to its wetting configuration by relating the punch 13 to the die 14 in order to close the housing 15. In one embodiment, the tooling 10 is closed sealingly to prevent leakage of material outside the mold 12. The tightness of the closed mold 12 can be achieved by means of the sealing member. In the wetting configuration, the mold 12 is closed so that a space is provided between the fibrous reinforcement 2 and the mold 12, while sealing the mold 12. The volume of this internal space corresponds to the volume of metal alloy 3 that it is desired to impregnate in the fibrous reinforcement 2, so as to form the piece 1 of composite material. This volume corresponds generally to the internal volume of the fibrous reinforcement 2, that is to say the volume of air present between the fibers of the reinforcement. In general, the height h is between a few tenths of a millimeter for a thickness e of between 1 and 2 mm and a few millimeters for a thickness e greater than 2 mm. For example, for a fibrous reinforcement 2 having a thickness e (dimension 20 along the axis of application of the force by the actuator 16) of about two millimeters, the space between the upper surface of the fibrous reinforcement 2 and the punch 13 has a height h (dimension along the axis of application of the force by the actuator 16) of the order of one millimeter. Of course, it will be understood that the volume of the space depends on the fiber content desired for the part 1. For example, the part 1 can comprise between 30% and 70% of metal matrix 3 for 70% to 30% of fibers (ie a fiber volume content of 30 to 70%), preferably between 35% and 60% by weight of metal matrix 3 for 65% to 40% (ie a fiber volume content of 40 to 65% ).
    [0022] During a fourth step S4, the metal alloy 3 is heated in a suitable container 18 until its melting temperature is reached, in order to allow its introduction into the mold 12 in liquid form. In an alternative embodiment, the punch 13 and / or the die 14 are preheated S40 in order to limit the thermal gradients and to avoid any shock that could change the metallurgical quality of the piece 1 obtained. For example, the punch 13 and / or the die 14 may be preheated to a temperature between 200 ° C and 600 ° C. The preheating temperature may optionally be adapted according to the melting temperature of the metal alloy 3. Thus, for an alloy based on aluminum or magnesium, the punch 13 and / or the matrix 14 may be preheated at a temperature of the order of 500 ° C. The preheating S40 of the mold 12 may be carried out conventionally, for example by induction.
    [0023] In an alternative embodiment, the preheating S40 of the mold 12 (punch 13 and / or matrix 14) can be performed prior to the introduction of the fibrous reinforcement 2 into the mold 12, or prior to the second step S2 of the method S.
    [0024] During a fifth step S5, the metal alloy 3 is introduced into the mold 12 closed through the through-orifice 11 through the through orifice 11. In a first embodiment, the metal alloy 3 penetrates by gravity in the mold 12. Its distribution on and in the fibrous reinforcement 2 can be optionally improved by the metal mesh. The mold 12 is then at atmospheric pressure. As a variant, the mold 12 can be evacuated S50 in order to improve the distribution of the metal alloy 3 in the fibrous reinforcement 2 and to avoid the formation of bubbles, especially when the fibrous reinforcement 2 has a large thickness or that the subsequent use of part 1 requires excellent mechanical performance. For example, the internal cavity of the mold 12 can be brought to a pressure of the order of 20 bars. For this purpose, the mold 12 may then comprise a vent (not shown in the figures) opening into the housing 15 of the mold 12 and in fluid communication with a pump configured to put the mold 12 under vacuum. Following this step S5, the mold 12 then contains the fibrous reinforcement 2, if necessary a wire mesh on and / or under the fibrous reinforcement 2, and 5 of the molten metal alloy 3 distributed around the fibrous reinforcement 2. a sixth step S6, a force is applied using the actuator 16 on the mold 12 (that is to say on the punch 13 and / or the matrix 14) so as to bring the mold 12 in its impregnation configuration by bringing the punch 13 closer to the matrix 14. This bringing together of the punch 13 and the die 14 has the effect of forcing the metal alloy 3 to infiltrate the asperities of the fibrous reinforcement 2 by reducing the internal volume of the housing 15 of the mold 12. The force can be applied by the actuator 16 in a direction substantially perpendicular to a main plane of extension of the fibrous reinforcement 2. Typically, for a part 1 comprising a plate extends usually in an extension plane P it is possible to apply a force in a direction normal to this extension plane P. The force applied by the actuator 16 is then more homogeneous than when it is applied along an axis included in the extension plane P, and Thus, the metal alloy 3 can be impregnated more homogeneously in the fibrous reinforcement 2. Preferably, the steps S5 and S6 are carried out sufficiently rapidly so that the impregnation of the fibrous reinforcement 2 with the metal alloy 3 to 1 The actuator 16 is completed before the metal alloy 3 has begun to cure. In addition, the step S6 of impregnating the fibrous reinforcement 2 with the metal alloy 3 may optionally be carried out under vacuum.
    [0025] Following this step S6, the metal alloy 3 is impregnated homogeneously in the fibrous reinforcement 2.
    [0026] During a seventh step S7, the part 1 is cooled. The cooling can take place in the open air in the tooling 10. For example, the mold 12 can be extracted from the tooling 10 and then allowed to cool while a different mold 12 is used in the tooling 10 for the realization of another part 1. It will of course be understood that the cooling mode of the part 1 is chosen as a function of the metallurgical quality that it is desired to obtain for the part 1. If necessary, it is for example possible to Quenching of the workpiece 1. Following the cooling step S7, the metal alloy 3 is homogeneously distributed in the fibrous reinforcement 2, which gives the workpiece 1 thus obtained good mechanical properties, and thermal and conductive properties that can be adjusted according to the material used for the metal alloy 3. In particular, the invention makes it possible to generate a network of electrical and thermal bridging through a fibrous reinforcement 2 in order to dissipate and / or conduct energy through the piece 1 obtained, by minimizing the contact strengths between the fibers 20 of the fibrous reinforcement 2 and the metal alloy 3 of the metal alloy 3 in order to optimize the flow passages. Finally, the part 1 can undergo finishing steps, such as machining, riveting, gluing, welding, etc. 25
    权利要求:
    Claims (18)
    [0001]
    REVENDICATIONS1. A method of manufacturing (S) a workpiece (1) in a composite material comprising a fibrous reinforcement (2) densified by a metal matrix (3), for example a workpiece (1) of an aeronautical engine, the method manufacturing device (S) comprising the following steps: - opening (51) a tool (10) comprising a support part (14) and a molding part (13), by spreading the molding part (13) from the support part (14) in order to delimit with the support part (14) a housing (15), - to place a fibrous reinforcement (2) in the housing (15) of the tooling (10) (S2), - to close (S3) in a sealed manner. tooling (10), by fixing the molding part (13) on the support part (14) and by providing a space between the fibrous reinforcement (2) and the parts of the tool (10), - melting the matrix metal (3) (S4), - introducing the metal matrix (3) into the tool (10) (S5) so as to fill the space between the fibrous reinforcement (2) and the parts (13, 14) of tools (10 ), 20 - apply a force (S6) on the molding part (13) and / or on the support part (14) so as to bring the molding part (13) and the support part (14) closer together and reduce the space between the fibrous reinforcement (2) and the parts (13, 14) of the tool (10) for impregnating the fibrous reinforcement (2) with the metal matrix (3). 25
    [0002]
    2. Manufacturing method (S) according to claim 1, wherein the support portion and / or the molding portion (13) are preheated to a preheating temperature less than or equal to the melting temperature of the metal matrix (3), preferably between about 200 ° C and 600 ° C. 30
    [0003]
    The manufacturing method (S) according to claim 2, wherein the support portion (14) and / or the molding portion (13) are preheated, the molding portion (13) being preheated to a temperature above the temperature. of the support part (14).
    [0004]
    4. Manufacturing method (S) according to one of claims 1 to 3, 5 further comprising a step (S21) during a wire mesh is placed between the support portion (14) and the fibrous reinforcement (2) and / or between the molding part (13) and the fibrous reinforcement (2), prior to closing (S3) of the tool (10).
    [0005]
    5. Manufacturing process (S) according to one of claims 1 to 4, further comprising a treatment step (S20) of the fibrous reinforcement (2) adapted to increase the permeability of the fibers forming the fibrous reinforcement (2).
    [0006]
    6. Manufacturing method (S) according to claim 5, wherein the pretreatment step (S20) comprises a step of desensitizing fibers forming the fibrous reinforcement (2) and a chemical treatment step with fluoride salt, by depositing carbide or by nickel deposition.
    [0007]
    7. Method according to one of claims 1 to 6, wherein the step of filling (S5) the space between the fibrous reinforcement (2) and the parts (13, 14) of the tool (10) and / or the impregnation step (S6) of the fibrous reinforcement (2) with the metal matrix (3) are carried out under vacuum.
    [0008]
    8. Part (1) in a composite material comprising a fibrous reinforcement (2) densified by a metal matrix (3), for example for an aeronautical engine, characterized in that it is obtained according to a manufacturing process (S ) according to one of claims 1 to 7.
    [0009]
    9. Part (1) according to claim 8, comprising an elongated piece, for example a plate or a rod, an avionics housing for a motor or a metal reinforcement of a leading edge. 3021669 21
    [0010]
    10. Part (1) according to one of claims 8 or 9, comprising a fiber volume of between 30% and 70%, preferably between 40% and 65%. 5
    [0011]
    11. Part (1) according to one of claims 8 to 10, wherein the fibrous reinforcement (2) comprises synthetic fibers.
    [0012]
    12. Part (1) according to claim 11, wherein the fibrous reinforcement (2) comprises carbon fibers, glass fibers, aramid fibers, boron fibers, and / or Kevlar fibers, for example high modulus carbon fibers of thermal conductivity.
    [0013]
    13. Part (1) according to one of claims 8 to 12, wherein the fibrous reinforcement (2) comprises between one and ten folds of superposed fibers, preferably between two and eight folds, typically between four and eight folds.
    [0014]
    14. Part (1) according to one of claims 8 to 13, wherein the metal matrix (3) comprises an aluminum alloy and / or a magnesium alloy.
    [0015]
    15. Part (1) according to one of claims 8 to 14, wherein the fibrous reinforcement (2) is woven in two dimensions, woven in three dimensions, plaited in two dimensions, braided in three dimensions and / or laminated. 25
    [0016]
    Tooling (10) for manufacturing a workpiece (1) according to one of claims 8 to 15, comprising: a mold (12), the mold (12) comprising: * a support portion (14), a molding part (13) movable relative to the support part (14) in order to delimit with the support part (14) a housing (15) adapted to receive a fibrous reinforcement (2), 302 166 9 22 * an organ seal (17), arranged between the support part (14) and the molding part (13), adapted to seal the mold (12) when the molding part (13) is fixed on the support part (14) while providing a space between the fibrous reinforcement (2) and the parts (13, 14) of the tooling (10), and * a through hole (11) formed in the molding part (13) or in the support part (14). ) of the mold (12) and opening into the housing (15), said through orifice (11) being adapted to allow the introduction of a metal matrix (3) in the housing (15), and 10 - an actuator (18). ) configured to apply a force on the molding portion (13) and / or on the support portion (14) of the mold (12) so as to bring the molding portion (13) and the support portion closer together and reduce the space between the reinforcement fibrous (2) and parts of the tool (10), for impregnating the fibrous reinforcement (2) with the metal matrix (3). 15
    [0017]
    17. Mold (12) for a tool (10) according to claim 16, characterized in that it comprises: - a support part (14), - a molding part (13), movable relative to the support part (14) ) In order to delimit with the support part (14) a housing (15) adapted to receive a fibrous reinforcement (2), - a sealing member (17) arranged between the support part (14) and the molding part ( 13) adapted to seal the tooling (10) when the molding portion (13) is attached to the support portion (14) while providing a gap between the fibrous reinforcement (2) and the portions (13, 14) of the tooling (10), and - a through orifice (11), formed in the molding part (13) or in the support part (14) and opening into the housing (15), said through orifice (11) being adapted to allow the introduction of a metal matrix (3) into the housing (15). 3021669 23
    [0018]
    The mold (12) of claim 17, further comprising a vent opening into the housing (15) of the mold (12) and configured to be in fluid communication with a vacuum pump. 5
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    同族专利:
    公开号 | 公开日
    WO2015185578A8|2016-01-28|
    WO2015185578A1|2015-12-10|
    EP3151990B1|2019-02-20|
    US10843257B2|2020-11-24|
    CN107148490B|2019-11-29|
    EP3151990A1|2017-04-12|
    CN107148490A|2017-09-08|
    FR3021669B1|2017-08-25|
    US20170216911A1|2017-08-03|
    引用文献:
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    EP0164536A2|1984-06-15|1985-12-18|Toyota Jidosha Kabushiki Kaisha|Composite material with carbon reinforcing fibers and magnesium alloy matrix metal including zinc|
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    WO2005097377A1|2004-04-08|2005-10-20|Composite Metal Technology Ltd|Liquid pressure forming|
    EP2474638A2|2011-01-06|2012-07-11|General Electric Company|Fiber-reinforced Al-Li compressor airfoil and method of fabricating|
    DE102012011264A1|2012-06-07|2013-12-12|Technische Universität Dresden|Metal casting composite component has component main portion with which textile fiber reinforcement formed from fibers, threads, fiber bundles or metallic wires is embedded|
    GB1359554A|1971-03-05|1974-07-10|Secr Defence|Composite materials|
    US4828460A|1986-08-13|1989-05-09|Toshiba Kikai Kabushiki Kaisha|Electromagnetic pump type automatic molten-metal supply apparatus|
    CN103695815B|2013-12-20|2015-07-01|西北工业大学|Device and method for separate preheating and one-step infiltration extrusion forming of magnesium-based composite|FR3039839B1|2015-08-06|2019-12-20|Safran Aircraft Engines|PROCESS FOR MANUFACTURING A PART OF COMPOSITE MATERIAL|
    CN109930088A|2017-12-17|2019-06-25|宜兴安纳西智能机械设备有限公司|A kind of pole plate cleaning brush mill apparatus motor cabinet slide unit material|
    GB2582148A|2019-03-12|2020-09-16|Airbus Operations Ltd|Impact resistant panels|
    CN112355279B|2020-11-04|2021-09-07|哈尔滨工业大学|Method for regulating and controlling integrated casting composite interface of nickel-based superalloy/SiC ceramic composite component|
    法律状态:
    2015-05-26| PLFP| Fee payment|Year of fee payment: 2 |
    2015-12-04| PLSC| Search report ready|Effective date: 20151204 |
    2016-05-26| PLFP| Fee payment|Year of fee payment: 3 |
    2017-01-13| CD| Change of name or company name|Owner name: SAFRAN, FR Effective date: 20161214 Owner name: SAGEM DEFENSE SECURITE, FR Effective date: 20161214 |
    2017-01-13| CJ| Change in legal form|Effective date: 20161214 |
    2017-05-23| PLFP| Fee payment|Year of fee payment: 4 |
    2018-05-25| PLFP| Fee payment|Year of fee payment: 5 |
    2020-05-20| PLFP| Fee payment|Year of fee payment: 7 |
    2021-05-19| PLFP| Fee payment|Year of fee payment: 8 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1455038A|FR3021669B1|2014-06-03|2014-06-03|PROCESS FOR MANUFACTURING A WORKPIECE IN A METALLIC MATRIX COMPOSITE MATERIAL AND TOOLS|FR1455038A| FR3021669B1|2014-06-03|2014-06-03|PROCESS FOR MANUFACTURING A WORKPIECE IN A METALLIC MATRIX COMPOSITE MATERIAL AND TOOLS|
    US15/315,674| US10843257B2|2014-06-03|2015-06-02|Method for manufacturing a part out of a metal matrix composite material, and related device|
    CN201580029970.7A| CN107148490B|2014-06-03|2015-06-02|By the method and relevant apparatus of metal matrix composite materials manufacture part|
    EP15726161.1A| EP3151990B1|2014-06-03|2015-06-02|Method for manufacturing a part out of a metal matrix composite material, and related device|
    PCT/EP2015/062305| WO2015185578A1|2014-06-03|2015-06-02|Method for manufacturing a part out of a metal matrix composite material, and related device|
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