Method for manufacturing a turbine engine vane made of a composite material, resulting vane and turbine engine including same

Patent metadata

Field	Value
Publication number	US-2017198591-A1
Application number	US-201515312944-A
Country	US
Kind code	A1
Filing date	May 21, 2015
Priority date	May 22, 2014
Publication date	Jul 13, 2017
Grant date	—

Abstract

The invention relates to a method of fabricating a turbine engine blade out of composite material comprising fiber reinforcement densified by a matrix, the blade comprising an airfoil, a platform situated at a longitudinal end of the airfoil, and at least one functional element projecting from the outside face of the platform. The method comprises:
making a single-piece fiber blank by multilayer weaving; shaping the fiber blank to obtain a single-piece fiber preform having a first portion ( 302 ) forming a preform for the blade airfoil ( 320 ) and a second portion ( 314 ) forming a preform for the platform ( 340 ) and at least one preform for a functional element ( 352; 354 ); and densifying the fiber preform with a matrix.

The second preform portion comprises a set of yarn layers interlinked by weaving with at least one zone of non-interlinking being provided to make it possible to deploy the functional element preform relative to the first platform preform.

First claim

1 . A method of fabricating a turbine engine blade, the blade being made of composite material comprising fiber reinforcement densified by a matrix and comprising an airfoil, a first platform situated at one longitudinal end of the airfoil and having an inside face defining a flow passage and an outside face opposite from the inside face, and at least one functional element projecting from the outside face of the first platform and connecting with said outside face in a direction that is substantially circumferential, the method comprising:
making a single-piece fiber blank by multilayer weaving; shaping the fiber blank to obtain a single-piece fiber preform having a first portion forming a preform for the blade airfoil and a second portion forming a preform for the first platform and a preform for at least one functional element; and densifying the fiber preform with a matrix in order to obtain a composite material blade having fiber reinforcement formed by the preform and densified by the matrix and forming a single piece incorporating the airfoil, the first platform, and said at least one functional element; in which method the second portion of the preform comprises a set of yarn layers interlinked by weaving with at least one non-interlinked zone being arranged therein enabling the or each functional element preform to be deployed relative to the preform for the first platform, and wherein the fiber blank portion corresponding to the second preform portion includes one or more yarn layers taken from the portion of the fiber blank corresponding to the airfoil preform at one or more locations positioned in the longitudinal direction, the airfoil preform being of varying thickness in the longitudinal direction.

2 . A method according to claim 1 , wherein the set of layers of the second preform portion includes a group of yarn layers in common with the airfoil preform.

3 . A method according to claim 1 , wherein the fiber blank is shaped in order to obtain a single-piece fiber preform also having a third portion forming a preform for a second platform situated at a longitudinal end of the airfoil remote from its end where the first platform is located, and the set of yarn layers of the fiber blank portion corresponding to the second preform portion includes a group of yarn layers in common with the portion of the fiber blank corresponding to the airfoil preform and a group of yarn layers in common with the blank portion corresponding to the second platform preform.

4 . A method of fabricating a turbine engine rotor blade, the blade being made of composite material comprising fiber reinforcement densified by a matrix and comprising a root, an airfoil, an outer platform forming a head situated at one longitudinal end of the airfoil and having an inside face defining a flow passage and an outside face opposite from the inside face, and head wipers each projecting from the outside face of the head and connecting with said outside face in a direction that is substantially circumferential, the method comprising:
making a single-piece fiber blank by multilayer weaving; shaping the fiber blank to obtain a single-piece fiber preform having a first portion forming a preform for the airfoil, a second portion forming a preform for the head and preforms for the wipers, and a third portion extending the first portion and forming a preform for the root; and densifying the fiber preform with a matrix in order to obtain a composite material blade having fiber reinforcement formed by the preform and densified by the matrix and forming a single piece incorporating the root, the airfoil, the head, and the head wipers; in which method the second portion of the preform comprises a set of yarn layers interlinked by weaving with non-interlinked zones being arranged therein enabling the preforms for the head wipers to be deployed relative to the preform for the head, and wherein the fiber blank portion corresponding to the second preform portion includes one or more yarn layers taken from the portion of the fiber blank corresponding to the airfoil preform at one or more locations positioned in the longitudinal direction, the airfoil preform being of varying thickness in the longitudinal direction.

5 . A method according to claim 4 , wherein the set of layers of the second preform portion includes a group of yarn layers in common with the blade airfoil preform.

6 . A method according to claim 4 , wherein the fiber blank is shaped in order to obtain a single-piece fiber preform also having a fourth portion forming a preform for an inner platform, and the set of yarn layers of the fiber blank portion corresponding to the second preform portion includes a group of yarn layers in common with the portion of the fiber blank corresponding to the airfoil preform and a group of yarn layers in common with the blank portion corresponding to the inner platform preform.

7 . A method according to claim 4 , wherein the blade root preform comprises a number of yarn layers that is greater than the number of yarn layers of the airfoil preform, and, in the fiber blank, the set of yarn layers of the portion of the blank corresponding to the second preform portion comprises a group of yarn layers in common with the portion of the blank corresponding to the airfoil preform, and a group of yarn layers in common with the portion of the blank corresponding to the root preform and not used in the airfoil preform.

8 . A method according to claim 5 , wherein the set of layers of the second preform portion includes an additional group of yarn layers not in common with the root preform or with the blade preform.

9 . A method according to claim 4 , wherein the fiber blank is shaped to obtain a single-piece fiber preform also having a fourth portion forming an inner platform preform, and the airfoil preform includes a set of yarn layers in common with the root preform and crossed by a set of yarn layers of the inner platform preform at the location of the inner platform.

10 . A method of fabricating a turbine engine stator blade, the blade being made of composite material comprising fiber reinforcement densified by a matrix and comprising an airfoil, a first platform situated at one longitudinal end of the airfoil and having an inside face defining a flow passage and an outside face opposite from the inside face, and mounting hooks projecting from the outside face of the first platform and connecting with said outside face in a direction that is substantially circumferential, the method comprising:
making a single-piece fiber blank by multilayer weaving; shaping the fiber blank to obtain a single-piece fiber preform having a first portion forming a preform for the airfoil, a second portion forming a preform for the first platform, and preforms for the mounting hooks; and densifying the fiber preform with a matrix in order to obtain a composite material blade having fiber reinforcement formed by the preform and densified by the matrix and forming a single piece incorporating the airfoil, the first platform, and the mounting hooks; in which method the second portion of the preform comprises a set of yarn layers interlinked by weaving with non-interlinked zones being arranged therein enabling the mounting hook preforms to be deployed relative to the preform for the first platform, and wherein the fiber blank portion corresponding to the second preform portion includes one or more yarn layers taken from the portion of the fiber blank corresponding to the airfoil preform at one or more locations positioned in the longitudinal direction, the airfoil preform being of varying thickness in the longitudinal direction.

11 . A method according to claim 10 , wherein

Assignees

• Safran Aircraft Engines

Inventors

• Roussille Clément
• Blachier Jéremy
• Lefebvre Marie

Classifications

• B29B11/16

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title

• F01D5/282 Primary

  Selecting composite materials, e.g. blades with reinforcing filaments · CPC title

• C04B2235/5256

  Two-dimensional, e.g. woven structures · CPC title

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title

• C04B2235/48

  Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins · CPC title