Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
  • C22C47/02—Pretreatment of the fibres or filaments
  • C22C47/04—Pretreatment of the fibres or filaments by coating, e.g. with a protective or activated covering
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
  • C22C47/20—Making alloys containing metallic or non-metallic fibres or filaments by subjecting to pressure and heat an assembly comprising at least one metal layer or sheet and one layer of fibres or filaments
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49316—Impeller making
  • Y10T29/49336—Blade making
  • Y10T29/49337—Composite blade
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49801—Shaping fiber or fibered material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49826—Assembling or joining
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49826—Assembling or joining
  • Y10T29/49863—Assembling or joining with prestressing of part
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49826—Assembling or joining
  • Y10T29/49863—Assembling or joining with prestressing of part
  • Y10T29/49865—Assembling or joining with prestressing of part by temperature differential [e.g., shrink fit]

Definitions

• the present invention relates to the manufacture of metal parts having internal reinforcements formed of ceramic fibers and obtained from the incorporation of a fibrous insert into a metal matrix.
• ceramic fibers are for example silicon carbide fibers, SiC, which have a tensile strength and compression much higher than that of a metal such as titanium.
• a known method of manufacturing such parts with reinforcement comprises producing a winding son coated around a mandrel.
• the coil is then incorporated into a metal container or main body in which a groove forming the housing for the insert has been previously machined.
• the depth of the groove is greater than the height of the winding.
• a lid is placed on the container and welded to its periphery.
• the cover has a post complementary shape to that of the groove, and its height is adapted to that of the coil placed in the groove so as to fill the groove.
• a hot isostatic compaction step is then carried out during which the lid is deformed and the winding is compressed by the tenon.
• the container surface along the edge of the groove is sloped in the shape of a cutaway to ensure progressive deformation of the lid during the compaction phase.
• the technique of hot isostatic pressing consists in placing the part in an enclosure where it is subjected to high pressure, of the order of 1000 bars, and also a high temperature of about 1000 0 C for a few hours.
• the metallic sheaths of the coated wires are welded together and with the walls of the groove, by diffusion bonding, to form a dense assembly composed of a metal alloy in which the ceramic fibers extend.
• the resulting part is then machined to the desired shape.
• the method allows the manufacture of axisymmetric aeronautical parts, such as rotor discs or bladed disks monobloc but also non-axisymmetric, such as connecting rods, shafts, cylinder bodies, housings.
• the machining of the groove in the main body is a difficult operation to achieve especially because of the small connection radii in the bottom of the groove between the bottom surface and the side walls. This small radius of connection is necessary to allow housing with a game as low as possible Pinsert which has a rectangular section and which is formed of son of small rays.
• the machining of the corresponding post in the cover is not easy either because of the non-opening angles and because it must have a shape perfectly complementary to the groove.
• the applicant has developed a method of manufacturing elongated parts incorporating an insert with straight portions contributing to the transmission of tensile forces and / or compression unidirectional. This process is described in the patent application FR07 / 05453 of July 26, 2007.
• the Applicant has also developed a method of manufacturing a rectilinear insert. It consists in producing a blank of a coil-shaped insert, compacting it in a container by hot isostatic compaction and then machining the rectilinear inserts in the compacted container. Such a process is described in the patent application FR 07/05454 of July 26, 2007.
• FR 2886290 in the name of Snecma proposes to perform, alternatively, the winding directly on the main body. Instead of a groove there are two shoulders in it. The first has a bearing surface for the direct winding of a coated wire. This surface is parallel to the winding direction. When the winding is complete, the groove is reconstructed by placing a piece on the main body which is of complementary shape to that of a second shoulder forming a step relative to the first shoulder. Then we have the cover with the pin on the insert that has just wound and compacts the whole. This solution only partially solves the manufacturing problem because the assembly remains complex.
• the patent application FR0709171 in the name of the applicant specifies that the housing of the insert in the metal body has the shape of a notch L-section, the lid having an internal slot L-shaped section and complementary shape to that metal body with said insert.
• the cover is shaped externally so that the pressure forces are exerted perpendicularly to the faces of the notch.
• the current manufacturing techniques make it possible to create metal parts comprising one or more reinforcements made of metal matrix composites from coils of coated fibers and a container.
• the applicant has set itself the objective of improving the process for manufacturing elongated parts in the sense of simplifying the steps of the range and reducing costs.
• the cover is covered with a lid, the interstitial space around Pinsert is evacuated and said vacuum space is closed in a hermetic manner,
• the whole metal body with lid is treated by hot isostatic compaction and the treated assembly is machined to obtain said part.
• the method is characterized in that the insert is rectilinear, and the housing of the insert in the metal body has a groove of corresponding shape, the cover being dimensioned so as to allow its placement on the insert with play. in the housing, after being shrunk by cooling, and to make a tight fit in the groove by expansion to seal said gap.
• the lid is cooled by means of a liquid gas, such as liquid nitrogen, reducing its dimensions.
• a liquid gas such as liquid nitrogen
• the groove comprises a first housing portion of the insert and at least a second portion extending from the first portion, the cover being in the form of a block comprising a central branch covering the insert and an extension of shape corresponding to the second part of the groove.
• the lid thus forms a metal block of simple geometry and easily achievable.
• the cover comprises a zone of progressive deformation between the central branch and the extension. This zone of progressive deformation avoids the cracking of the lid at the time of the compaction step.
• the insert is of polygonal cross section, in particular rectangular, oval or circular.
• the insert is formed of bundled metal-coated fibers, which reduces the preparation operations.
• the solution of the invention is of particular interest with the introduction of two inserts, of elongate shape, arranged in two parallel rectilinear branches or not.
• an annular insert with two rectilinear branches interconnected by two parts in an arc of a circle is made beforehand.
• the housing is machined according to the precise shape of the insert. Adjusting the shape of the housing to that of the insert has proved to be a very delicate and expensive operation.
• the machining and setting up more simple without sacrificing the strength of the piece in the end since the fibers work essentially in their longitudinal direction in the central section of the piece.
• FIG. 1 shows the various steps 1a, 1b, 1c, 1 Id of manufacture of a piece of elongate shape according to the known prior art of the present applicant;
• FIG. 2 shows an example of a part obtained after machining a container incorporating inserts
• Figure 3 shows in perspective a metal body with a groove machined according to the invention and the introduction of the insert and the paver-shaped lid;
• Figure 4 shows in perspective and by transparency, the insert and the pavé-shaped lid in place in the metal block, the assembly being ready for the hot isostatic compaction treatment;
• FIG. 5 shows in section an alternative embodiment of the invention.
• FIG 1 extracted from the patent application FR 07/05453, there is shown a container 1 with a main body 4 of elongate shape, for forming a connecting rod of a landing gear for example. It has machined a groove 41 on each of the two faces of the body 4. This groove allows the housing of an insert 3 which comprises two straight portions parallel or not between them joined at the ends by a portion in an arc.
• the inserts are of the ceramic fiber type coated with metal such as titanium.
• the grooves and inserts are complementary shapes so that the insert is fit without play in the groove or with minimal clearance.
• Two covers 5 are provided with a projecting portion forming a pin 51 and cover the faces of the body 4. The ten bears on the insert housed in the groove and closes the latter.
• the cover 5 is welded, for example by electron beam, to the body 4, providing a vacuum inside the container.
• This assembly is intended to prevent the fibers, which have a very small diameter, of the order of 0.25 mm, can not move or escape during hot isostatic compaction.
• the container is visible in Figure Ib; it is partly torn off to show the inserts.
• the container is then placed in an enclosure to undergo hot isostatic compaction treatment.
• the cross-section of the container of FIG. 1c shows that the edges 42 of the groove 41 are chamfered so as to provide clearance with the part of the cover 5 adjacent to the post 51.
• the pressure is exerted in the direction perpendicular to the surface of the cover generating the collapse of the covers.
• the blank is then machined so as to obtain the part 8 shown in FIG. 2.
• This part 8 has recesses 81 between the branches 82.
• the ceramic fibers are incorporated in the branches 82 which ensure the transmission of the forces in traction and compression .
• the inserts used are annular but as described in the patent application FR 07/05454 they can be formed of straight elements bars. In the latter case, the rectilinear elements are incorporated into the container after having been compacted beforehand.
• FIG. 3 there is shown a metal body 10 elongate with respect to the figure an upper face 10B.
• a rectilinear groove 10A has been machined, the bottom of which is flat and the walls perpendicular to the bottom; the connecting surface between the bottom and the walls has a small radius of curvature to allow adjustment of the insert with a game as low as possible.
• the groove has a central portion 10A1 and two end portions 10A2 and 10A3 in the longitudinal extension of this one. The end portions are rounded.
• the groove serves as a housing for a rectilinear insert 11 formed of an assembly of coated ceramic fibers and of length 1 less than or equal to the length of the central portion 10Al of the groove.
• the insert forms a beam fitting in the central portion 10Al of the groove.
• a cover 12 covers the insert 1 1 disposed in its housing.
• the cover 12 has the same shape and the same dimensions, with the clearance for its implementation in the groove, when viewed from above the groove 1OA. It forms a block with a central portion 12Al covering the insert and two end portions 12A2 and 12A3 in the longitudinal extension of the central portion on either side of the latter.
• the thickness of the two end portions corresponds to the thickness of the central portion plus that of the insert placed in the groove and is slightly greater than the depth of the groove.
• the cover 12 is supported on the bottom of the groove by the two end portions 12A2 and 12A3. It is observed that the end portions each have a cutaway 12A2 'and 12A3' leaving a space with the bottom of the groove on the side of the insert.
• the manufacture of an example of a part according to the invention with an insert thus comprises the following steps: a metal body, of titanium alloy for example, is prepared with at least one upper planar face;
• At least one open rectilinear groove 10A is machined on one side, upper or lower.
• This operation is relatively simple because one only has to consider the depth and the width of the groove.
• the insert 11 is placed in the groove formed of an assembled bundle of coated rectilinear fibers. - It sets up the pavement-shaped lid 12 after lowering its temperature sufficiently for it has shrunk. A simple way is to put it in contact with liquid nitrogen. The dimensions of the paver-shaped lid and the groove are determined so that the lid can be easily placed in the groove after being cooled. By expanding, the lid comes to rest against the side walls eliminating any play.
• the whole After putting in place the lid in the form of a block, the whole is put under vacuum. The vacuum is created and the temperature of the lid is raised so that when the space surrounding the insert is under vacuum the lid is expanded and forms a seal around the lid.
• the top of the lid protrudes from the surface of the metal body.
• the blank obtained is ready to be machined. After machining, for example, the piece of FIG. 2 is obtained insofar as the number of corresponding inserts has been put in place.
• a sheet 14 which is welded to the periphery of the metal body with a bead 15 to improve the seal.
• the sheet as seen in the figure, comprises a housing 14 'allowing its adjustment to the cover of which a part is projecting and substantially corresponds to the expected volume reduction of the insert during the compaction operation.
• the method of the invention thus makes it possible to produce any elongate piece incorporating one or more rectilinear inserts.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Mechanical Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Manufacture Of Alloys Or Alloy Compounds (AREA)
• Powder Metallurgy (AREA)
• Forging (AREA)
• Pressure Vessels And Lids Thereof (AREA)

Applications Claiming Priority (2)

Publications (2)

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• 2008
  • 2008-07-04 FR FR0854589A patent/FR2933422B1/fr active Active
• 2009
  • 2009-07-03 JP JP2011515580A patent/JP5512666B2/ja active Active
  • 2009-07-03 EP EP09772750.7A patent/EP2310547B1/de active Active
  • 2009-07-03 BR BRPI0914700A patent/BRPI0914700A2/pt not_active IP Right Cessation
  • 2009-07-03 WO PCT/FR2009/051306 patent/WO2010001068A2/fr not_active Ceased
  • 2009-07-03 US US13/002,580 patent/US8418343B2/en active Active
  • 2009-07-03 CA CA2730069A patent/CA2730069C/fr active Active
  • 2009-07-03 CN CN2009801258145A patent/CN102084016A/zh active Pending
  • 2009-07-03 RU RU2011103914/02A patent/RU2500831C2/ru not_active IP Right Cessation

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