FR3124965A1 - Process for manufacturing a composite material part by injecting a loaded slip into a fibrous texture - Google Patents
Process for manufacturing a composite material part by injecting a loaded slip into a fibrous texture Download PDFInfo
- Publication number
- FR3124965A1 FR3124965A1 FR2107329A FR2107329A FR3124965A1 FR 3124965 A1 FR3124965 A1 FR 3124965A1 FR 2107329 A FR2107329 A FR 2107329A FR 2107329 A FR2107329 A FR 2107329A FR 3124965 A1 FR3124965 A1 FR 3124965A1
- Authority
- FR
- France
- Prior art keywords
- refractory ceramic
- fibrous
- particles
- fibrous texture
- mold
- 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.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 20
- 239000002131 composite material Substances 0.000 title claims abstract description 12
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 10
- 239000002245 particle Substances 0.000 claims abstract description 37
- 239000011214 refractory ceramic Substances 0.000 claims abstract description 31
- 238000009826 distribution Methods 0.000 claims abstract description 21
- 238000001914 filtration Methods 0.000 claims abstract description 21
- 239000007788 liquid Substances 0.000 claims abstract description 15
- 239000000843 powder Substances 0.000 claims abstract description 12
- 238000002347 injection Methods 0.000 claims abstract description 5
- 239000007924 injection Substances 0.000 claims abstract description 5
- 230000014759 maintenance of location Effects 0.000 claims abstract description 3
- 239000000463 material Substances 0.000 claims description 15
- 239000002243 precursor Substances 0.000 claims description 12
- 239000012528 membrane Substances 0.000 claims description 10
- 238000005470 impregnation Methods 0.000 claims description 9
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 8
- 238000005056 compaction Methods 0.000 claims description 7
- 230000035699 permeability Effects 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 6
- 229910052799 carbon Inorganic materials 0.000 claims description 6
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical class O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 6
- 239000011159 matrix material Substances 0.000 claims description 6
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 6
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 6
- 239000012530 fluid Substances 0.000 claims description 5
- 150000004767 nitrides Chemical class 0.000 claims description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 4
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 4
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 4
- 239000000835 fiber Substances 0.000 claims description 4
- 229910052863 mullite Inorganic materials 0.000 claims description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 4
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- 238000002485 combustion reaction Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000007769 metal material Substances 0.000 claims description 3
- 229920000642 polymer Polymers 0.000 claims description 3
- -1 polytetrafluoroethylene Polymers 0.000 claims description 3
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- 230000015572 biosynthetic process Effects 0.000 claims description 2
- 238000001035 drying Methods 0.000 claims description 2
- 239000011148 porous material Substances 0.000 claims description 2
- 239000004744 fabric Substances 0.000 claims 3
- 239000007791 liquid phase Substances 0.000 description 10
- 239000000919 ceramic Substances 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 229910016006 MoSi Inorganic materials 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 239000011153 ceramic matrix composite Substances 0.000 description 1
- 238000002468 ceramisation Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000001802 infusion Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 229910021332 silicide Inorganic materials 0.000 description 1
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
- B28B1/261—Moulds therefor
- B28B1/262—Mould materials; Manufacture of moulds or parts thereof
- B28B1/263—Plastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
- B28B1/265—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor pressure being applied on the slip in the filled mould or on the moulded article in the mould, e.g. pneumatically, by compressing slip in a closed mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/003—Pressing by means acting upon the material via flexible mould wall parts, e.g. by means of inflatable cores, isostatic presses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
- B28B7/364—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article of plastic material or rubber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
- B28B7/368—Absorbent linings
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/111—Fine ceramics
- C04B35/117—Composites
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- C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/185—Mullite 3Al2O3-2SiO2
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/447—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on phosphates, e.g. hydroxyapatite
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- C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
- C04B35/486—Fine ceramics
- C04B35/488—Composites
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- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
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- C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
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- C04B35/5805—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on borides
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
- C04B35/83—Carbon fibres in a carbon matrix
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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
- F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
- F01D25/005—Selecting particular materials
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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
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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
- F01D5/284—Selection of ceramic materials
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- C04B2235/5224—Alumina or aluminates
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Abstract
Procédé de fabrication d’une pièce en matériau composite par injection d’une barbotine chargée dans une texture fibreuse L’invention décrit un procédé de fabrication d’une pièce en matériau composite comprenant le placement d’une texture fibreuse (10) dans un moule (110) comportant dans sa partie inférieure une strate de filtration (130) sur laquelle repose la texture fibreuse (10) et comportant une portion perforée (150) interposée entre la strate de filtration et le fond du moule, l’injection sous pression d’un liquide contenant une poudre de particules céramiques réfractaires dans la texture fibreuse, le drainage par la strate de filtration du liquide ayant traversé la texture fibreuse et la rétention de la poudre de particules céramiques réfractaires à l’intérieur de ladite texture fibreuse par ladite strate de filtration. Un élément de distribution (140) est interposé entre la strate de filtration (130) et la portion perforée (150). Figure pour l’abrégé : Fig. 1Method for manufacturing a composite material part by injecting a filled slip into a fibrous texture The invention describes a method for manufacturing a composite material part comprising placing a fibrous texture (10) in a mold (110) comprising in its lower part a filtration stratum (130) on which the fibrous texture (10) rests and comprising a perforated portion (150) interposed between the filtration stratum and the bottom of the mould, the injection under pressure of a liquid containing a powder of refractory ceramic particles in the fibrous texture, the drainage by the filtration stratum of the liquid having passed through the fibrous texture and the retention of the powder of refractory ceramic particles inside the said fibrous texture by the said stratum of filtration. A distribution element (140) is interposed between the filtration layer (130) and the perforated portion (150). Figure for abstract: Fig. 1
Description
La présente invention concerne un procédé de fabrication d'une pièce en matériau composite thermostructural notamment de type Oxyde/Oxyde ou à matrice céramique (CMC), c’est-à-dire comportant un renfort fibreux formé à partir de fibres en matériau céramique réfractaire densifié par une matrice également en matériau céramique réfractaire.The present invention relates to a method for manufacturing a part made of thermostructural composite material, in particular of the oxide/oxide type or with a ceramic matrix (CMC), that is to say comprising a fibrous reinforcement formed from fibers of refractory ceramic material. densified by a matrix also in refractory ceramic material.
Les pièces en matériau composite Oxyde/Oxyde sont généralement élaborées par drapage dans un moule d’une pluralité de strates fibreuses réalisées à partir de fibres en oxyde réfractaire, les strates étant chacune préalablement imprégnées avec une barbotine chargée de particules d’oxyde réfractaire. L’ensemble des strates ainsi disposées est ensuite compacté à l’aide d’un contre-moule ou d’une bâche à vide et un passage en autoclave. La préforme chargée ainsi obtenue est alors soumise à un frittage ou un traitement thermique de céramisation afin de former une matrice en oxyde réfractaire dans la préforme et obtenir une pièce en matériau composite Oxyde/Oxyde. Cette technique peut être également utilisée pour réaliser des pièces en matériau composite à matrice céramique (CMC) base carbone ou base carbure de silicium. Dans ce cas, les strates fibreuses sont réalisées à partir de fibres de carbure de silicium (SiC) ou de carbone et sont imprégnées avec une barbotine chargée de particules de carbure (ex. SiC), de borure (ex. TiB2), de siliciure (ex. MoSi2), de nitrure (ex. Si3N4) ou de carbone.Oxide/oxide composite material parts are generally produced by draping in a mold a plurality of fibrous strata made from refractory oxide fibers, the strata each being impregnated beforehand with a slip charged with refractory oxide particles. All of the strata thus arranged are then compacted using a counter-mold or a vacuum cover and passage through an autoclave. The filled preform thus obtained is then subjected to sintering or ceramization heat treatment in order to form a refractory oxide matrix in the preform and to obtain a part made of oxide/oxide composite material. This technique can also be used to produce parts in ceramic matrix composite material (CMC) based on carbon or based on silicon carbide. In this case, the fibrous strata are made from silicon carbide (SiC) or carbon fibers and are impregnated with a slip charged with particles of carbide (ex. SiC), boride (ex. TiB 2 ), silicide (eg MoSi 2 ), nitride (eg Si 3 N 4 ) or carbon.
Cependant, ce type de procédé d’élaboration ne permet de réaliser que des pièces en matériau composite Oxyde/Oxyde ou CMC ayant des caractéristiques mécaniques limitées dans certaines directions. En particulier, ces matériaux ont une faible tenue au délaminage et ne résistent pas bien aux efforts de cisaillement.However, this type of production process only makes it possible to produce parts in Oxide/Oxide or CMC composite material with limited mechanical characteristics in certain directions. In particular, these materials have a low resistance to delamination and do not resist shear stresses well.
La réalisation de textures fibreuses obtenues par tissage tridimensionnel entre des fils continues de chaîne et de trame permet d’augmenter la résistance mécanique du matériau et en particulier sa résistance au délaminage. Dans ce cas et également pour des textures 2D de forte épaisseur, seuls les procédés utilisant un gradient de pression, comme les procédés de type infusion, moulage par injection dits « RTM » ou aspiration de poudre submicronique dits « APS », permettent de faire pénétrer une barbotine chargée dans la texture fibreuse dont l’épaisseur peut atteindre plusieurs dizaines de millimètres selon les applications visées.The production of fibrous textures obtained by three-dimensional weaving between continuous warp and weft threads makes it possible to increase the mechanical resistance of the material and in particular its resistance to delamination. In this case and also for very thick 2D textures, only processes using a pressure gradient, such as infusion type processes, injection molding known as “RTM” or submicron powder suction known as “APS”, make it possible to penetrate a slurry charged in the fibrous texture, the thickness of which can reach several tens of millimeters depending on the intended applications.
Cependant, le gradient de pression entre la partie de la texture fibreuse par laquelle la barbotine chargée est injectée et l’autre partie de la texture fibreuse par laquelle la phase liquide de la barbotine doit être évacuée est difficile à contrôler sur l’ensemble de la texture fibreuse. Si la pression n’est pas équilibrée sur l’ensemble de la surface de la texture fibreuse en regard du fond du moule comportant un ou plusieurs évents d’évacuation par lequel ou lesquels la phase liquide de la barbotine doit être évacuée, il se crée une différence de pression entre les zones proches des évents et les zones plus éloignées. Dans ce cas, l’évacuation de la phase liquide est délicate car celle-ci doit être retirée de la texture sans perturber la répartition des particules solides (oxyde réfractaire, carbure, borure, nitrure, etc.) déposées via la barbotine. En effet, lors de son évacuation, la phase liquide peut emmener avec elle des particules et/ou modifier la répartition de ces dernières dans la texture fibreuse et conduire à l’apparition d’importantes porosités dans le matériau final en raison du manque de matrice à certains endroits.However, the pressure gradient between the part of the fibrous texture through which the filled slip is injected and the other part of the fibrous texture through which the liquid phase of the slip must be evacuated is difficult to control over the whole of the fibrous texture. If the pressure is not balanced over the entire surface of the fibrous texture facing the bottom of the mold comprising one or more evacuation vents through which the liquid phase of the slip must be evacuated, it is created a difference in pressure between areas near the vents and areas further away. In this case, the evacuation of the liquid phase is delicate because it must be removed from the texture without disturbing the distribution of the solid particles (refractory oxide, carbide, boride, nitride, etc.) deposited via the slip. Indeed, during its evacuation, the liquid phase can take particles with it and/or modify the distribution of the latter in the fibrous texture and lead to the appearance of significant porosities in the final material due to the lack of matrix. in certain places.
Pour résoudre ces problématiques, on peut interposer un élément rigide ajouré, ou une portion perforée, entre le fond du moule et la texture fibreuse. La phase liquide de la barbotine peut ainsi atteindre facilement le ou les évents d’évacuation quel que soit son point de sortie au niveau de la texture fibreuse. Un tel élément est par exemple décrit dans le document WO2017187050.To solve these problems, it is possible to interpose a rigid perforated element, or a perforated portion, between the bottom of the mold and the fibrous texture. The liquid phase of the slurry can thus easily reach the evacuation vent or vents regardless of its exit point at the level of the fibrous texture. Such an element is for example described in the document WO2017187050.
En revanche, l’utilisation d’un tel élément rigide ajouré ne permet pas d’obtenir une vitesse d’écoulement homogène de la phase liquide dans la texture fibreuse. En effet, au sein de la texture fibreuse, la phase liquide s’écoulera plus vite dans les zones situées au-dessus des perçages de l’élément rigide ajourée et moins vite dans les autres zones, provoquant une répartition non-homogène des particules dans la texture fibreuse. Cette hétérogénéité des vitesses d’écoulement est présente même pour les éléments rigides ayant un taux de perçage élevé.On the other hand, the use of such a perforated rigid element does not make it possible to obtain a homogeneous flow rate of the liquid phase in the fibrous texture. Indeed, within the fibrous texture, the liquid phase will flow more quickly in the zones located above the holes of the perforated rigid element and less quickly in the other zones, causing a non-homogeneous distribution of the particles in fibrous texture. This heterogeneity of flow velocities is present even for rigid elements having a high drilling rate.
En outre, afin de faciliter l’écoulement de la phase liquide, l’élément rigide ajouré doit comporter de nombreux perçages, encoches et découpes, ce qui rend sa fabrication longue et coûteuse.In addition, in order to facilitate the flow of the liquid phase, the perforated rigid element must include numerous holes, notches and cutouts, which makes its manufacture long and expensive.
La présente invention a pour but de remédier aux inconvénients précités et de proposer une solution qui permet de réaliser des pièces en matériau composite notamment de type Oxyde/Oxyde ou CMC, et ce de manière rapide et fiable tout en permettant un bon contrôle du dépôt et de la répartition des particules solides dans la texture fibreuse afin d’obtenir un matériau sans macroporosité.The purpose of the present invention is to remedy the aforementioned drawbacks and to propose a solution which makes it possible to produce parts in composite material, in particular of the oxide/oxide or CMC type, and this in a rapid and reliable manner while allowing good control of the deposit and the distribution of solid particles in the fibrous texture in order to obtain a material without macroporosity.
A cet effet, l’invention propose un procédé de fabrication d’une pièce en matériau composite comprenant les étapes suivantes :To this end, the invention proposes a process for manufacturing a composite material part comprising the following steps:
- formation d’une texture fibreuse à partir de fibres céramiques réfractaires,- formation of a fibrous texture from refractory ceramic fibers,
- placement de la texture fibreuse dans un moule comportant dans sa partie inférieure une strate de filtration sur laquelle repose une première face de ladite texture fibreuse, le moule comprenant en outre une portion perforée interposée entre le fond du moule et la strate de filtration,- placement of the fibrous texture in a mold comprising in its lower part a filtration stratum on which rests a first face of said fibrous texture, the mold further comprising a perforated portion interposed between the bottom of the mold and the filtration stratum,
- fermeture du moule avec un contre-moule ou un couvercle placé en regard d’une deuxième face de la texture fibreuse,- closing of the mold with a counter-mold or a cover placed opposite a second face of the fibrous texture,
- injection sous pression d’un liquide contenant une poudre de particules céramiques réfractaires ou de particules d’un précurseur de céramique réfractaire dans la texture fibreuse,- pressure injection of a liquid containing a powder of refractory ceramic particles or particles of a refractory ceramic precursor into the fibrous texture,
- drainage par la strate du filtration du liquide ayant traversé la texture fibreuse et rétention de la poudre de particules céramiques réfractaires ou de particules d’un précurseur de céramique réfractaire à l’intérieur de ladite texture par ladite strate de filtration de manière à obtenir une préforme fibreuse chargée de particules céramiques réfractaires ou de particules d’un précurseur de céramique réfractaire, le liquide étant évacué par la portion perforée et par au moins un évent présent sur le fond du moule,- drainage by the filtration stratum of the liquid having passed through the fibrous texture and retention of the powder of refractory ceramic particles or particles of a refractory ceramic precursor inside said texture by said filtration stratum so as to obtain a fibrous preform filled with refractory ceramic particles or particles of a refractory ceramic precursor, the liquid being evacuated through the perforated portion and through at least one vent present on the bottom of the mould,
- séchage de la préforme fibreuse,- drying of the fibrous preform,
- démoulage de la préforme fibreuse, et- demoulding of the fibrous preform, and
- traitement thermique des particules céramiques réfractaires ou des particules d’un précurseur de céramique réfractaire présentes dans la préforme fibreuse afin de former une matrice céramique réfractaire dans ladite préforme,- heat treatment of the refractory ceramic particles or of the particles of a refractory ceramic precursor present in the fibrous preform in order to form a refractory ceramic matrix in the said preform,
le procédé étant caractérisé en ce qu’un élément de distribution présentant une perméabilité supérieure à celle de la strate de filtration est interposé entre ladite strate de filtration et la portion perforée.the method being characterized in that a distribution element having a permeability greater than that of the filtration stratum is interposed between said filtration stratum and the perforated portion.
L’élément de distribution a pour fonction de drainer la phase liquide filtrée par la strate de filtration, en comprenant un réseau de porosité qui permet une répartition plus homogène de la phase liquide au niveau de la portion perforée du moule. En utilisant un tel élément de distribution, le procédé de l’invention permet une vitesse d’écoulement du liquide plus homogène en tout point de la texture fibreuse, permettant une meilleure homogénéité de répartition des particules dans la texture fibreuse et réduisant ainsi les risques de macroporosité. En outre, la présence de l’élément de distribution permet de réduire le nombre de perçages, d’encoches et découpes de la portion perforée du moule, tout en conservant un écoulement satisfaisant du liquide de la barbotine. Ainsi, la fabrication d’une telle portion perforée est simplifiée, entraînant une réduction des coûts.The function of the distribution element is to drain the liquid phase filtered by the filtration stratum, comprising a porosity network which allows a more homogeneous distribution of the liquid phase at the level of the perforated portion of the mould. By using such a distribution element, the method of the invention allows a more homogeneous flow rate of the liquid at any point of the fibrous texture, allowing a better homogeneity of distribution of the particles in the fibrous texture and thus reducing the risks of macroporosity. In addition, the presence of the distribution element makes it possible to reduce the number of holes, notches and cutouts of the perforated portion of the mold, while maintaining a satisfactory flow of liquid from the slip. Thus, the manufacture of such a perforated portion is simplified, leading to a reduction in costs.
La portion perforée peut être un élément rigide ajouré distinct du moule. Le contre-moule ou le couvercle utilisé pour fermer le moule peut être une bâche ou une membrane imperméable déformable.The perforated portion may be a rigid perforated element separate from the mould. The counter-mold or the cover used to close the mold can be a tarpaulin or a deformable waterproof membrane.
L’élément de distribution présente une perméabilité supérieure à celle de la portion perforée.The distribution element has a higher permeability than the perforated portion.
Selon une caractéristique particulière de l’invention, l’élément de distribution présente une perméabilité longitudinale comprise entre 10-8et 10-10m2.According to a particular characteristic of the invention, the distribution element has a longitudinal permeability of between 10 -8 and 10 -10 m 2 .
Par perméabilité longitudinale de l’élément de distribution, on désigne la perméabilité de l’élément de distribution dans les directions perpendiculaires à l’axe de superposition de l’élément de distribution avec la portion perforée et la strate de filtration.Longitudinal permeability of the distribution element means the permeability of the distribution element in the directions perpendicular to the axis of superposition of the distribution element with the perforated portion and the filtration stratum.
Selon une autre caractéristique particulière de l’invention, l’élément de distribution présente un taux de porosité d’au moins 60% avec une taille des pores supérieure à 0,1 mm.According to another particular characteristic of the invention, the dispensing element has a porosity rate of at least 60% with a pore size greater than 0.1 mm.
Selon une autre caractéristique particulière de l’invention, l’élément de distribution est en un matériau choisi parmi un des matériaux suivants : polytétrafluoroéthylène (PTFE), matériau métallique, polymère.According to another particular characteristic of the invention, the distribution element is made of a material chosen from one of the following materials: polytetrafluoroethylene (PTFE), metallic material, polymer.
Selon une autre caractéristique particulière de l’invention, la portion perforée est en un matériau choisi parmi un des matériaux suivants : polytétrafluoroéthylène (PTFE), matériau métallique, polymère.According to another particular characteristic of the invention, the perforated portion is made of a material chosen from one of the following materials: polytetrafluoroethylene (PTFE), metallic material, polymer.
Selon une autre caractéristique particulière de l’invention, le moule dans lequel est placé la texture fibreuse comprend une chambre d'imprégnation comportant dans sa partie inférieure la strate de filtration sur laquelle repose une première face (20b) de ladite texture et la portion perforée présente sur le fond du moule, la chambre d'imprégnation étant fermée dans sa partie supérieure par une membrane imperméable déformable placée en regard d'une deuxième face de la texture fibreuse, ladite membrane séparant la chambre d'imprégnation d'une chambre de compaction, le liquide contenant la poudre de particules céramiques réfractaires ou de particules d'un précurseur de céramique réfractaire étant injecté dans la chambre d'imprégnation entre la deuxième face de la texture fibreuse et la membrane, un fluide de compaction étant injecté dans la chambre de compaction, le fluide exerçant une pression sur la membrane pour forcer le liquide contenant la poudre de particules céramiques réfractaires ou de particules d'un précurseur de céramique réfractaire à traverser la texture fibreuse.According to another particular characteristic of the invention, the mold in which the fibrous texture is placed comprises an impregnation chamber comprising in its lower part the filtration stratum on which rests a first face (20b) of said texture and the perforated portion present on the bottom of the mould, the impregnation chamber being closed in its upper part by a deformable impermeable membrane placed opposite a second face of the fibrous texture, said membrane separating the impregnation chamber from a compaction chamber , the liquid containing the powder of refractory ceramic particles or of particles of a refractory ceramic precursor being injected into the impregnation chamber between the second face of the fibrous texture and the membrane, a compaction fluid being injected into the compaction, the fluid exerting pressure on the membrane to force the liquid containing the powder of ceramic particles refracted ires or particles of a refractory ceramic precursor to cross the fibrous texture.
Ainsi, l’utilisation d’une membrane permet d’améliorer l’homogénéité des particules dans la texture fibreuse, réduisant ainsi les risques de macroporosité. L’injection du liquide contenant la poudre de particules peut être réalisée avant, pendant ou après l’injection du fluide de compaction.Thus, the use of a membrane makes it possible to improve the homogeneity of the particles in the fibrous texture, thus reducing the risks of macroporosity. The injection of the liquid containing the particle powder can be carried out before, during or after the injection of the compaction fluid.
Selon une autre caractéristique particulière de l’invention, lors de l’étape de la formation de la texture fibreuse, les fils sont tissés suivant un tissage tridimensionnel ou multicouche.According to another particular characteristic of the invention, during the step of forming the fibrous texture, the threads are woven according to a three-dimensional or multilayer weave.
Selon une autre caractéristique particulière de l’invention, les fils de la préforme sont formés de fibres constituées d’un ou plusieurs des matériaux suivants : l’alumine, la mullite, la silice, un aluminosilicate, un aluminophosphate, la zircone, un carbure, un borure, un nitrure et du carbone.According to another particular characteristic of the invention, the yarns of the preform are formed of fibers made up of one or more of the following materials: alumina, mullite, silica, an aluminosilicate, an aluminophosphate, zirconia, a carbide , a boride, a nitride and carbon.
Selon une autre caractéristique particulière de l’invention, les particules céramiques réfractaires sont en un matériau choisi parmi : l’alumine, la mullite, la silice, un aluminosilicate, un aluminophosphate, la zircone, un carbure, un borure, un nitrure et du carbone.According to another particular characteristic of the invention, the refractory ceramic particles are made of a material chosen from: alumina, mullite, silica, an aluminosilicate, an aluminophosphate, zirconia, a carbide, a boride, a nitride and carbon.
Selon une autre caractéristique particulière de l’invention, la pièce en matériau composite obtenue constitue un anneau, une aube, une chambre de combustion de turbomachine, une pièce d’arrière-corps, un volet ou un bras postcombustion.According to another particular characteristic of the invention, the composite material part obtained constitutes a ring, a blade, a turbomachine combustion chamber, an afterbody part, a flap or a post-combustion arm.
Claims (9)
- formation d’une texture fibreuse (10) à partir de fibres céramiques réfractaires,
- placement de la texture fibreuse (10) dans un moule (110) comportant dans sa partie inférieure une strate de filtration (130) sur laquelle repose une première face (10b) de ladite texture fibreuse, le moule (110) comprenant en outre une portion perforée (150) interposée entre le fond (111) du moule (110) et la strate de filtration (130),
- fermeture du moule avec un contre-moule ou un couvercle (120) placé en regard d’une deuxième face (10a) de la texture fibreuse (10),
- injection sous pression d’un liquide (160) contenant une poudre de particules céramiques réfractaires ou de particules d’un précurseur de céramique réfractaire dans la texture fibreuse (10),
- drainage par la strate du filtration (130) du liquide (160) ayant traversé la texture fibreuse (10) et rétention de la poudre de particules céramiques réfractaires ou de particules d’un précurseur de céramique réfractaire à l’intérieur de ladite texture (10) par ladite strate de filtration (130) de manière à obtenir une préforme fibreuse (15) chargée de particules céramiques réfractaires ou de particules d’un précurseur de céramique réfractaire, le liquide étant évacué par la portion perforée et par au moins un évent présent sur le fond du moule,
- séchage de la préforme fibreuse (15),
- démoulage de la préforme fibreuse (15), et
- traitement thermique des particules céramiques réfractaires ou des particules d’un précurseur de céramique réfractaire présentes dans la préforme fibreuse afin de former une matrice céramique réfractaire dans ladite préforme,
le procédé étant caractérisé en ce qu’un élément de distribution (140) présentant une perméabilité supérieure à celle de la strate de filtration (130) est interposé entre ladite strate de filtration (130) et la portion perforée (150).Method for manufacturing a part made of composite material comprising the following steps:
- formation of a fibrous texture (10) from refractory ceramic fibers,
- placement of the fibrous texture (10) in a mold (110) comprising in its lower part a filtration stratum (130) on which rests a first face (10b) of said fibrous texture, the mold (110) further comprising a perforated portion (150) interposed between the bottom (111) of the mold (110) and the filtration layer (130),
- closing of the mold with a counter-mold or a lid (120) placed opposite a second face (10a) of the fibrous texture (10),
- pressure injection of a liquid (160) containing a powder of refractory ceramic particles or of particles of a refractory ceramic precursor into the fibrous fabric (10),
- drainage by the filtration stratum (130) of the liquid (160) having passed through the fibrous texture (10) and retention of the powder of refractory ceramic particles or of particles of a refractory ceramic precursor inside said texture ( 10) through said filtration stratum (130) so as to obtain a fibrous preform (15) loaded with refractory ceramic particles or particles of a refractory ceramic precursor, the liquid being evacuated through the perforated portion and through at least one vent present on the bottom of the mould,
- drying of the fibrous preform (15),
- demoulding of the fibrous preform (15), and
- heat treatment of the refractory ceramic particles or particles of a refractory ceramic precursor present in the fibrous preform in order to form a refractory ceramic matrix in said preform,
the method being characterized in that a distribution element (140) having a permeability greater than that of the filtration stratum (130) is interposed between said filtration stratum (130) and the perforated portion (150).
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR2107329A FR3124965B1 (en) | 2021-07-07 | 2021-07-07 | Process for manufacturing a part made of composite material by injecting a slip loaded into a fibrous texture |
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| Application Number | Priority Date | Filing Date | Title |
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| FR2107329 | 2021-07-07 | ||
| FR2107329A FR3124965B1 (en) | 2021-07-07 | 2021-07-07 | Process for manufacturing a part made of composite material by injecting a slip loaded into a fibrous texture |
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|---|---|---|---|---|
| FR2702475A1 (en) * | 1993-03-08 | 1994-09-16 | Agency Ind Science Techn | Process for the manufacture of ceramics reinforced with fibres arranged in three dimensions, and apparatus for implementing this process |
| US9102571B2 (en) | 2013-01-14 | 2015-08-11 | Coi Ceramics, Inc. | Methods of forming ceramic matrix composite structures |
| WO2017187050A1 (en) | 2016-04-25 | 2017-11-02 | Safran | Method for producing a part from composite material by injecting a loaded slip into a fibrous texture |
| FR3080113A1 (en) | 2018-04-13 | 2019-10-18 | Safran Ceramics | PROCESS FOR MANUFACTURING A COMPOSITE MATERIAL PART BY INJECTING A BARBOTIN CHARGED WITH FIBROUS TEXTURE |
| US20200339480A1 (en) * | 2017-12-28 | 2020-10-29 | Safran Ceramics | Method for the production of a part made from a composite material, by means of the injection of powder into a fibrous reinforcement with drainage through a composite filtration layer |
-
2021
- 2021-07-07 FR FR2107329A patent/FR3124965B1/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2702475A1 (en) * | 1993-03-08 | 1994-09-16 | Agency Ind Science Techn | Process for the manufacture of ceramics reinforced with fibres arranged in three dimensions, and apparatus for implementing this process |
| US9102571B2 (en) | 2013-01-14 | 2015-08-11 | Coi Ceramics, Inc. | Methods of forming ceramic matrix composite structures |
| US20150328799A1 (en) | 2013-01-14 | 2015-11-19 | Coi Ceramics, Inc. | Systems for forming a ceramic matrix composite structure, and related advanced fiber placement apparatuses |
| WO2017187050A1 (en) | 2016-04-25 | 2017-11-02 | Safran | Method for producing a part from composite material by injecting a loaded slip into a fibrous texture |
| US20190134848A1 (en) * | 2016-04-25 | 2019-05-09 | Safran | A method of fabricating a composite material part by injecting a filled slurry into a fiber texture |
| US20200339480A1 (en) * | 2017-12-28 | 2020-10-29 | Safran Ceramics | Method for the production of a part made from a composite material, by means of the injection of powder into a fibrous reinforcement with drainage through a composite filtration layer |
| FR3080113A1 (en) | 2018-04-13 | 2019-10-18 | Safran Ceramics | PROCESS FOR MANUFACTURING A COMPOSITE MATERIAL PART BY INJECTING A BARBOTIN CHARGED WITH FIBROUS TEXTURE |
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|---|---|
| FR3124965B1 (en) | 2024-04-05 |
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