Process for manufacturing a component with an insert made of a composite consisting of a metal matrix and ceramic fibers
View Patent ↗A process for manufacturing a component with an insert made of a composite is disclosed. The composite includes a metal matrix, within which ceramic fibers extend. The insert is made of a composite which is obtained from a plurality of coated filaments, each filament includes a ceramic fiber coated with a metal sheath. The process includes winding a bundle or bonded sheet of coated filaments around a body of revolution perpendicular to the axis of rotation of said body. The insert is then subjected to a hot isostatic pressing step in a container. The process is applied to the manufacture of aeronautical turbomachine components.
1. A process for manufacturing a component with an insert made of a composite comprising a metal matrix, within which ceramic fibers extend, the insert made of a composite being obtained from a plurality of coated filaments, each filament comprising a ceramic fiber coated with a metal sheath, the process comprising:
manufacturing a bonded sheet of coated filaments by spot welding at a contact point between successive coated filaments using a laser device; and
winding the bonded sheet of coated filaments around a body of revolution perpendicular to the axis of rotation of said body.
2. The process for manufacturing a component with an insert made of a metal-matrix composite according to claim 1 , wherein winding includes, at the start of winding, winding a metal shim for catching a internal part of the insert and, at the end of winding, winding a metal shim for catching a external part of the insert, and
wherein the process further comprises inserting the coiled insert thus formed into an annular cavity of a container,
adding a lid to the container to form an assembly, and
compacting the assembly by hot isostatic pressing.
3. The process for manufacturing a component with an insert made of a metal-matrix composite according to claim 1 , wherein the sheet of coated filaments is wound around a mandrel, and
wherein the process further comprises inserting the mandrel into an annular cavity of a container,
adding a lid to the container to form an assembly, and
compacting the assembly by hot isostatic pressing.
4. The process for manufacturing a part with an insert made of a metal-matrix composite according to claim 3 , wherein, at the start of winding, the sheet of coated filaments is fastened to the body of revolution by a contact welding process between two electrodes and passage of a medium-frequency current.
5. The process for manufacturing a component with an insert made of a metal-matrix composite according to claim 3 , wherein, at the end of winding, the sheet of coated filaments is fastened to a wound coil by a contact welding process between two electrodes and passage of a medium-frequency current.
6. The process for manufacturing a component with an insert made of a metal-matrix composite according to claim 1 , wherein the bonded sheet of coated filaments is wound around a body of revolution forming an internal part of a container, and
wherein the process further comprises adding an external part and a lid to the container to form an assembly, and
compacting the assembly by hot isostatic pressing.
7. The process for manufacturing a part with an insert made of a metal-matrix composite according to claim 6 , wherein, at the start of winding, the sheet of coated filaments is fastened to the body of revolution by a contact welding process between two electrodes and passage of a medium-frequency current.
8. The process for manufacturing a component with an insert made of a metal-matrix composite according to claim 6 , wherein, at the end of winding, the sheet of coated filaments is fastened to a wound coil by a contact welding process between two electrodes and passage of a medium-frequency current.
9. The process for manufacturing a component with an insert made of a metal-matrix composite according to claim 1 , wherein the coated filaments are wound in a staggered fashion within the insert.
10. The process for manufacturing a component with an insert made of a metal-matrix composite according to claim 1 , wherein the welding is performed in an inert atmosphere.
11. The process for manufacturing a component with an insert made of a metal-matrix composite according to claim 1 , wherein the manufacturing of the bonded sheet comprises:
unwinding the coated filaments from a plurality of bobbins;
warping the coated filaments by stretching the coated filaments parallel to one another as a layer in a single plane without mutual overlap in contact with one another; and
welding the coated filaments while moving the warped coated filaments over a flat support.