Method for manufacturing an oxide/oxide composite material turbomachine blade provided with internal channels

Patent metadata

Field	Value
Publication number	US-9802869-B2
Application number	US-201314099094-A
Country	US
Kind code	B2
Filing date	Dec 6, 2013
Priority date	Dec 10, 2012
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

An oxide/oxide composite material turbomachine blade including a fiber reinforcement obtained by weaving a first plurality of threads and a second plurality of threads, with the threads of said first plurality of threads being arranged in successive layers and extending in the longitudinal direction of the fiber blank corresponding to the longitudinal direction of the blade is disclosed. The reinforcement is densified by a matrix, with the blade further including one or several internal channels having a coiled shape extending in the longitudinal direction of the blade.

First claim

The invention claimed is:

1. A method for manufacturing a composite material turbomachine blade, which comprises a fiber reinforcement densified by a matrix obtained by sintering particles and which has at least one cooling channel, the method comprising:
a) shaping a fiber blank in order to obtain a preform of the blade to be manufactured, with said fiber blank comprising a first plurality of threads and a second plurality of threads woven together, with the threads of the first plurality of threads being arranged in successive layers and extending in a longitudinal direction of the fiber blank which corresponds to a longitudinal direction of the blade to be manufactured, at least one layer of threads of the first plurality of threads located in the internal portion of the fiber blank comprising one or more threads made of a first sacrificial material and one or more threads made of a second sacrificial material, at least one thread made of the first sacrificial material being surrounded along its longitudinal direction by a thread made of the second sacrificial material;
b) a first densification of the preform comprising a first impregnation of the preform with an aqueous suspension containing particles of the matrix and a first sintering of the impregnated preform at a first temperature in order to obtain a blade having a fiber reinforcement constituted by said preform and densified by the matrix;
c) eliminating each thread made of the first sacrificial material, thus forming, for each thread of the first sacrificial material, an internal channel in the blade;
d) a second densification of the preform comprising a second impregnation of the preform with an aqueous suspension containing particles of the matrix, with the aqueous suspension being introduced through each internal channel formed at step c) and a second sintering of the impregnated preform at a second temperature;
e) eliminating each thread made of the second sacrificial material, thus forming, for each thread of the second sacrificial material, a cooling channel in the blade; and
f) if the second temperature of the second sintering is lower than a sintering temperature of the matrix, a third sintering of the matrix at a temperature greater than or equal to the sintering temperature of the matrix.

2. The method according to claim 1 , wherein the first and second sacrificial materials are materials chosen amongst heat-fusible materials, materials that can be eliminated by a chemical agent and materials that can be eliminated by combustion under air, with these materials being non-soluble in the aqueous suspension and respectively having a melting or combustion temperature (T 1 ) and (T 2 ), with (T 1 ) lower than (T 2 ).

3. The method according to claim 2 , wherein step b) and step c) are concomitant.

4. The method according to claim 2 , wherein step c) is carried out by thermal treatment at a temperature greater than or equal to a melting or combustion temperature of each thread made of the first material and lower than a melting or combustion temperature of each thread made of the second material, and step e) is carried out by thermal treatment at a temperature greater than or equal to the melting or combustion temperature of each thread made of the second material or by application of a chemical agent.

5. The method according to claim 4 , wherein the melting or combustion temperatures of the first and second sacrificial materials (T 1 ) and (T 2 ) are lower than the sintering temperature of the matrix, the first sintering is carried out at a temperature greater than the melting or combustion temperature of the first material and lower than or equal to the melting or combustion temperature of the second material, and the second sintering is carried out at a temperature lower than the melting or combustion temperature of the second material.

6. The method according to claim 4 , wherein the melting or combustion temperatures of the first (T 1 ) and of the second (T 2 ) sacrificial material are respectively lower than or equal to and greater than the sintering temperature of the matrix, the first sintering is carried out at a temperature greater than the melting or combustion temperature of the first material (T 1 ) and lower than or equal to the sintering temperature of the matrix, and the second sintering is carried out at a temperature lower than or equal to the sintering temperature of the matrix.

7. The method according to claim 1 , wherein the particles of the aqueous suspension are made from an oxide ceramic material.

8. The method according to claim 1 , wherein threads of the first plurality of threads, other than the one or more threads made of the first sacrificial material and the one or more threads of the second sacrificial material are made of an oxide ceramic material, and the threads of the second plurality of threads are made of an oxide ceramic material.

Assignees

• Snecma

Inventors

• Podgorski Michael
• Dambrine Bruno Jacques Gerard
• Molliex Ludovic Edmond Camille
• Mereaux Beryl Cassandre Anne

Classifications

• B29B11/16

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

• F01D5/187

  Convection cooling · CPC title

• C04B2235/5212

  Organic · CPC title

• C04B35/803

  Chemistry & Metallurgy · mapped topic

• F01D5/18

  Hollow blades, {i.e. blades with cooling or heating channels or cavities (structure of hollow blades in general F01D5/147)}; Heating, heat-insulating or cooling means on blades · CPC title