CN111936303A - 由复合材料制造用于燃气涡轮发动机的具有装配金属前缘的叶片的方法 - Google Patents

由复合材料制造用于燃气涡轮发动机的具有装配金属前缘的叶片的方法 Download PDF

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CN111936303A
CN111936303A CN201980022718.1A CN201980022718A CN111936303A CN 111936303 A CN111936303 A CN 111936303A CN 201980022718 A CN201980022718 A CN 201980022718A CN 111936303 A CN111936303 A CN 111936303A
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blade
layer
foil
leading edge
layers
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CN111936303B (zh
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M·布兰夸特
M·弗兰德斯
R·皮康
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Safran SA
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Safran SA
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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Abstract

一种由复合材料制造具有装配金属前缘的叶片的方法，所述方法包括：‑在待制造叶片的前缘的模板(211)上依次披盖第一基础材料层(20)和第二粘合剂材料层(30)，‑将第一和第二披盖层(20、30)转移到金属箔(140)的凹部(141)中，‑将包括第一和第二披盖层(20、30)的箔(140)定位在叶片预制件的前缘旁边，所述叶片预制件包括浸渍有基质前体的纤维增强材料，‑叶片预制件与第一和第二披盖层共固化，以获得由复合材料制成的叶片，所述叶片包括在其前缘上的粘结金属箔。

Description

由复合材料制造用于燃气涡轮发动机的具有装配金属前缘的 叶片的方法
背景技术
本发明涉及由复合材料制造用于航空燃气涡轮发动机的包括金属前缘的叶片的一般领域。
在由复合材料制成的航空燃气涡轮发动机叶片的前缘上存在金属箔可以保护复合叶片组件免受磨损/侵蚀以及异物撞击期间的磨损。对于暴露于鸟、冰雹、冰等吸入物的航空涡轮机风扇叶片，而且对于燃气涡轮矫直机或扩散器的叶片而言尤其如此。
存在许多用复合材料生产燃气涡轮发动机叶片的方法。例如，可以提及手动层压/披盖工艺、纤维预制件注塑工艺、绣花工艺(embroidery process)、热压工艺等。这些工艺主要基于热固性(TS)或热塑性(TP)树脂的使用。
一旦获得复合材料叶片，则必须在其前缘上组装保护性金属箔。为此目的，例如，将通过机械工艺(如冲压、成形或电铸)生产的金属箔粘结至复合材料叶片的前缘。该操作可以在确保金属箔粘结的模具中进行。在其前缘上设有金属箔的复合材料叶片的示例具体见述于文件US2007092379和US20160167269。
然而，金属箔与复合材料叶片前缘的粘结是易碎操作，在控制叶片和箔之间的粘合剂材料安装和分配的可再现性方面尤为如此。如果粘合剂材料层不均匀地存在于叶片和箔之间，则粘结质量下降，导致箔的机械强度降低，因此，在与物体碰撞或承受分层力的情况下，存在箔丢失的风险。
发明目的和概述
因此，本发明的主要目的在于提出一种由复合材料制造设置有金属前缘的叶片的方法，该方法不具有上述缺陷。
根据本发明，其目的是通过一种用于由复合材料制造用于航空燃气涡轮发动机的具有装配金属前缘的叶片的方法来实现的，所述方法包括：
-在待制造的叶片前缘的模板上依次披盖第一基础材料层和第二粘合剂材料层，
-将第一和第二披盖层转移至金属箔的凹部中，
-将包括第一和第二披盖层的箔定位在叶片预制件的前缘旁边，所述叶片预制件包括浸渍有基质前体的纤维增强材料，
-使叶片预制件与第一和第二披盖层共固化，以获得由复合材料制成的叶片，所述叶片包括在其前缘上的粘结金属箔。
通过使第一基础材料层和第二粘合剂材料层符合与待制造叶片的前缘形状对应的模板，并通过将这些层从模板转移至箔，确保了箔和预制件前缘之间的连续固定界面。因此，这防止了在由箔所形成的凹部或槽(spout)的底部出现孔，由此改进了叶片上的所述箔的强度，同时确保了装配组件在由箔、基础材料层和粘合剂材料层构成的叶片上的定位具有非常好的再现性。
根据本发明方法的第一特定特征，将第一和第二披盖层转移至金属箔凹部中的步骤包括：将金属箔安装在粘合剂材料层上，并且从前缘模板取下由箔以及第一和第二层形成的组件。
根据本发明方法的第二特定特征，该方法还包括：在将金属箔安装在粘合剂材料层之后且在取下由箔以及第一和第二披盖层所形成的组件之前，切掉所述第一和第二披盖层延伸超出所述箔的部分。
根据本发明方法的第三特定特征，该方法还包括：在将第一层和第二层披盖在前缘模板上之前，在模板上沉积防粘层。由此，这允许容易地除去由箔、基础材料层和粘合剂材料层构成的组件。
根据本发明方法的第四特定特征，该方法还包括：在将第一层和第二层披盖在前缘模板上之前，调整模板上的箔。
根据本发明方法的第五特定特征，第一层的基础材料选自：玻璃纤维、细青铜纱、碳纤维。
根据本发明方法的第六特定特征，第二层的粘合剂材料选自：环氧粘合剂、增强环氧粘合剂、环氧粘合剂膜、增强环氧粘合剂膜。
本发明方法具体应用于制造风扇叶片、出口导流叶片、入口导流叶片或可变定子叶片。
附图说明
参考所附的附图，本发明的其它特征和优点将显现于下文所提供的说明，所述附图显示了其不含任意限制性质的示例性实施方式。在附图中：
-图1是本发明一个实施方式的出口导流叶片的示意性透视图；
-图2是一示意性透视图，显示在模板上披盖基础层和粘合剂层；
-图3是一示意性透视图，显示在图2的模板旁边定位金属箔；
-图4是一示意性透视图，显示出基础层和粘合剂层与金属箔压紧；
-图5是一示意性透视图，显示出将基础层和粘合剂层从所述金属箔突出的部分切掉；
-图6是一示意性透视图，显示出从模板上取下设置有基础层和粘合剂层的金属箔；
-图7是一示意性透视图，显示出将设置有基础层和粘合剂层的金属箔定位在出口倒流叶片预制件旁边，然后对组件进行模塑；
-图8是一示意性透视图，显示出图7中的叶片预制件与设置有基础层和粘合剂层的金属箔在模具中共固化。
具体实施方式
本发明应用于生产由复合材料制成的叶片，该叶片用于航空燃气涡轮发动机，具有金属前缘。
该叶片的非限制性示例具体是风扇叶片、出口导流叶片(称为OGV)、入口导流叶片(称为IGV)、可变定子叶片(称为VSV)等。
将就出口导流叶片(如图1所示的叶片100)的制造来描述根据本发明的方法，所述叶片100包括叶片主体110，该叶片主体110沿着在内部平台120和外部平台130之间的纵向方向DL并沿着在前缘111和后缘112之间的横向方向DT延伸。叶片主体110还包括内凸面113和外凸面114。由金属材料140制成的箔在前缘111处进一步粘结至叶片主体120。
用于制造叶片100的方法开始于在待制造的叶片的前缘的模板上依次披盖第一基础材料层和第二粘合剂材料层，如图2所示。更具体地说，如图2所示，使用模板200，所述模板200包括再现待制造叶片100的前缘111的形状和尺寸的至少一个部分211。模板200可以是特别为实施本发明方法而制成的部件，或者对应于拒收部件，或者甚至对应于测试部件。
在披盖之前，模板200的部分211优选覆盖有由防粘材料(例如聚四氟乙烯(PTFE))构成的层10。第一基础材料层20首先披盖在覆盖有或未覆盖有层10的部分211上。第一层20可以是由选自以下材料之一的材料制成的组织层(stratum)或双向(2D织造)层(ply)：玻璃纤维、由
Figure BDA0002703869450000041
公司生产的青铜网(Bronze Mesh)产品中使用的细青铜纱线、碳纤维。然后将第二粘合剂材料层30披盖在层20上。第二层20可以由增强或未增强的环氧基粘合剂构成，或者由增强或未增强的环氧基粘合剂材料膜构成。粘合剂材料可以例如对应于：由
Figure BDA0002703869450000042
公司制造的环氧树脂EA914，
Figure BDA0002703869450000043
公司制造的粘合剂膜AF191，
Figure BDA0002703869450000045
公司制造的粘合剂膜FM300或
Figure BDA0002703869450000044
公司制造的环氧树脂EA9396。
通过在模板200上披盖层20和30，将使这些层符合与待制造叶片前缘的几何形状精确对应的几何形状。
一旦第一层120和第二层20披盖在模板200的部分211上，就将金属材料制成的箔140放置在第二粘合剂材料层30上，如图3所示。例如，箔140可以由不锈钢制成。箔140具有与待制造的叶片后缘相对应的形状和尺寸。箔140具有槽形状，该槽形状限定了壁141a上的凹部141，其中将会固定第一和第二披盖层20和30。
在将第一层20和第二层30披盖在模板200上之前，可以在模板200上调整箔140。箔140在模板200上的调整可以对应于箔尺寸(例如，其长度)、和/或箔形状(例如，其曲率或其扭曲)的调整。金属箔的厚度非常薄，并且其在模板上的顺应是通过手动压力产生的。
第一层20和第二层30可以通过向箔140施加压实压力PC来压紧，如图4所示。为此目的，将设置有第一层20和第二层30以及箔140的模板200置于能够在箔140上施加压实压力PC的工具(未显示于图4中)中。
如图5所示，然后切掉第一层20和第二层30的延伸到箔140外侧的部分，箔的边缘140a和140b用于标记模板200上的切割线。该操作是任选的，并且根据实施方式的变体，允许箔140的第一层20和第二层30突出。
从模板200取下由箔140以及固定到箔凹部141的表面141a的第一层20和第二层30所形成的组件(图6)。该组件随后定位在出口导流叶片预制件300的前缘311旁边(图7)。层20和30已经顺应待制造的叶片的后缘的确切形状，并且从模板转移至箔140的凹部141中，从而确保了箔片140和预制件300的前缘311之间的连续固定界面。
复合材料叶片由用基质致密化的纤维增强材料获得。在该情况下，其由纤维预制件制成，所述纤维预制件可以本领域技术人员已知的不同方式获得。通常，可以通过纱线(例如由碳纤维形成纱线)进行三维(3D)织造或通过二维纤维织物披盖直接获得预制件。在文件WO2013088040中具体描述了由复合材料制造出口导流叶片，该复合材料由通过三维织造产生并且由基质致密化的纤维增强材料获得。在此处所述的示例中，出口导流叶片预制件300由多个二维(2D织物)组织层或由预浸渍和披盖的碳纤维制成的层获得。出口导流叶片预制件也可以由纤维增强材料制成，所述纤维增强材料由通过三维织造产生的碳纤维制成，该增强材料已经浸渍有热固性树脂，例如环氧型树脂。
或者，这些复合材料叶片可以通过注入由短、长载荷(load)等增强的热塑性树脂(TP)的模具中而直接获得。在这种情况下，为了使树脂与由箔以及固定在箔凹部表面上的第一和第二层所形成的组件共固化，所述树脂并未完全转变(聚合)。
通过将预制件300和位于预制件300的前缘311上的由箔140以及第一层20和第二层30所形成的组件放入固化模具50中，来继续叶片制造方法。在已知方式中，固化模具50包括两个壳51和52，所述两个壳51和52各自分别包括腔室510和520，腔室510和520一旦结合(即，在模具闭合之后)将形成与待制造叶片形状相对应的模具凹部530(图8)。
随后，将模具50加热至一定温度，以使其能够实现预制件300与由箔140和第一层20和第二层30所形成的组件的共固化。不同的层(即，预浸渍预制件和第二层(粘合剂层))具有兼容的固化循环，从而允许元件同时聚合。模具可以通过压机的板，在高压釜中进行加热，或设置有加热装置，加热是根据限定直至使各种聚合物进行聚合的温度的升温速率(temperature ramp)进行的，在该温度上升过程中施加压力以控制蠕变。然后施加聚合水平，随后按照新限定的速率降低温度。层20和30的聚合与预制件300的树脂的聚合同时进行。由于树脂是相容的，所以层20、30和预制件300在固化期间彼此固定。
在共固化后，从模具中取出叶片。叶片可能会经历后固化循环以改进其热机械特性(提高玻璃化转变温度)。无需机械加工，因为待模塑的部件符合所需尺寸。然后获得图1中所示的叶片100，其包括具有由复合材料制成的内部平台120和外部平台130的叶片主体110，其中，金属箔140结合至叶片100的前缘111。
本发明的方法还特别地适用于制造具有或不具有平台的叶片，例如用于无涵道发动机(unducted engines)(“开放转子”)的可变定子叶片和风扇叶片。

Claims (8)

1.一种由复合材料制造用于航空燃气涡轮发动机的具有装配金属前缘的叶片(100)的方法，所述方法包括：
-在待制造叶片(100)的前缘(111)的模板(211)上依次披盖第一基础材料层(20)和第二粘合剂材料层(30)，
-将第一和第二披盖层(20、30)转移到金属箔(140)的凹部(141)中，
-将包括第一和第二披盖层(20、30)的箔(140)定位在叶片预制件(300)的前缘(311)旁边，所述叶片预制件(300)包括浸渍有基质前体的纤维增强材料，
-使叶片预制件(300)与第一和第二披盖层(20,30)共固化，以获得由复合材料制成的叶片(100)，所述叶片(100)包括在其前缘(111)上的粘结金属箔(140)。
2.如权利要求1所述的方法，其中，将第一和第二披盖层(20,30)转移至金属箔(140)的凹部(414)中的步骤包括：将金属箔安装在粘合剂材料层(30)上，并且从前缘的模板(211)取下由箔(140)以及第一和第二层(20,30)形成的组件。
3.如权利要求2所述的方法，所述方法还包括：在将金属箔(140)安装在粘合剂材料层(30)上之后且在取下由箔以及第一和第二披盖层(20,30)所形成的组件之前，切掉所述第一和第二披盖层延伸超出所述箔的部分。
4.如权利要求1至3中任一项所述的方法，所述方法还包括：在将第一层和第二层(20,30)披盖在前缘的模板(211)上之前，在模板上沉积防粘层。
5.如权利要求1至4中任一项所述的方法，所述方法还包括：在将第一和第二层(20,30)披盖在前缘的模板(211)上之前，在模板上对箔进行调整。
6.如权利要求1至5中任一项所述的方法，其中，第一层(20)中的基础材料选自：玻璃纤维、细青铜纱、碳纤维。
7.如权利要求1至6中任一项所述的方法，其中，第二层(30)中的粘合剂材料选自：环氧粘合剂、增强环氧粘合剂、环氧粘合剂膜、增强环氧粘合剂膜。
8.如权利要求1至7中任一项所述的方法的应用，用于制造风扇叶片、出口导流叶片、入口导流叶片或可变定子叶片。
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