EP3930991A1 - Repairing or resuming production of a component made of composite material - Google Patents

Repairing or resuming production of a component made of composite material

Info

Publication number
EP3930991A1
EP3930991A1 EP20713712.6A EP20713712A EP3930991A1 EP 3930991 A1 EP3930991 A1 EP 3930991A1 EP 20713712 A EP20713712 A EP 20713712A EP 3930991 A1 EP3930991 A1 EP 3930991A1
Authority
EP
European Patent Office
Prior art keywords
recessed portion
filling
bevels
matrix
fiber preform
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20713712.6A
Other languages
German (de)
French (fr)
Inventor
Bruno Jacques Gérard DAMBRINE
Yann Didier Simon MARCHAL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran SA
Original Assignee
Safran SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Safran SA filed Critical Safran SA
Publication of EP3930991A1 publication Critical patent/EP3930991A1/en
Pending legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/005—Selecting particular materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B29C73/14—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using elements composed of two parts joined together after having been placed one on each side of the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B29C73/10—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/008—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D21/00—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for
    • F01D21/04—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for responsive to undesired position of rotor relative to stator or to breaking-off of a part of the rotor, e.g. indicating such position
    • F01D21/045—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for responsive to undesired position of rotor relative to stator or to breaking-off of a part of the rotor, e.g. indicating such position special arrangements in stators or in rotors dealing with breaking-off of part of rotor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/005—Repairing methods or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/748—Machines or parts thereof not otherwise provided for
    • B29L2031/7504—Turbines
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/48—Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/48—Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
    • C04B2235/483—Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5252—Fibers having a specific pre-form
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/616—Liquid infiltration of green bodies or pre-forms
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/94—Products characterised by their shape
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/38—Fiber or whisker reinforced
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
    • F05D2220/32—Application in turbines in gas turbines
    • F05D2220/323—Application in turbines in gas turbines for aircraft propulsion, e.g. jet engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
    • F05D2220/36—Application in turbines specially adapted for the fan of turbofan engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/80—Repairing, retrofitting or upgrading methods
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Definitions

  • the invention relates to gas turbine composite material parts, and more particularly, but not exclusively, gas turbine housings for aeronautical engines such as fan housings.
  • the fan housing performs several functions. It defines in particular the air inlet duct in the engine, possibly supports an abradable material facing the blades of the fan and / or a sound wave absorption structure for the acoustic treatment at the engine inlet. and incorporates or supports a retention shield.
  • the housings like the fan housing, are now made of composite material, that is to say from a fiber preform densified by an organic matrix, which makes it possible to produce parts having a lower overall mass than these same parts when they are made of metallic material while having a mechanical strength at least equivalent if not greater.
  • the manufacture of a fan casing in composite material is described in particular in document US Pat. No. 8,322,971.
  • 2007/0095457 consists in sticking a fibrous patch pre-impregnated on the area
  • the patch may consist of one or more fibrous folds.
  • this type of solution presents a risk of delamination of the glued patch. It is, therefore, necessary to form additional mechanical connections between the patch and the part made of composite material, for example with members of the bolting type. The addition of such connections leads to an increase in the mass of the part and impacts the initial composite material structure of the part (making passages in the composite material part for the insertion of the connecting members). This problem also arises for the repair or resumption of manufacture of other parts made of gas turbine composite material.
  • the aim of the invention is to provide a solution for the repair or resumption of manufacture of a gas turbine part made of composite material, for example a casing, which does not have the drawbacks of the prior art.
  • a gas turbine part made of composite material comprising a fibrous reinforcement having a three-dimensional weaving between a plurality of warp yarns and a plurality of weft yarns, said fibrous reinforcement being densified by a matrix, said densified fiber reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that the fibrous reinforcement densified by the matrix comprises at at least one recessed portion extending over the entire thickness of the fibrous reinforcement and in that a filling part made of composite material is present in the free volume of the part delimited by said at least one recessed portion, the filling part comprising a fiber preform having a three-dimensional weave, said fiber preform being densified by a matrix.
  • a filling piece comprising a fiber preform exhibiting a three-dimensional weave, it is possible to carry out repairs or rework which exhibit high resistance to delamination.
  • the repair of a damaged area or the recovery of a non-compliant area in the part is therefore particularly robust while having a very limited impact on the overall mass of the part.
  • each recessed portion has at least two vis-à-vis edges each comprising first and second bevels, the filling part made of composite material comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the facing edges and a second part having a complementary geometry of the other part of the volume of the part of the recessed portion defined between the second bevels of the facing edges.
  • each vis-à-vis edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the recessed portion. . This optimizes the transmission of mechanical loads on the bonding interface between the filling part and the composite material structure of the part.
  • the first and second parts of the filling piece are linked together by weaving. This makes it possible to further strengthen the mechanical strength of the filling part.
  • the piece of the invention According to a fourth characteristic of the piece of the invention, the piece of
  • filler further comprises at least one fastener extending into said filler piece. It is thus possible to strengthen the strength of the filling part if necessary, and this without impacting the composite structure of the part since the fixing member (s) are fully integrated into the filling part.
  • the invention also relates to an aeronautical gas turbine engine having a part according to the invention, for example a fan casing, as well as an aircraft comprising one or more of these aeronautical engines.
  • a further subject of the invention is a method for repairing a part made of composite material for a gas turbine having a shape of revolution, the part comprising a fibrous reinforcement having a three-dimensional weaving between a plurality of warp yarns and a plurality of weft thread, said fibrous reinforcement being densified by a matrix, said densified fibrous reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that it comprises:
  • the production of the recessed portion comprises the formation of at least two facing edges each comprising first and second bevels, the fiber preform of the filling piece comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the opposite edges and a second part having a complementary geometry of the other part of the volume of the defined recessed portion between the second bevels of the opposite edges.
  • each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the portion. hollowed out.
  • the first and second parts of the fiber preform of the filling part are linked together by weaving.
  • the latter further comprises the integration of at least one fixing member in the filling part.
  • the invention also relates to a method of manufacturing a part made of composite material for a gas turbine, the method comprising the weaving in one piece by three-dimensional weaving of a fibrous texture in the form of a strip, the shaping of said texture by winding on a support tool so as to form a fibrous reinforcement of the part and the densification of the fibrous reinforcement by a matrix, said densified fibrous reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that it comprises:
  • the production of the hollowed-out portion comprises the formation of at least two facing edges each comprising first and second bevels, the fiber preform of the filling piece comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the opposite edges and a second part having a complementary geometry of the other part of the volume of the defined recessed portion between the second bevels of the opposite edges.
  • each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the recessed portion.
  • Figure 1 is a perspective view of an aircraft engine comprising a fan casing
  • Figure 2 is a half-view in axial section of the fan housing of the engine of Figure 1,
  • Figure 3 is a partial perspective view of the fan casing of Figure 1 showing the production of a recessed portion in the fan casing
  • Figure 4 is a radial sectional view of the recessed portion illustrated in Figure 3 along the sectional plane IV,
  • Figure 5 is a radial sectional view of the recessed portion illustrated in Figure 3 showing the placement of a fiber preform of a filler piece in the recessed portion,
  • FIG. 6 schematically illustrates a three-dimensional weaving weave of the interlock type used to make a part of the fiber preform of a filler piece
  • Figure 7 is a radial sectional view showing the presence of a filling part in the recessed portion illustrated in Figure 3,
  • Figure 8 is a radial sectional view showing the presence of a filling piece provided with a fixing member in the recessed portion illustrated in Figure 3,
  • FIG. 9 schematically illustrates a three-dimensional weaving weave of the interlock type used to make a fiber preform for a one-piece filler piece.
  • Such an engine as shown very schematically in FIG. 1 comprises, from upstream to downstream in the direction of the gas flow, a fan 1 placed at the inlet of the engine, a compressor 2, a combustion chamber 3, a high-pressure turbine 4 and a low-pressure turbine 5.
  • the engine is housed inside a housing comprising several parts
  • the fan 1 is surrounded by a fan casing 10 having a shape of revolution.
  • Figure 2 shows the profile (in axial section) of the fan casing 10 which is here made of a composite material with an organic matrix, that is to say from a reinforcement of fibers, for example of carbon, glass, aramid or ceramic, densified with a polymer matrix, for example epoxy, bismaleimide or polyimide.
  • the fibrous reinforcement is made from a fibrous texture in the form of a strip obtained by three-dimensional weaving in a single piece, the texture being shaped by winding on a support tool. The fibrous reinforcement thus formed is then densified by a matrix.
  • the manufacture of such a casing is described in particular in document US Pat. No. 8,322,971.
  • the internal surface 11 of the casing defines the air inlet duct of the engine.
  • the casing 10 made of composite material has a shape of revolution and extends in width between a downstream end 17 and an upstream end 18 in an axial direction D A and in thickness between an internal surface 11 and an outer surface 12 in a radial direction D R.
  • the casing 10 can be provided with external flanges 14, 15 at its upstream and downstream ends in order to allow its assembly and its connection with other elements. Between its upstream 17 and downstream 18 ends, the casing 10 has a variable thickness, a part 16 of the casing having a greater thickness than the end parts by gradually connecting to the latter.
  • Part 16 extends on either side of the location of the blower, upstream and downstream, in order to form a retention zone capable of retaining debris, particles or objects ingested at the inlet of the engine, or from damage to fan blades, and thrown radially by rotation of the fan, to prevent them from passing through the casing and damaging other parts of the aircraft.
  • the housing 10 has a damaged area 20 resulting, for example, from debris of a blade projected onto the internal surface 11 of the housing.
  • the housing is machined at the damaged area 20 in order to remove the affected composite material.
  • the removal of the composite material is carried out on a determined surface of the casing covering at least the area identified as damaged and over the entire thickness of the casing.
  • a recessed portion 30 which opens out both on the internal surface 11 and on the external surface 12 of the housing 10.
  • the edges 31, 32, 33 and 34 of the recessed portion each comprise respectively a first bevel like the bevels 310 and 330 illustrated in FIG. 4 respectively for the edges 31 and 33 and a second bevel like the bevels 311 and 331 illustrated in FIG. 4 respectively for the edges 31 and 33.
  • the recessed portion 30 delimits a free volume of material 35 intended to be occupied by a filling part as explained below.
  • a fiber preform of a filling piece intended to be placed in the volume delimited by the recessed portion 30 is produced by three-dimensional weaving.
  • a fiber preform for a filling piece 40 is composed of a first part 41 and a second part 42.
  • the three-dimensional weaving of the fiber preform of the filling piece can be carried out with an interlock type weave with several layers of warp threads and weft threads.
  • FIG. 6 shows an example of interlock weaves for the first part 41 of the fiber preform of the filling piece 40.
  • the weft threads are in section.
  • a three-dimensional weaving with interlock weave is a weaving in which each warp thread connects several layers of weft threads together, the paths of the warp threads being identical.
  • a gradual increase / decrease in thickness is obtained by adding / removing one or more layers of warp and weft yarns.
  • the second part 42 of the fiber preform of the filling piece 40 can be made with the same weaving weave.
  • Other three-dimensional weaving modes can be envisaged, such as, for example, multi-layer weaves with multi-satin or multi-canvas weaves. Armors of this type are described in document US 2010/0144227.
  • the fibrous filling part preform is preferably woven with fibers of the same type as those used to produce the fibrous reinforcement of the casing.
  • the fiber preform of the filling piece 40 is placed in the free volume 35 delimited by the recessed portion 30.
  • the first and second parts 41 and 42 of the fiber preform 40 each have a geometry adapted to the part of the free volume 35 to be filled. More precisely, in the example described here and as illustrated in FIG. 5, the first part 41 has a geometry complementary to the part of the free volume 35 of the recessed portion defined between the first bevels of the edges facing each other. screw (first bevels 310 and 330 of the edges 31 and 33 illustrated in Figure 5) while the second part 42 has a geometry complementary to the other part of the free volume 35 of the recessed portion 30 defined between the second bevels of the edges in vis-à-vis (second bevels 311 and 331 of the edges 31 and 33 illustrated in Figure 5).
  • Each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the housing at the level of the recessed portion.
  • the edges 31 and 33 each extend respectively over a length L31 and L33 which is equal to at least ten times the value of the thickness E 10 of the housing 10 at the level of the recessed portion 30. This makes it possible to optimize the transmission of mechanical loads on the bonding interface between the filling part and the composite material structure of the casing.
  • the fiber fill preform 40 is impregnated with a matrix precursor resin.
  • the impregnation of the preform 40 can be carried out before or after the placement of the fiber preform of the filling piece 40 in the recessed portion 30.
  • the resin is preferably chosen so as to correspond to a matrix precursor of the same type as the resin. matrix with which the fibrous reinforcement of the casing is densified.
  • the resin is then transformed into a matrix, for example by heat treatment, in order to obtain, as shown in FIG. 7, a part of filling in composite material 50 comprising a 3D woven fiber preform densified by a matrix, the filling part 50 occupying the free volume defined by the recessed portion.
  • the filling piece made of composite material 50 comprises a first part 51 having a geometry complementary to part of the volume of the recessed portion defined between the first bevels 310 and 330 of the facing edges 31 and 33 and a second part 52 with geometry
  • the filling part 50 integrates completely into the structure of the housing.
  • a bonding agent can further be deposited on the bonding interface between the filling piece and the edges of the recessed portion in order to strengthen the bonding interface.
  • the mechanical strength of the part can be reinforced by the integration of one or more fixing members in the filling part, such as for example the member 60 shown in FIG. 8 which comprises a screw 61 passing through the filling part 50 and a clamping nut 62 cooperating with the free end of the screw 61.
  • the fixing member (s) have no impact on the structure of the casing because they are not in contact with it but only with the filling piece.
  • the first and second parts of the fiber preform of the filling piece can be linked together by weaving.
  • FIG. 9 shows an example of interlock weaves of a fiber preform for a filling piece 70 in which the first and second parts 71 and 72 are linked together by weaving.
  • the weft threads are in section.
  • the deformability of the fiber preform 70 is used to insert it into the free volume defined by the recessed portion.
  • the invention also applies to the rework or retouching of the manufacture of a housing made of composite material.
  • the production of a casing in composite material begins with the formation of a fibrous texture in the form of a strip obtained by three-dimensional weaving such as for example a weaving with an "interlock" weave or a weaving according to one of the weaves described. in document US 2010/0144227.
  • the fibrous structure can in particular be woven from son of carbon fibers, ceramic such as silicon carbide, glass or aramid.
  • the fibrous reinforcement of the casing is formed by winding on a mandrel of the fibrous texture, the mandrel having a profile corresponding to that of the casing to be produced.
  • the fibrous reinforcement constitutes a complete tubular fibrous preform of the casing forming a single piece.
  • the mandrel has an external surface whose profile corresponds to the internal surface of the casing to be produced and two flanges to form parts of the fiber preform corresponding to the flanges of the casing.
  • the fibrous reinforcement is then densified with a matrix.
  • the densification of the fibrous reinforcement consists in filling the porosity of the reinforcement, in all or part of the volume thereof, with the material constituting the matrix.
  • the matrix can be obtained in a manner known per se using the liquid process.
  • the liquid process consists in impregnating the fibrous reinforcement with a
  • liquid composition containing an organic precursor of the matrix material.
  • the organic precursor is usually in the form of a polymer, such as a resin, optionally diluted in a solvent.
  • the fiber reinforcement is placed in a sealable mold with a housing in the shape of the final molded part. Then, the liquid matrix precursor, for example a resin, is injected into the entire housing to impregnate the entire fibrous part of the reinforcement.
  • the transformation of the precursor into an organic matrix is carried out by heat treatment, generally by heating the mold, after removal of any solvent and crosslinking of the polymer, the reinforcement still being kept in the mold having a shape corresponding to that of the part to be produced.
  • the organic matrix can in particular be obtained from epoxy resins, such as, for example, the high performance epoxy resin sold, or from liquid precursors of carbon or ceramic matrices.
  • the heat treatment consists in pyrolyzing the organic precursor to transform the organic matrix into a carbon or ceramic matrix depending on the precursor used and the pyrolysis conditions.
  • liquid carbon precursors can be resins with a relatively high coke content, such as phenolic resins
  • liquid ceramic precursors, especially of SiC can be polycarbosilane (PCS) type resins. or polytitanocarbosilane (PTCS) or polysilazane (PSZ).
  • PCS polycarbosilane
  • PTCS polytitanocarbosilane
  • PSZ polysilazane
  • Densification of the fibrous reinforcement can be carried out by the well-known transfer molding process called RTM (“Resin Transfer Molding”).
  • RTM Resin Transfer Molding
  • the fibrous reinforcement is placed in a mold having the shape of the casing to be produced.
  • a thermosetting resin is injected into the internal space delimited between the piece of rigid material and the mold and which includes the fibrous reinforcement.
  • a pressure gradient is generally established in this internal space between the place where the resin is injected and the discharge orifices of the latter in order to control and optimize the impregnation of the reinforcement by the resin.
  • the resin used can be, for example, an epoxy resin.
  • Resins suitable for RTM processes are well known. They preferably have a low viscosity to facilitate their injection into the fibers. The choice of the temperature class and / or the chemical nature of the resin is determined according to the thermomechanical stresses to which the part must be subjected. Once the resin has been injected into all the reinforcement, it is polymerized by heat treatment in accordance with the RTM process.
  • the part After injection and polymerization, the part is demolded. In the end, the part is trimmed to remove the excess resin and the chamfers are machined to obtain a housing made of composite material like the housing 10 illustrated in Figures 1 and 2.
  • the casing may have defects such as, for example, one or more so-called “dry” areas corresponding to parts of the casing where the fibrous reinforcement is devoid of a matrix or does not contain sufficient matrix.
  • the method of manufacturing a casing made of composite material according to the invention further comprises the following steps:
  • the removal of the composite material is carried out on a determined surface of the casing covering at least the non-conforming zone and over the entire thickness of the casing.
  • a recessed portion is thus obtained which opens out both on the internal surface and on the external surface of the casing, like the recessed portion 30 illustrated in FIGS. 3 and 4, the edges of which each comprise respectively first and second bevels.
  • the recessed portion defines a free volume of material intended to be occupied by a filling part as explained below.
  • the fiber preform of the filling piece is obtained by weaving
  • three-dimensional and can be formed of two distinct parts like the first and second parts 41 and 42 of the fiber preform of the filling part 40 illustrated in FIG. 5, or of two parts linked together by weaving like the first and second parts 71 and 72 of the workpiece fiber preform
  • the fibrous filling part preform is preferably woven with fibers of the same type as those used to produce the fibrous reinforcement of the casing.
  • the first and second parts of the fiber preform of the filling part each have a geometry adapted to the part of the free volume defined by the recessed portion to be filled as already described above. Once the fiber preform of the filler piece has been produced, it is placed in the free volume delimited by the recessed portion.
  • the fiber fill preform is impregnated with a matrix precursor resin.
  • the impregnation of the preform can be carried out before or after the placement of the fiber preform of the filler piece in the recessed portion.
  • the resin is preferably chosen so as to correspond to a matrix precursor of the same nature as the matrix with which the fibrous reinforcement of the casing is densified.
  • the resin is then transformed into a matrix, for example by heat treatment, in order to obtain a filling part made of composite material comprising a 3D woven fiber preform densified by a matrix such as the filling part made of composite material 50 shown. in FIG. 7, the filling part occupying the free volume defined by the recessed portion.
  • the mechanical strength of the part can be reinforced by the integration of one or more fixing members in the filling part, such as for example the member 60 shown in FIG. 8 which comprises a screw 61 passing through the filling part 50 and a clamping nut 62 cooperating with the free end of the screw 61.
  • the fixing member (s) have no impact on the structure of the casing because they are not in contact with it but only with the filling piece.

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Abstract

A gas turbine component (10) made of composite material comprises a fibrous reinforcement exhibiting a three-dimensional weave between a plurality of warp threads and a plurality of weft threads, the fibrous reinforcement being densified by a matrix. The densified fibrous reinforcement extends in width between a downstream end and an upstream end in an axial direction and in thickness between an inner surface (11) and an outer surface (12) in a radial direction. The fibrous reinforcement densified by the matrix comprises a recessed portion extending over the entire thickness of the fibrous reinforcement. A filling part made of composite material (50) is present in the free volume of the component defined by the recessed portion, the filling part (50) comprising a fibrous preform exhibiting a three-dimensional weave, the fibrous preform being densified by a matrix.

Description

Description Description
Titre de l'invention : Réparation ou reprise de fabrication d'une pièce en matériau composite Title of the invention: Repair or resumption of manufacture of a composite material part
Domaine Technique Technical area
L'invention concerne les pièces en matériau composite de turbine à gaz, et plus particulièrement, mais non exclusivement, les carters de turbine à gaz pour moteurs aéronautiques comme les carters de soufflante. The invention relates to gas turbine composite material parts, and more particularly, but not exclusively, gas turbine housings for aeronautical engines such as fan housings.
Technique antérieure Prior art
Dans un moteur aéronautique à turbine à gaz, le carter de soufflante remplit plusieurs fonctions. Il définit notamment la veine d'entrée d'air dans le moteur, supporte éventuellement un matériau abradable en regard des sommets d'aubes de la soufflante et/ou une structure d'absorption d'ondes sonores pour le traitement acoustique en entrée du moteur et incorpore ou supporte un bouclier de rétention. In an aeronautical gas turbine engine, the fan housing performs several functions. It defines in particular the air inlet duct in the engine, possibly supports an abradable material facing the blades of the fan and / or a sound wave absorption structure for the acoustic treatment at the engine inlet. and incorporates or supports a retention shield.
Précédemment réalisés en matériau métallique, les carters, comme le carter de soufflante, sont maintenant réalisés en matériau composite, c’est-à-dire à partir d’une préforme fibreuse densifiée par une matrice organique, ce qui permet de réaliser des pièces ayant une masse globale moins élevée que ces mêmes pièces lorsqu'elles sont réalisées en matériau métallique tout en présentant une résistance mécanique au moins équivalente sinon supérieure. La fabrication d’un carter de soufflante en matériau composite est notamment décrite dans le document US 8 322 971. Previously made of metallic material, the housings, like the fan housing, are now made of composite material, that is to say from a fiber preform densified by an organic matrix, which makes it possible to produce parts having a lower overall mass than these same parts when they are made of metallic material while having a mechanical strength at least equivalent if not greater. The manufacture of a fan casing in composite material is described in particular in document US Pat. No. 8,322,971.
Si l’utilisation de carters en matériau composite permet de réduire la masse globale du moteur, sa réparation en cas d’endommagement ou la reprise locale de certaines zones non conformes dans le matériau composite du carter peut être problématique. En effet, une solution existante, comme celle décrite dans le document US While the use of composite material housings reduces the overall mass of the engine, repairing it in the event of damage or local reworking of certain non-compliant areas in the composite housing material can be problematic. Indeed, an existing solution, such as that described in the document US
2007/0095457, consiste à coller un patch fibreux pré-imprégné sur la zone 2007/0095457, consists in sticking a fibrous patch pre-impregnated on the area
endommagée ou la zone à reprendre de la pièce en matériau composite, le patch pouvant être constitué d’un ou plusieurs plis fibreux. Toutefois, ce type de solution présente un risque de délaminage du patch collé. Il est, par conséquent, nécessaire de former des liaisons mécaniques supplémentaires entre le patch et la pièce en matériau composite par exemple avec des organes de type boulonnerie. L’ajout de telles liaisons entraîne une augmentation de la masse de la pièce et impacte la structure en matériau composite initiale de la pièce (réalisation de passages dans la pièce en matériau composite pour l’insertion des organes de liaison). Ce problème se pose également pour la réparation ou la reprise de fabrication d’autres pièces en matériau composite de turbine à gaz. damaged or the area to be recovered from the composite material part, the patch may consist of one or more fibrous folds. However, this type of solution presents a risk of delamination of the glued patch. It is, therefore, necessary to form additional mechanical connections between the patch and the part made of composite material, for example with members of the bolting type. The addition of such connections leads to an increase in the mass of the part and impacts the initial composite material structure of the part (making passages in the composite material part for the insertion of the connecting members). This problem also arises for the repair or resumption of manufacture of other parts made of gas turbine composite material.
Exposé de l’invention Disclosure of the invention
L’invention a pour but de proposer une solution pour la réparation ou la reprise de fabrication d’une pièce de turbine à gaz en matériau composite, par exemple un carter, ne présentant pas les inconvénients de l’art antérieur. The aim of the invention is to provide a solution for the repair or resumption of manufacture of a gas turbine part made of composite material, for example a casing, which does not have the drawbacks of the prior art.
Ce but est atteint grâce à une pièce de turbine à gaz en matériau composite, la pièce comprenant un renfort fibreux présentant un tissage tridimensionnel entre une pluralité de fils de chaîne et une pluralité de fils de trame, ledit renfort fibreux étant densifié par une matrice, ledit renfort fibreux densifié s’étendant en largeur entre une extrémité aval et une extrémité amont suivant une direction axiale et en épaisseur entre une surface interne et une surface externe suivant une direction radiale, caractérisé en ce que le renfort fibreux densifié par la matrice comporte au moins une portion évidée s’étendant sur toute l’épaisseur du renfort fibreux et en ce qu’une pièce de comblement en matériau composite est présente dans le volume libre de la pièce délimité par ladite au moins une portion évidée, la pièce de comblement comprenant une préforme fibreuse présentant un tissage tridimensionnel, ladite préforme fibreuse étant densifiée par une matrice. This goal is achieved by means of a gas turbine part made of composite material, the part comprising a fibrous reinforcement having a three-dimensional weaving between a plurality of warp yarns and a plurality of weft yarns, said fibrous reinforcement being densified by a matrix, said densified fiber reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that the fibrous reinforcement densified by the matrix comprises at at least one recessed portion extending over the entire thickness of the fibrous reinforcement and in that a filling part made of composite material is present in the free volume of the part delimited by said at least one recessed portion, the filling part comprising a fiber preform having a three-dimensional weave, said fiber preform being densified by a matrix.
En utilisant une pièce de comblement comprenant une préforme fibreuse présentant un tissage tridimensionnel, il est possible de réaliser des réparations ou des reprises de fabrication qui présentent une grande résistance à la délamination. La réparation d’une zone endommagée ou la reprise d’une zone non conforme dans la pièce est donc particulièrement robuste tout en ayant un impact très limité sur la masse globale de la pièce. By using a filling piece comprising a fiber preform exhibiting a three-dimensional weave, it is possible to carry out repairs or rework which exhibit high resistance to delamination. The repair of a damaged area or the recovery of a non-compliant area in the part is therefore particularly robust while having a very limited impact on the overall mass of the part.
Selon une première caractéristique de la pièce de l’invention, chaque portion évidée comporte au moins deux bords en vis-à-vis comprenant chacun des premier et deuxième biseaux, la pièce de comblement en matériau composite comprenant une première partie présentant une géométrie complémentaire d’une partie du volume de la portion évidée définie entre les premiers biseaux des bords en vis-à-vis et une deuxième partie présentant une géométrie complémentaire de l’autre partie du volume de la partie de la portion évidée définie entre les deuxièmes biseaux des bords en vis-à-vis. On optimise ainsi l’intégration et la tenue mécanique de la pièce de comblement dans la portion évidée. According to a first characteristic of the part of the invention, each recessed portion has at least two vis-à-vis edges each comprising first and second bevels, the filling part made of composite material comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the facing edges and a second part having a complementary geometry of the other part of the volume of the part of the recessed portion defined between the second bevels of the facing edges. This optimizes the integration and the mechanical strength of the filling part in the hollow portion.
Selon une deuxième caractéristique de la pièce de l’invention, chaque bord en vis-à- vis comprenant des premier et deuxième biseaux s’étend sur une longueur correspondant à au moins dix fois l’épaisseur de la pièce au niveau de la portion évidée. Cela permet d’optimiser la transmission des charges mécaniques sur l’interface de collage entre la pièce de comblement et la structure en matériau composite de la pièce. According to a second characteristic of the part of the invention, each vis-à-vis edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the recessed portion. . This optimizes the transmission of mechanical loads on the bonding interface between the filling part and the composite material structure of the part.
Selon une troisième caractéristique de la pièce de l’invention, les première et deuxième parties de la pièce de comblement sont liées entre elles par tissage. Cela permet de renforcer encore la tenue mécanique de la pièce de comblement. According to a third characteristic of the piece of the invention, the first and second parts of the filling piece are linked together by weaving. This makes it possible to further strengthen the mechanical strength of the filling part.
Selon une quatrième caractéristique de la pièce de l’invention, la pièce de According to a fourth characteristic of the piece of the invention, the piece of
comblement comprend en outre au moins un organe de fixation s’étendant dans ladite pièce de comblement. Il est ainsi possible de renforcer la tenue de la pièce de comblement si nécessaire, et ce sans impact sur la structure en composite de la pièce puisque que le ou les organes de fixation sont entièrement intégrés à la pièce de comblement. filler further comprises at least one fastener extending into said filler piece. It is thus possible to strengthen the strength of the filling part if necessary, and this without impacting the composite structure of the part since the fixing member (s) are fully integrated into the filling part.
L’invention a également pour objet un moteur aéronautique à turbine à gaz ayant une pièce selon l’invention, par exemple un carter de soufflante, ainsi qu’un aéronef comprenant un ou plusieurs de ces moteurs aéronautiques. The invention also relates to an aeronautical gas turbine engine having a part according to the invention, for example a fan casing, as well as an aircraft comprising one or more of these aeronautical engines.
L’invention a encore pour objet un procédé de réparation d'une pièce en matériau composite pour une turbine à gaz présentant une forme de révolution, la pièce comprenant un renfort fibreux présentant un tissage tridimensionnel entre une pluralité de fils de chaîne et une pluralité de file de trame, ledit renfort fibreux étant densifié par une matrice, ledit renfort fibreux densifié s’étendant en largeur entre une extrémité aval et une extrémité amont suivant une direction axiale et en épaisseur entre une surface interne et une surface externe suivant une direction radiale, caractérisé en ce qu’il comprend : A further subject of the invention is a method for repairing a part made of composite material for a gas turbine having a shape of revolution, the part comprising a fibrous reinforcement having a three-dimensional weaving between a plurality of warp yarns and a plurality of weft thread, said fibrous reinforcement being densified by a matrix, said densified fibrous reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that it comprises:
- l’identification d’au moins une zone endommagée dans la pièce, - the identification of at least one damaged area in the room,
- la réalisation d’une portion évidée par retrait du matériau composite au niveau de la zone endommagée de manière à former une portion évidée s’étendant sur toute l’épaisseur du renfort fibreux, - the production of a recessed portion by removing the composite material from the damaged area so as to form a recessed portion extending over the entire thickness of the fiber reinforcement,
- le tissage tridimensionnel d’une préforme fibreuse de pièce de comblement, - the three-dimensional weaving of a fiber preform of a filling piece,
- le placement de la préforme fibreuse de pièce de comblement dans le volume libre de la pièce délimité par la portion évidée, - the placement of the fiber preform of the filling part in the free volume of the part delimited by the recessed portion,
- l’imprégnation, avant ou après le placement de la préforme fibreuse de pièce de comblement dans la portion évidée, de ladite préforme avec une résine précurseur d’une matrice, - the impregnation, before or after the placement of the fiber preform of the filler piece in the hollowed out portion, of said preform with a precursor resin of a matrix,
- la polymérisation de la résine en matrice afin d’obtenir une pièce de comblement en matériau composite comprenant une préforme fibreuse tissée 3D, ladite pièce de comblement occupant le volume défini par la portion évidée. - Polymerization of the matrix resin to obtain a composite material filling piece comprising a 3D woven fiber preform, said filling piece occupying the volume defined by the recessed portion.
Selon une première caractéristique du procédé de réparation de l’invention, la réalisation de la portion évidée comprend la formation d’au moins deux bords en vis- à-vis comprenant chacun des premier et deuxième biseaux, la préforme fibreuse de pièce de comblement comprenant une première partie présentant une géométrie complémentaire d’une partie du volume de la portion évidée définie entre les premiers biseaux des bords en vis-à-vis et une deuxième partie présentant une géométrie complémentaire de l’autre partie du volume de la portion évidée définie entre les deuxièmes biseaux des bords en vis-à-vis. According to a first characteristic of the repair method of the invention, the production of the recessed portion comprises the formation of at least two facing edges each comprising first and second bevels, the fiber preform of the filling piece comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the opposite edges and a second part having a complementary geometry of the other part of the volume of the defined recessed portion between the second bevels of the opposite edges.
Selon une deuxième caractéristique du procédé de réparation de l’invention, chaque bord en vis-à-vis comprenant des premier et deuxième biseaux s’étend sur une longueur correspondant à au moins dix fois l’épaisseur de la pièce au niveau de la portion évidée. According to a second characteristic of the repair method of the invention, each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the portion. hollowed out.
Selon une troisième caractéristique du procédé de réparation de l’invention, les première et deuxième parties de la préforme fibreuse de pièce de comblement sont liées entre elles par tissage. According to a third characteristic of the repair process of the invention, the first and second parts of the fiber preform of the filling part are linked together by weaving.
Selon une quatrième caractéristique du procédé de réparation de l’invention, celui-ci comprend en outre l’intégration d’au moins un organe de fixation dans la pièce de comblement. L’invention concerne aussi un procédé de fabrication d’une pièce en matériau composite pour une turbine à gaz, le procédé comprenant le tissage en une seule pièce par tissage tridimensionnel d’une texture fibreuse en forme de bande, la mise en forme de ladite texture par enroulement sur un outillage de support de manière à former un renfort fibreux de la pièce et la densification du renfort fibreux par une matrice, ledit renfort fibreux densifié s’étendant en largeur entre une extrémité aval et une extrémité amont suivant une direction axiale et en épaisseur entre une surface interne et une surface externe suivant une direction radiale, caractérisé en ce qu’il comprend : According to a fourth characteristic of the repair method of the invention, the latter further comprises the integration of at least one fixing member in the filling part. The invention also relates to a method of manufacturing a part made of composite material for a gas turbine, the method comprising the weaving in one piece by three-dimensional weaving of a fibrous texture in the form of a strip, the shaping of said texture by winding on a support tool so as to form a fibrous reinforcement of the part and the densification of the fibrous reinforcement by a matrix, said densified fibrous reinforcement extending in width between a downstream end and an upstream end in an axial direction and in thickness between an internal surface and an external surface in a radial direction, characterized in that it comprises:
- l’identification d’au moins une zone non conforme dans la pièce, - the identification of at least one non-compliant area in the room,
- la réalisation d’une portion évidée par retrait du matériau composite au niveau de la zone non conforme de manière à former une portion évidée s’étendant sur toute l’épaisseur du renfort fibreux, - the production of a hollowed-out portion by removing the composite material from the non-conforming zone so as to form a hollowed-out portion extending over the entire thickness of the fiber reinforcement,
- le tissage tridimensionnel d’une préforme fibreuse de pièce de comblement, - the three-dimensional weaving of a fiber preform of a filling piece,
- le placement de la préforme fibreuse de pièce de comblement dans le volume libre de la pièce délimité par la portion évidée, - the placement of the fiber preform of the filling part in the free volume of the part delimited by the recessed portion,
- l’imprégnation, avant ou après le placement de la préforme fibreuse de pièce de comblement dans la portion évidée, de ladite préforme avec une résine précurseur d’une matrice, - the impregnation, before or after the placement of the fiber preform of the filler piece in the hollowed out portion, of said preform with a precursor resin of a matrix,
- la polymérisation de la résine en matrice afin d’obtenir une pièce de comblement en matériau composite comprenant une préforme fibreuse tissée 3D, ladite pièce de comblement occupant le volume défini par la portion évidée. - Polymerization of the matrix resin to obtain a composite material filling piece comprising a 3D woven fiber preform, said filling piece occupying the volume defined by the recessed portion.
Selon une première caractéristique du procédé de fabrication de l’invention, la réalisation de la portion évidée comprend la formation d’au moins deux bords en vis- à-vis comprenant chacun des premier et deuxième biseaux, la préforme fibreuse de pièce de comblement comprenant une première partie présentant une géométrie complémentaire d’une partie du volume de la portion évidée définie entre les premiers biseaux des bords en vis-à-vis et une deuxième partie présentant une géométrie complémentaire de l’autre partie du volume de la portion évidée définie entre les deuxièmes biseaux des bords en vis-à-vis. According to a first characteristic of the manufacturing method of the invention, the production of the hollowed-out portion comprises the formation of at least two facing edges each comprising first and second bevels, the fiber preform of the filling piece comprising a first part having a complementary geometry of part of the volume of the recessed portion defined between the first bevels of the opposite edges and a second part having a complementary geometry of the other part of the volume of the defined recessed portion between the second bevels of the opposite edges.
Selon une deuxième caractéristique du procédé de fabrication de l’invention, chaque bord en vis-à-vis comprenant des premier et deuxième biseaux s’étend sur une longueur correspondant à au moins dix fois l’épaisseur de la pièce au niveau de la portion évidée. According to a second characteristic of the manufacturing method of the invention, each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the part at the level of the recessed portion.
Brève description des dessins Brief description of the drawings
[Fig. 1] La figure 1 est une vue en perspective d’un moteur aéronautique comprenant un carter de soufflante, [Fig. 1] Figure 1 is a perspective view of an aircraft engine comprising a fan casing,
[Fig. 2] La figure 2 est une demi-vue vue en coupe axiale du carter de soufflante du moteur de la figure 1 , [Fig. 2] Figure 2 is a half-view in axial section of the fan housing of the engine of Figure 1,
[Fig. 3] La figure 3 est vue partielle en perspective du carter de soufflante de la figure 1 montrant la réalisation d’une portion évidée dans la carter de soufflante [Fig. 3] Figure 3 is a partial perspective view of the fan casing of Figure 1 showing the production of a recessed portion in the fan casing
conformément à un mode de réalisation de l’invention, in accordance with one embodiment of the invention,
[Fig. 4] La figure 4 est une vue en coupe radiale de la portion évidée illustrée sur la figure 3 suivant le plan de coupe IV, [Fig. 4] Figure 4 is a radial sectional view of the recessed portion illustrated in Figure 3 along the sectional plane IV,
[Fig. 5] La figure 5 est une vue en coupe radiale de la portion évidée illustrée sur la figure 3 montrant le placement d’une préforme fibreuse de pièce de comblement dans la portion évidée, [Fig. 5] Figure 5 is a radial sectional view of the recessed portion illustrated in Figure 3 showing the placement of a fiber preform of a filler piece in the recessed portion,
[Fig. 6] La figure 6 illustre schématiquement une armure de tissage tridimensionnel de type interlock utilisée pour réaliser une partie de préforme fibreuse de pièce de comblement, [Fig. 6] FIG. 6 schematically illustrates a three-dimensional weaving weave of the interlock type used to make a part of the fiber preform of a filler piece,
[Fig. 7] La figure 7 est une vue en coupe radiale montrant la présence d’une pièce de comblement dans la portion évidée illustrée sur la figure 3, [Fig. 7] Figure 7 is a radial sectional view showing the presence of a filling part in the recessed portion illustrated in Figure 3,
[Fig. 8] La figure 8 est une vue en coupe radiale montrant la présence d’une pièce de comblement munie d’un organe de fixation dans la portion évidée illustrée sur la figure 3, [Fig. 8] Figure 8 is a radial sectional view showing the presence of a filling piece provided with a fixing member in the recessed portion illustrated in Figure 3,
[Fig. 9] illustre schématiquement une armure de tissage tridimensionnel de type interlock utilisée pour réaliser une préforme fibreuse de pièce de comblement en une seule pièce. [Fig. 9] schematically illustrates a three-dimensional weaving weave of the interlock type used to make a fiber preform for a one-piece filler piece.
Description des modes de réalisation L'invention s'applique d'une manière générale à toute pièce en matériau composite à matrice organique de turbine à gaz. Description of embodiments The invention applies generally to any part made of composite material with an organic matrix of a gas turbine.
L'invention sera décrite ci-après dans le cadre de son application à un carter de soufflante de moteur aéronautique à turbine à gaz. The invention will be described below in the context of its application to a fan casing of a gas turbine aeronautical engine.
Un tel moteur, comme montré très schématiquement par la figure 1 comprend, de l'amont vers l'aval dans le sens de l'écoulement de flux gazeux, une soufflante 1 disposée en entrée du moteur, un compresseur 2, une chambre de combustion 3, une turbine haute-pression 4 et une turbine basse pression 5. Such an engine, as shown very schematically in FIG. 1 comprises, from upstream to downstream in the direction of the gas flow, a fan 1 placed at the inlet of the engine, a compressor 2, a combustion chamber 3, a high-pressure turbine 4 and a low-pressure turbine 5.
Le moteur est logé à l'intérieur d'un carter comprenant plusieurs parties The engine is housed inside a housing comprising several parts
correspondant à différents éléments du moteur. Ainsi, la soufflante 1 est entourée par un carter de soufflante 10 présentant une forme de révolution. corresponding to different parts of the engine. Thus, the fan 1 is surrounded by a fan casing 10 having a shape of revolution.
La figure 2 montre le profil (en coupe axiale) du carter de soufflante 10 qui est ici réalisé en matériau composite à matrice organique, c’est-à-dire à partir d’un renfort en fibres par exemple de carbone, verre, aramide ou céramique, densifié par une matrice en polymère, par exemple époxide, bismaléimide ou polyimide. Le renfort fibreux est réalisé à partir d’une texture fibreuse en forme de bande obtenue par tissage tridimensionnel en une seule pièce, la texture étant mise en forme par enroulement sur un outillage de support. Le renfort fibreux ainsi constitué est ensuite densifié par une matrice. La fabrication d’un tel carter est notamment décrite dans le document US 8 322 971. La surface interne 11 du carter définit la veine d’entrée d’air du moteur. Figure 2 shows the profile (in axial section) of the fan casing 10 which is here made of a composite material with an organic matrix, that is to say from a reinforcement of fibers, for example of carbon, glass, aramid or ceramic, densified with a polymer matrix, for example epoxy, bismaleimide or polyimide. The fibrous reinforcement is made from a fibrous texture in the form of a strip obtained by three-dimensional weaving in a single piece, the texture being shaped by winding on a support tool. The fibrous reinforcement thus formed is then densified by a matrix. The manufacture of such a casing is described in particular in document US Pat. No. 8,322,971. The internal surface 11 of the casing defines the air inlet duct of the engine.
Le carter 10 en matériau composite (renfort fibreux densifié par une matrice) présente une forme de révolution et s’étend en largeur entre une extrémité aval 17 et une extrémité amont 18 suivant une direction axiale DA et en épaisseur entre une surface interne 11 et une surface externe 12 suivant une direction radiale DR. Le carter 10 peut être muni de brides externes 14, 15 à ses extrémités amont et aval afin de permettre son montage et sa liaison avec d'autres éléments. Entre ses extrémités amont 17 et aval 18, le carter 10 présente une épaisseur variable, une partie 16 du carter ayant une plus forte épaisseur que les parties d'extrémité en se raccordant progressivement à celle-ci. La partie 16 s'étend de part et d'autre de l'emplacement de la soufflante, vers l'amont et l'aval, afin de former une zone de rétention capable de retenir des débris, particules ou objets ingérés en entrée du moteur, ou provenant de l'endommagement d'aubes de la soufflante, et projetés radialement par rotation de la soufflante, pour éviter qu'ils traversent le carter et endommagent d'autres parties de l'aéronef. The casing 10 made of composite material (fiber reinforcement densified by a matrix) has a shape of revolution and extends in width between a downstream end 17 and an upstream end 18 in an axial direction D A and in thickness between an internal surface 11 and an outer surface 12 in a radial direction D R. The casing 10 can be provided with external flanges 14, 15 at its upstream and downstream ends in order to allow its assembly and its connection with other elements. Between its upstream 17 and downstream 18 ends, the casing 10 has a variable thickness, a part 16 of the casing having a greater thickness than the end parts by gradually connecting to the latter. Part 16 extends on either side of the location of the blower, upstream and downstream, in order to form a retention zone capable of retaining debris, particles or objects ingested at the inlet of the engine, or from damage to fan blades, and thrown radially by rotation of the fan, to prevent them from passing through the casing and damaging other parts of the aircraft.
Sur la figure 1 , le carter 10 présente une zone endommagée 20 résultant par exemple d’un débris d’aube projetée sur la surface interne 11 du carter. In Figure 1, the housing 10 has a damaged area 20 resulting, for example, from debris of a blade projected onto the internal surface 11 of the housing.
Conformément au procédé de réparation de l’invention, on usine le carter au niveau de la zone endommagée 20 afin de retirer le matériau composite touché. Le retrait du matériau composite est réalisé sur une surface déterminée du carter couvrant au moins la zone identifiée comme endommagée et sur toute l’épaisseur du carter. On obtient ainsi, comme illustrée sur les figures 3 et 4, une portion évidée 30 qui débouche à la fois sur la surface interne 11 et sur la surface externe 12 du carter 10. Dans l’exemple décrit ici et selon une caractéristique particulière de l’invention, les bords 31 , 32, 33 et 34 de la portion évidée comportent chacun respectivement un premier biseau comme les biseaux 310 et 330 illustrés sur la figure 4 respectivement pour les bords 31 et 33 et un deuxième biseau comme les biseaux 311 et 331 illustrés sur la figure 4 respectivement pour les bords 31 et 33. La portion évidée 30 délimite un volume libre de matière 35 destinée à être occupé par une pièce de comblement comme expliqué ci-après. In accordance with the repair process of the invention, the housing is machined at the damaged area 20 in order to remove the affected composite material. The removal of the composite material is carried out on a determined surface of the casing covering at least the area identified as damaged and over the entire thickness of the casing. There is thus obtained, as illustrated in FIGS. 3 and 4, a recessed portion 30 which opens out both on the internal surface 11 and on the external surface 12 of the housing 10. In the example described here and according to a particular characteristic of the housing. 'invention, the edges 31, 32, 33 and 34 of the recessed portion each comprise respectively a first bevel like the bevels 310 and 330 illustrated in FIG. 4 respectively for the edges 31 and 33 and a second bevel like the bevels 311 and 331 illustrated in FIG. 4 respectively for the edges 31 and 33. The recessed portion 30 delimits a free volume of material 35 intended to be occupied by a filling part as explained below.
Toujours conformément au procédé de réparation de l’invention, on réalise par tissage tridimensionnel une préforme fibreuse de pièce de comblement destinée à être placée dans le volume délimité par la portion évidée 30. Dans l’exemple décrit ici et comme illustrée sur la figure 5, une préforme fibreuse de pièce de comblement 40 est composée d’une première partie 41 et d’une deuxième partie 42. Still in accordance with the repair method of the invention, a fiber preform of a filling piece intended to be placed in the volume delimited by the recessed portion 30 is produced by three-dimensional weaving. In the example described here and as illustrated in FIG. 5 , a fiber preform for a filling piece 40 is composed of a first part 41 and a second part 42.
Le tissage tridimensionnel de la préforme fibreuse de pièce de comblement peut être réalisé avec une armure de type interlock à plusieurs couches de fils de chaîne et de fils de trame. La figure 6 montre un exemple d'armures interlock pour la première partie 41 de la préforme fibreuse de pièce de comblement 40. Sur la figure 6, les fils de trame sont en coupe. Un tissage tridimensionnel avec armure interlock est un tissage dans lequel chaque fil de chaîne relie entre elles plusieurs couches de fils de trame, les trajets des fils de chaîne étant identiques. Une augmentation/diminution progressive d'épaisseur est obtenue par ajout/retrait d'une ou plusieurs couches de fils de chaîne et de trame. La deuxième partie 42 de la préforme fibreuse de pièce de comblement 40 peut être réalisée avec la même armure de tissage. D'autres modes de tissage tridimensionnel sont envisageables tel que par exemple des tissages multicouches à armures multi-satin ou multi-toile. Des armures de ce type sont décrites dans le document US 2010/0144227. The three-dimensional weaving of the fiber preform of the filling piece can be carried out with an interlock type weave with several layers of warp threads and weft threads. FIG. 6 shows an example of interlock weaves for the first part 41 of the fiber preform of the filling piece 40. In FIG. 6, the weft threads are in section. A three-dimensional weaving with interlock weave is a weaving in which each warp thread connects several layers of weft threads together, the paths of the warp threads being identical. A gradual increase / decrease in thickness is obtained by adding / removing one or more layers of warp and weft yarns. The second part 42 of the fiber preform of the filling piece 40 can be made with the same weaving weave. Other three-dimensional weaving modes can be envisaged, such as, for example, multi-layer weaves with multi-satin or multi-canvas weaves. Armors of this type are described in document US 2010/0144227.
La préforme fibreuse de pièce de comblement est tissée de préférence avec des fibres de même nature que celles utilisées pour réaliser le renfort fibreux du carter. The fibrous filling part preform is preferably woven with fibers of the same type as those used to produce the fibrous reinforcement of the casing.
Une fois la préforme fibreuse de pièce de comblement 40 réalisée, on place celle-ci dans le volume libre 35 délimité par la portion évidée 30. Once the fiber preform of the filling piece 40 has been produced, the latter is placed in the free volume 35 delimited by the recessed portion 30.
Les première et deuxième parties 41 et 42 de la préforme fibreuse 40 présentent chacune une géométrie adaptée à la partie du volume libre 35 à combler. Plus précisément, dans l’exemple décrit ici et telle qu’illustrée sur la figure 5, la première partie 41 présente une géométrie complémentaire de la partie du volume libre 35 de la portion évidée définie entre les premiers biseaux des bords en vis-à-vis (premiers biseaux 310 et 330 des bords 31 et 33 illustrés sur la figure 5) tandis que la deuxième partie 42 présente une géométrie complémentaire de l’autre partie du volume libre 35 de la portion évidée 30 définie entre les deuxièmes biseaux des bords en vis-à-vis (deuxième biseaux 311 et 331 des bords 31 et 33 illustrés sur la figure 5). Chaque bord en vis-à-vis comprenant des premier et deuxième biseaux s’étend sur une longueur correspondant à au moins dix fois l’épaisseur du carter au niveau de la portion évidée. Comme illustrés par exemple sur les figures 4 et 5, les bords 31 et 33 s’étendent chacun respectivement sur une longueur L31 et L33 qui est égale à au moins dix fois la valeur de l’épaisseur E10 du carter 10 au niveau de la portion évidée 30. Cela permet d’optimiser la transmission des charges mécaniques sur l’interface de collage entre la pièce de comblement et la structure en matériau composite du carter. The first and second parts 41 and 42 of the fiber preform 40 each have a geometry adapted to the part of the free volume 35 to be filled. More precisely, in the example described here and as illustrated in FIG. 5, the first part 41 has a geometry complementary to the part of the free volume 35 of the recessed portion defined between the first bevels of the edges facing each other. screw (first bevels 310 and 330 of the edges 31 and 33 illustrated in Figure 5) while the second part 42 has a geometry complementary to the other part of the free volume 35 of the recessed portion 30 defined between the second bevels of the edges in vis-à-vis (second bevels 311 and 331 of the edges 31 and 33 illustrated in Figure 5). Each facing edge comprising first and second bevels extends over a length corresponding to at least ten times the thickness of the housing at the level of the recessed portion. As illustrated for example in Figures 4 and 5, the edges 31 and 33 each extend respectively over a length L31 and L33 which is equal to at least ten times the value of the thickness E 10 of the housing 10 at the level of the recessed portion 30. This makes it possible to optimize the transmission of mechanical loads on the bonding interface between the filling part and the composite material structure of the casing.
La préforme fibreuse de pièce de comblement 40 est imprégnée avec une résine précurseur d’une matrice. L’imprégnation de la préforme 40 peut être réalisée avant ou après le placement de la préforme fibreuse de pièce de comblement 40 dans la portion évidée 30. La résine est de préférence choisie de manière à correspondre à un précurseur de matrice de même nature que la matrice avec laquelle le renfort fibreux du carter est densifié. The fiber fill preform 40 is impregnated with a matrix precursor resin. The impregnation of the preform 40 can be carried out before or after the placement of the fiber preform of the filling piece 40 in the recessed portion 30. The resin is preferably chosen so as to correspond to a matrix precursor of the same type as the resin. matrix with which the fibrous reinforcement of the casing is densified.
On procède ensuite à la transformation de la résine en matrice, par exemple par traitement thermique, afin d’obtenir, comme représenté sur la figure 7, une pièce de comblement en matériau composite 50 comprenant une préforme fibreuse tissée 3D densifiée par une matrice, la pièce de comblement 50 occupant le volume libre défini par la portion évidée. La pièce de comblement en matériau composite 50 comprend une première partie 51 présentant une géométrie complémentaire d’une partie du volume de la portion évidée définie entre les premiers biseaux 310 et 330 des bords en vis-à-vis 31 et 33 et une deuxième partie 52 présentant une géométrie The resin is then transformed into a matrix, for example by heat treatment, in order to obtain, as shown in FIG. 7, a part of filling in composite material 50 comprising a 3D woven fiber preform densified by a matrix, the filling part 50 occupying the free volume defined by the recessed portion. The filling piece made of composite material 50 comprises a first part 51 having a geometry complementary to part of the volume of the recessed portion defined between the first bevels 310 and 330 of the facing edges 31 and 33 and a second part 52 with geometry
complémentaire de l’autre partie du volume de la partie de la portion évidée définie entre les deuxièmes biseaux 311 et 331 des bords en vis-à-vis 31 et 32. La pièce de comblement 50 s’intégre complètement dans la structure du carter. La complementary to the other part of the volume of the part of the recessed portion defined between the second bevels 311 and 331 of the facing edges 31 and 32. The filling part 50 integrates completely into the structure of the housing. The
transformation de la résine en matrice permet à la pièce de comblement d’adhérer avec les portions de matériau composite du carter avec lesquelles elle est en contact, ici les premier et deuxième biseaux de chaque bord de la portion évidée. Un agent de collage peut être en outre déposé sur l’interface de collage entre la pièce de comblement et les bords de la portion évidée afin de renforcer l’interface de collage. transformation of the resin into a matrix allows the filler to adhere to the portions of composite material of the housing with which it is in contact, here the first and second bevels of each edge of the recessed portion. A bonding agent can further be deposited on the bonding interface between the filling piece and the edges of the recessed portion in order to strengthen the bonding interface.
Selon une caractéristique particulière de l’invention, la tenue mécanique de la pièce peut être renforcée par l’intégration d’un ou plusieurs organes de fixation dans la pièce de comblement, comme par exemple l’organe 60 représenté sur la figure 8 qui comprend une vis 61 traversant la pièce de comblement 50 et un écrou de serrage 62 coopérant avec l’extrémité libre de la vis 61. Le ou les organes de fixation n’ont pas d’impact sur la structure du carter car ils ne sont pas en contact avec celle-ci mais seulement avec la pièce de comblement. According to a particular characteristic of the invention, the mechanical strength of the part can be reinforced by the integration of one or more fixing members in the filling part, such as for example the member 60 shown in FIG. 8 which comprises a screw 61 passing through the filling part 50 and a clamping nut 62 cooperating with the free end of the screw 61. The fixing member (s) have no impact on the structure of the casing because they are not in contact with it but only with the filling piece.
Selon une autre caractéristique particulière de l’invention, les première et deuxième parties de la préforme fibreuse de pièce de comblement peuvent être liées entre elles par tissage. According to another particular characteristic of the invention, the first and second parts of the fiber preform of the filling piece can be linked together by weaving.
La figure 9 montre un exemple d'armures interlock d’une préforme fibreuse de pièce de comblement 70 dans laquelle les première et deuxième parties 71 et 72 sont liées entre elles par tissage. Sur la figure 9, les fils de trame sont en coupe. Dans ce cas, on utilise la déformabilité de la préforme fibreuse 70 pour l’insérer dans le volume libre défini par la portion évidée. FIG. 9 shows an example of interlock weaves of a fiber preform for a filling piece 70 in which the first and second parts 71 and 72 are linked together by weaving. In FIG. 9, the weft threads are in section. In this case, the deformability of the fiber preform 70 is used to insert it into the free volume defined by the recessed portion.
L’invention s’applique également pour la reprise ou retouche de fabrication d’un carter en matériau composite. De manière connue, la réalisation d’un carter en matériau composite débute par la formation d’une texture fibreuse sous forme d’une bande obtenue par tissage tridimensionnel comme par exemple un tissage à armure "interlock" ou un tissage suivant une des armures décrites dans le document US 2010/0144227. La structure fibreuse peut être notamment tissée à partir de fils de fibres de carbone, de céramique telle que du carbure de silicium, de verre, ou encore d’aramide. The invention also applies to the rework or retouching of the manufacture of a housing made of composite material. In a known manner, the production of a casing in composite material begins with the formation of a fibrous texture in the form of a strip obtained by three-dimensional weaving such as for example a weaving with an "interlock" weave or a weaving according to one of the weaves described. in document US 2010/0144227. The fibrous structure can in particular be woven from son of carbon fibers, ceramic such as silicon carbide, glass or aramid.
Le renfort fibreux du carter est formé par enroulement sur un mandrin de la texture fibreuse, le mandrin ayant un profil correspondant à celui du carter à réaliser. Le renfort fibreux constitue une préforme fibreuse tubulaire complète du carter formant une seule pièce. A cet effet, le mandrin présente une surface externe dont le profil correspond à la surface interne du carter à réaliser et deux flasques pour former des parties de préforme fibreuse correspondant aux brides du carter. The fibrous reinforcement of the casing is formed by winding on a mandrel of the fibrous texture, the mandrel having a profile corresponding to that of the casing to be produced. The fibrous reinforcement constitutes a complete tubular fibrous preform of the casing forming a single piece. To this end, the mandrel has an external surface whose profile corresponds to the internal surface of the casing to be produced and two flanges to form parts of the fiber preform corresponding to the flanges of the casing.
On procède ensuite à la densification du renfort fibreux par une matrice. La densification du renfort fibreux consiste à combler la porosité du renfort, dans tout ou partie du volume de celui-ci, par le matériau constitutif de la matrice. La matrice peut être obtenue de façon connue en soi suivant le procédé par voie liquide. The fibrous reinforcement is then densified with a matrix. The densification of the fibrous reinforcement consists in filling the porosity of the reinforcement, in all or part of the volume thereof, with the material constituting the matrix. The matrix can be obtained in a manner known per se using the liquid process.
Le procédé par voie liquide consiste à imprégner le renfort fibreux par une The liquid process consists in impregnating the fibrous reinforcement with a
composition liquide contenant un précurseur organique du matériau de la matrice. Le précurseur organique se présente habituellement sous forme d'un polymère, tel qu'une résine, éventuellement dilué dans un solvant. Le renfort fibreux est placé dans un moule pouvant être fermé de manière étanche avec un logement ayant la forme de la pièce finale moulée. Ensuite, on injecte le précurseur liquide de matrice, par exemple une résine, dans tout le logement pour imprégner toute la partie fibreuse du renfort. liquid composition containing an organic precursor of the matrix material. The organic precursor is usually in the form of a polymer, such as a resin, optionally diluted in a solvent. The fiber reinforcement is placed in a sealable mold with a housing in the shape of the final molded part. Then, the liquid matrix precursor, for example a resin, is injected into the entire housing to impregnate the entire fibrous part of the reinforcement.
La transformation du précurseur en matrice organique, à savoir sa polymérisation, est réalisée par traitement thermique, généralement par chauffage du moule, après élimination du solvant éventuel et réticulation du polymère, le renfort étant toujours maintenu dans le moule ayant une forme correspondant à celle de la pièce à réaliser. La matrice organique peut être notamment obtenue à partir de résines époxydes, telle que, par exemple, la résine époxyde à hautes performances vendue, ou de précurseurs liquides de matrices carbone ou céramique. Dans le cas de la formation d'une matrice carbone ou céramique, le traitement thermique consiste à pyrolyser le précurseur organique pour transformer la matrice organique en une matrice carbone ou céramique selon le précurseur utilisé et les conditions de pyrolyse. A titre d'exemple, des précurseurs liquides de carbone peuvent être des résines à taux de coke relativement élevé, telles que des résines phénoliques, tandis que des précurseurs liquides de céramique, notamment de SiC, peuvent être des résines de type polycarbosilane (PCS) ou polytitanocarbosilane (PTCS) ou polysilazane (PSZ). Plusieurs cycles consécutifs, depuis l'imprégnation jusqu'au traitement thermique, peuvent être réalisés pour parvenir au degré de densification souhaité. The transformation of the precursor into an organic matrix, namely its polymerization, is carried out by heat treatment, generally by heating the mold, after removal of any solvent and crosslinking of the polymer, the reinforcement still being kept in the mold having a shape corresponding to that of the part to be produced. The organic matrix can in particular be obtained from epoxy resins, such as, for example, the high performance epoxy resin sold, or from liquid precursors of carbon or ceramic matrices. In the case of the formation of a carbon or ceramic matrix, the heat treatment consists in pyrolyzing the organic precursor to transform the organic matrix into a carbon or ceramic matrix depending on the precursor used and the pyrolysis conditions. By way of example, liquid carbon precursors can be resins with a relatively high coke content, such as phenolic resins, while liquid ceramic precursors, especially of SiC, can be polycarbosilane (PCS) type resins. or polytitanocarbosilane (PTCS) or polysilazane (PSZ). Several consecutive cycles, from impregnation to heat treatment, can be carried out to achieve the desired degree of densification.
La densification du renfort fibreux peut être réalisée par le procédé bien connu de moulage par transfert dit RTM ("Resin Transfert Moulding"). Conformément au procédé RTM, on place le renfort fibreux dans un moule présentant la forme du carter à réaliser. Une résine thermodurcissable est injectée dans l'espace interne délimité entre la pièce en matériau rigide et le moule et qui comprend le renfort fibreux. Un gradient de pression est généralement établi dans cet espace interne entre l'endroit où est injecté la résine et les orifices d'évacuation de cette dernière afin de contrôler et d'optimiser l'imprégnation du renfort par la résine. Densification of the fibrous reinforcement can be carried out by the well-known transfer molding process called RTM (“Resin Transfer Molding”). In accordance with the RTM process, the fibrous reinforcement is placed in a mold having the shape of the casing to be produced. A thermosetting resin is injected into the internal space delimited between the piece of rigid material and the mold and which includes the fibrous reinforcement. A pressure gradient is generally established in this internal space between the place where the resin is injected and the discharge orifices of the latter in order to control and optimize the impregnation of the reinforcement by the resin.
La résine utilisée peut être, par exemple, une résine époxyde. Les résines adaptées pour les procédés RTM sont bien connues. Elles présentent de préférence une faible viscosité pour faciliter leur injection dans les fibres. Le choix de la classe de température et/ou la nature chimique de la résine est déterminé en fonction des sollicitations thermomécaniques auxquelles doit être soumise la pièce. Une fois la résine injectée dans tout le renfort, on procède à sa polymérisation par traitement thermique conformément au procédé RTM. The resin used can be, for example, an epoxy resin. Resins suitable for RTM processes are well known. They preferably have a low viscosity to facilitate their injection into the fibers. The choice of the temperature class and / or the chemical nature of the resin is determined according to the thermomechanical stresses to which the part must be subjected. Once the resin has been injected into all the reinforcement, it is polymerized by heat treatment in accordance with the RTM process.
Après l'injection et la polymérisation, la pièce est démoulée. Au final, la pièce est détourée pour enlever l'excès de résine et les chanfreins sont usinés pour obtenir un carter en matériau composite comme le carter 10 illustré en figures 1 et 2. After injection and polymerization, the part is demolded. In the end, the part is trimmed to remove the excess resin and the chamfers are machined to obtain a housing made of composite material like the housing 10 illustrated in Figures 1 and 2.
A l’issue de cette fabrication, il se peut que le carter présente des défauts comme par exemple une ou plusieurs zones dites « sèches » correspondant à des parties de carter où le renfort fibreux est dépourvu de matrice ou n’en contient pas suffisamment. Dans ce cas, après la fabrication du carter, celui-ci est inspecté pour détecter éventuellement une ou plusieurs zones non conformes dans celui-ci. Si c’est le cas, le procédé de fabrication d’un carter en matériau composite selon l’invention comprend en outre les étapes suivantes : At the end of this manufacture, the casing may have defects such as, for example, one or more so-called “dry” areas corresponding to parts of the casing where the fibrous reinforcement is devoid of a matrix or does not contain sufficient matrix. In this case, after manufacture of the housing, it is inspected for possibly detecting one or more non-conforming zones therein. If this is the case, the method of manufacturing a casing made of composite material according to the invention further comprises the following steps:
- la réalisation d’une portion évidée par retrait du matériau composite au niveau de la zone non conforme de manière à former une portion évidée s’étendant sur toute l’épaisseur du renfort fibreux, - the production of a hollowed-out portion by removing the composite material from the non-conforming zone so as to form a hollowed-out portion extending over the entire thickness of the fiber reinforcement,
- le tissage tridimensionnel d’une préforme fibreuse de pièce de comblement, - the three-dimensional weaving of a fiber preform of a filling piece,
- le placement de la préforme fibreuse de pièce de comblement dans le volume libre du carter délimité par la portion évidée, - the placement of the fiber preform of the filling part in the free volume of the casing delimited by the recessed portion,
- l’imprégnation, avant ou après le placement de la préforme fibreuse de pièce de comblement dans la portion évidée, de ladite préforme avec une résine précurseur d’une matrice, - the impregnation, before or after the placement of the fiber preform of the filler piece in the hollowed out portion, of said preform with a precursor resin of a matrix,
- la transformation de la résine en matrice afin d’obtenir une pièce de comblement en matériau composite comprenant une préforme fibreuse tissée 3D, ladite pièce de comblement occupant le volume défini par la portion évidée. - the transformation of the resin into a matrix in order to obtain a filling piece made of composite material comprising a 3D woven fiber preform, said filling piece occupying the volume defined by the recessed portion.
Le retrait du matériau composite est réalisé sur une surface déterminée du carter couvrant au moins la zone non conforme et sur toute l’épaisseur du carter. On obtient ainsi une portion évidée qui débouche à la fois sur la surface interne et sur la surface externe du carter, comme la portion évidée 30 illustrée sur les figures 3 et 4 dont les bords comportent chacun respectivement des premier et deuxième biseaux. La portion évidée délimite un volume libre de matière destinée à être occupé par une pièce de comblement comme expliqué ci-après. The removal of the composite material is carried out on a determined surface of the casing covering at least the non-conforming zone and over the entire thickness of the casing. A recessed portion is thus obtained which opens out both on the internal surface and on the external surface of the casing, like the recessed portion 30 illustrated in FIGS. 3 and 4, the edges of which each comprise respectively first and second bevels. The recessed portion defines a free volume of material intended to be occupied by a filling part as explained below.
La préforme fibreuse de pièce de comblement est obtenue par tissage The fiber preform of the filling piece is obtained by weaving
tridimensionnel et peut être formée de deux parties distinctes comme les première et deuxième parties 41 et 42 de la préforme fibreuse de pièce de comblement 40 illustrée sur la figure 5, ou de deux parties liées entre elles par tissage comme les première et deuxième parties 71 et 72 de la préforme fibreuse de pièce de three-dimensional and can be formed of two distinct parts like the first and second parts 41 and 42 of the fiber preform of the filling part 40 illustrated in FIG. 5, or of two parts linked together by weaving like the first and second parts 71 and 72 of the workpiece fiber preform
comblement 70 illustrées sur la figure 9. filling 70 illustrated in Figure 9.
La préforme fibreuse de pièce de comblement est tissée de préférence avec des fibres de même nature que celles utilisées pour réaliser le renfort fibreux du carter. Les première et deuxième parties de la préforme fibreuse de pièce de comblement présentent chacune une géométrie adaptée à la partie du volume libre défini par la portion évidée à combler comme déjà décrit précédemment. Une fois la préforme fibreuse de pièce de comblement réalisée, on place celle-ci dans le volume libre délimité par la portion évidée. The fibrous filling part preform is preferably woven with fibers of the same type as those used to produce the fibrous reinforcement of the casing. The first and second parts of the fiber preform of the filling part each have a geometry adapted to the part of the free volume defined by the recessed portion to be filled as already described above. Once the fiber preform of the filler piece has been produced, it is placed in the free volume delimited by the recessed portion.
La préforme fibreuse de pièce de comblement est imprégnée avec une résine précurseur d’une matrice. L’imprégnation de la préforme peut être réalisée avant ou après le placement de la préforme fibreuse de pièce de comblement dans la portion évidée. La résine est de préférence choisie de manière à correspondre à un précurseur de matrice de même nature que la matrice avec laquelle le renfort fibreux du carter est densifié. The fiber fill preform is impregnated with a matrix precursor resin. The impregnation of the preform can be carried out before or after the placement of the fiber preform of the filler piece in the recessed portion. The resin is preferably chosen so as to correspond to a matrix precursor of the same nature as the matrix with which the fibrous reinforcement of the casing is densified.
On procède ensuite à la transformation de la résine en matrice, par exemple par traitement thermique, afin d’obtenir, une pièce de comblement en matériau composite comprenant une préforme fibreuse tissée 3D densifiée par une matrice comme la pièce de comblement en matériau composite 50 représentée sur la figure 7, la pièce de comblement occupant le volume libre défini par la portion évidée. The resin is then transformed into a matrix, for example by heat treatment, in order to obtain a filling part made of composite material comprising a 3D woven fiber preform densified by a matrix such as the filling part made of composite material 50 shown. in FIG. 7, the filling part occupying the free volume defined by the recessed portion.
Selon une caractéristique particulière de l’invention, la tenue mécanique de la pièce peut être renforcée par l’intégration d’un ou plusieurs organes de fixation dans la pièce de comblement, comme par exemple l’organe 60 représenté sur la figure 8 qui comprend une vis 61 traversant la pièce de comblement 50 et un écrou de serrage 62 coopérant avec l’extrémité libre de la vis 61. Le ou les organes de fixation n’ont pas d’impact sur la structure du carter car ils ne sont pas en contact avec celle-ci mais seulement avec la pièce de comblement. According to a particular characteristic of the invention, the mechanical strength of the part can be reinforced by the integration of one or more fixing members in the filling part, such as for example the member 60 shown in FIG. 8 which comprises a screw 61 passing through the filling part 50 and a clamping nut 62 cooperating with the free end of the screw 61. The fixing member (s) have no impact on the structure of the casing because they are not in contact with it but only with the filling piece.

Claims

Revendications Claims
[Revendication 1] Pièce (10) de turbine à gaz en matériau composite, la pièce comprenant un renfort fibreux présentant un tissage tridimensionnel entre une pluralité de fils de chaîne et une pluralité de fils de trame, ledit renfort fibreux étant densifié par une matrice, ledit renfort fibreux densifié s'étendant en largeur entre une extrémité aval (17) et une extrémité amont (18) suivant une direction axiale (DA) et en épaisseur entre une surface interne (11) et une surface externe (12) suivant une direction radiale (DR), caractérisé en ce que le renfort fibreux densifié par la matrice comporte au moins une portion évidée (30) s'étendant sur toute l'épaisseur (Ei0) du renfort fibreux et en ce qu'une pièce de comblement en matériau composite (50) est présente dans le volume libre (35) de la pièce délimité par ladite au moins une portion évidée, la pièce de comblement (50) comprenant une préforme fibreuse (40) présentant un tissage tridimensionnel, ladite préforme fibreuse étant densifiée par une matrice. [Claim 1] Gas turbine part (10) made of composite material, the part comprising a fibrous reinforcement having a three-dimensional weaving between a plurality of warp yarns and a plurality of weft yarns, said fibrous reinforcement being densified by a matrix, said densified fibrous reinforcement extending in width between a downstream end (17) and an upstream end (18) in an axial direction (D A ) and in thickness between an internal surface (11) and an external surface (12) along a radial direction (D R ), characterized in that the fibrous reinforcement densified by the matrix comprises at least one recessed portion (30) extending over the entire thickness (E i0 ) of the fibrous reinforcement and in that a piece of filling in composite material (50) is present in the free volume (35) of the part delimited by said at least one recessed portion, the filling part (50) comprising a fiber preform (40) having a three-dimensional weave, said fiber preform being d ensified by a matrix.
[Revendication 2] Pièce selon la revendication 1, dans lequel chaque portion évidée (30) comporte au moins deux bords en vis-à-vis (31, 33) comprenant chacun des premier et deuxième biseaux (310, 311, 330, 331), la pièce de comblement en matériau composite (50) comprenant une première partie (51) présentant une géométrie complémentaire d'une partie du volume de la portion évidée définie entre les premiers biseaux (310, 330) des bords en vis- à-vis (31, 33) et une deuxième partie (52) présentant une géométrie complémentaire de l'autre partie du volume de la partie de la portion évidée définie entre les deuxièmes biseaux (311, 331) des bords en vis-à-vis (31, [Claim 2] Part according to claim 1, wherein each recessed portion (30) has at least two facing edges (31, 33) each comprising first and second bevels (310, 311, 330, 331) , the filling piece made of composite material (50) comprising a first part (51) having a geometry complementary to part of the volume of the recessed portion defined between the first bevels (310, 330) of the facing edges (31, 33) and a second part (52) having a geometry complementary to the other part of the volume of the part of the recessed portion defined between the second bevels (311, 331) of the facing edges (31 ,
33). 33).
[Revendication 3] Pièce selon la revendication 2, dans lequel chaque bord en vis-à-vis (31, 33) comprenant des premier et deuxième biseaux (310, 311, 330, 331) s'étend sur une longueur (L3I, L33) correspondant à au moins dix fois l'épaisseur (Ei0) de la pièce au niveau de la portion évidée (30). [Claim 3] Part according to claim 2, wherein each facing edge (31, 33) comprising first and second bevels (310, 311, 330, 331) extends over a length (L 3 I , L 33 ) corresponding to at least ten times the thickness (E i0 ) of the part at the level of the recessed portion (30).
[Revendication 4] Pièce selon la revendication 2 ou 3, dans lequel les première et deuxième parties de la pièce de comblement sont liées entre elles par tissage. [Claim 4] A part according to claim 2 or 3, in which the first and second parts of the filling part are linked together by weaving.
[Revendication 5] Pièce selon l'une quelconque des revendications 1 à 4, dans lequel la pièce de comblement (50) comprend en outre au moins un organe de fixation (60) s'étendant dans ladite pièce de comblement. [Claim 5] A part according to any of claims 1 to 4, wherein the filling piece (50) further comprises at least one fastener (60) extending into said filling piece.
[Revendication 6] Moteur aéronautique à turbine à gaz ayant une pièce en matériau composite (10) selon l'une quelconque des revendications 1 à 5. [Claim 6] A gas turbine aircraft engine having a composite material part (10) according to any one of claims 1 to 5.
[Revendication 7] Aéronef comprenant un ou plusieurs moteurs selon la revendication 6. [Claim 7] An aircraft comprising one or more engines according to claim 6.
[Revendication 8] Procédé de réparation d’une pièce (10) en matériau [Claim 8] A method of repairing a part (10) of material
composite pour une turbine à gaz, la pièce comprenant un renfort fibreux présentant un tissage tridimensionnel entre une pluralité de fils de chaîne et une pluralité de file de trame, ledit renfort fibreux étant densifié par une matrice, ledit renfort fibreux densifié s'étendant en largeur entre une extrémité aval (17) et une extrémité amont (18) suivant une direction axiale (DA) et en épaisseur entre une surface interne (11) et une surface externe (12) suivant une direction radiale (DR), caractérisé en ce qu'il comprend : composite for a gas turbine, the part comprising a fibrous reinforcement having a three-dimensional weaving between a plurality of warp yarns and a plurality of weft yarns, said fibrous reinforcement being densified by a matrix, said densified fibrous reinforcement extending in width between a downstream end (17) and an upstream end (18) in an axial direction (DA) and in thickness between an internal surface (11) and an external surface (12) in a radial direction (DR), characterized in that 'He understands :
- l'identification d'au moins une zone endommagée (20) dans la pièce,- identification of at least one damaged area (20) in the room,
- la réalisation d'une portion évidée par retrait du matériau composite au niveau de la zone endommagée (20) de manière à former une portion évidée (20) s'étendant sur toute l'épaisseur (E10) du renfort fibreux, - the production of a hollowed-out portion by removing the composite material from the damaged area (20) so as to form a hollowed-out portion (20) extending over the entire thickness (E10) of the fiber reinforcement,
- le tissage tridimensionnel d'une préforme fibreuse de pièce de comblement (40), - the three-dimensional weaving of a fiber preform of a filling piece (40),
- le placement de la préforme fibreuse de pièce de comblement (40) dans le volume libre (35) de la pièce délimité par la portion évidée (30), - the placement of the fiber preform of the filling part (40) in the free volume (35) of the part delimited by the recessed portion (30),
- l'imprégnation, avant ou après le placement de la préforme fibreuse de pièce de comblement dans la portion évidée, de ladite préforme avec une résine précurseur d'une matrice, - the impregnation, before or after the placement of the fiber preform of the filler piece in the hollowed out portion, of said preform with a precursor resin of a matrix,
- la polymérisation de la résine en matrice afin d'obtenir une pièce de comblement en matériau composite (50) comprenant une préforme fibreuse tissée 3D, ladite pièce de comblement occupant le volume défini par la portion évidée. - Polymerization of the matrix resin in order to obtain a filling part made of composite material (50) comprising a fiber preform 3D woven, said filling piece occupying the volume defined by the hollowed out portion.
[Revendication 9] Procédé de réparation selon la revendication 8, dans lequel la réalisation de la portion évidée (30) comprend la formation d'au moins deux bords en vis-à-vis (31, 33) comprenant chacun des premier et deuxième biseaux (310, 311, 330, 331), la préforme fibreuse de pièce de comblement (40) comprenant une première partie (41) présentant une géométrie complémentaire d'une partie du volume de la portion évidée définie entre les premiers biseaux (310, 330) des bords en vis-à-vis (31, 33) et une deuxième partie (42) présentant une géométrie complémentaire de l'autre partie du volume de la portion évidée définie entre les deuxièmes biseaux (311, 331) des bords en vis-à-vis (31, 33). [Claim 9] The method of repair according to claim 8, wherein making the recessed portion (30) comprises forming at least two facing edges (31, 33) each comprising first and second bevels. (310, 311, 330, 331), the fiber preform of the filling piece (40) comprising a first part (41) having a geometry complementary to a part of the volume of the recessed portion defined between the first bevels (310, 330 ) facing edges (31, 33) and a second part (42) having a geometry complementary to the other part of the volume of the recessed portion defined between the second bevels (311, 331) of the facing edges -à -vis (31, 33).
[Revendication 10] Procédé de réparation selon la revendication 9, dans lequel chaque bord en vis-à-vis (31, 33) comprenant des premier et deuxième biseaux (310, 311, 330, 331) s'étend sur une longueur (L3I, l_33) [Claim 10] A repair method according to claim 9, wherein each facing edge (31, 33) including first and second bevels (310, 311, 330, 331) extends over a length (L 3 I, l_ 33 )
correspondant à au moins dix fois l'épaisseur (Ei0) de la pièce au niveau de la portion évidée (30). corresponding to at least ten times the thickness (Ei 0 ) of the part at the level of the recessed portion (30).
[Revendication 11] Procédé de réparation selon la revendication 9 ou 10, dans lequel les première et deuxième parties (71, 72) de la préforme fibreuse de pièce de comblement (70) sont liées entre elles par tissage. [Claim 11] A repair method according to claim 9 or 10, wherein the first and second portions (71, 72) of the fiber fill preform (70) are bonded together by weaving.
[Revendication 12] Procédé de réparation selon l'une quelconque des [Claim 12] A repair method according to any one of
revendications 8 à 11, comprenant en outre l'intégration d'au moins un organe de fixation (60) dans la pièce de comblement (50). claims 8 to 11, further comprising integrating at least one fastener (60) in the filling piece (50).
[Revendication 13] Procédé de fabrication d’une pièce (10) en matériau [Claim 13] A method of manufacturing a part (10) of material
composite pour une turbine à gaz, le procédé comprenant le tissage en une seule pièce par tissage tridimensionnel d'une texture fibreuse en forme de bande, la mise en forme de ladite texture par enroulement sur un outillage de support de manière à former un renfort fibreux de la pièce et la densification du renfort fibreux par une matrice, ledit renfort fibreux densifié s'étendant en largeur entre une extrémité aval (17) et une extrémité amont (18) suivant une direction axiale (DA) et en épaisseur entre une surface interne (11) et une surface externe (12) suivant une direction radiale (DR), caractérisé en ce qu'il comprend : composite for a gas turbine, the method comprising weaving in one piece by three-dimensional weaving a fibrous texture in the form of a strip, shaping said texture by winding on a support tool so as to form a fibrous reinforcement of the part and the densification of the fibrous reinforcement by a matrix, said densified fibrous reinforcement extending in width between a downstream end (17) and an upstream end (18) in an axial direction (DA) and in thickness between an internal surface (11) and an outer surface (12) in a radial direction (DR), characterized in that that it includes:
- l'identification d'au moins une zone non conforme dans la pièce, - identification of at least one non-compliant area in the room,
- la réalisation d'une portion évidée par retrait du matériau composite au niveau de la zone non conforme de manière à former une portion évidée (30) s'étendant sur toute l'épaisseur du renfort fibreux, - the production of a hollowed-out portion by removing the composite material at the non-conforming zone so as to form a hollowed-out portion (30) extending over the entire thickness of the fibrous reinforcement,
- le tissage tridimensionnel d'une préforme fibreuse de pièce de comblement (40), - the three-dimensional weaving of a fiber preform of a filling piece (40),
- le placement de la préforme fibreuse de pièce de comblement (40) dans le volume libre (35) de la pièce délimité par la portion évidée (30), - the placement of the fiber preform of the filling part (40) in the free volume (35) of the part delimited by the recessed portion (30),
- l'imprégnation, avant ou après le placement de la préforme fibreuse de pièce de comblement dans la portion évidée, de ladite préforme avec une résine précurseur d'une matrice, - the impregnation, before or after the placement of the fiber preform of the filler piece in the hollowed out portion, of said preform with a precursor resin of a matrix,
- la polymérisation de la résine en matrice afin d'obtenir une pièce de comblement en matériau composite (50) comprenant une préforme fibreuse tissée 3D, ladite pièce de comblement occupant le volume défini par la portion évidée. - Polymerization of the matrix resin in order to obtain a filling part made of composite material (50) comprising a 3D woven fiber preform, said filling part occupying the volume defined by the recessed portion.
[Revendication 14] Procédé de fabrication selon la revendication 13, dans lequel la réalisation de la portion évidée (30) comprend la formation d'au moins deux bords en vis-à-vis (31, 33) comprenant chacun des premier et deuxième biseaux (310, 311, 330, 331), la préforme fibreuse de pièce de comblement (40) comprenant une première partie (41) présentant une géométrie complémentaire d'une partie du volume de la portion évidée définie entre les premiers biseaux (310, 330) des bords en vis-à-vis (31, 33) et une deuxième partie (42) présentant une géométrie complémentaire de l'autre partie du volume de la portion évidée définie entre les deuxièmes biseaux (311, 331) des bords en vis-à-vis (31, 33). [Claim 14] The manufacturing method according to claim 13, wherein making the recessed portion (30) comprises forming at least two facing edges (31, 33) each comprising first and second bevels. (310, 311, 330, 331), the fiber preform of the filling piece (40) comprising a first part (41) having a geometry complementary to a part of the volume of the recessed portion defined between the first bevels (310, 330 ) facing edges (31, 33) and a second part (42) having a geometry complementary to the other part of the volume of the recessed portion defined between the second bevels (311, 331) of the facing edges -à -vis (31, 33).
[Revendication 15] Procédé selon la revendication 14, dans lequel chaque bord en vis-à-vis (31, 33) comprenant des premier et deuxième biseaux (310, 311, 330, 331) s'étend sur une longueur (L3I, l_33) correspondant à au moins dix fois l'épaisseur (Ei0) de la pièce au niveau de la portion évidée (30). [Claim 15] The method of claim 14, wherein each facing edge (31, 33) comprising first and second bevels (310, 311, 330, 331) extends over a length (L 3 I , l_ 33 ) corresponding to at least ten times the thickness (Ei 0 ) of the part at the level of the recessed portion (30).
EP20713712.6A 2019-03-01 2020-02-24 Repairing or resuming production of a component made of composite material Pending EP3930991A1 (en)

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FR1902143A FR3093298B1 (en) 2019-03-01 2019-03-01 Repair or resumption of manufacture of a composite material part
PCT/FR2020/050341 WO2020178500A1 (en) 2019-03-01 2020-02-24 Repairing or resuming production of a component made of composite material

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