METHOD FOR MANUFACTURING A COMPOSITE MATERIAL PART HAVING A CELLULAR STRUCTURE AND CORRESPONDING PART

Abstract

A method for manufacturing a composite material part having a cellular structure that includes at least one cell delimited by walls. The method includes supplying at least a first core, providing a web of a first fibrous reinforcement comprising a plurality of long discontinuous fibers randomly distributed in a plane, and producing at least one strip of the first fibrous reinforcement. The method further includes producing a second fibrous reinforcement in the shape of a sock, inserting the first core into the sock, draping the strip around the sock containing the first core, placing the sock containing the first core and the wrapped strip in a mold, and thermocompression.

Claims

1. A method for manufacturing a part made of composite material comprising a cellular structure, in particular for a turbomachine, the cellular structure comprising at least one cell delimited by walls and the method comprising the steps of: supplying at least one first core, providing a lap of a first fibrous reinforcement comprising a plurality of discontinuous long fibers randomly distributed in a plane, producing at least one strip of the first fibrous reinforcement, producing a second fibrous reinforcement in a form of a continuous braided sock and obtained by braiding, the second fibrous reinforcement comprising continuous long fibers, inserting the first core into the sock, draping the strip of the first fibrous reinforcement around the sock containing the first core, placing an assembly formed by the sock containing the first core and the strip draped around the sock in a mold, and thermocompressing the assembly installed in the mold.

2. The manufacturing method according to claim 1, further comprising a cutting step in which the sock is cut so as to form a first sock segment having a length corresponding to a height of the first core.

3. The manufacturing method according to that claim 1, wherein the fibers of the strip and the sock are pre-impregnated.

4. The manufacturing method according to claim 1, wherein each assembly is placed in the mold in the form of a row.

5. The manufacturing method according to claim 4, wherein the step of placing in the mold comprises a sub-step of placing a ply between each row.

6. The manufacturing method according to claim 1, further comprising a step of partial polymerization of the assembly formed by the sock containing the first core and the strip draped around the sock, the step being carried out before the step of polymerization or before the step of placing in the mold.

7. The manufacturing method according to claim 2, wherein at least one second core is inserted into the same sock which is cut into a second sock segment and at least one strip is draped around the second sock segment, and in that the assembly formed by the second sock segment around the second core and the band draped around the sock is placed in the mold.

8. The manufacturing method according to claim 8, further comprising the step of placing at least one third sock segment around at least two assemblies of cores, each contained in a sock segment, which are draped with at least one strip, wherein the two assemblies are juxtaposed.

9. The manufacturing method according to claim 1, wherein the sock is obtained by biaxial or triaxial braiding.

10. The manufacturing method according to claim 1, wherein the first and/or the second core or cores is or are fusible.

11. A turbomachine part made of composite material comprising at least one fibrous reinforcement densified by a matrix, the turbomachine part being produced by the method according to claim 1 and comprising a cellular structure with at least one cell delimited and separated by walls.

12. The turbomachine part according to claim 11, wherein the turbomachine part is a thrust reverser grid, a thrust reverser flap, a pair of vanes connected by a radially internal platform and by a radially external platform, the cell separating the pair of vanes in a circumferential direction, a multiplet comprising at least three vanes spaced apart by cells, or a turbomachine wheel.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0036] The invention will be better understood, and other purposes, details, characteristics and advantages thereof will become clearer upon reading the following detailed explanatory description of embodiments of the invention given as purely illustrative and non-limiting examples, with reference to the appended schematic drawings in which:

[0037] FIG. 1 is a partial and axial sectional view of an example of a turbomachine to which the invention applies;

[0038] FIG. 2 is a schematic and perspective view of an example of a composite material part with a cellular structure according to the invention;

[0039] FIG. 3 is a schematic and perspective view of another example of a composite material part with a cellular structure and a bottom according to the invention;

[0040] FIG. 4 shows a perspective view of a DLF lap of a first fibrous reinforcement according to the invention;

[0041] FIG. 5 shows an example of a strip cut from the DLF lap of the previous figure according to the invention;

[0042] FIG. 6 is a schematic and perspective view of an example of a fibrous reinforcement in the form of a continuous hollow sock according to the invention;

[0043] FIG. 7 is a schematic and perspective view of a core and a sock according to the invention;

[0044] FIG. 8 is a schematic and perspective view of a sock segment surrounding the surfaces of a core according to the invention;

[0045] FIG. 9 is a schematic and perspective view of the core inserted in the continuous hollow sock according to FIG. 8 and the rest of the cut sock according to the invention;

[0046] FIG. 10 is a schematic and top view of a mould in which are placed cores surrounded respectively by sock segment and at least one DLF strip surrounding each sock segment according to the invention;

[0047] FIG. 11 is a schematic and perspective view of a blank example of a pair of straighteners in which the cell separating the vanes is at least obtained by using at least one sock containing a core and DLF strips according to the invention;

[0048] FIG. 12 is a schematic and top view of an example of a blank for producing a one-piece composite material turbomachine wheel multiplet or sector according to the invention; and

[0049] FIG. 13 shows a flow chart of a method for manufacturing a composite material part according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0050] FIG. 1 shows an axial and partial cross-section of a turbomachine 1 of longitudinal axis X which comprises various parts and/or members that can be made of composite materials. Of course, the invention is generally applicable to all parts made of composite material with complex shapes (e.g. profiles with changing cross-sections) and in various fields in which the parts allow a transmission of the forces and a mass reduction while being economical.

[0051] The turbomachine 1 in FIG. 1 is a dual-flow and dual-body turbomachine intended for mounting on an aircraft. The turbomachine 1 comprises a fan 2 which is mounted upstream of a gas generator 3 or engine along the flow of the gases in the turbomachine and here along the longitudinal axis X (and even from left to right in FIG. 1). The gas generator 3 comprises, from upstream to downstream, a low-pressure compressor 4a, a high-pressure compressor 4b, a combustion chamber 5, a high-pressure turbine 6a and a low-pressure turbine 6b. The fan 2 comprises a plurality of fan vanes 7 which extend along a radial axis Z and whose free ends are surrounded by a fan casing 8. The longitudinal axis X is perpendicular to the radial axis Z and also to a transverse axis Y. The fan casing 8 is carried by a nacelle 9, the nacelle 9 and the fan casing 8 being centred on the longitudinal axis X. The fan 2 divides the air entering the turbomachine into a primary airflow which passes through the gas generator and in particular into a primary duct 10, and a secondary airflow which flows around the gas generator in a secondary duct 11. Outlet Guide Vane (OGV) 12 which are downstream of the fan vanes 7, extending around the longitudinal axis X and across the secondary duct to straighten the secondary airflow.

[0052] FIGS. 2 and 3 each illustrate a part 20 made of composite material with a fibrous reinforcement embedded in a matrix. In particular, the part 20 comprises a cellular structure. Each cell 21a, 21b is delimited by several walls 22 forming a parallelepiped. However, the cells 21a, 21b may have cross-sections with other shapes such as hexagonal, circular, triangular. As can be seen in FIG. 2, the walls also allow to separate the cells from each other. The cellular structure here forms a honeycomb structure (NIDA). The part 20 of FIG. 2, made of a composite material with a cellular structure, allow to produce thrust reverser grids 20a which are intended to be installed in a fan casing, for example. The part 20 comprises a panel 23 forming a bottom from which the walls 22 of the cellular structure rise. This type of part 20 allow advantageously to produce thrust reverser flaps or acoustic panels 20b. The latter are typically arranged on a radially internal wall 13 of the fan casing 8 and downstream of the fan vanes 7 along the longitudinal axis.

[0053] The part made of composite material with a cellular structure as above is composed of a first fibrous reinforcement with discontinuous long fibres and a second fibrous reinforcement with continuous long fibres. The fibrous reinforcements are intended to provide strength to the final part 20 obtained in particular at the level of the walls or junctions of the part. The cells of the part are obtained by removable cores around which the fibrous reinforcements are placed. The fibrous reinforcements are densified by a matrix to obtain the final rigid part with the cells (whose respective shapes are obtained by the cores).

[0054] We will now describe in detail the manufacturing method 100 of such a cellular part. This method is shown in FIG. 13. With reference to FIGS. 7 and 8, the method 100 comprises a step 110 of supplying or providing at least one first core 40 having a shape corresponding to that of the cell 21 of the cellular structure of the final part 20, 20a, 20b. In the present example, the core 40 has a generally cubic shape with a height h, depth p and width I. The core 40 has external draping surfaces 41, 42.

[0055] The method 100 comprises a step 120 of providing a lap 50 of the first fibrous reinforcement as shown in FIG. 4. The lap 50 comprises a plurality of discontinuous long fibres which are randomly oriented in all directions in a plane. The discontinuous long fibres are known by the acronym “DLF” (Discontinuous Long Fiber). In particular, the DLF lap 50 comprises the fibres and a matrix. In particular, the fibres are pre-impregnated.

[0056] The DLF lap 50 itself is manufactured from a number of “chips” or coupons comprising oriented fibres. More specifically, the manufacture of the DLF lap 50 comprises cutting a number of coupons from an original lap which comprises unidirectional fibres impregnated with a matrix. Each coupon (of unidirectional pre-impregnated fibres) is approximately 50 mm long and 10 mm wide. Each coupon is also approximately 0.15 mm thick. The manufacture of the DLF lap 50 also comprises the random layering of several coupons. This implies that the fibres of the DLF lap 50 are also randomly (and in all directions) oriented in the plane. The DLF lap is considered isotropic in the plane (same mechanical properties in all directions in the plane of the DLF lap) and is assimilated to an orthotropic material (three planes of orthogonal symmetry).

[0057] The manufacturing method 100 of the part comprises a step 130 of producing at least one strip 50a of the DLF lap 50, hereinafter referred to as DLF strip 50a. An example of a DLF strip 50a is shown in FIG. 5. In particular, this step comprises cutting the DLF lap to make one or more DLF strips 50a. In other words, the fibres of the strips 50a of the first reinforcement are pre-impregnated and comprise fibres oriented in all directions in a same plane. Each DLF strip 50a comprises, for example, a length L1 of approximately 100 mm and a width 12 of approximately 50 mm. These dimensions can be applied to the manufacture of a thrust reverser grid. Of course, the size of the DLF strips depends on the draping and/or the part to be manufactured. Each DLF strip has a thickness corresponding to the thickness of several pre-impregnated plies. The number of plies can be equal to about ten plies. The discontinuous long fibres are between 10 and 60 mm long.

[0058] The fibres are advantageously pre-impregnated with a polymeric impregnation matrix. The latter comprises in particular a thermoplastic or thermosetting resin. An example of a thermoplastic resin is a polyamide, polyetheretherketone, polyetherketoneketone, polyphenylene sulfide or polyaryl etherketone. The thermosetting resin comprises, for example, an epoxide or a polyimide. The fibres are mineral, metallic, thermoplastic polymer or thermosetting polymer fibres or a mixture of these fibres. An example of fibre is carbon, glass or aramid fibre.

[0059] Preferably, but not restrictively, the DLF lap 50 is of the type marketed under the name HexMC®. The matrix or resin can be an epoxy resin such as 8552® and the fibres are carbon.

[0060] With reference to FIG. 6, the method comprises a step 140 of making the second fibrous reinforcement in the form of a sock 30, a hose, or else an envelope. The sock 30 is hollow or tubular and continuous. In the present example, the fibrous reinforcement of the sock 30 is obtained by braiding along a longitudinal direction L (direction of advance of the braid) so as to provide dimensional stability of the fibrous reinforcement in terms of its thickness and length along the longitudinal direction. The sock 30 comprises a first end 31 which is open. The first end 31 comprises a first border 32 which delimits a first aperture 33 opening into the interior of the hollow sock 30. The sock 30 also comprises a second end 34 (opposite the first end 31) along the longitudinal direction L) which also comprises a second aperture 35 delimited by a second border 36.

[0061] The threads or strands used to produce the sock 30 comprise mineral, metallic, thermoplastic polymer or thermosetting polymer fibres or a mixture of these fibres. As mineral fibres we have carbon, glass, ceramic, silica, silicon carbide. Thermoplastic or thermosetting polymer fibres can be made of aramid, polyamide or alumina. The metal fibres may comprise steel, titanium, Inconel®, bronze or else copper.

[0062] Advantageously, the second fibrous reinforcement of the sock 30 consists of continuous long fibres.

[0063] Advantageously, the braiding of the fibrous reinforcement (forming the sock) is a triaxial or biaxial type braiding. A triaxial braiding allows the braid to have a perimeter that does not deform when it is pulled or, conversely, to have a constant height when the perimeter is compressed. This is because it provides stiffness in the longitudinal direction of the braid, which corresponds to the braiding direction. In triaxial braiding, the fibres extend in the preform in three directions, a first direction parallel to the longitudinal direction (forming an angle of 0°) and a second and third direction each forming an angle of between 0° and 90° to the longitudinal direction. The biaxial braiding allows to facilitate the deformation prior to the densification with a matrix.

[0064] With reference to FIGS. 7 and 8, the method comprises a step 150 of inserting the first core 40 into (inside) the braided sock 30. After insertion, the fibres of the sock 30 are applied to four draping surfaces 41, 42 of the core which are juxtaposed around a central axis C of the core 40 as shown in FIG. 7. The core 40 comprises faces 45, 46 which are opposite each other along the axis C (and here along the longitudinal direction L of the sock 30 with reference to FIG. 6). In particular, each face 45, 46 is defined in a plane perpendicular to the plane of the draping surfaces 41, 42. Once the core 40 is inserted into the sock 30, the faces 45, 46 are not covered by the sock 30.

[0065] With reference to FIG. 9, the method comprises a step 160 of cutting the sock so as to form a first sock segment 37 having a predetermined length corresponding to the height h of the core. Similarly, the length of the cut sock corresponds substantially to the height of the wall of the cellular structure of the final part.

[0066] The method comprises a step 170 of draping at least one DLF strip 50a of the first fibrous reinforcement over (around) the sock 30. The DLF strip 50a is arranged so as to produce the walls or junctions that separate the cells from the final part. Several DLF strips are arranged and/or stacked around the sock (opposite the draping surfaces) and overlap all or part of the draping surfaces 41, 42. Alternatively, a single and unique DLF strip 50a surrounds the sock segment 37.

[0067] The assembly (first assembly) “first sock segment 37 (cut out) containing the first core 40a and a strip 50a draped around the sock 30” is placed (step 180) in a mould 60, which is shown in FIG. 10. The mould 60 comprises lateral panels 61 which rise from a bottom wall 62. The assembly is installed so that the undraped face 45 of the core turned outwards from the mould 60 (or opposite and spaced from the bottom wall 62 of the mould 60).

[0068] These last steps are repeated several times with the same continuous hose sock. That is, a second core 40b is inserted into the same sock 30 which is cut to form a second sock segment 37b (see FIG. 10) at the height of the second core 40b. Then one or more DLF strips 50a are draped over the second sock segment 37b, and this assembly (second assembly) is then placed in the mould 60. The second assembly is arranged next to the first assembly in a first row R1. These operations are repeated until the surface of the mould is filled, row after row.

[0069] Alternatively, as shown in FIG. 10, the step 180 may comprise a sub-step 181 of placing a ply 51 (or other fibrous reinforcement) between each row R1, R2 of cores, socks, DLF strip or strips assembly. The ply 51 is arranged after each row R1, R2 has been completed. In other words, two rows are separated in a direction parallel to the bottom wall 62 (and/or perpendicular to the ply direction) by a ply 51. Advantageously, the unidirectional ply is in the form of a rectangular plate or a stacking of plies that forms a plate. The ply 51 has a thickness, a length and a width. The thickness is between 0.010 mm and 10 mm. The length and the width depend on the dimensions of the final part. Each ply 51 may consist of a unidirectional lap in which the fibres are parallel to each other. The ply 51 can also be made from a DLF strip or be woven. Advantageously, the fibres of the ply 50 are pre-impregnated. Such a ply is used, for example, in the scope of the manufacture of a thrust reverser grid.

[0070] In the scope of producing the part 20b, the method 100 may comprise, prior to the step 180, a step 190 of arranging a layer of a third fibrous reinforcement on the bottom wall 62 of the mould 60. This third fibrous reinforcement may be a segment of the DLF lap or a continuous long fibre laminate. The various assemblies are placed in the mould on this third reinforcement layer.

[0071] The method further comprises a step 200 of polymerising the preform so as to densify the fibrous reinforcements. Advantageously, the polymerisation is a thermocompression. The thermocompression is the application of a predetermined pressure and temperature cycle. The mould 60 is installed in an oven which will be heated. In particular, the polymerisation temperature is between 150° C. and 400° C. The temperature can be stationary or variable during the cycle. During the polymerisation, the pressure applied is between 0.1 and 200 bar. In the case of thermocompression, a force is exerted, for example, on the surface of the sock or by the outer surfaces of the mould. The pressure is applied to the surfaces/faces of each core (in each sock segment) in at least two directions. Advantageously, the pressure is applied in several directions. The pressure can be produced by means of pistons. In the case of a sock produced by triaxial braiding, the height of the sock does not change and the perimeter of the sock is fixed after the polymerisation.

[0072] Advantageously, each sock, core, DLF strip or strips assembly may undergo a partial polymerisation or pre-cure step 210. This is a first thermal treatment that starts the polymerisation of the resin or matrix to adapt the minimum viscosity and avoid that the resin is too fluid when pressure is applied while still being malleable. We understand that this step takes place before the polymerisation step 200. Advantageously, this step 210 is carried out before the step 180 of placing in the mould. Such partial polymerisation allows to prevent the migration of too much resin through the sock and the DLF strips. Also, if the resin is too fluid, the resin can flow faster than the fibres, which can cause the resin to be ejected. In this way, the uniform migration of the resin during this partial polymerisation step is controlled and allows the reduction of the porosity areas so as to achieve the expected mechanical performance.

[0073] A partial polymerisation step 210 may take place for the ply 51 before the polymerisation step 200. Advantageously, this step 210 is carried out before the ply 51 is placed in the mould 60.

[0074] Similarly, in the step 210, the resin is heated to a temperature of between 50° and 150° C. and for a period of between 1 min and 60 min. This temperature depends on the nature of the impregnating resin. The partial polymerisation rate of the impregnating resin is preferably between 10% and 60%. At the end of this step, the sock or socks 30 and the DLF strip or strips 50a are relatively stiff, dry and not sticky.

[0075] The solidified part after polymerisation (step 200) is then unmoulded. In the present example, in order to facilitate demoulding, each core 40, 40a, 40b is made of a meltable material such as salt or a eutectic material. Other examples of fusible materials are of course possible. Alternatively, each core 40, 40a, 40b consists of several blocks to facilitate subsequent demoulding. In other words, each core is rigid.

[0076] With reference to FIGS. 2 and 3, the final part, in this case a cellular structure, is a monobloc part (made integral) whose walls 22 delimiting the cells (voids) are formed of several fibrous reinforcements densified by a matrix.

[0077] FIG. 11 illustrates a blank 80 of a segment of a turbomachine wheel (not shown). This blank 80 is intended to form a doublet with a pair of vanes of a turbomachine which are spaced apart by a cell 21 in a circumferential direction. The doublet is manufactured integral and in one-piece. The vanes may be vanes OGV, as described above, arranged downstream of the fan or straightener vanes (IGV for Inlet Guide Vane) arranged at the inlet to the primary duct. Each vane comprises a blade, a radially external platform at the head of the blade and a radially internal platform at the root of the blade. Each vane is made of a fibrous reinforcement. The cell is made in the same way as described above.

[0078] In particular, the cell is made by means of a core 40 which is inserted (step 150) into a sock 30 which will be cut (step 160) into a sock segment 38 at the height of the core. The braiding of the sock could be carried out directly on the core which would act as a support mandrel. The sock segment 38 will allow to at least partly delimit the intrados and extrados surfaces of each blade, which are connected upstream by the leading edge and downstream by the trailing edge for each blade. Each blade is made from one or more DLF strips 50a to form a preform 70 of vane blade. To this end, one or more DLF strips 50a are then draped (step 170) around the sock segment containing the core, and in particular on either side of the core (in a direction perpendicular to the face 45). This assembly is then placed (step 180) in the mould 60. The face 45 of the core is arranged so as to be substantially parallel to the bottom wall 62 of the mould. A polymerisation (thermocompression) step 200 is performed to densify the assembly (which is placed in the mould as described above). As in the previous embodiments, a partial polymerisation step 210 may be carried out prior to the polymerisation step. These steps are repeated several times for each pair of vanes spaced by one cell to form a complete wheel.

[0079] The method can also allow to manufacture the complete (360°) turbomachine wheel, a multiplet or a sector of a turbomachine wheel. The multiplet or wheel sector comprises at least three vanes (OGV or IGV) spaced by at least two cells. As with the doublet, the multiplet is made integral and in one-piece. To manufacture this multiplet or sector, the same steps described in connection with FIGS. 10 and 11 are implemented. In particular, FIG. 12 shows three cores 40a, 40b, 40c and around the DLF strips 50a to form four blade preforms. The cores are respectively inserted into a sock 30 which is cut at the height of said core to form sock segments. One or more DLF laps 50a are draped around the sock segments containing the core to form the preforms of the blades of the vanes. In the scope of the multiplet or sector, the method comprises a step 220 of placing the or a sock 30 around the assemblies here comprising three cores each surrounded by a sock segment and DLF strips. The assemblies are juxtaposed substantially in a row with the face 45 turned outwards. The or the other sock will be cut into a (third) sock segment 39 at a height corresponding to the chord of the blade or height of the cores. In this way, the cut sock segment 39 is arranged at the radially lower and upper portion of the preforms (along a direction perpendicular to the face 45 of the cores defined in a plane which is parallel to the bottom wall of the mould) to connect the four blade preforms and the three cores. A polymerisation step 200 is performed to densify the assembly, possibly with a partial polymerisation step beforehand.