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CN112654495B - 由复合材料制成并具有增强侵蚀保护膜的叶片以及相关的保护方法 - Google Patents

由复合材料制成并具有增强侵蚀保护膜的叶片以及相关的保护方法 Download PDF

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CN112654495B
CN112654495B CN201980056907.0A CN201980056907A CN112654495B CN 112654495 B CN112654495 B CN 112654495B CN 201980056907 A CN201980056907 A CN 201980056907A CN 112654495 B CN112654495 B CN 112654495B
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blade
blade body
erosion
reinforcing layer
thermosetting polymer
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CN112654495A (zh
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马蒂厄·朱利安·沙尔拉斯
迈赫迪·巴朱拉兹
亚历山大·阿卢
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Safran Aircraft Engines SAS
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SNECMA SAS
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    • 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
    • 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
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/887—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced locally reinforced, e.g. by fillers
    • 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
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of pure plastics material, e.g. foam layers
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/76—Moulding on edges or extremities of the preformed part
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78—Moulding material on one side only of the preformed part
    • 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
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/286—Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion
    • 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
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/32—Rotors specially for elastic fluids for axial flow pumps
    • F04D29/321—Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
    • F04D29/324—Blades
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • 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
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/76—Moulding on edges or extremities of the preformed part
    • B29C70/763—Moulding on edges or extremities of the preformed part the edges being disposed in a substantial flat plane
    • 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
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • 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
    • B29K2263/00—Use of EP, i.e. epoxy resins or derivatives thereof as reinforcement
    • 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
    • B29K2675/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, for preformed parts, e.g. for inserts
    • 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
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C27/00—Rotorcraft; Rotors peculiar thereto
    • B64C27/32—Rotors
    • B64C27/46—Blades
    • B64C27/473—Constructional 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
    • F05D2230/00—Manufacture
    • F05D2230/60—Assembly methods
    • 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods
    • 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
    • F05D2240/305—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 pressure side 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
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    • 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
    • F05D2240/307—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 tip of a rotor blade
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • 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
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

本发明涉及一种涡轮机叶片，该涡轮机叶片包括：由纤维增强有机基质复合材料制成的叶片主体，该叶片主体具有内拱面和设置有顶端的头部；侵蚀保护膜(22)，该侵蚀保护膜由热塑性聚合物制成并粘结到叶片主体上；增强层(23)，该增强层由热固性聚合物制成并且位于叶片头部上的侵蚀保护膜(22)上。

Description

由复合材料制成并具有增强侵蚀保护膜的叶片以及相关的保 护方法
技术领域
本发明涉及一种复合材料的叶片，该叶片在叶片顶端附近具有增强抗侵蚀膜，以及一种用于保护由复合材料制成的叶片的方法。本发明尤其涉及用于涡轮机、特别是涡轮喷气发动机的风扇叶片。
背景技术
在航空领域中，涡轮机通常由包括压缩机和低压涡轮的所谓的冷部分以及包括压缩机和高压涡轮的所谓的热部分组成。风扇位于低压压缩机的上游，该风扇是由转子和定子组成的结构，该转子由大尺寸的宽弦叶片构成，该定子由风扇壳体构成。应当指明，术语“上游”是根据涡轮机内的主要气体流动方向来考虑的。
在经常积极寻求减轻重量的涡轮机中，复合材料通常用于制造部件，尤其是关于所谓的冷部分，更确切地说是关于低压风扇，因为温度水平最有利于使用有机基质复合材料。这就是为什么采用复合材料开发出最新一代的低压风扇(尤其是风扇叶片)的原因。
与传统的钛叶片(TA6V)相比，复合材料叶片在工作中提供出色的机械性能，并为涡轮机节省大量重量。但是，这些叶片的热机械强度必须通过施加不同的保护元件来提高。
这些复合叶片确实必须承受不同类型的工作应力，并且尤其必须要确保(对摄入物、异物、侵蚀物类型等的)冲击抵抗性。通常通过在冲击敏感的位置施加金属部件(例如，通常使用粘合到叶片的前缘的金属保护性边缘(通常称为屏蔽层或箔))，通过施加PTFE织物涂层和/或抗侵蚀保护元件(油漆、聚氨酯膜)来确保这种冲击抵抗性。
这些复合叶片还必须提供对风扇壳体的可磨损部分的接触型磨损的抵抗力。要记住的是，为了使叶片和风扇壳体之间的工作间隙最优化，风扇壳体上涂覆了一层所谓的“耐磨”材料，该材料通常由环氧树脂和微米级玻璃珠的混合物组成。在涡轮机运行期间，叶片可能摩擦这种耐磨材料，以优化壳体上任何位点的间隙。然而，这种接触导致叶片的自加热，从而导致复合材料的过度局部化的但不可逆转的劣化，这恶化了叶片的机械性能。这些特性特别是当风扇叶片高速旋转时恶化。
因此，复合材料风扇叶片顶端的磨损保护被证明是至关重要的，特别是当发动机制造商通过减小工作间隙、尤其是风扇叶片顶端间隙从而增加摩擦接触点的出现而不断寻求提高发动机性能时。
通常通过设置在风扇叶片顶端处并完全覆盖叶片顶端的金属箔来提供对风扇壳体上的耐磨接触型磨损的抵抗力。
然而，使用金属箔的缺点是：向风扇叶片引入了显著的额外重量，这影响了风扇叶片的离心负荷，从而影响了风扇盘的寿命和涡轮机的性能。
因此，由有机基质复合材料制成的最新一代风扇叶片在叶片顶端不包含金属箔。这种设计使它们更容易因接触风扇外壳的耐磨部分而损坏。特别地，由接触引起的自加热由于在工作期间叶片顶端的移位而影响叶片的压力侧，并且特别地，自加热影响设置在叶片上以改善其侵蚀抵抗性的一个或多个保护元件。例如，在加热的作用下，粘结在叶片的压力侧的由热塑性聚合物制成的侵蚀保护膜(例如聚氨酯膜)在高于200℃的温度下以及在经受大的离心力时具有蠕流的可能性。结果，在使用中，该抗侵蚀膜的碎片可被离心并与叶片分离，这导致叶片复合材料的侵蚀保护性能下降，因此使叶片的使用寿命受到质疑。
本发明旨在提供金属箔的替代方案。更具体地，本发明旨在使有机基质复合材料的叶片的顶端能够在不必使用金属箔的情况下被保护免受摩擦接触。
发明内容
为此，本发明的一个目的是一种涡轮机叶片，该涡轮机叶片包括：
-由纤维增强有机基质复合材料制成的叶片主体，该叶片主体具有压力侧和设置有顶端的头部；
-粘结到叶片主体上的由热塑性聚合物制成的侵蚀保护膜；
其特征在于，叶片在其头部上还包括位于侵蚀保护膜上的由热固性聚合物制成的增强层。
侵蚀保护膜(或抗侵蚀膜)是指抗侵蚀的涂层，并且该抗侵蚀的涂层通过覆盖叶片主体的一区域、通过提高该区域对侵蚀现象的抵抗性来保护该区域免受侵蚀。
优选地，叶片是风扇叶片。
应当理解，热塑性聚合物(或树脂)由具有共价键的直链或支链组成，这些链通过弱范德华力或氢型键连接在一起。热固性聚合物(或树脂)由交联的直链组成，这些链通过强共价型键在空间上连接。热固性聚合物变成不可逆的固体，这与热塑性聚合物不同，热塑性聚合物在加热到给定温度以上时会软化。
该增强层增强了抗侵蚀膜对与壳体的耐磨部分接触进行抵抗的能力。
本发明的另一个目的是一种保护涡轮机叶片免于侵蚀的方法，该叶片包括由纤维增强有机基质复合材料制成的叶片主体，该主体具有压力侧和设置有顶端的头部，该方法包括以下连续步骤：
a)例如通过粘结将由热塑性聚合物制成的侵蚀保护膜组装到叶片主体上；
b)将由热固性聚合物制成的增强层施加到叶片主体的头部上，使得增强层位于保护膜上；
c)可能将抗侵蚀涂料层施加到叶片主体上，以覆盖保护膜和增强层。
抗侵蚀涂料的应用是已知的步骤；抗侵蚀涂料通常选自热固性聚氨酯配方树脂，通常与热塑性聚氨酯弹性体相关。热固性部分与热塑性部分的比例允许在抗侵蚀行为和抗崩裂性之间找到折衷。这些所谓的终饰聚氨酯涂料通常与利用环氧树脂基配制的底漆相关。
根据本发明的方法的一个实施例，叶片是待修补的叶片，该待修补的叶片包括粘结到叶片主体上的由热塑性聚合物制成的损坏的侵蚀保护膜，该损坏的侵蚀保护膜的位于叶片的顶端附近的至少一部分被损坏，并且在步骤a)之前进行至少去除损坏的保护膜的损坏部分的操作。
根据本发明的方法的该实施例使得可以开发一种方案，该方案用于修补由复合材料制成的叶片，该叶片的抗侵蚀膜被损坏，以便根据证实的限定对抗侵蚀膜进行复原。
根据该实施例的一个替代方案，待修补的叶片覆盖有抗侵蚀涂料层，该方法还包括在去除损坏的保护膜的损坏的所述至少一部分的操作之前，去除该抗侵蚀涂料层的操作。
以下是根据本发明的叶片和保护方法的一些优选但非限制性的方面：
-加强层以条带的形式沿着顶端延伸，并且保护膜和加强层仅布置在叶片主体的压力侧上。
-保护膜利用与增强层的热固性聚合物相同的热固性聚合物的层粘结到叶片主体上；
-增强层的热固性聚合物与形成叶片的有机基质的热固性聚合物相同；
-增强层的热固性聚合物是环氧树脂；
-加强层是条带。
最后，本发明涉及一种包括风扇的涡轮机，该风扇包括多个根据本发明的叶片。
本发明提供的方案通过添加优选为条带类型的由热固性聚合物制成的增强层使得可以省去金属箔以保护由复合材料制成的叶片的顶端的完整性，该增强层沿着叶片头部设置以限制存在于压力侧上的热塑性聚合物抗侵蚀膜的蠕变和撕裂。
附图说明
通过阅读以下通过非限制性示例给出的并参考附图进行的本发明的优选实施例的详细说明，本发明的其他优点和特征将变得更加清楚，在附图中：
-图1是涡轮风扇发动机的示意性轴向截面图；
-图2a至图2d示出了根据本发明的保护方法的实施例的步骤；
-图3是沿着图2d的方向I-I截取的示意性截面图，示出了叶片主体上的各种元件的布置的示例；
-图4a至图4d示出了根据本发明的保护方法的另一实施例的步骤。
具体实施方式
参考图1，示出了涡轮机1，该涡轮机具有中央纵向轴线2，涡轮机的各种部件围绕该中央纵向轴线延伸。该涡轮机沿着穿过该涡轮机的气流的主方向5从上游到下游包括风扇3、低压压缩机4、高压压缩机6、燃烧室11、高压涡轮7和低压涡轮8。
常规地，在通过风扇之后，空气被分成中央主流12a和围绕该主流的次级流12b。主流12a流入穿过压缩机4、6、燃烧室11和涡轮机7、8的气体的主循环流道14a。次级流12b在次级流道14b中流动，该次级流道径向向外地由曲轴箱界定并由机舱9包围。
参考图2a，示出了用于涡轮机风扇的复合材料风扇叶片主体15的示例。叶片主体15尤其包括压力侧16、吸力侧(在图中不可见)、前缘17、根部18、头部19和顶端20。叶片主体15由通过热固性树脂(例如环氧树脂)连接在一起的纤维或细丝组成。细丝或纤维可以由碳或玻璃、二氧化硅、碳化硅、氧化铝等制成。叶片主体可以例如通过3D编织的预成型件的树脂传递模塑(Resin Transfer Moulding，RTM)注射而获得。
该叶片主体的侵蚀敏感和/或冲击敏感部位应加以保护，尤其是前缘17和压力侧16，前缘以已知的方式用金属防护层21保护，压力侧使用由热塑性聚合物(通常是聚氨酯膜)制成的侵蚀保护膜22进行保护，该侵蚀保护膜粘结到压力侧以增强压力侧。热塑性膜的使用使得该膜具有足够的延展性以紧密贴合叶片主体的三维形状。但是，另一方面，该膜的抗蠕变的机械性能较差。
本发明提供的技术方案是通过利用增强层23(通过施加热固性聚合物的薄层形成)来覆盖由热塑性聚合物制成的抗侵蚀膜22的靠近叶片的顶端20的部分来增强该膜22至少在该部分中的抗蠕变性。优选地，薄膜热固性聚合物为条带形式，这使得能够获得预期的结果，即，保持抗侵蚀膜22并提高其抗蠕变性，同时沉积最少量的热固性聚合物，以免不必要地增加了叶片的重量。
现在将详细描述根据本发明的保护方法的步骤。
提供由有机基质复合材料(CMO)制成的叶片主体15(图2a)。
前缘17的金属防护层21和抗侵蚀膜22(通常是聚氨酯膜)组装到叶片主体15上(图2b)；可以在将金属防护层和抗侵蚀膜施加到叶片主体上之前，通过粘合，例如通过将具有或没有支撑体的呈膜或糊剂形式的选自环氧树脂、聚酯等的热固性聚合物的粘合剂层24施加到叶片主体上来进行组装。然后，例如在高压釜中在150℃下固化3小时。
将热固性聚合物条带在叶片的压力侧放置在叶片主体的顶端上，使该条带覆盖侵蚀保护膜(图2c)。该条带将用作增强层23。
有利地，通过对除前缘防护层21、叶片的上边缘和根部18之外的整个叶片主体施加抗侵蚀涂料27来完成对叶片主体的保护(图2d)。
根据本发明的优选实施例，获得了一种叶片，其中使用粘合剂将聚氨酯膜22粘合到叶片主体的压力侧16，由以下各项形成组件：该膜及其厚度为0.4mm的粘合剂，位于叶片主体15的前缘17上的金属防护层21、和沉积在整个叶片主体上、特别是沉积在压力侧和吸力侧部分上的大约0.1毫米厚的抗侵蚀涂料27(除了金属防护层21、叶片的上边缘(即，其顶端20)(因为这不经受侵蚀)，和根部18)。
如图3所示，在截面图中，在叶片的顶端20附近获得多层结构。这是因为由热塑性聚合物(聚氨酯膜)制成的侵蚀控制膜22被夹在两种热固性聚合物之间，这两种热固性聚合物即为：用于将抗侵蚀膜粘合到叶片主体上的粘合层24和安装到叶片主体的顶端的条带状加强层23，这导致，通过提供刚性来限制抗侵蚀膜的运动，从而显著提高抗侵蚀膜的抗蠕变性，并且这还限制了叶片顶端20与风扇壳体的耐磨材料接触之后抗侵蚀膜撕裂的风险。
根据本发明的方法还可以用于修补由复合材料制成的风扇叶片(待修补叶片25)，该风扇叶片的顶端(未受到防止与耐磨材料接触的保护)已损坏。如图4a所示，此待修补叶片25以有缺口的抗侵蚀涂料的形式示出了在叶片的顶端处的磨损，该有缺口的抗侵蚀涂料显示出损坏的抗侵蚀膜26。
例如通过剥离方法，例如通过手工打磨，部分或全部去除抗侵蚀涂料27，以便至少去除在损坏的侵蚀膜26的损坏区域中的抗侵蚀涂料(主要位于叶片的顶端附近)。
然后修复损坏的抗侵蚀膜26。为此，损坏的抗侵蚀膜26被部分或全部去除，以便去除损坏的抗侵蚀膜的损坏部分，并且在叶片主体上重新涂覆新的抗侵蚀膜22(图4b)。
将条带形式的由热固性聚合物制成的增强层23(图4c)布置成使得该增强层覆盖新的抗侵蚀膜22且在压力侧壁16施加到叶片的顶端，并且例如在高压釜中进行固化，例如应用与组装前缘和抗侵蚀膜的周期的参数(在150℃下3小时)相同的参数。
最后，有利地，施加抗侵蚀涂料27(图4d)。例如，可以施用用于终饰涂装的底漆；然后可以进行底漆的烘烤(例如，在80℃下烘烤30分钟)；然后将抗侵蚀涂料施加在底漆上并进行高压釜烘烤(例如，在80℃下烘烤60分钟)。
应当记住，控制风扇叶片的厚度至关重要，因为它与发动机性能直接相关。类似地，在备用涡轮机上要求不要部署在重量上代价大的方案，以免降低涡轮机的性能。因此，所提供的方案，无论是在保护新叶片时还是在保护受损叶片(并因此对其进行修补)时，都应确保在厚度控制方面可接受的且持久的性能水平。在这种情况下，本发明提供的技术方案使得可以通过引入具有可控制厚度的热固性聚合物层来满足该厚度控制标准。优选地，将沉积厚度在0.05mm至0.15mm(包括端值)之间的热固性聚合物层。该应用局限于叶片的顶端，优选仅位于叶片的压力侧上的顶端，这确保了风扇叶片的重量的增加可以忽略不计，与旨在在叶片的顶端引入金属箔的当前方案相反。
关于用于增强层的热固性聚合物的选择，必须考虑风扇叶片固有的各种参数。
首先，针对增强层选择的热固性聚合物必须能够在固化过程中交联而不损害风扇叶片主体的机械性能。对于由碳纤维增强环氧基质复合材料制成的风扇叶片主体，可以选择其性能允许在等于形成叶片主体的基质的聚合物的聚合温度的温度水平下进行交联的环氧型聚合物。在市场上可买到的环氧聚合物中，聚合的温度范围为从70℃至理论上250℃。应当注意，在由碳纤维增强环氧基质复合材料制成的LEAP风扇叶片上使用时，作为预防措施，仅使用最高聚合温度为150℃的环氧聚合物，以遵守复合材料的健康。例如，可以选择来自3M的AF191型聚合物，该聚合物在约150℃下固化。
优选地，无论是在新叶片上还是在损坏的叶片上，保护叶片所花费的时间应该最少。因此，应当优选地选择增强层的热固性聚合物的材料，使得其交联不需要太长的固化周期。使用与用于粘结前缘的金属防护层的热固性聚合物或用于粘结抗侵蚀膜的热固性聚合物(可能与用于粘结防护层的热固性聚合物相同)相同的热固性聚合物限制了对保护叶片所花费的时间的影响。
最后，针对增强层的热固性聚合物的选择不应对风扇叶片对发动机环境中存在的流体(液压油、发动机油等)的抵抗性产生质疑。对于其他应用(例如，金属前缘的粘结和/或抗侵蚀膜的粘结)，由于选择的热固性聚合物已经适用于流体阻力，因此使用已经存在于风扇叶片上的热固性聚合物是有利的。
因此，本发明提供的方案，即，作为薄层布置在横跨热塑性聚合物抗侵蚀膜和叶片主体的叶片顶端处的热固性聚合物的应用，使得无论是在保护新叶片还是损坏叶片时都可以改善这种抗侵蚀膜的抵抗力，而无需使用金属箔。

Claims (10)

1.一种涡轮机叶片，所述涡轮机叶片包括：
-由纤维增强有机基质复合材料制成的叶片主体(15)，所述叶片主体具有压力侧(16)和设置有顶端(20)的头部(19)；
-粘结到所述叶片主体上的由热塑性聚合物制成的侵蚀保护膜(22)；
其特征在于，所述叶片在所述叶片主体的头部(19)上还包括位于所述侵蚀保护膜(22)上的由热固性聚合物制成的增强层(23)，并且所述增强层覆盖所述叶片主体的顶端，所述增强层的热固性聚合物是环氧树脂。
2.一种用于保护涡轮机叶片免受侵蚀的方法，所述叶片包括由纤维增强有机基质复合材料制成的叶片主体(15)，所述主体具有压力侧(16)和设置有顶端(20)的头部(19)，所述方法包括以下连续步骤：
a)将由热塑性聚合物制成的侵蚀保护膜(22)组装到所述叶片主体上；
b)将由热固性聚合物制成的增强层(23)施加到所述叶片主体的所述头部(19)上，以使所述增强层位于所述侵蚀保护膜(22)上并覆盖所述叶片主体的顶端，所述增强层的热固性聚合物是环氧树脂。
3.根据权利要求2所述的方法，其中，组装步骤通过粘结进行。
4.根据权利要求2或3所述的方法，所述方法进一步包括在步骤b)之后的步骤c)：将抗侵蚀涂料层(27)施加到所述叶片主体上，以覆盖所述保护膜(22)和所述增强层(23)。
5.根据权利要求2至4中任一项所述的方法，其中，所述叶片是待修补的叶片(25)，所述待修补的叶片包括粘结到所述叶片主体上的由热塑性聚合物制成的损坏的侵蚀保护膜(26)，所述损坏的侵蚀保护膜的位于所述叶片主体的顶端(20)附近的至少一部分被损坏，并且其中，在步骤a)之前进行至少去除所述损坏的保护膜(26)的损坏部分的操作。
6.根据权利要求5所述的方法，其中，所述待修补的叶片覆盖有抗侵蚀涂料层，所述方法还包括：在去除所述损坏的保护膜的损坏的所述至少一部分的操作之前，去除该抗侵蚀涂料层的操作。
7.根据权利要求1所述的叶片，或根据权利要求2至6中任一项所述的保护方法，其中，所述增强层以条带形式沿着所述顶端延伸，并且其中，所述保护膜和所述增强层仅设置在所述叶片主体的压力侧。
8.根据权利要求1或权利要求7所述的叶片，或根据权利要求2至7中任一项所述的保护方法，其中，所述保护膜借助于与所述增强层的热固性聚合物相同的热固性聚合物的层而粘结到所述叶片主体上。
9.根据权利要求1、7或8所述的叶片，或根据权利要求2至8中任一项所述的保护方法，其中，所述增强层的热固性聚合物与形成所述叶片的有机基质的热固性聚合物相同。
10.一种涡轮机，所述涡轮机包括风扇，所述风扇包括多个根据权利要求1、7至9中任一项所述的叶片。
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