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WO2025068647A1 - Composite blade with leading edge made from thermoplastic material - Google Patents

Composite blade with leading edge made from thermoplastic material Download PDF

Info

Publication number
WO2025068647A1
WO2025068647A1 PCT/FR2024/051197 FR2024051197W WO2025068647A1 WO 2025068647 A1 WO2025068647 A1 WO 2025068647A1 FR 2024051197 W FR2024051197 W FR 2024051197W WO 2025068647 A1 WO2025068647 A1 WO 2025068647A1
Authority
WO
WIPO (PCT)
Prior art keywords
impregnation
thermoplastic
aeronautical
leading edge
trailing edge
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
PCT/FR2024/051197
Other languages
French (fr)
Inventor
Hervé Grelin
Mattéo MINERVINO
Nicolas DROZ
Didier Fromonteil
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 Aircraft Engines SAS
Original Assignee
Safran Aircraft Engines SAS
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 Aircraft Engines SAS filed Critical Safran Aircraft Engines SAS
Publication of WO2025068647A1 publication Critical patent/WO2025068647A1/en
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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
    • B29C70/003—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties
    • B29C70/0035—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties comprising two or more matrix materials
    • 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
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/105—Coating or impregnating independently of the moulding or shaping step of reinforcement of definite length with a matrix in solid form, e.g. powder, fibre or sheet form
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • 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
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/141—Shape, i.e. outer, aerodynamic form
    • 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
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/141—Shape, i.e. outer, aerodynamic form
    • F01D5/145—Means for influencing boundary layers or secondary circulations
    • 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
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • 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
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • 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
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • 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
    • 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
    • F05D2230/20—Manufacture essentially without removing material
    • 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
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • 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
    • F05D2230/50—Building or constructing in particular ways
    • F05D2230/51—Building or constructing in particular ways in a modular way, e.g. using several identical or complementary parts or features
    • 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
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05D2240/303—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the leading edge of a rotor blade
    • 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
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05D2240/304—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the trailing edge of a rotor blade
    • 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
    • F05D2250/00—Geometry
    • F05D2250/10—Two-dimensional
    • F05D2250/11—Two-dimensional triangular
    • 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
    • F05D2250/00—Geometry
    • F05D2250/10—Two-dimensional
    • F05D2250/18—Two-dimensional patterned
    • F05D2250/181—Two-dimensional patterned ridged
    • 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
    • F05D2250/00—Geometry
    • F05D2250/10—Two-dimensional
    • F05D2250/18—Two-dimensional patterned
    • F05D2250/182—Two-dimensional patterned crenellated, notched
    • 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
    • F05D2250/00—Geometry
    • F05D2250/10—Two-dimensional
    • F05D2250/18—Two-dimensional patterned
    • F05D2250/183—Two-dimensional patterned zigzag
    • 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
    • F05D2250/00—Geometry
    • F05D2250/10—Two-dimensional
    • F05D2250/18—Two-dimensional patterned
    • F05D2250/184—Two-dimensional patterned sinusoidal
    • 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
    • F05D2250/00—Geometry
    • F05D2250/10—Two-dimensional
    • F05D2250/18—Two-dimensional patterned
    • F05D2250/185—Two-dimensional patterned serpentine-like
    • 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
    • F05D2300/40—Organic materials
    • F05D2300/43—Synthetic polymers, e.g. plastics; Rubber
    • 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
    • F05D2300/40—Organic materials
    • F05D2300/43—Synthetic polymers, e.g. plastics; Rubber
    • F05D2300/434—Polyimides, e.g. AURUM
    • 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
    • F05D2300/40—Organic materials
    • F05D2300/43—Synthetic polymers, e.g. plastics; Rubber
    • F05D2300/436—Polyetherketones, e.g. PEEK
    • 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
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced

Definitions

  • the invention relates to a turbomachine blade, such as an industrial gas turbine, an aeronautical turbine of an aircraft or helicopter engine, or an auxiliary power unit (APU).
  • a turbomachine blade such as an industrial gas turbine, an aeronautical turbine of an aircraft or helicopter engine, or an auxiliary power unit (APU).
  • the invention applies in particular to fan, turbine and OGV rectifier blades.
  • air is admitted into an inlet sleeve 2 to pass through a fan 3 before splitting into a central primary flow and a secondary flow surrounding the primary flow.
  • the primary flow is compressed by low pressure 4 and high pressure 5 compressors before reaching a combustion chamber 6, after which it expands by passing through a high pressure turbine 7 and a low pressure turbine 8, before being evacuated, generating auxiliary thrust.
  • the secondary flow is propelled directly by the fan to generate main thrust.
  • Each turbine 7, 8, as well as the fan 3 comprises radially oriented blade rings regularly spaced around an axis of rotation AX, an external casing 9 surrounding the blade rings.
  • Fixed OGV rectifiers which are interposed between the blade rings also comprise blade rings.
  • Each blade 10 comprises a blade body 11 made of composite material and a root P by which it is mounted to a cell of a rotating disk of the turbojet, which is extended by a blade 12 extending in a main direction EV, called the span direction.
  • This blade 12 is the aerodynamic part of this blade, and it is terminated by a tip. It comprises a trailing edge 13 substantially parallel to the span direction EV and located downstream AV, relative to the direction of circulation of the gases in the turbomachine and a leading edge 14 substantially parallel to the trailing edge 13 and spaced from it along the axis AX to be upstream AM of the blade.
  • the blade 12 is terminated by a tip S.
  • a metal leading edge element 15 is attached by gluing to the trailing edge 13 in order to improve its resistance to shocks and abrasion. Assembling by gluing is prohibited for the production of aeronautical parts when it can lead to a so-called "hazardous" phenomenon, i.e. critical for safety.
  • the production of the leading edge element in metal limits the possibility of acting on its geometry to improve its performance.
  • such a leading edge element adds mass to a part moving at high speed.
  • climate change is a major concern for many legislative and regulatory bodies around the world. Various states have, are, or will adopt various carbon emission restrictions. In particular, an eager standard applies to both new aircraft types and those already in operation, requiring the implementation of technological solutions to comply with current regulations. For several years now, civil aviation has been mobilizing to contribute to the fight against climate change.
  • the invention is the result of technological research aimed at very significantly improving the performance of aircraft and, in this sense, contributes to reducing the environmental impact of aircraft.
  • the invention relates to an aeronautical part comprising a body made of composite material which has a portion which is at least partially impregnated with a thermoplastic-type impregnation material.
  • a protective element comprising a thermoplastic-type construction material is attached by welding to the portion.
  • the aeronautical part comprises a turbomachine blade comprising a blade body made of composite material extending in a main direction, the body having a lower surface and an upper surface connected in an upstream part of the body by a leading edge and in a downstream part of the body on the other hand by a trailing edge, the upstream and downstream parts being located on either side of the main direction.
  • the portion which is at least partially impregnated with a thermoplastic type impregnation material is a portion of an edge chosen from the leading edge and the trailing edge.
  • the protective element is a leading edge element or a trailing edge element.
  • the protective element has serrations
  • the impregnation material is chosen from the following types of materials: PolyEtherimide, Polyetheretherketone, Polyetherketone; - the portion which is at least partially impregnated with thermoplastic has a thickness substantially equal to a strand of a fiber of the composite material;
  • the composite material is at least partially impregnated with a thermosetting resin
  • the protective element comprises at least one metal reinforcement.
  • the invention also relates to a method for manufacturing an aeronautical part comprising the following steps:
  • a step of prefabricating a fiber preform of an aeronautical part body comprising a portion such as a leading edge or a trailing edge;
  • thermoplastic type impregnation material a step of impregnating at least part of the portion using a first thermoplastic type impregnation material
  • the impregnation step includes the following steps:
  • thermoplastic film - a step of applying impregnation pressure to the thermoplastic film
  • the impregnation step comprises a step of monitoring the impregnation pressure and/or the impregnation temperature as well as a step of stopping the impregnation when the impregnation pressure and/or the impregnation temperature is lower than a predefined value.
  • the resin injection step is carried out using the resin transfer molding process and/or the prefabrication, impregnation and resin injection steps take place in a single tool mold kept closed during all of these steps.
  • Figure 1 is a schematic longitudinal sectional view of an aircraft engine
  • Figure 2 is a schematic perspective view of a turbomachine blade
  • Figure 3 is a partial schematic cross-sectional view of the first and second steps of the method according to the invention.
  • Figure 4 is a partial schematic cross-sectional view of a fourth step of the method according to the invention.
  • Figure 5 is a partial schematic cross-sectional view of a fifth step of the method according to the invention.
  • Figure 6 is a partial schematic cross-sectional view of a sixth step of the method according to the invention.
  • Figure 7 is a partial schematic cross-sectional view of a seventh step of the method according to the invention.
  • Figure 8 is a schematic side view of a leading edge element according to the invention.
  • Figure 9 is a partial schematic cross-sectional view of an eighth step of the method according to the invention.
  • Figure 10 is a schematic perspective view of a turbomachine blade according to the invention.
  • a fiber preform 20 of the body 11 of the blade 10 is manufactured.
  • This preform 20 is here made of fiber 3D woven carbon.
  • the body 11 of the blade 10 has been partially represented in the form of a downstream portion of a trailing edge 13 composed of fifteen strands 21.
  • a continuous film 30 made of Polyetherketone (PEK) is positioned in a tooling mold 25.
  • the film 30 is, here, made up of two portions 31 and 32 intended to be applied respectively to a portion of the intrados 16 and a portion of the extrados 17 of the blade body 11 to cover the trailing edge 13 over the entire height of the blade 12.
  • the preform 20 is introduced into the mold 25 to come into contact with the film 30.
  • the mold 25 is then closed.
  • two jaws 26 and T1 of the mold 25 are activated to apply an impregnation pressure to the film 30.
  • the jaws 26 and T1 are also heated to an impregnation temperature of, here, between three hundred and four hundred degrees centigrade.
  • an impregnation temperature of, here, between three hundred and four hundred degrees centigrade.
  • a fifth step of monitoring the impregnation pressure and the impregnation temperature is implemented. When the impregnation pressure and/or the impregnation temperature becomes lower than a predefined value, the impregnation step is stopped by stopping the application of pressure and heat to the film 30 (FIG. 5).
  • an epoxy resin 33 of the epoxy type is injected into the mold 25 according to the resin transfer molding method.
  • the mold 25 is then opened, and the preform 20 - thus injected with epoxy resin 33 and a portion of the trailing edge 13 of which is impregnated with PEK - is extracted from the mold 25.
  • a trailing edge element 34 made of Polyetheretherketone (PEEK) is presented on the trailing edge 13 impregnated with the film 30.
  • the trailing edge element 34 has serrations 35, also called serrations (figure 8).
  • the trailing edge element 34 is assembled on the trailing edge 13 of the blade 12 by thermoplastic welding.
  • This produces a blade 10 comprising a blade body 11 made of carbon fiber/epoxy resin composite material 33 extending in a main direction EV.
  • the body 11 has a lower surface 16 and an upper surface 17 connected in an upstream portion of the body 11 by a trailing edge 13 and in a downstream portion of the body 11 on the other hand by a trailing edge 14.
  • the upstream and downstream portions are located on either side of the main direction EV and the trailing edge 13 comprises a trailing edge portion 13 which is at least partially impregnated with PEK.
  • the blade 10 comprises a trailing edge element 34 made of PEEK added by welding to the blade body 11.
  • leading edge 14 of the blade 10 is also impregnated with PEK using a method identical to that described previously.
  • a leading edge element 44 made of PEEK is attached to the leading edge 14 by thermoplastic welding.
  • the preform is made of 3D woven carbon fibers
  • the invention also applies to other types of preform such as for example a preform made of glass fiber or aramid, partially or totally co-woven or not.
  • the fiber preform can be of the interlock type, or with added 1D unidirectional folds; although here the film applied to the leading edge is made of Polyetherketone, the invention also applies to other types of first thermoplastic material such as for example Polyetheretherketone or Polyetherimide; although here the impregnation is carried out using a continuous film applied over the entire height of the blade, the invention also applies to other types of impregnation, for example using a discontinuous film or spray or brush deposition, or discontinuous impregnation which may also not extend over the entire height of the blade; although here the injected resin is an epoxy resin, the invention also applies to other types of resins, preferably thermosetting, such as for example a Bismaleimide type resin; although here the trailing edge element is made of Polyetheretherketone, the invention
  • the trailing edge element may not be composed exclusively of the thermoplastic construction material but comprise a mixture of material comprising at least one thermoplastic type material; although here the film applied to the trailing edge is made of Polyetherketone, the invention also applies to other types of other thermoplastic impregnation material such as for example Polyetherketone or Polyetherimide; although here the leading edge element is made of Polyetherketone, the invention also applies to other types of other thermoplastic construction material such as for example Polyetherimide or Polyetherketone.
  • the leading edge element may not be composed exclusively of the second thermoplastic material but comprise a mixture of material comprising at least one thermoplastic type material;
  • the invention also applies to a blade in which one edge among the leading edge and the trailing edge receives an edge element, such as for example a blade in which only the leading edge comprises an edge element.

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Abstract

An aeronautical part (10) comprising a body (11) made from composite material which has a portion that is at least partially impregnated with a thermoplastic impregnation material (30) and a protective element (34, 44) comprising a thermoplastic construction material which is attached to the portion by welding. Method for manufacturing such a part.

Description

DESCRIPTION DESCRIPTION

TITRE DE L'INVENTION : Aube composite à bord d'attaque en matériau thermoplastique TITLE OF THE INVENTION: Composite blade with leading edge made of thermoplastic material

DOMAINE TECHNIQUE TECHNICAL FIELD

L'invention concerne une pale de turbomachine, telle qu'une turbine à gaz industrielle, une turbine aéronautique de moteur d'avion ou d'hélicoptère, ou encore une unité de puissance auxiliaire (APU). L'invention s'applique notamment aux pales de soufflante, de turbine et de redresseurs OGV. The invention relates to a turbomachine blade, such as an industrial gas turbine, an aeronautical turbine of an aircraft or helicopter engine, or an auxiliary power unit (APU). The invention applies in particular to fan, turbine and OGV rectifier blades.

ÉTAT DE LA TECHNIQUE ANTÉRIEURE STATE OF THE PRIOR ART

Dans un moteur de type turboréacteur, repéré par 1 dans la figure 1, l'air est admis dans une manche d'entrée 2 pour traverser une soufflante 3 avant de se scinder en un flux primaire central et un flux secondaire entourant le flux primaire. In a turbojet engine, marked 1 in Figure 1, air is admitted into an inlet sleeve 2 to pass through a fan 3 before splitting into a central primary flow and a secondary flow surrounding the primary flow.

Le flux primaire est compressé par des compresseurs basse pression 4 et haute pression 5 avant d'atteindre une chambre de combustion 6, après quoi il se détend en traversant une turbine haute pression 7 et une turbine basse pression 8, avant d'être évacué en générant une poussée auxiliaire. Le flux secondaire est quant à lui propulsé directement par la soufflante pour générer une poussée principale. The primary flow is compressed by low pressure 4 and high pressure 5 compressors before reaching a combustion chamber 6, after which it expands by passing through a high pressure turbine 7 and a low pressure turbine 8, before being evacuated, generating auxiliary thrust. The secondary flow is propelled directly by the fan to generate main thrust.

Chaque turbine 7, 8, ainsi que la soufflante 3 comporte des couronnes d'aubes orientées radialement et régulièrement espacées autour d'un axe de rotation AX, un carter externe 9 entourant les couronnes d'aubes. Des redresseurs OGV fixes et qui sont intercalés entre les couronnes d'aubes comprennent eux aussi des couronnes d'aubes. Each turbine 7, 8, as well as the fan 3, comprises radially oriented blade rings regularly spaced around an axis of rotation AX, an external casing 9 surrounding the blade rings. Fixed OGV rectifiers which are interposed between the blade rings also comprise blade rings.

Chaque aube 10 comporte un corps d'aube 11 en matériau composite et un pied P par lequel elle est montée à une alvéole d'un disque rotatif du turboréacteur, qui est prolongé par une pale 12 s'étendant selon une direction principale EV, dite direction d'envergure. Cette palel2 est la partie aérodynamique de cette aube, et elle est terminée par un sommet. Elle comprend un bord de fuite 13 sensiblement parallèle à la direction d'envergure EV et situé à l'aval AV, par rapport au sens de circulation des gaz dans la turbomachine et un bord d 'attaque 14 sensiblement parallèle au bord de fuite 13 et espacé de celui-ci le long de l'axe AX pour être à l'amont AM de l'aube. La pale 12 est terminée par un sommet S. Un élément de bord d'attaque 15 métallique est rapporté par collage sur le bord de fuite 13 afin d'en améliorer la résistance aux chocs et à l'abrasion. L'assemblage par collage est proscrit pour la réalisation de pièces aéronautiques lorsque celui-ci peut amener à un phénomène dits « hazardous », c'est-à-dire critiques pour la sécurité . La réalisation de l'élément de bord d'attaque en métal limite la possibilité d'agir sur la géométrie de celui-ci pour en améliorer les performances. Enfin, un tel élément de bord d'attaque rajoute de la masse sur une pièce mobile à haute vitesse. Each blade 10 comprises a blade body 11 made of composite material and a root P by which it is mounted to a cell of a rotating disk of the turbojet, which is extended by a blade 12 extending in a main direction EV, called the span direction. This blade 12 is the aerodynamic part of this blade, and it is terminated by a tip. It comprises a trailing edge 13 substantially parallel to the span direction EV and located downstream AV, relative to the direction of circulation of the gases in the turbomachine and a leading edge 14 substantially parallel to the trailing edge 13 and spaced from it along the axis AX to be upstream AM of the blade. The blade 12 is terminated by a tip S. A metal leading edge element 15 is attached by gluing to the trailing edge 13 in order to improve its resistance to shocks and abrasion. Assembling by gluing is prohibited for the production of aeronautical parts when it can lead to a so-called "hazardous" phenomenon, i.e. critical for safety. The production of the leading edge element in metal limits the possibility of acting on its geometry to improve its performance. Finally, such a leading edge element adds mass to a part moving at high speed.

Le changement climatique est une préoccupation majeure pour de nombreux organes législatifs et de régulation à travers le monde. En effet, diverses restrictions sur les émissions de carbone ont été, sont ou seront adoptées par divers états. En particulier, une norme ambitieuse s'applique à la fois aux nouveaux types d'avions mais aussi ceux en circulation nécessitant de devoir mettre en oeuvre des solutions technologiques afin de les rendre conformes aux réglementations en vigueur. L'aviation civile se mobilise depuis maintenant plusieurs années pour apporter une contribution à la lutte contre le changement climatique. Climate change is a major concern for many legislative and regulatory bodies around the world. Various states have, are, or will adopt various carbon emission restrictions. In particular, an ambitious standard applies to both new aircraft types and those already in operation, requiring the implementation of technological solutions to comply with current regulations. For several years now, civil aviation has been mobilizing to contribute to the fight against climate change.

Les efforts de recherche technologique ont déjà permis d'améliorer de manière très significative les performances environnementales des avions. La Déposante prend en considération les facteurs impactant dans toutes les phases de conception et de développement pour obtenir des composants et des produits aéronautiques moins énergivores, plus respectueux de l'environnement et dont l'intégration et l'utilisation dans l'aviation civile ont des conséquences environnementales modérées dans un but d'amélioration de l'efficacité énergétique des avions. Technological research efforts have already led to very significant improvements in the environmental performance of aircraft. The Applicant takes into consideration the impact factors in all phases of design and development to obtain less energy-intensive, more environmentally friendly aeronautical components and products whose integration and use in civil aviation have moderate environmental consequences with the aim of improving the energy efficiency of aircraft.

Par voie de conséquence, la Déposante travaille en permanence à la réduction de son incidence climatique négative par l'emploi de méthodes et l'exploitation de procédés de développement et de fabrication vertueux et minimisant les émissions de gaz à effet de serre au minimum possible pour réduire de l'empreinte environnementale de son activité. Ces travaux de recherche et de développement soutenus portent à la fois sur les nouvelles générations de moteurs d'avions, l'allègement des appareils, notamment par les matériaux employés et les équipements embarqués allégés, le développement de l'emploi des technologies électriques pour assurer la propulsion, et, indispensables compléments aux progrès technologiques, les biocarburants aéronautiques. Consequently, the Applicant is constantly working to reduce its negative climate impact by using methods and operating virtuous development and manufacturing processes that minimize greenhouse gas emissions to the minimum possible in order to reduce the environmental footprint of its activity. This sustained research and development work covers new generations of aircraft engines, the weight reduction of aircraft, in particular through the materials used and lighter on-board equipment, the development of the use of electric technologies to ensure propulsion, and, essential complements to technological progress, aeronautical biofuels.

EXPOSÉ DE L'INVENTION STATEMENT OF THE INVENTION

A cet effet, l'invention est le résultat des recherches technologiques visant à améliorer de manière très significative les performances des avions et, en ce sens, contribue à la réduction de l'impact environnemental des avions. Pour cela, l'invention concerne une pièce aéronautique comprenant un corps en matériau composite qui présente une portion qui est au moins partiellement imprégné d'un matériau d'imprégnation de type thermoplastique. Un élément de protection comprenant un matériau de construction de type thermoplastique est rapporté par soudage sur la portion. To this end, the invention is the result of technological research aimed at very significantly improving the performance of aircraft and, in this sense, contributes to reducing the environmental impact of aircraft. For this purpose, the invention relates to an aeronautical part comprising a body made of composite material which has a portion which is at least partially impregnated with a thermoplastic-type impregnation material. A protective element comprising a thermoplastic-type construction material is attached by welding to the portion.

On obtient ainsi une aube à la durabilité améliorée qui présente un corps léger en composite à résine thermodurcissable et dont une portion est renforcé à l'aide d'un élément de protection réalisé en un matériau léger, résistant et économique à façonner. Le soudage de l'élément de bord améliore la durabilité et autorise d'étendre ce type de renfort à des aubes considérées critiques. This results in a blade with improved durability, which has a lightweight body made of thermosetting resin composite, a portion of which is reinforced with a protective element made of a lightweight, strong and economically processable material. Welding the edge element improves durability and allows this type of reinforcement to be extended to blades considered critical.

Selon d'autres modes de réalisation particuliers, non exclusifs et optionnels de l'invention : According to other particular, non-exclusive and optional embodiments of the invention:

- la pièce aéronautique comprend une pale de turbomachine comprenant un corps de pale en matériau composite s'étendant selon une direction principale, le corps ayant un intrados et un extrados reliés en une partie amont du corps par un bord d'attaque et en une partie avale du corps d'autre part par un bord de fuite, les parties amont et aval étant situées de part et d'autre de la direction principale. La portion qui est au moins partiellement imprégnée d'un matériau d'imprégnation de type thermoplastique est une portion d'un bord choisi parmi le bord d'attaque et le bord de fuite. L'élément de protection est un élément de bord d'attaque ou un élément de bord de fuite. - the aeronautical part comprises a turbomachine blade comprising a blade body made of composite material extending in a main direction, the body having a lower surface and an upper surface connected in an upstream part of the body by a leading edge and in a downstream part of the body on the other hand by a trailing edge, the upstream and downstream parts being located on either side of the main direction. The portion which is at least partially impregnated with a thermoplastic type impregnation material is a portion of an edge chosen from the leading edge and the trailing edge. The protective element is a leading edge element or a trailing edge element.

- l'élément de protection présente des serrations ; - the protective element has serrations;

- le matériau d'imprégnation est choisi parmi les types de matériaux suivants : PolyEtherimide, Polyétherétherketone, Polyétherketone ; - la portion la portion qui est au moins partiellement imprégnée de thermoplastique possède une épaisseur sensiblement égale à un toron d'une fibre du matériau composite;- the impregnation material is chosen from the following types of materials: PolyEtherimide, Polyetheretherketone, Polyetherketone; - the portion which is at least partially impregnated with thermoplastic has a thickness substantially equal to a strand of a fiber of the composite material;

- le matériau composite est au moins partiellement imprégné d'une résine thermodurcissable ; - the composite material is at least partially impregnated with a thermosetting resin;

- l'élément de protection comprend au moins un renfort métallique. - the protective element comprises at least one metal reinforcement.

L'invention concerne également un procédé de fabrication de pièce aéronautique comprenant les étapes suivantes : The invention also relates to a method for manufacturing an aeronautical part comprising the following steps:

- une étape de préfabrication d'une préforme fibreuse d'un corps de pièce aéronautique comportant une portion telle qu'un bord d'attaque ou un bord de fuite; - a step of prefabricating a fiber preform of an aeronautical part body comprising a portion such as a leading edge or a trailing edge;

- une étape d'imprégnation d'au moins une partie de la portion à l'aide d'un premier matériau d'imprégnation de type thermoplastique ; - a step of impregnating at least part of the portion using a first thermoplastic type impregnation material;

- une étape d'injection de résine ; - a resin injection step;

- une étape de présentation d'un élément de protection comprenant un deuxième matériau de type thermoplastique sur la portion ; - a step of presenting a protective element comprising a second thermoplastic type material on the portion;

- une étape d'assemblage de l'élément de protection sur la portion par une méthode de liaison par apport de chaleur telle que le soudage. - a step of assembling the protective element on the portion by a heat-applying bonding method such as welding.

Avantageusement, l'étape d'imprégnation comprend les étapes suivantes : Advantageously, the impregnation step includes the following steps:

- une étape de positionnement d'un film en le premier matériau thermoplastique sur la portion ; - a step of positioning a film made of the first thermoplastic material on the portion;

- une étape d'application d'une pression d'imprégnation sur le film thermoplastique ;- a step of applying impregnation pressure to the thermoplastic film;

- et/ou une étape de chauffe à une température d'imprégnation du film thermoplastique. Préférentiellement, l'étape d'imprégnation comprend une étape de surveillance de la pression d'imprégnation et/ou de la température d'imprégnation ainsi qu'une étape d'arrêt de l'imprégnation lorsque la pression d'imprégnation et/ou la température d'imprégnation, est inférieure à une valeur prédéfinie. - and/or a step of heating the thermoplastic film to an impregnation temperature. Preferably, the impregnation step comprises a step of monitoring the impregnation pressure and/or the impregnation temperature as well as a step of stopping the impregnation when the impregnation pressure and/or the impregnation temperature is lower than a predefined value.

Selon un mode de réalisation particulier, l'étape d'injection de résine se fait selon le procédé de moulage par transfert de résine et/ou les étapes de préfabrication, d'imprégnation et d'injection de résine se déroulent dans un unique moule d'outillage maintenu fermé durant toutes ces étapes. D'autres caractéristiques et avantages de l'invention apparaîtront à la lecture de la description qui suit d'un mode de réalisation particulier non limitatif de l'invention. According to a particular embodiment, the resin injection step is carried out using the resin transfer molding process and/or the prefabrication, impregnation and resin injection steps take place in a single tool mold kept closed during all of these steps. Other characteristics and advantages of the invention will appear on reading the following description of a particular non-limiting embodiment of the invention.

BRÈVE DESCRIPTION DES DESSINS BRIEF DESCRIPTION OF THE DRAWINGS

Il sera fait référence aux figures jointes parmi lesquelles : Reference will be made to the attached figures, including:

[Fig.1 ] La figure 1 est une vue schématique en coupe longitudinale d'un moteur d'aéronef ; [Fig.1] Figure 1 is a schematic longitudinal sectional view of an aircraft engine;

[Fig.2] La figure 2 est une vue schématique en perspective d'une aube de turbomachine ; [Fig.2] Figure 2 is a schematic perspective view of a turbomachine blade;

[Fig.3] La figure 3 est une vue schématique partielle en coupe transversale des première et deuxième étapes du procédé selon l'invention ; [Fig.3] Figure 3 is a partial schematic cross-sectional view of the first and second steps of the method according to the invention;

[Fig.4] La figure 4 est une vue schématique partielle en coupe transversale d'une quatrième étape du procédé selon l'invention ; [Fig.4] Figure 4 is a partial schematic cross-sectional view of a fourth step of the method according to the invention;

[Fig.5] La figure 5 est une vue schématique partielle en coupe transversale d'une cinquième étape du procédé selon l'invention ; [Fig.5] Figure 5 is a partial schematic cross-sectional view of a fifth step of the method according to the invention;

[Fig.6] La figure 6 est une vue schématique partielle en coupe transversale d'une sixième étape du procédé selon l'invention ; [Fig.6] Figure 6 is a partial schematic cross-sectional view of a sixth step of the method according to the invention;

[Fig.7] La figure 7 est une vue schématique partielle en coupe transversale d'une septième étape du procédé selon l'invention ; [Fig.7] Figure 7 is a partial schematic cross-sectional view of a seventh step of the method according to the invention;

[Fig.8] La figure 8 est une vue schématique de côté d'un élément de bord d'attaque selon l'invention ; [Fig.8] Figure 8 is a schematic side view of a leading edge element according to the invention;

[Fig.9] La figure 9 est une vue schématique partielle en coupe transversale d'une huitième étape du procédé selon l'invention ; [Fig.9] Figure 9 is a partial schematic cross-sectional view of an eighth step of the method according to the invention;

[Fig .10] La figure 10 est une vue schématique en perspective d'une aube de turbomachine selon l'invention. [Fig. 10] Figure 10 is a schematic perspective view of a turbomachine blade according to the invention.

EXPOSÉ DÉTAILLÉ DE MODES DE RÉALISATION PARTICULIERS DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Le procédé de fabrication d'une aube 10 de turbine selon l'invention va être décrite en référence aux figures 1 à 9. Selon une première étape de préfabrication, on fabrique une préforme 20 fibreuse du corps 11 de l'aube 10. Cette préforme 20 est ici en fibre de carbone entissés 3D. Sur l'ensemble des figures et par souci de clarté, on a représenté partiellement le corps 11 de l'aube 10 sous la forme d'une portion aval d'un bord de fuite 13 composé de quinze torons 21. The method of manufacturing a turbine blade 10 according to the invention will be described with reference to Figures 1 to 9. According to a first prefabrication step, a fiber preform 20 of the body 11 of the blade 10 is manufactured. This preform 20 is here made of fiber 3D woven carbon. In all the figures and for the sake of clarity, the body 11 of the blade 10 has been partially represented in the form of a downstream portion of a trailing edge 13 composed of fifteen strands 21.

Selon une deuxième étape d'imprégnation, on positionne dans un moule 25 d'outillage, un film 30 continu en Polyetherketone (PEK). Le film 30 est, ici, constitué de deux portions 31 et 32 destinées à être appliquées respectivement sur une portion de l'intrados 16 et une portion de l'extrados 17 du corps d'aube 11 pour recouvrir le bord de fuite 13 sur toute la hauteur de la pale 12. Selon une troisième étape représentée en figure 3, la préforme 20 est introduite dans le moule 25 pour venir au contact du film 30. Le moule 25 est ensuite fermé. Selon une quatrième étape représentée en figure 4, on active deux mors 26 et Tl du moule 25 pour appliquer une pression d'imprégnation sur le film 30. Les mors 26 et Tl sont également chauffés à une température d'imprégnation comprise, ici, entre trois cent et quatre cent degrés centigrades. Au cours de cette quatrième étape, une cinquième étape de surveillance de la pression d'imprégnation et de la température d'imprégnation est mise en œuvre. Lorsque la pression d'imprégnation et/ou la température d'imprégnation devient inférieure à une valeur prédéfinie, l'étape imprégnation est arrêtée en stoppant l'application de pression et de chaleur sur le film 30 (figure 5). According to a second impregnation step, a continuous film 30 made of Polyetherketone (PEK) is positioned in a tooling mold 25. The film 30 is, here, made up of two portions 31 and 32 intended to be applied respectively to a portion of the intrados 16 and a portion of the extrados 17 of the blade body 11 to cover the trailing edge 13 over the entire height of the blade 12. According to a third step shown in FIG. 3, the preform 20 is introduced into the mold 25 to come into contact with the film 30. The mold 25 is then closed. According to a fourth step shown in FIG. 4, two jaws 26 and T1 of the mold 25 are activated to apply an impregnation pressure to the film 30. The jaws 26 and T1 are also heated to an impregnation temperature of, here, between three hundred and four hundred degrees centigrade. During this fourth step, a fifth step of monitoring the impregnation pressure and the impregnation temperature is implemented. When the impregnation pressure and/or the impregnation temperature becomes lower than a predefined value, the impregnation step is stopped by stopping the application of pressure and heat to the film 30 (FIG. 5).

Les différents paramètres de pression, température ainsi que les valeurs prédéfinies pour ces paramètres sont choisis de manière à ce que la portion 13.1 du bord de fuite 13 qui est imprégnée possède une épaisseur e .i sensiblement égale au diamètre d'un toron 21 (figure 5) The various pressure and temperature parameters as well as the predefined values for these parameters are chosen so that the portion 13.1 of the trailing edge 13 which is impregnated has a thickness e.i substantially equal to the diameter of a strand 21 (figure 5)

Selon une sixième étape d'injection de résine représentée en figure 6, on injecte dans le moule 25 une résine époxy 33 de type epoxy selon le procédé de moulage par transfert de résine. Le moule 25 est alors ouvert, et la préforme 20- ainsi injectée de résine époxy 33 et dont une portion du bord de fuite 13 est imprégnée de PEK - est extraite du moule 25. According to a sixth resin injection step shown in Figure 6, an epoxy resin 33 of the epoxy type is injected into the mold 25 according to the resin transfer molding method. The mold 25 is then opened, and the preform 20 - thus injected with epoxy resin 33 and a portion of the trailing edge 13 of which is impregnated with PEK - is extracted from the mold 25.

Selon une septième étape de présentation représentée en figure 7, on vient présenter un élément de bord de fuite 34 en Polyetheretherketone (PEEK) sur le bord de fuite 13 imprégné du film 30. L'élément de bord de fuite 34 présente des serrations 35, également appelées dentelures (figure 8). According to a seventh presentation step shown in figure 7, a trailing edge element 34 made of Polyetheretherketone (PEEK) is presented on the trailing edge 13 impregnated with the film 30. The trailing edge element 34 has serrations 35, also called serrations (figure 8).

Selon une huitième étape d'assemblage représentée en figure 9, l'élément de bord de fuite 34 est assemblé sur le bord de fuite 13 de la pale 12 par soudage thermoplastique. On obtient ainsi une aube 10 comprenant un corps d'aube 11 en matériau composite de fibre de carbone/résine époxy 33 s'étendant selon une direction principale EV. Le corps 11 possède un intrados 16 et un extrados 17 reliés en une partie amont du corps 11 par un bord de fuite 13 et en une partie avale du corps 11 d'autre part par un bord de fuite 14. Les parties amont et avale sont situées de part et d'autre de la direction principale EV et le bord de fuite 13 comprend une portion de bord de fuite 13 qui est au moins partiellement imprégné de PEK. L'aube 10 comprend un élément de bord de fuite 34 en PEEK rapporté par soudage sur le corps d'aube 11. According to an eighth assembly step shown in Figure 9, the trailing edge element 34 is assembled on the trailing edge 13 of the blade 12 by thermoplastic welding. This produces a blade 10 comprising a blade body 11 made of carbon fiber/epoxy resin composite material 33 extending in a main direction EV. The body 11 has a lower surface 16 and an upper surface 17 connected in an upstream portion of the body 11 by a trailing edge 13 and in a downstream portion of the body 11 on the other hand by a trailing edge 14. The upstream and downstream portions are located on either side of the main direction EV and the trailing edge 13 comprises a trailing edge portion 13 which is at least partially impregnated with PEK. The blade 10 comprises a trailing edge element 34 made of PEEK added by welding to the blade body 11.

Selon un deuxième mode de réalisation de l'invention représenté en figure 10 et de manière homologue au bord de fuite 13, le bord d'attaque 14de l'aube 10 est également imprégné de PEK selon un procédé identique à celui décrit précédemment. Un élément de bord d'attaque 44 en PEEK est rapporté sur le bord d'attaque 14 par soudage thermoplastique. According to a second embodiment of the invention shown in Figure 10 and in a manner similar to the trailing edge 13, the leading edge 14 of the blade 10 is also impregnated with PEK using a method identical to that described previously. A leading edge element 44 made of PEEK is attached to the leading edge 14 by thermoplastic welding.

Bien entendu, l'invention n'est pas limitée aux modes de réalisation décrits mais englobe toute variante entrant dans le champ de l'invention telle que définie par les revendications. Of course, the invention is not limited to the embodiments described but encompasses any variant falling within the scope of the invention as defined by the claims.

En particulier, bien qu'ici la préforme soit constituée de fibres de carbone tissés 3D, l'invention s'applique également à d'autres types de préforme comme par exemple une préforme constituée de fibre de verre ou d'aramide, partiellement ou totalement co-tissées ou non. La préforme fibreuse peut être de type interlock, ou à plis unidirectionnels 1D rapportés ; bien qu'ici le film appliqué sur le bord d'attaque soit en Polyetherketone, l'invention s'applique également à d'autres types de premier matériau thermoplastique comme par exemple le Polyétherétherketone ou le Polyétherimide ; bien qu'ici l'imprégnation se fasse à l'aide d'un film continu appliqué sur toute la hauteur de la pale, l'invention s'applique également à d'autres types d'imprégnation, par exemple à l'aide d'un film discontinu ou d'un dépôt par pulvérisation ou au pinceau, ou d'une imprégnation discontinue pouvant également ne pas s'étendre sur toute la hauteur de la pale ; bien qu'ici le la résine injectée soit une résine epoxy, l'invention s'applique également à d'autres types de résines, préférentiellement thermodurcissables, comme par exemple une résine de type Bismaléimide ; bien qu'ici l'élément de bord de fuite soit en Polyetheretherketone, l'invention s'applique également à d'autres types de matériau de construction de type thermoplastique comme par exemple du Polyetherimide ou du Polyetherketone. L'élément de bord de fuite peut ne pas être composé exclusivement du matériau thermoplastique de construction mais comprendre un mélange de matériau comprenant au moins un matériau de type thermoplastique ; bien qu'ici le film appliqué sur le bord de fuite soit en Polyetherketone, l'invention s'applique également à d'autres types d'autre matériau thermoplastique d'imprégnation comme par exemple le Polyétherétherketone ou le Polyétherimide ; bien qu'ici l'élément de bord d'attaque soit en Polyetheretherketone, l'invention s'applique également à d'autres types d'autre matériau de construction de de type thermoplastique comme par exemple du Polyetherimide ou du Polyetherketone. L'élément de bord d'attaque peut ne pas être composé exclusivement du deuxième matériau thermoplastique mais comprendre un mélange de matériau comprenant au moins un matériau de type thermoplastique ; In particular, although here the preform is made of 3D woven carbon fibers, the invention also applies to other types of preform such as for example a preform made of glass fiber or aramid, partially or totally co-woven or not. The fiber preform can be of the interlock type, or with added 1D unidirectional folds; although here the film applied to the leading edge is made of Polyetherketone, the invention also applies to other types of first thermoplastic material such as for example Polyetheretherketone or Polyetherimide; although here the impregnation is carried out using a continuous film applied over the entire height of the blade, the invention also applies to other types of impregnation, for example using a discontinuous film or spray or brush deposition, or discontinuous impregnation which may also not extend over the entire height of the blade; although here the injected resin is an epoxy resin, the invention also applies to other types of resins, preferably thermosetting, such as for example a Bismaleimide type resin; although here the trailing edge element is made of Polyetheretherketone, the invention also applies to other types of thermoplastic type construction material such as for example Polyetherimide or Polyetherketone. The trailing edge element may not be composed exclusively of the thermoplastic construction material but comprise a mixture of material comprising at least one thermoplastic type material; although here the film applied to the trailing edge is made of Polyetherketone, the invention also applies to other types of other thermoplastic impregnation material such as for example Polyetherketone or Polyetherimide; although here the leading edge element is made of Polyetherketone, the invention also applies to other types of other thermoplastic construction material such as for example Polyetherimide or Polyetherketone. The leading edge element may not be composed exclusively of the second thermoplastic material but comprise a mixture of material comprising at least one thermoplastic type material;

- bien qu'ici on ait décrit une aube comprenant un bord de fuite pourvu d'un élément de bord de fuite ou une aube pourvue d'un élément de bord de fuite et d'un élément de bord d'attaque, l'invention s'applique également à une aube dont un bord parmi le bord d'attaque et le bord de fuite reçoit un élément de bord, comme par exemple une aube dont seul le bord d'attaque comprend un élément de bord. - although here a blade comprising a trailing edge provided with a trailing edge element or a blade provided with a trailing edge element and a leading edge element has been described, the invention also applies to a blade in which one edge among the leading edge and the trailing edge receives an edge element, such as for example a blade in which only the leading edge comprises an edge element.

Claims

REVENDICATIONS 1. Pièce aéronautique (10) comprenant un corps (11) en matériau composite qui présente une portion qui est au moins partiellement imprégnée d'un matériau d'imprégnation (30) de type thermoplastique et un élément de protection (34, 44) comprenant un matériau de construction de type thermoplastique qui est rapporté par soudage sur la portion, dans laquelle la portion qui est au moins partiellement imprégnée de thermoplastique possède une épaisseur sensiblement égale au diamètre d'un toron (21) d'une fibre du matériau composite. 1. Aeronautical part (10) comprising a body (11) made of composite material which has a portion which is at least partially impregnated with an impregnation material (30) of thermoplastic type and a protective element (34, 44) comprising a construction material of thermoplastic type which is attached by welding to the portion, in which the portion which is at least partially impregnated with thermoplastic has a thickness substantially equal to the diameter of a strand (21) of a fiber of the composite material. 2. Pièce aéronautique (10) selon la revendication 1, dans laquelle la pièce aéronautique (10) comprend une pale (12) de turbomachine comprenant : un corps (11) de pale (12) en matériau composite s'étendant selon une direction principale (EV), le corps (11) ayant un intrados (16) et un extrados (17) reliés en une partie amont du corps (11) par un bord d'attaque (13) et en une partie avale du corps (11) d'autre part par un bord de fuite (14), les parties amont et aval étant situées de part et d'autre de la direction principale (EV) ; la portion qui est au moins partiellement imprégnée d'un matériau d'imprégnation (30) de type thermoplastique est une portion d'un bord choisi parmi le bord d'attaque (13) et le bord de fuite (14) ; l'élément de protection (34,44) est un élément de bord (34) d'attaque (34) ou un élément de bord de fuite (44). 2. Aeronautical part (10) according to claim 1, wherein the aeronautical part (10) comprises a turbomachine blade (12) comprising: a body (11) of the blade (12) made of composite material extending in a main direction (EV), the body (11) having a lower surface (16) and an upper surface (17) connected in an upstream part of the body (11) by a leading edge (13) and in a downstream part of the body (11) on the other hand by a trailing edge (14), the upstream and downstream parts being located on either side of the main direction (EV); the portion which is at least partially impregnated with an impregnating material (30) of thermoplastic type is a portion of an edge chosen from the leading edge (13) and the trailing edge (14); the protection element (34,44) is a leading edge element (34) or a trailing edge element (44). 3. Pièce aéronautique (10)selon la revendication 1 ou 2, dans laquelle l'élément de protection présente des serrations (35). 3. Aeronautical part (10) according to claim 1 or 2, in which the protective element has serrations (35). 4. Pièce aéronautique (10) selon l'une quelconque des revendications précédentes, dans laquelle le matériau d'imprégnation est choisi parmi les types de matériaux suivants : PolyEtherimide, Polyétherétherketone, Polyétherketone. 4. Aeronautical part (10) according to any one of the preceding claims, in which the impregnation material is chosen from the following types of materials: PolyEtherimide, Polyetheretherketone, Polyetherketone. 5. Pièce aéronautique (10) selon l'une quelconque des revendications précédentes, dans lequel le matériau composite est au moins partiellement imprégné d'une résine thermodurcissable. 5. Aeronautical part (10) according to any one of the preceding claims, in which the composite material is at least partially impregnated with a thermosetting resin. 6. Pièce aéronautique (10) selon l'une quelconque des revendications précédentes, dans lequel l'élément de protection (34,44) comprend au moins un renfort métallique. 6. Aeronautical part (10) according to any one of the preceding claims, in which the protective element (34, 44) comprises at least one metal reinforcement. 7. Procédé de fabrication d'une pièce aéronautique de turbine comprenant les étapes suivantes : une étape de préfabrication d'une préforme fibreuse (20) d'un corps (11) de pièce aéronautique (10) comportant une portion (13, 14) telle qu'un bord d'attaque (13) ou un bord de fuite (14) ; une étape d'imprégnation d'au moins une partie de la portion (13,14) à l'aide d'un matériau d'imprégnation de type thermoplastique ; une étape d'injection de résine (33); une étape de présentation d'un élément de protection (34, 44) comprenant un matériau de construction de type thermoplastique sur la portion (13,14); une étape d'assemblage de l'élément de protection (34, 44) sur la portion (13, 14) par une méthode de liaison par apport de chaleur telle que le soudage, dans laquelle la portion qui est au moins partiellement imprégnée de thermoplastique possède une épaisseur sensiblement égale au diamètre d'un toron (21) d'une fibre du matériau composite. 7. A method of manufacturing an aeronautical turbine part comprising the following steps: a step of prefabricating a fiber preform (20) of a body (11) of an aeronautical part (10) comprising a portion (13, 14) such as a leading edge (13) or a trailing edge (14); a step of impregnating at least part of the portion (13, 14) using a thermoplastic-type impregnation material; a step of injecting resin (33); a step of presenting a protective element (34, 44) comprising a thermoplastic-type construction material on the portion (13, 14); a step of assembling the protective element (34, 44) on the portion (13, 14) by a heat-applying bonding method such as welding, in which the portion which is at least partially impregnated with thermoplastic has a thickness substantially equal to the diameter of a strand (21) of a fiber of the composite material. 8. Procédé de fabrication selon la revendication 7, dans lequel l'étape d'imprégnation comprend les étapes suivantes : une étape de positionnement d'un film (30) en le matériau d'imprégnation thermoplastique sur la portion (13, 14) ; une étape d'application d'une pression d'imprégnation sur le film (30) ; et/ou une étape de chauffe à une température d'imprégnation du film (30). 8. Manufacturing method according to claim 7, wherein the impregnation step comprises the following steps: a step of positioning a film (30) of the thermoplastic impregnation material on the portion (13, 14); a step of applying an impregnation pressure to the film (30); and/or a step of heating the film (30) to an impregnation temperature. 9. Procédé de fabrication selon la revendication 8, dans lequel l'étape d'imprégnation comprend une étape de surveillance de la pression d'imprégnation et/ou de la température d'imprégnation ainsi qu'une étape d'arrêt de l'imprégnation lorsque la pression d'imprégnation et/ou la température d'imprégnation, est inférieure à une valeur prédéfinie. 9. Manufacturing method according to claim 8, wherein the impregnation step comprises a step of monitoring the impregnation pressure and/or the impregnation temperature as well as a step of stopping the impregnation when the impregnation pressure and/or impregnation temperature, is lower than a predefined value. 10. Procédé de fabrication selon l'une quelconque des revendications 7 à 9, dans lequel l'étape d'injection de résine (33) se fait selon le procédé de moulage par transfert de résine. 10. Manufacturing method according to any one of claims 7 to 9, wherein the resin injection step (33) is carried out according to the resin transfer molding method. 11. Procédé de fabrication selon l'une quelconque des revendications 7 à 10, dans lequel les étapes de préfabrication, d'imprégnation et d'injection de résine se déroulent dans un unique moule d'outillage (25) maintenu fermé durant toutes ces étapes. 11. Manufacturing method according to any one of claims 7 to 10, in which the steps of prefabrication, impregnation and resin injection take place in a single tooling mold (25) kept closed during all these steps.
PCT/FR2024/051197 2023-09-26 2024-09-13 Composite blade with leading edge made from thermoplastic material Pending WO2025068647A1 (en)

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FR2310222A FR3153277A1 (en) 2023-09-26 2023-09-26 Composite blade with leading edge made of thermoplastic material

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Citations (3)

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Publication number Priority date Publication date Assignee Title
US20110049297A1 (en) * 2009-09-01 2011-03-03 Rolls-Royce Plc Aerofoil with erosion resistant leading edge
US20120257984A1 (en) * 2009-12-22 2012-10-11 Lm Glasfiber A/S Method of producing a composite shell structure
US20160215757A1 (en) * 2013-08-01 2016-07-28 Blade Dynamics Limited Erosion resistant aerodynamic fairing

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Publication number Priority date Publication date Assignee Title
FR3040147B1 (en) * 2015-08-18 2018-04-20 Safran Aircraft Engines COMPOSITE AUBE WITH INTEGRATED AERODYNAMIC CLADDING ELEMENT AND METHOD OF MANUFACTURING SAME

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110049297A1 (en) * 2009-09-01 2011-03-03 Rolls-Royce Plc Aerofoil with erosion resistant leading edge
US20120257984A1 (en) * 2009-12-22 2012-10-11 Lm Glasfiber A/S Method of producing a composite shell structure
US20160215757A1 (en) * 2013-08-01 2016-07-28 Blade Dynamics Limited Erosion resistant aerodynamic fairing

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