Classifications

• • 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
  • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
  • B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B11/00—Making preforms
  • B29B11/14—Making preforms characterised by structure or composition
  • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
• • 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 [3D] 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
  • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
  • B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
• • 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
  • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
  • B29C70/446—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B1/00—Layered products having a non-planar shape
  • B32B1/08—Tubular products
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/022—Non-woven fabric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/024—Woven fabric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/026—Knitted fabric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
  • B32B5/265—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
  • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
  • D03D15/267—Glass
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
  • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
  • D03D15/275—Carbon fibres
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
  • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
  • D03D15/573—Tensile strength
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D25/00—Woven fabrics not otherwise provided for
  • D03D25/005—Three-dimensional woven fabrics
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D41/00—Looms not otherwise provided for, e.g. for weaving chenille yarn; Details peculiar to these looms
  • D03D41/004—Looms for three-dimensional fabrics
• • 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
  • F01D21/00—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for
  • F01D21/04—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for responsive to undesired position of rotor relative to stator or to breaking-off of a part of the rotor, e.g. indicating such position
  • F01D21/045—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for responsive to undesired position of rotor relative to stator or to breaking-off of a part of the rotor, e.g. indicating such position special arrangements in stators or in rotors dealing with breaking-off of part of rotor
• • 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
  • F01D25/24—Casings; Casing parts, e.g. diaphragms, casing fastenings
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
  • F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
  • F02C7/04—Air intakes for gas-turbine plants or jet-propulsion plants
• • 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
  • B29L2031/748—Machines or parts thereof not otherwise provided for
  • B29L2031/7504—Turbines
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2597/00—Tubular articles, e.g. hoses, pipes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2603/00—Vanes, blades, propellers, rotors with blades
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2101/00—Inorganic fibres
  • D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
  • D10B2101/06—Glass
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2101/00—Inorganic fibres
  • D10B2101/10—Inorganic fibres based on non-oxides other than metals
  • D10B2101/12—Carbon; Pitch
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2101/00—Inorganic fibres
  • D10B2101/10—Inorganic fibres based on non-oxides other than metals
  • D10B2101/14—Carbides; Nitrides; Silicides; Borides
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
  • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2505/00—Industrial
  • D10B2505/02—Reinforcing materials; Prepregs
• • 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
  • F05D2220/00—Application
  • F05D2220/30—Application in turbines
  • F05D2220/36—Application in turbines specially adapted for the fan of turbofan engines
• • 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
  • F05D2300/6034—Orientation of fibres, weaving, ply angle

Definitions

• the present invention relates to the general field of manufacturing parts of revolution in composite material for propulsion units such as gas turbine fan casings, air inlets or nacelle covers for aeronautical engines.
• the fan housing serves several functions. It defines the air inlet stream into the engine, supports an abradable material facing the fan blade tips, supports a possible sound wave absorption structure for acoustic treatment at the engine inlet and incorporates or supports a retention shield.
• the retention shield constitutes a debris trap trapping debris, such as ingested objects or fragments of damaged blades, projected by centrifugation, to prevent them from passing through the casing and reaching other parts of the aircraft .
• the casings like the fan casing, are now made of composite material, that is to say from a fibrous preform densified by an organic matrix, which makes it possible to produce parts having a lower overall mass than these same parts when they are made of metallic material while having at least equivalent, if not greater, mechanical strength.
• the retention shield is constituted by a portion of extra thickness obtained at the level of the fibrous reinforcement of the casing which has an evolving thickness.
• the fibrous reinforcement is obtained by winding a texture 3D woven fibrous material which has an extra thickness portion capable of forming a retention shield.
• the extra thickness portion must always have a significant dimension in the radial direction, which significantly increases the overall mass of the composite material part. The same applies to an air inlet or a nacelle cowl of a propulsion assembly.
• the production of the fibrous preform comprises the formation of a fibrous blank in the form of a strip comprising at least one layer of continuous fibers and at least one layer of discontinuous fibers, the fibrous blank being shaped on the mandrel, said at least one layer of continuous fibers of the fibrous blank extending at least over a complete turn around the mandrel.
• the method of the invention thus makes it possible to obtain a part made of composite material having an increased retention capacity thanks to the presence of one or more layers of discontinuous fibers in its fibrous reinforcement.
• the layer(s) of discontinuous fibers are in fact capable of being damaged to dissipate energy in the event of impact with a projected object such as a blade in the case of an aeronautical engine casing (FBO for "Fan Blade”). Out”).
• the layer(s) of continuous fibers ensure the cohesion and mechanical resistance of the part. It is thus possible to manufacture parts of revolution in composite material having a very good retention capacity without requiring too significant an increase in thickness, the parts having an overall mass lower than that of the parts in composite material of the prior art.
• the layer(s) of staple fibers are a non-woven texture with long staple fibers or a mat of random fibers.
• the layer(s) of continuous fibers are chosen from at least one of the following fibrous structures: three-dimensional woven structure, stack of unidirectional layers, stack of two-dimensional woven layers, braid.
• the fibrous blank may comprise a single layer of continuous fibers corresponding to a strip-shaped fibrous structure having a three-dimensional weave between a plurality of warp threads and a plurality of weft threads.
• the production of the fibrous preform includes winding the fibrous blank on the mandrel on one or more turns.
• the fibrous blank may comprise a single layer of continuous fibers also corresponding to a fibrous structure in the form of a strip having a three-dimensional weave which comprises in the lengthwise direction a first part in which the warp threads are linked by the weft threads over the entire thickness of the fibrous structure and a second part comprising a debonding zone present at an intermediate position in the thickness of the fibrous structure and extending in the fibrous structure along a plane parallel to the surface of the fibrous structure , the debonding zone separating the fibrous structure into first and second skins, the layer of discontinuous fibers being placed between the first and second skins.
• the production of the fibrous structure includes winding the fibrous blank on the mandrel over one or more turns.
• the invention also relates to a part of revolution made of composite material for a propulsion assembly comprising a fibrous reinforcement, said fibrous reinforcement being densified by a matrix, characterized in that the fibrous reinforcement comprises in the direction of the thickness at least one layer of continuous fibers and at least one layer of discontinuous fibers.
• the composite material part of the invention offers very good retention capacity while having a controlled thickness and, consequently, a reduced overall mass compared to that of the composite material parts of the art. prior.
• the layer(s) of staple fibers are a non-woven texture with long staple fibers or a mat of random fibers.
• the layer(s) of continuous fibers are chosen from at least one of the following fibrous structures: three-dimensional woven structure, stack of unidirectional layers, stack of two-dimensional woven layers, braid.
• the fibrous reinforcement may comprise a single layer of continuous fibers consisting of a fibrous structure in the form of a strip having a three-dimensional or multilayer weave comprising a first part in which warp threads are linked by weft threads over the entire thickness of the fibrous structure and a second part comprising a debonding zone present at an intermediate position in the thickness of the fibrous structure, the debonding zone separating the fibrous structure into first and second skins, the layer of staple fibers being present between the first and second skins.
• a casing comprising a ferrule comprising a portion of extra thickness forming a retention zone, the ferrule further comprising at its axial ends a flange.
• Figure 1 is a perspective view and partial section of an aeronautical engine equipped with a fan casing made of composite material in accordance with one embodiment of the invention
• FIG. 2 Figure 2 is a sectional view along plane ll-ll of the casing of figure 1
• Figure 3 is a schematic perspective view of a loom showing the weaving of a fibrous texture used for the formation of the fibrous reinforcement of the casing of Figures 1 and 2
• Figure 4 is a schematic perspective view of a continuous fiber layer
• Figure 5 is a schematic perspective view of a layer with staple fibers
• Figure 6 is a schematic perspective view of a fibrous blank formed with the layers of Figures 4 and 5 in accordance with one embodiment of the invention
• Figure 7 is a schematic perspective view showing the shaping of the fibrous blank of Figure 6,
• Figure 8 is a sectional view of a fibrous preform obtained from the fibrous blank of Figure 6,
• Figure 9 is a schematic view showing tools for densifying the preform of Figure 8,
• Figure 10 is a schematic perspective view showing the formation of a fibrous blank in accordance with another embodiment of the invention.
• Figure 11 is a sectional view of a casing made from the fibrous blank of Figure 10.
• the invention applies generally to any part of revolution made of composite material for a propulsion assembly, the part of revolution being likely to be exposed to impacts.
• Such parts for propulsion units concern in particular, but not exclusively, gas turbine fan casings, nacelle air inlets and nacelle cowls present in aeronautical engines.
• Such an engine comprises, from upstream to downstream in the direction of the flow of gas flow, a fan 1 arranged at the inlet of the engine, a compressor 2, a combustion chamber 3, a high-pressure turbine 4 and a low-pressure turbine 5.
• the motor is housed inside a casing comprising several parts corresponding to different elements of the motor.
• the fan 1 is surrounded by a fan casing 100.
• FIG. 2 shows a profile of a fan casing 100 made of composite material as it can be obtained by a method according to the invention.
• the internal surface 101 of the casing defines the air inlet vein. It can be provided with an abradable coating layer 102 to the right of the trajectory of the tips of the fan blades, a blade 13 being partially shown very schematically.
• the abradable coating is therefore placed over only part of the length (in the axial direction) of the casing.
• An acoustic treatment coating (not shown) can also be placed on the internal surface 101, particularly upstream of the abradable coating 102.
• the casing 100 can be provided with external flanges 104, 105 at its upstream and downstream ends in order to allow its assembly and connection with other elements.
• the casing 100 is made of composite material with fibrous reinforcement densified by a matrix.
• the reinforcement is made of fibers, for example carbon, glass, aramid or ceramic
• the matrix is made of polymer, for example epoxy, bismaleimide or polyimide, carbon or ceramic.
• the fibrous reinforcement is formed by winding a fibrous blank onto a mandrel, the mandrel having a profile corresponding to that of the casing to be produced.
• the fibrous reinforcement constitutes a complete tubular fibrous preform of the casing 100 forming a single piece with reinforcing parts corresponding to the flanges 104, 105.
• the fibrous blank consists of at least one layer of continuous fibers and at least one layer of discontinuous fibers assembled together as described below.
• the layer of continuous fibers is constituted by a fibrous structure in the form of a strip having a three-dimensional weave. More precisely and as illustrated in Figure 3, a fibrous structure 50 is produced in a known manner by weaving three-dimensional by means of a jacquard type loom 10 on which a bundle of warp threads or strands 20 has been arranged in a plurality of layers, the warp threads being linked by weft threads or strands 30.
• the threads used for weaving the fibrous structure 50 are for example carbon fiber threads, for example HexTow® IM7, HexTow® AS4 or HexTow® AS7 fibers, or ceramic fibers such as silicon carbide, glass, or even aramid.
• Wire gauge is typically 12k, 24k or 48k. Different types of wires can be used within the same preform.
• the fibrous structure is produced by three-dimensional weaving.
• three-dimensional weaving” or “3D weaving” we mean here a mode of weaving by which at least some of the weft threads bind warp threads on several layers of warp threads or vice versa.
• An example of three-dimensional weaving is the so-called “interlock” weave.
• interlock weaving, we mean here a weaving weave in which each layer of warp threads links several layers of weft threads with all the threads of the same column of warp having the same movement in the plane of the armor.
• the fibrous structure 50 has a strip shape which extends in length in a direction corresponding to the direction of the wires or weft strands 30.
• the fibrous structure 50 has a strip shape having a thickness E 50 , for example 5 mm, corresponding to a 3D weaving with between three and five layers of warp woven together in the plane and in the thickness of the strip using weft threads.
• the fibrous structure 50 extends over a width l 50 defined as a function of the width of the casing to be manufactured, the width l 50 being able to be for example 2 m, and over a length L 50 defined as a function of the diameter of the casing to be manufactured and the desired number of turns in the fibrous reinforcement.
• the length of the fibrous structure to be woven is approximately 25 m.
• the layer of staple fibers consists of a mat of fibers.
• fiber mat is meant a fibrous texture corresponding to an agglomerate of discontinuous fibers, the fibers generally being arranged randomly or in bulk so as to obtain isotropic behavior in the plane.
• the production of the fiber mat can be adapted in order to obtain a mat with orthotropic properties making it possible to have modules in the plane as close as possible to the modules in the warp direction and/or in the weft direction of the structure. 3D woven fibrous material which may be different.
• the percentage of fibers in the direction of the sheet and the transverse direction can be influenced by the speed of advance of the conveying system.
• the faster the feed the more the fibers are oriented statistically in the direction of the roller. It is also possible to define drop wells which more or less reorient the fibers.
• Figure 5 illustrates a fiber mat 60 in the form of a strip comprising fibers 61 randomly distributed over a thickness E 6 o preferably between 1 mm and 5 mm.
• the fiber mat 60 has a width l 6 o equivalent to the width l 50 of the fibrous structure 50 and a length L 6 o less than the length L 50 of the fibrous structure 50 so that that only the fibrous structure 50 is present in the last winding turn of the fibrous blank.
• the fiber mat 60 preferably comprises the same type of fibers as the fibrous structure 50.
• the weight of the fiber mat is typically between 200 g/m 2 and 1000 g/m 2 even if higher weights can be used.
• a fibrous blank 140 is then produced by arranging the fiber mat 60 on the 3D woven fibrous structure 50 as illustrated in Figure 6.
• a step of sewing the assembly edges between the fiber mat 60 and the fibrous structure 50 can be also produced in order to hold them in position in the fibrous blank 140.
• the fibrous blank 140 can be compacted in order to reduce the expansion before its winding.
• a fibrous preform is then formed by winding in a direction S R on a mandrel 200 of the fibrous blank 140 with the fibrous structure 50 placed against the mandrel 200, the mandrel having a profile corresponding to that of the casing to be made.
• the mandrel 200 has an external surface 201 whose profile corresponds to the internal surface of the casing to be produced. By its winding on the mandrel 200, the fibrous blank 140 follows the profile thereof.
• the mandrel 200 also includes two flanges 220 and 230 to form parts of fibrous preform corresponding to the flanges 104 and 105 of the casing 100.
• Figure 8 shows a sectional view of the fibrous preform 300 obtained after winding the fibrous blank 140 in several layers on the mandrel 200.
• the number of turns or turns depends on the desired thickness and the thickness of the fibrous texture. It is preferably at least equal to 2.
• the preform 300 comprises, according to the direction of its thickness, two layers 51 and 52 of fibrous structure 50 and two layers 62 and 63 of fiber mat 60, the layer 62 being interposed between the adjacent layers 51 and 52 while the layer 63 is present on the external periphery of the preform 300.
• the fibrous preform 300 also comprises end parts 320, 330 corresponding to the flanges 104, 105 of the casing.
• the densification of the fibrous preform consists of filling the porosity of the preform, in all or part of its volume, with the material constituting the matrix.
• the matrix can be obtained in a manner known per se following the liquid process.
• the liquid process consists of impregnating the preform with a liquid composition containing an organic precursor of the matrix material.
• the organic precursor is usually in the form of a polymer, such as a resin, optionally diluted in a solvent.
• the fibrous preform is placed in a sealable mold with a housing having the shape of the final molded part. As illustrated in Figure 9, the fibrous preform 300 is here placed between a plurality of sectors 240 forming a counter-mold and the mandrel 200 forming a support, these elements respectively having the exterior shape and the interior shape of the casing to be produced. Then, the liquid matrix precursor, for example a resin, is injected throughout the housing to impregnate the entire fibrous part of the preform.
• the liquid matrix precursor for example a resin
• the transformation of the precursor into an organic matrix is carried out by heat treatment, generally by heating the mold, after elimination of any solvent and crosslinking of the polymer, the preform always being maintained in the mold having a shape corresponding to that of the part to be made.
• the organic matrix can in particular be obtained from epoxy resins, such as, for example, the high-performance epoxy resin sold, or from liquid precursors of carbon or ceramic matrices.
• the heat treatment consists of pyrolyzing the organic precursor to transform the organic matrix into a carbon or ceramic matrix depending on the precursor used and the pyrolysis conditions.
• liquid carbon precursors can be resins with a relatively high coke content, such as phenolic resins
• liquid ceramic precursors, in particular SiC can be polycarbosilane (PCS) type resins. or polytitanocarbosilane (PTCS) or polysilazane (PSZ).
• PCS polycarbosilane
• PTCS polytitanocarbosilane
• PSZ polysilazane
• the densification of the fibrous preform can be carried out by the well-known transfer molding process known as RTM ("Resin Transfer Molding").
• RTM Resin Transfer Molding
• the fibrous preform is placed in a mold presenting the shape of the casing to be produced.
• a thermosetting resin is injected into the internal space defined between the mandrel 200 and the counter-molds 240.
• the resin used can be, for example, an epoxy resin.
• Resins suitable for RTM processes are well known. They preferably have a low viscosity to facilitate their injection into the fibers. The choice of the temperature class and/or the chemical nature of the resin is determined according to the thermomechanical stresses to which the part must be subjected. Once the resin has been injected throughout the reinforcement, it is polymerized by heat treatment in accordance with the RTM process.
• the casing 100 of composite material thus comprises a fibrous reinforcement constituted in the direction of its thickness of two layers 51 and 52 of fibrous structure 50 and two layers 62 and 63 of fiber mat 60, the layer 62 being interposed between adjacent layers 51 and 52 while layer 63 is present on the external periphery of the casing 100.
• the number of turns or turns of layers of continuous fibers (here the fibrous structure 50) is a function of the thickness desired and the thickness of the layer. It is preferably at least equal to 2.
• the number of turns or turns of layers of discontinuous fibers (here the fiber mat 60) is a function of the desired retention capacity.
• the casing 100 thus presents over its entire width a retention zone or shield capable of retaining debris, particles or objects ingested at the engine inlet, or coming from damaged fan blades, and projected radially by rotation of the fan, to prevent them from passing through the casing and damaging other parts of the aircraft.
• the layer of discontinuous fibers constituted here by the fiber mat 60 may have a width less than that of the layer of continuous fibers constituted here by the fibrous structure 50. In this case, the layer of discontinuous fibers forms an extra thickness in the casing as described below corresponding to the crankcase retention zone or shield.
• FIG 10 illustrates the formation of a fibrous blank 440 according to another embodiment of the invention.
• the fibrous blank 440 is formed by assembling a layer of continuous fibers with a layer of discontinuous fibers. More precisely and as illustrated in Figure 10, a fibrous structure 70 is produced in a known manner by 3D weaving with for example carbon fiber threads, for example HexTow® IM7, HexTow® AS4 or HexTow® AS7 fibers, or ceramic such as silicon carbide, glass, or even aramid.
• Wire gauge is typically 12k, 24k or 48k. Different types of wires can be used within the same preform.
• the fibrous structure 70 has a strip shape which extends in length in a direction direction of the weft threads or strands.
• the fibrous structure 70 has the shape of a strip having a thickness E 7 o, for example of 10 mm corresponding to a 3D weave with between six and ten layers of warp woven together in the plane and in the thickness of the strip using weft threads.
• the fibrous structure 70 extends over a width l 70 defined as a function of the width of the casing to be manufactured, the width l 70 being able to be for example 2 m, and over a length L 70 defined as a function of the diameter of the casing to be manufactured and the desired number of turns in the fibrous reinforcement.
• the length of the fibrous structure to be woven is approximately 25 m.
• the length can be extended to prevent the start and end of the fibrous structure from being at the same angular position, which could create a weakness in the part.
• the fibrous blank 440 further comprises a layer of staple fibers.
• the layer of staple fibers consists of a non-woven texture with long staple fibers 80 (DLF).
• the long staple fibers have a length of between 8 mm and 100 mm, for example 12.5, 25 or 50 mm.
• the non-woven texture with long discontinuous fibers 80 has dimensions smaller than the fibrous structure 70 so as to form an extra thickness portion in the final casing as described below.
• the texture 80 has a strip shape having a width l 80 less than the width l 70 of the fibrous structure 70 and a length L 8 o corresponding less than or equal to half the length L 70 of the fibrous structure 70 of so that only the fibrous structure 70 is present in the first or last winding turn of the fibrous blank following the winding arrangement of the blank on the mandrel.
• the texture 80 has a thickness E 80 preferably between 1 mm and 5 mm.
• the texture 80 preferably comprises the same type of fibers as the fibrous structure 70.
• the fibrous texture 80 is preferably compacted before its insertion into the structure 70.
• the fibrous structure 70 can also be compacted in order to facilitate the insertion of the texture 80.
• the fibrous blank 440 further differs from the fibrous blank 140 described above in that the non-woven texture with long discontinuous fibers 80 is inserted into an untied portion of the fibrous structure 70. More precisely, the fibrous structure 70 comprises a first part 75 comprising an internal zone unbinding 71 and a second part 76 without unbinding. The first part 75 can for example have a length of 12 m while the second part can have a length of 13 m. In this case, the nonwoven texture with long discontinuous fibers 80 has a length less than or equal to 12 m.
• the detachment zone 71 locally forms in the fibrous structure 70 first and second superimposed skins 73 and 74 and separated from each other along a plane parallel to the surface of the fibrous structure 70 so as to delimit a housing between them internal 72.
• the unbinding zone 71 is obtained by defining a plane parallel to the surface of the fibrous structure 70 and typically located at half the thickness E 70 of the structure 70 which is not crossed by of weft threads.
• the weft threads present in the first skin 73 do not extend into the layers of warp threads of the second skin 74 while the weft threads present in the second skin 74 do not do not extend into the layers of warp threads of the first skin 73 in order to form the unbinding zone 71.
• the skins 73 and 74 each comprise, for example, three to five layers of warp woven together in the plane and in the thickness of the strip using weft threads.
• the skins can of course have a different number of warp layers.
• the unbinding zone does not extend to the lateral edges of the fibrous structure, thus forming a “sock”-shaped housing.
• the unbinding zone can, however, extend to the lateral edges of the fibrous structure, thus separating the fibrous structure into two skins over its entire width.
• the fibrous blank 440 is formed by inserting the non-woven texture with long discontinuous fibers 80 into the housing 72 of the fibrous structure 70 as illustrated in Figure 10.
• a fibrous preform is then formed by winding the fibrous blank 440 on a mandrel as for the fibrous blank 140 of Figure 7.
• Winding on the mandrel can begin with the first part 75 or the second part 76 of the fibrous structure 70 depending on the stacking order that one wishes to obtain in the direction of thickness (i.e. first skin 73, texture 80, second skin 74 and second part 76 or second part 76, first skin 73, texture 80 and second skin 74).
• first skin 73, texture 80, second skin 74 and second part 76 or second part 76, first skin 73, texture 80 and second skin 74 it is the first part 75 of the fibrous structure 70 which is wound first on the mandrel.
• the part After injection and polymerization, the part is demolded. Finally, the part is trimmed to remove excess resin and the chamfers are machined to obtain a casing 600 illustrated in Figure 1 1.
• the internal surface 601 of the casing defines the air inlet vein. It can be provided with an abradable coating layer and/or an acoustic treatment coating (not shown in Figure 1 1).
• the casing 600 here has external flanges 604, 605 at its upstream and downstream ends in order to allow its assembly and connection with other elements.
• the casing 600 made of composite material thus comprises a fibrous reinforcement consisting, between its internal periphery and its external periphery, of the first skin 73 of the first part 75 of the fibrous structure 70, of the non-woven texture with long discontinuous fibers 80, of the second skin 74 of the first part 75 of the fibrous structure 70 and of the second part 76 of the fibrous structure 70.
• the number of turns or turns of layers of continuous fibers (here the fibrous structure 70) is a function of the thickness desired and the thickness of the layer. It is preferably at least equal to 2.
• the number of turns or turns of layers of staple fibers (here the non-woven texture with long staple fibers 80) is a function of the desired retention capacity.
• the casing 600 further comprises an extra thickness portion 610 formed by the insertion of the non-woven texture with long discontinuous fibers 80 into the fibrous structure 70.
• This extra thickness portion forms a zone or shield of retention capable of retaining debris, particles or objects ingested at the engine inlet, or coming from damaged fan blades, and projected radially by rotation of the fan, to prevent them from crossing the casing and damaging other parts of the aircraft.
• the presence of a layer of staple fibers over the entire width of the part (casing 100) or over part of the width of the part (casing 600) makes it possible to give the part a very good retention capacity.
• the layer of continuous fibers is a strip having a 3D weave.
• the layer of continuous fibers can also be a stack of unidirectional layers, a stack of two-dimensional woven layers, or even a braid.
• the layer of staple fibers may in particular be a non-woven texture with long staple fibers or a mat of random fibers.

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• 2022
  • 2022-04-06 FR FR2203153A patent/FR3134337B1/fr active Active
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