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CN115867521A - 由陶瓷基复合材料制造喷嘴叶片的方法 - Google Patents

由陶瓷基复合材料制造喷嘴叶片的方法 Download PDF

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CN115867521A
CN115867521A CN202180047859.6A CN202180047859A CN115867521A CN 115867521 A CN115867521 A CN 115867521A CN 202180047859 A CN202180047859 A CN 202180047859A CN 115867521 A CN115867521 A CN 115867521A
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preform
fiber
fiber preform
blade
central portion
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CN115867521B (zh
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马修·阿诺德·吉马
朱利安·马蒂奥
克莱门特·玛丽·伯努瓦·鲁西尔
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Safran Ceramics SA
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Abstract

本发明涉及一种制造由陶瓷基复合材料制成的涡轮喷嘴叶片的方法。

Description

由陶瓷基复合材料制造喷嘴叶片的方法
技术领域
本发明涉及由陶瓷基质复合材料(“CMC材料”)制成的涡轮喷嘴叶片的制造方法。这些叶片可以集成到航空涡轮发动机或工业涡轮发动机的喷嘴中。
背景技术
涡轮喷嘴是与涡轮喷气发动机外壳相连的部件，可以引流和引导主流中的气体。涡轮级包括一个称为“喷嘴”(或定子)的叶片组件，然后是叶片组件或转子(涡轮盘和叶片组)。涡轮喷嘴由空心翼型叶片制成，也就是说，翼型在其外端和内端之间的整个长度上具有内部纵向通道。这种通道允许将气流从外部输送到内部，特别是用于冷却涡轮转子轮盘。
CMC材料已被提议作为涡轮机的热段部件。事实上，这些材料具有显著的热结构特性，也就是说，机械特性使它们能够构成结构部件，并能够在高温下保持这些特性。此外，CMC材料的密度比传统上用于涡轮发动机热段部件的金属材料低得多。
喷嘴受到与流动路径中的空气动力流相关的力，以及喷嘴下方壳体上的活塞效应(喷嘴下方上游腔和下游腔之间的压力差)。这些力在喷嘴和壳体之间的紧固件周围产生力矩。
喷嘴叶片必须通过确保足够结构阻力的区域来引导这些力，同时具有相对复杂的形状，确保各种功能，例如，特别是气流向下游级(翼型的气动外形)的定向和分布，通过上部和下部流动路径(平台)引导气流，以及向内部壳体提供冷却空气。
期望有一种容易制造由CMC材料制成的喷嘴叶片的方法，以令人满意的方式确保对所施加的力的抵抗力以及期望的功能。
发明内容
本发明涉及一种制造由陶瓷基复合材料制成的涡轮机喷嘴叶片的方法，所述方法包括：
提供第一纤维预制件，其包括(i)用于形成待获得的叶片的翼型的纤维增强件的中空中心部分，(ii)从所述中心部分的内部部分在其每一侧上延伸并横向于所述中心部分的内部横向部分，以及(iii)从所述中心部分的外部部分在其每一侧上延伸并横向于所述中心部分的外部横向部分，
提供一对第二纤维预制件，每个第二预制件具有开口，所述开口具有待获得的叶片的翼型的形状，所述开口通向所考虑的第二纤维预制件的第一边缘，每个第二纤维预制件具有连接在所考虑的第二纤维预制件的第二边缘上的两个表层，所述第二边缘与所述第一边缘不同，这些表层在所述开口的任一侧上限定未连接区域，从而能够彼此间隔开，
通过将所述中心部分插入所考虑的第二纤维预制件的开口，并将所述内部横向部分置于所考虑的第二纤维预制件的表层之间，将其中一个第二纤维预制件与所述第一纤维预制件组装起来，这种组装旨在形成待获得的叶片的内部平台的纤维增强件，
通过将所述中心部分插入所考虑的第二纤维预制件的开口，并将所述外部横向部分置于所考虑的第二纤维预制件的表层之间，将另一个第二纤维预制件与所述第一纤维预制件组装起来，这种组装旨在形成待获得的叶片的外部平台的纤维增强件，以及
通过在这些预制件之间形成共同的陶瓷基质，将如此组装的第二预制件固定到所述第一预制件上。
第一预制件和第二预制件的单独制造，它们各自支持有限数量的功能，与叶片的纤维增强件形成为单件的情况相比，允许简化制造。此外，在第二纤维预制件的表层之间插入横向部分的事实允许获得对操作中的力具有良好抵抗力的组件。
在一个示例性实施例中，通过三维编织获得第一纤维预制件。
在一个示例性实施例中，通过三维编织来编织第二预制件，并且在第二边缘上将表层编织在一起，第二预制件具有限定未连接区域的分离区域。
在一个示例性实施例中，第一预制件的中心部分在外部横向部分的外侧延伸出一部分，形成用于将待获得的叶片安装在壳体中的附接部分预制件。
在一个示例性实施例中，第一纤维预制件的中心部分旨在限定待获得的叶片的空气动力学轮廓。作为一种变型，第一纤维预制件还包括添加到中心部分上的异形(profiled)纤维织构，该异形纤维织构用于限定待获得的叶片的空气动力学轮廓。
在一个示例性实施例中，至少通过化学蒸汽渗透(“CVI”)形成公共基质。作为变型或组合，至少通过液体工艺形成公共基质。因此，例如可以通过化学蒸汽渗透形成第一公共基质相，然后通过液体工艺例如通过熔融状态的渗透形成第二公共基质相。
附图说明
图1是在根据本发明的方法的示例的情况下实施的第一纤维预制件的透视图。
图2表示第二纤维预制件中的一个，其旨在在根据本发明的方法的示例的情况下在与第一纤维预制件组装之后形成外部平台。
图3表示第二纤维预制件中的另一个，其旨在在根据本发明的方法的示例的情况下在与第一纤维预制件组装之后形成内部平台。
图4是在将第二纤维预制件组装到第一纤维预制件上之后获得的组件的透视图。
图5是图4所示组件的纵向截面示意图。
图6是第一纤维预制件的另一个变体的示意性纵向截面图，其包括可以在根据本发明的方法变体的情况下实施的附加异形纤维织构。
图7是图6所示第一纤维预制件的俯视图。
具体实施方式
图1是第一纤维预制件1的透视图，该预制件可用于根据本发明的方法的示例的情况下。
第一纤维预制件1包括中心部分11，其旨在形成待获得的叶片的翼型的结构部分。在这里考虑的示例中，中心部分11呈现空气动力学轮廓，旨在限定叶片的内弧面和外弧面。中心部分11的第一侧11a旨在限定外弧面，而中心部分11的第二侧11b旨在限定内弧面。应当注意，结构部分不一定形成叶片的空气动力学轮廓，如下面将关于图6和图7所描述的那样。
中心部分11是中空部分，其具有在其内部部分11c和其外部部分11d之间延伸的内部纵向通道12。纵向通道12旨在被冷却气流穿过。第一侧11a和第二侧11b界定纵向通道12，纵向通道12存在于这些侧11a和11b之间。
在整个文本中，术语“内部”和“外部”是相对于喷嘴的轴线(箭头A)的径向方向(箭头R)使用的，也就是说相对于喷嘴的半径方向(连接喷嘴中心和外围的直线)。
第一纤维预制件1还包括从内部部分11c在其每一侧并与其横向延伸的内部横向部分13。第一纤维预制件1还包括从外部部分11d在其每一侧并与其横向延伸的外部横向部分15。
在所示的示例中，中心部分11与内部横向部分13和外部横向部分15属于通过三维编织获得的同一纤维织构。在该示例中，因此在中心部分11与内部横向部分13和外部横向部分15之间存在织物连续性。内部横向部分13和外部横向部分15在此通过纤维织构的折叠来限定。在所示示例中，纤维织构具有从分离底部11e限定的分离区域。外部横向部分15的纱线在分离区域不与中心部分11结合。
此外，在所示的示例中，中心部分11在外部横向部分15的外侧延伸出一部分14，形成用于将叶片安装在壳体中的附接部分的预制件。
第一纤维预制件的可能的制造可以首先包括生产通过三维编织编织的带状纤维坯料。用于形成坯料的纱线可以由陶瓷，特别是碳化硅(SiC)或碳制成。
坯料的编织是在分离底部11e的水平处进行局部分离的。以本身已知的方式，通过使纬纱不穿过分离区而在两层经纱之间进行分离，纬纱用于将位于分离区两侧的经纱层结合。在本文中，经纱和纬纱之间的角色是可互换的。
在坯料编织之后，可以制作切口以消除计划不在第一纤维预制件中结束的多余部分。然后将坯料放置在成型工具中对其进行成型，从而获得第一纤维预制件1。坯料可以围绕形状自身折叠以获得中心部分11。坯料可以在内部部分11c的水平上折叠，以形成下横向部分13，在外部部分11d的水平上折叠，以形成部分14，部分14形成附接部分预制件。外部横向部分15可以在分离底部11e的水平处展开。
所示的情况涉及由通过三维编织获得的单一织构形成的第一纤维预制件。然而，本发明不限于这种情况，作为变型，第一预制件能够通过覆盖多个单向纤维网或二维或三维织物层而获得。
刚刚描述了第一纤维预制件1的结构和制造。关于图2和图3，以下说明了第二纤维预制件的可能结构示例，该第二纤维预制件旨在与第一纤维预制件组装，以获得平台的纤维增强件。
第二纤维预制件20a/20b各自具有相似的形状，以下描述适用于这些第二预制件20a/20b中的每一个。
第二纤维预制件20a/20b可以由通过三维编织获得的条带形成。第二纤维预制件20a/20b具有在两个分离底部32a/32b和34a/34b之间延伸的分离区域。该分离区域限定了两个可以彼此间隔开的表层23a/23b和25a/25b。两个表层23a/23b和25a/25b在所考虑的第二预制件20a/20b的相对纵向边缘27a/27b和29a/29b上编织在一起。第二纤维预制件20a/20b具有通孔201a/201b，该通孔具有待获得的叶片的翼型的形状，该开口201a/201a在入口203a/203b的水平处通向所考虑的第二纤维预制件20a/20b的侧边缘21a/21b。
为了进行第二纤维预制件与第一纤维预制件的组装，将中心部分11通过入口203a/203b插入开口201a/201b中，并且将表层25a/23a或25b/23b间隔开，以便在每个第二纤维预制件的分离区域中将横向部分15和13插入其间。图4显示了组装后获得的纤维增强件。外部横向部分15存在于表层23a和25a之间，内部横向部分13存在于表层23b和25b之间。中心部分11位于第二纤维预制件的开口201a/201b中。图4所示的纤维增强件定义了机翼和平台的纤维增强件。
应注意的是，在组装期间，第一和第二纤维预制件可以是固结的或不是固结的。固结预的制件的孔隙由固结基质相部分填充，从而允许其在无需保持工具的帮助下保持其形状。第一和第二预制件可以在不同的阶段组装，例如，在组装过程中第一预制件可以是固结的，而第二预成形件不是固结的。此外，在组装之前，第一预制件和第二预制件的纱线可以涂覆有脆化释放中间相或可以没有涂覆脆化释放中间相。脆化释放中间相或固结中间相的形成技术本身是已知的。
一旦组装完成，就形成第一和第二预制件共用的陶瓷基体。
这种常见的基质可以全部或部分通过化学蒸汽渗透产生，或者全部或部分地通过液体工艺产生。液体工艺技术可以是熔融渗透(“MI”)或聚合物浸渍热解(“PIP”)技术。通过上述技术形成陶瓷基质本身是已知的。应注意，这些技术的组合可用于形成基质。例如，普通基质可以包括碳化硅。在第二预制件和第一预制件之间可以存在公共基质的连续性。
在形成矩阵之后，获得涡轮发动机(例如航空涡轮发动机)的涡轮喷嘴叶片。叶片由CMC材料制成，包括翼型和内外平台。在外部平台的外侧，翼型通过连接部分延伸，该连接部分用于将叶片安装在壳体中。内部平台的外表面和外部平台的内表面旨在在将叶片安装在喷嘴中之后限定喷嘴中气流的流动路径。涡轮喷嘴可通过在涡轮壳体内安装一组如上所述的叶片来获得。
图6和图7示出了第一纤维预制件的变型。以与上述相同的方式表示相同的组件。在该示例中，叶片的结构部分110不具有待获得的叶片的空气动力学轮廓的形状。在该示例中，具有待获得的叶片的空气动力学轮廓的附加异型织构112已被添加到结构部分上。该异型织构112特别限定了待获得的叶片的前缘BA和后缘BF。

Claims (8)

1.一种制造由陶瓷基复合材料制成的涡轮喷嘴叶片的方法，所述方法包括：
提供第一纤维预制件(1)，其包括(i)用于形成待获得的叶片的翼型的纤维增强件的中空中心部分(11；110)，(ii)从所述中心部分的内部部分(11c)在其每一侧上延伸并横向于所述中心部分的内部横向部分(13)，以及(iii)从所述中心部分的外部部分(11d)在其每一侧上延伸并横向于所述中心部分的外部横向部分(15)，
提供一对第二纤维预制件(20a；20b)，每个第二预制件具有开口(201a；201b)，所述开口具有待获得的叶片的翼型的形状，所述开口通向所考虑的第二纤维预制件的第一边缘(21a；21b)，每个第二纤维预制件具有连接在所考虑的第二纤维预制件的第二边缘(27a；27b)上的两个表层(23a-25a；23b-25b)，所述第二边缘与所述第一边缘不同，这些表层在所述开口的任一侧上限定分离区域，从而能够彼此间隔开，
通过将所述中心部分插入所考虑的第二纤维预制件的开口，并将所述内部横向部分置于所考虑的第二纤维预制件的表层之间，将其中一个第二纤维预制件与所述第一纤维预制件组装起来，这种组装旨在形成待获得的叶片的内部平台的纤维增强件，
通过将所述中心部分插入所考虑的第二纤维预制件的开口，并将所述外部横向部分置于所考虑的第二纤维预制件的表层之间，将另一个第二纤维预制件与所述第一纤维预制件组装起来，这种组装旨在形成待获得的叶片的外部平台的纤维增强件，以及
通过在这些预制件之间形成共同的陶瓷基质，将如此组装的第二预制件固定到所述第一预制件上。
2.根据权利要求1所述的方法，其中，所述第一纤维预制件(1)通过三维编织获得。
3.根据权利要求1所述的方法，其中，通过三维编织来编织所述第二预制件(20a；20b)，并且在所述第二边缘(27a；27b)上将所述表层(23a-25a；23b-25b)编织在一起，所述第二预制件具有限定未连接的区域的分离区域。
4.根据权利要求1至3中任一项所述的方法，其中，所述第一预制件(1)的中心部分(11；110)在所述外部横向部分(15)的外侧延伸出一部分(14)，以形成用于将待获得的叶片安装在壳体中的附接部分预制件。
5.根据权利要求1至4中任一项所述的方法，其中，所述第一纤维预制件的中心部分(11)旨在限定待获得的叶片的空气动力学轮廓。
6.根据权利要求1至4中任一项所述的方法，其中，所述第一纤维预制件还包括添加到所述中心部分(110)上的异形纤维织构(112)，所述异形纤维织构用于限定待获得的叶片的空气动力学轮廓。
7.根据权利要求1至6中任一项所述的方法，其中，所述公共基质至少通过化学气相渗透形成。
8.根据权利要求1至7中任一项所述的方法，其中，所述公共基质至少通过液体工艺形成。
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