Method for manufacturing a sample of a turbine blade from composite materials

FIELD: engine maintenance.

SUBSTANCE: invention relates to the non-destructive inspection through the radiography of a gas turbine engine blade made from composite materials. A control sample of a blade is manufactured from composite materials to standardise the radiographic inspection of such blades. A three dimensional raw piece is braided from composite materials and elements made from resin are positioned in certain points of the piece. The raw piece is then placed into the casting box and then resin is fed to the casting box to produce the control sample of the blade.

EFFECT: standardisation of the engine blade radiographic inspection for a distinctive flaw - accumulation of the resin inside the blade.

4 cl, 5 dwg, 1 ex

 

The present invention relates to the field of non-destructive control method of imaging blades of a gas turbine engine made of composite materials, in particular blades, containing made in three dimensions of a woven base. The invention in particular relates to the manufacture control sample blades to calibrate a tomographic system designed for the systematic control of such blades in the process of their production. The blades are made of composite materials and has passed such a test, can be attributed, in particular, the blades of the blower turbojet engine with the expiration of the primary and secondary air.

The blades of the blower turbojet engine with the expiration of the primary and secondary air can be made of composite material, namely, of synthetic fibers coated with resin. Seeking for the possibility of systematic non-destructive testing of such blades. Taking into account the commonly used materials recognized that x-ray tomography is the most effective method of non-destructive control.

For example, in patent US 6041132 describes the implementation method of imaging non-destructive testing of the blades of the blower. The process of tomographic reconstruction of swasana structure of the fiber mass, consisting in this case of the layers of belt material. According to the document tomographic reconstruction corresponds to the data layers. More specifically, at least one reference layer model-model is stored non-Euclidean coordinate system, and then in the process control real blade point of the above-mentioned layer is converted to a Euclidean coordinate system of the real details. This dual transformation allows us to better show the defects, in particular the formation of folds, which are typical for this type of blades, fiber mass which consists of layers of strip material.

The invention relates to the field of non-destructive control method of imaging a different type of blades containing large blank or pre-designed element, made of wire or woven fiber. Such a workpiece is immersed in the resin. For example, belonging to the applicant's patent EP 1526285 describes such blades.

In the process of manufacturing this type of blade can be different defects. The identification and evaluation of these defects is provided by the NDT method tomography.

The characteristic defect is the accumulation of resin inside the structure. For the identification and evaluation of these defects should be carried out regularly is tonirovanie tomographic equipment using a control sample of the scapula, containing, in particular, such a concentration of the resin, the size and location of which is known.

The invention relates to the manufacture of this control sample of the scapula.

In particular, the invention relates to a method of manufacturing a reference standard blades from composite materials for calibration of the x-ray process control similar blades, characterized in that the produced three-dimensional workpiece made of synthetic fiber fabrics; place made of solid resin elements in a pre-selected location of the workpiece; placing the workpiece in a mold and served in a mold under pressure the resin to obtain a control sample of the scapula.

Preferably, the control sample blades were intended to calibrate a tomographic setup.

Made of solid resin elements may have a geometric shape. For example, can be used bulbs with virtually spherical shape.

For the simulation of relatively large concentrations of resin can be applied to samples of resins of different sizes, for example balls with different diameter. So, in practice, have been successfully tested balls with a diameter of 2-10 mm

In the course of the research it has been unexpectedly found that the injection pressure of the liquid resin and the latter is the one handling at elevated temperatures did not lead to significant changes of the position and integrity of the components, which were made of solid resin and before the injection of the liquid resin was pre-set in the workpiece made of interwoven cloth.

The invention is further illustrated by a description of the method of manufacturing a control sample blades, cited as an example, with reference to the accompanying drawings, in which:

Figure 1 depicts a three-dimensional process of the manufacturing method of weave three-dimensional work pieces;

Figure 2 - schematic form obtained in this way the workpiece;

Figure 3 - placement is made from solid resin elements in the workpiece;

Figure 4 - coating a workpiece with a liquid resin is supplied under pressure into the mold;

5 is a view of the control sample of the scapula.

In the drawings in schematic form shows a method of manufacturing a control sample of the scapula, which includes the step of creating three-dimensional work pieces by weaving synthetic fibers by weaving machine 11, represented in schematic form in figure 1. Due to the fact that the description of the same phase is contained in the patent EP 1526285, in this case, its description is omitted. While the invention can be applied to all types of three-dimensional weaving, which can be produced in the workpiece 12, similar to those shown in figure 2. For these purposes before occhialino to use fibers of carbon. However, it can also be applied to the glass and aramid fibers.

The next stage is presented in figure 3, consists of placing is made from solid resin element 14, in this case, round balls, in certain areas of the workpiece. At the same time set a cartographic representation of data placements balls remembering their diameters at various locations.

Processed in a similar manner, the workpiece 12 is placed in a mold 16, containing a reprint of the desired control sample vanes, in form and size similar to the type of blades that will be subjected to non-destructive testing method of imaging. Then in a mold under pressure is pumped liquid resin, which may be heated to a temperature promoting its polymerization. The specialists can exercise control over all parameters.

For example, can be used successfully tested epoxy resin brand PR 520. Can also be used and other thermosetting resins, in particular other brands of epoxy resin, polyester, phenolic resin, etc.

At the stage of casting the following conditions are met (which is not fully mandatory):

the injection of the resin at an angle of 165° with a flow rate of 300 cm3/min to fill the mold;

the injection pressure up to 17 bar;

- drying at 180° for two hours.

It should be noted that before the injection of liquid resin into the preform its integrity may be compromised and other actions.

These include, in particular, can be attributed impulse strands for weaving, which is detected in the imaging. To give a more specific nature of such defects in certain places it is enough to disconnect, for example, using a simple pair of scissors, some strands of fiber control sample blades and install a cartographic representation of data from the incisions. Such slits 20 is schematically shown in figure 3. After that, operations are performed on the casting in the form presented in figure 4.

The resulting casting control sample 22 is depicted in figure 5.

1. A method of manufacturing a control sample blades made of composite material for calibration of the x-ray process control similar blades, characterized in that form the bulk of the workpiece (12), woven from synthetic fibers; place made of solid resin elements (14) in certain areas of the blank; placing the workpiece in a mold and served in a mold under pressure the resin to obtain a control sample of the scapula.

2. The method according to claim 1, characterized in that the resin elements (14) are almost spherical in shape.

3. The method according to claim 2, characterized in that spherical the elements of the resin (14) have different diameters in the range of 2-10 mm

4. The method according to any of the preceding paragraphs, characterized in that prior to injection of the resin in certain places of this procurement exercise cut some of the strands (20) fibers.



 

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