Method for manufacturing a fibre reinforced metal disc preform

Abstract: Object: The present invention relates to an FRM disc preform for manufacturing an FRM disc used as compressor rotors of aircraft engines. In the prior art, a preform manufactured by a spirally formed reinforcing fiber collapses easily, because a spirally laminated reinforcing fiber are not fixed between an upper layer and a lower layer and there is a considerable difficulty in handling thereof in the post-processes such as a laminating process. Construction: An FRM disc preform (1) according to the present invention comprises a reinforcing fiber (2) wound in a spiral shape with flat faces and a spray coating (7) of a matrix metal formed on said flat face of the spirally wound reinforcing fiber (2) to hold the shape by fixing the upper layer and the lower layer of the spiral. Thereby, the spiral shape is held tightly without collapsing and handling in a laminating process and a combined forming process becomes extremely simplified, thus the manufacturing efficiency and accuracy of an FRM disc can be enhanced.

Description: BACKGROUND OF THE INVENTION: Field of the Invention: The present invention relates to a manufacturing method of a fiber reinforced metal disc preform (herein a fiber reinforced metal is referred to as "FRM"). Said manufacturing method is suitable for manufacturing an FRM disc used for manufacture of rotating disc-like products, such as compressor rotors of gas turbines using gas fuel or liquid fuel, specifically to be used under severe conditions accompanying high speed rotations and large stresses of the centrifugal force. Description of the Prior Art: In a development of next generation aircraft engines such as for high speed intermunicipal passenger aircrafts, increase of combustion temperature and weight reduction are the important target, and a development of new materials of a light weight and a high heat resistance is desired. Under this situation, an application of FRM discs to compressor rotors of gas turbines used in aircraft engines is presumed to bring a largest effect. Fig. 5 is a drawing showing a manufacturing process of an FRM disc in the prior art. As shown in Fig. 5(A) and Fig. 5(B), a matrix metal ribbon 01 made of a Ti alloy, such as a Ti-6Al-4V or a Ti-15V-3Cr-3Al-3Sn, and a reinforcing fiber 02, such as of a SiC, are lapped and wound in a spiral shape to form a preform 04, and the preform 04, the matrix metal ribbon 01 and a matrix metal foil 03 made of a same material as that of the matrix metal ribbon 01 are laminated one by one as shown in Fig. 5(C) and molded to a laminate 05 forming a disc of a desired diameter and thickness as shown in Fig. 5(D), and by said laminate 05 being heated and pressurized, the reinforcing fiber 02 and the matrix metal consisting of the matrix ribbon 01 and the foil 03 are combined by a combined forming, thus an FRM disc 06 is manufactured as shown in Fig. 5(E). In said manufacturing process, as shown in Fig. 5(A) and Fig. 5(B), forming of a spiral shape of the preform 04 using the matrix ribbon 01 and the reinforcing fiber 02, and handling thereof, are made simply by its winding tension given at the time of forming, the spiral shape of the preform 04 of the matrix metal ribbon 01 and the reinforcing fiber 02 collapses easily at the time of piling up to make a laminate as shown in Fig. 5(C), etc. and there is a disadvantage that handling thereof is very difficult. In order to avoid collapsing of the spiral shape during handling thereof in the manufacture of a fibre reinforced metal disc preform, i.e. to maintain both a regular fibre spacing and the shape of the preform according to FR-A-2,663,955 the matrix metal is spray coated on the surface of the fibre wound in a spiral shape on the mandrel. By that means the spiral shape is hold. According to DE-A-2,047,209 the planar shape of a preform of reinforcing fibres is maintained and may be easily handled by plasma spray coating aluminum on the surfaces of reinforcing fibres laid on a thin aluminum foil whereby the reinforcing fibres are embedded into the deposited aluminum. SUMMARY OF THE INVENTION: It is therefore an object of the present invention to provide a manufacturing method of a FRM disc preform which solves the above-mentioned shortcomings in the prior art, wherein a spiral shape manufactured and molded in the intermediate manufacturing process of an FRM disc does not easily collapse, handling thereof is extremely simplified and a manufacturing efficiency can be enhanced. For said purpose a FRM disc preform comprising a reinforcing fiber wound in a spiral shape having flat faces and a spray coating, made of a matrix metal, formed on one or both of said flat faces of the reinforcing fiber to hold said spiral shape is obtained by following means: (1) In order to form a disc of a certain thickness by laminating in the direction of flat faces, a reinforcing fiber is provided so that winding thereof is made in the direction of radius to form a spiral shape having flat faces on its both sides. Said reinforcing fiber as spirally wound is herein referred to as "preform". Incidentally, the diameter of a spiral shape is determined to a given size by changing numbers of winding of the reinforcing fiber to the diameter of a disc to be formed. Further, a spray coating made of a matrix metal, formed by a thermal spraying on one or both of the flat faces of the reinforcing fiber of a spiral shape to hold the spiral shape, is provided.Thereby, in the FRM disc preform obtainable according to the present invention, as a spiral shape formed by a reinforcing fiber is fixed and held (with adhesive) by a spray coating of a matrix metal formed by a thermal spraying on one or both of the flat faces, the spiral shape does not easily collapse, handling thereof is extremely simplified, the work of post-processes such as laminating becomes extremely simple and the manufacturing efficiency of FRM discs can be enhanced. And as the molded spiral shape holds its right shape as molded, the manufacturing accuracy can be also enhanced.A FRM disc preform of the typedisclosed above comprising as said reinforcing fiber one made of an Al 2 O 3 fiber or a SiC fiber and as said matrix metal one made of any one of an Al alloy, a Ti alloy or a Ti aluminide is obtained in addition to (1) above by following means: (2) For said reinforcing fiber mentioned in (1) above, an Al 2 O 3 fiber or a SiC fiber is used, and for said matrix metal to form a spray coating, any one of an Al alloy, a Ti alloy or a Ti aluminide is used. Thereby, in addition to the function and effect mentioned in (1) above, a combination of a reinforcing fiber and a matrix metal to form a spray coating, which is of a good compatibility, can be obtained, the spiral shape of the FRM disc preform is fixed and held more tightly, handling thereof is further simplified and the strength of FRM discs made by a combined forming of a high temperature and a high pressure can be enhanced.Further, a FRM disc preform of the type disclosed in (1) above comprising as said reinforcing fiber one made of a W fiber and as said matrix metal one made of a Ti aluminide is obtained in additior to (1) above by following means: (3) For said reinforcing fiber mentioned in (1) above, a W (tungsten) fiber is used, and for said matrix metal, a γ type Ti aluminide super alloy is used. Thereby, same function and effect mentioned in (2) above can be obtained.Further, a FRM disc preform set out above comprising a metal foil made of a same material as that of said matrix metal provided on one of said flat faces of the reinforcing fiber and said spray coating formed on the other side of said flat faces of the reinforcing fiber on which said metal foil is not provided is obtained in addition to (1), (2) or (3) above by following means: (4) To one of the flat faces of the reinforcing fiber formed in a spiral shape, a metal foil of a same material as the matrix metal is applied, and on the flat face opposite to the flat face to which the metal foil is applied, a spray coating made of the matrix metal is provided. Thereby, in addition to the function and effect mentioned in (1) to (3) above, the FRM disc preform on which said spray coating is formed on one flat face is easily taken off for handling, and a laminating process of FRM disc preforms for a combined forming to be carried out after molding of FRM disc preforms can be simplified.Further, a FRM disc preform set out above comprising a matrix metal wire made of a same material as that of said matrix metal provided between said reinforcing fibers wound in a spiral shape is obtained in addition to (1), (2), (3) or (4) above by following means: (5) Between an upper layer and a lower layer of the reinforcing fiber wound in a spiral shape, a matrix metal wire made of a same material as the matrix metal is provided. Thereby, in addition to the function and effect mentioned in (1) to (4) above, (a) at the time of forming a preform of a spiral shape by laminating the reinforcing fiber, as the matrix metal wire is interposed as spacing elements between the reinforcing fibers, the control of laminating becomes easier, and (b) as the same material as the matrix metal is used as the spacing elements, there occurs no lowering of the strength of FRM discs after a combined forming is made, and a process to take off the spacing elements after a spray coating is formed becomes unnecessary, thus the manufacturing can be simplified. Further, the basic manufacturing method of an FRM disc preform of the present invention comprises the step of winding a reinforcing fiber between two oppositely disposed discs in the direction of radius so as to form a preform of a spiral shape having flat faces on its both sides at least one of which discs is a disc (5) with borings forming blank places in the direction of radius, and further comprises the steps of spraying a matrix metal on one of said flat faces of the preform from the direction of said blank places provided on the disc with borings to form a spray coating to hold the spiral shape; and taking out said preform with the spray coating from between said discs. By employing this means, an FRM disc preform having the function and effect mentioned in (1) above can be manufactured accurately and easily. Further, the manufacturing method of an FRM disc preform set out in Claim 2 of the present invention is carried out - in addition to the steps mentioned above - as follows: In place of the process to form a preform of a spiral shape by winding a reinforcing fiber between two discs disposed oppositely, a process to form a preform in which a reinforcing fiber lapped with a spacing element is laminated and wound so that the spacing elements are interposed between the laminated reinforcing fibers, is employed. By employing this means, in addition to the function and effect mentioned in above, at the time of forming a preform of a spiral shape by laminating the reinforcing fibers, a matrix metal wire is interposed between the reinforcing fibers as a spacing element, the control of laminating becomes easier and a preform of a high accuracy can be manufactured. Further, the manufacturing method of an FRM disc preform set out in Claim 3 of the present invention is carried out - in addition to the steps mentioned in connection with claim 2 above - as follows: A step to take off the spacing element interposed between the laminated reinforcing fibers is added. By employing this means, in addition to the function and effect mentioned above, a spacing element of a given material can be used and by use of a spacing element of which material is easily worked, laminating of reinforcing fibers can be controlled more precisely. Further, the manufacturing method of an FRM disc preform set out in claim 4 of the present invention is carried out as is the basic method above and modified as follows: In place of the process to form a preform of a spiral shape by winding a reinforcing fiber between two discs disposed oppositely, a process to form a preform of a spiral shape with flat faces on both sides in which the reinforcing fiber is fitted in grooves of a spiral shape provided on the flat face, which is facing to the preform, of the disc with borings, out of the two discs, is employed. By employing this means, in addition to the function and effect mentioned in above, by changing the spaces between the grooves provided on the disc with borings in the direction of radius, the volumetric containing ratio V f distribution of the reinforcing fiber within the FRM disc preform can be freely changed. And as a matrix metal wire or a matrix metal ribbon of a Ti alloy which is hardly worked becomes unnecessary, FRM disc preforms can be manufactured at a lower cost. BRIEF DESCRIPTION OF THE DRAWINGS: In the accompanying drawings: Fig. 1 is a drawing showing a first preferred embodiment of an FRM disc preform obtainable according to the present invention, wherein Fig. 1(A) is a front view showing a state of winding a reinforcing fiber into a spiral shape, Fig. 1(B) is a sectional view taken along line A-A in the direction of arrows in Fig. 1(A), and Fig. 1(C) is a partial sectional view of the FRM disc preform of the first preferred embodiment. Fig. 2 is a drawing showing a second preferred embodiment of an FRM disc preform obtainable according to the present invention, wherein Fig. 2(A) is a front view showing a state of winding a reinforcing fiber into a spiral shape, Fig. 2(B) is a sectional view taken along line B-B in the direction of arrows in Fig. 2(A), and Fig. 2(C) is a partial sectional view of the FRM disc preform of the second preferred embodiment. Fig. 3 is a drawing showing a third preferred embodiment of an FRM disc preform obtainable according to the present invention, wherein Fig. 3(A) is a front view showing a state of winding a reinforcing fiber into a spiral shape, Fig. 3(B) is a sectional view taken along line C-C in the direction of arrows in Fig. 3(A), and Fig. 3(C) is a partial sectional view of the FRM disc preform of the third preferred embodiment. Fig. 4 is a drawing showing a disc with grooves and a fit mold used for winding a reinforcing fiber into a spiral shape in the third preferred embodiment obtainable according to the present invention, wherein Fig. 4(A) is a front view of the disc with grooves, Fig. 4(B) is a sectional view taken along line D-D in the direction of arrows in Fig. 4(A), and Fig. 4(C) is a sectional view of the disc with grooves and the fit mold taken along line E-E in the direction of arrows in Fig. 4(A). Fig. 5 is a perspective view showing a manufacturing process of an FRM disc in the prior art. DESCRIPTION OF THE PREFERRED EMBODIMENTS: Herebelow, preferred embodiments of FRM disc preforms obtainable according to the present invention are described with reference to figures. Fig. 1 is a drawing showing a first preferred embodiment of an FRM disc preform obtainable according to the present invention, wherein Fig. 1(A) is a front view showing a state of winding a reinforcing fiber into a spiral shape, Fig. 1(B) is a sectional view taken along line A-A in the direction of arrows in Fig. 1(A), and Fig. 1(C) is a sectional view of a completed FRM disc preform. As shown in the figure, two discs 5, 6 are disposed oppositely in parallel with a space of 140 (+5 to +10) µm which is slightly larger than the diameter of 140 µm of a wound reinforcing fiber 2 (a SiC fiber, a trade mark: SCS-6, a product of the TEXTRON Specialty Materials Co., USA). As shown in Fig. 1(A), one of the two discs is a disc 5 with borings which are blank spaces formed by twelve spokes extending in the direction of radius and the other disc 6 is a disc without a boring. The space length between the discs 5, 6 is controlled by placing a disc-shape spacer (not shown) of a same thickness as the space length, after adjusted, into the center part of the discs 5, 6. In this space portion, a reinforcing fiber 2 of a diameter of 140 µm and a Mo wire 4 of a diameter of 100 µm are lapped and wound as shown in Fig. 1(A). Upon completion of winding to the thickness corresponding to the diameter of a completed FRM disc preform 1, on the flat face of the disc 5 where the borings are provided as shown in Fig. 1(A), i.e. on one flat face of the spiral shape, a low pressure plasma spraying with Ti alloy powder is applied and a spray coating 7 is formed on the reinforcing fiber 2 and on the Mo wire 4. After forming of the spray coating 7, the reinforcing fiber 2 of a spiral shape and the Mo wire 4 together with the spray coating 7 are taken out from the discs 5, 6. Following the above, only the Mo wire 4 which harms the strength of an FRM disc when it is applied by a combined forming is taken off, and the remaining spiral fiber 2 of a disc shape with the spray coating 7 shown in Fig. 1(C) is made an FRM disc preform. Incidentally, as for the reinforcing fiber 2 of the first preferred embodiment, besides said SiC fiber, a W (tungsten) fiber or an Al 2 O 3 (alumina) fiber can be used, and as for the matrix metal to form the spray coating 7, besides said Ti alloy, an Al alloy, a metallic compound such as a Ti aluminide and a super alloy such as an Ni based alloy can be used. But a combination of a reinforcing fiber and a matrix metal is limited to that of a good compatibility and reinforcing fiber materials and their compatible matrix metal materials are shown in Table 1 below: Reinforcing fiber 2 Compatible matrix metal 7 Al 2 O 3 fiber Al alloy, Ti alloy, Ti aluminide SiC fiber Al alloy, Ti alloy, Ti aluminide W fiber Ti aluminide (γ type) super alloy Further, in a combined forming etc. of a laminate of FRM disc preforms 1 according to this preferred embodiment, as the case may be, metal foils 3 of a matrix metal compatible with a reinforcing fiber 2 shown in Table 1 are laminated between FRM disc preforms 1 and the laminate is applied by a combined forming. Fig. 2 is a drawing showing a second preferred embodiment of an FRM disc preform obtainable according to the present invention, wherein Fig. 2(A) is a front view showing a state of winding a reinforcing fiber into a spiral shape, Fig. 2(B) is a sectional view of a spray coating after a thermal spraying is applied taken along line B-B in the direction of arrows in Fig. 2(A), and Fig. 2(C) is a sectional view of a completed FRM disc preform. Two discs 5, 6 are disposed oppositely in parallel, a matrix metal foil 3 is applied to the side of the disc without a boring and the space between the discs is controlled by placing a spacer of a disc shape into the center part of the discs so as to make the space length larger by +5 to +10 µm than the diameter of 140 µm of the reinforcing fiber 2, wherein the discs 5, 6 are of same structures as those of the first preferred embodiment. In said space portion, a reinforcing fiber 2 of a diameter of 140 µm and a matrix metal wire 8 of a diameter of 100 µm or a matrix metal ribbon (100 µm x 50 µm) are wound in the same method as the first preferred embodiment. Upon completion of winding, a low pressure plasma spraying with matrix metal powder is applied on the reinforcing fiber 2 of a spiral shape from the direction of the flat face of the disc 5 where the borings are provided and a spray coating 7 is formed on the reinforcing fiber 2 and the matrix metal wire 8 or the matrix metal ribbon, and combines them as shown in Fig. 2(B). After the spray coating 7 is formed, the spiral reinforcing fiber 2, the matrix metal wire 8 or the matrix metal ribbon and the matrix metal foil 3 together with the spray coating 7, all in one unit, is taken out from the discs 5, 6 and is made an FRM disc preform 1. Incidentally, the reinforcing fiber 2 and the matrix metal used in the matrix metal foil 3 and the matrix wire 8 or the matrix metal ribbon in the second preferred embodiment are of same materials as used in the first preferred embodiment. And, in place of the Mo wire 4 in the first preferred embodiment which is used only as spacing elements to hold the spaces of the reinforcing fibers 2 and lowers the strength of the FRM disc preforms when a combined forming is applied thereto, a matrix metal wire 8 or a matrix metal ribbon is used in the second preferred embodiment and a process to take off the spacing elements after the spray coating 7 is formed becomes unnecessary, and the process can be simplified. Further, a matrix metal foil 3 is previously provided on the side of the disc 6 without a boring, a spiral shape of the reinforcing fiber 2 and the matrix metal wire 8 or the matrix metal ribbon is formed, and a low pressure plasma spraying is applied from the direction of the flat face of the disc 5 where the borings are provided, thus the FRM disc preform 1 is easily taken out from the disc 6 after the spray coating 7 is formed and the laminating process for a combined forming can be simplified. Fig. 3 is a drawing showing a third preferred embodiment of an FRM disc preform obtainable according to the present invention, wherein Fig. 3(A) is a front view showing a state of winding a reinforcing fiber into a spiral shape, Fig. 3(B) is a sectional view taken on line C-C in the direction of arrows in Fig. 3(A), and Fig. 3(C) is a sectional view of a completed FRM disc preform. Fig. 4 is a drawing showing a disc with grooves, wherein Fig. 4(A) is a front view, Fig. 4(B) is a sectional view taken on line D-D in the direction of arrows in Fig. 4(A), and Fig. 4(C) is a sectional view taken on line E-E in the direction of arrows in Fig. 4(A). In the third preferred embodiment, without such spacing element between the reinforcing fibers as the Mo wire 4 in the first preferred embodiment and without the matrix metal wire 8 or the matrix metal ribbon etc. in the second preferred embodiment, a spiral shape is formed only by a reinforcing fiber 2 and fixed of its shape by a spray coating 7, thus an FRM disc preform 1 is made. For this purpose, a disc 9 with grooves as shown in Fig. 4 is used for forming the reinforcing fiber 2 into a spiral shape. The disc 9 is applied by a boring work to make borings 92 and on the front faces 94 of spokes 91, grooves 93 in which the reinforcing fiber 2 to be formed into a spiral shape is placed are provided spirally. And in the borings 92, a fit mold 10 which is of a same shape as that of the borings 92 is fitted. A fit mold 10 is made so that the front face 101 thereof, when fitted into the borings 92, makes same face as the front faces 94 of the spokes 91 on which grooves 93 are provided: Further, on the front face 101 of the fit mold 10, grooves 102 are provided so as to connect continuously to the grooves 93 provided on the spokes 91 to form a spiral shape. While the fit mold 10 is fitted in the borings 92, a reinforcing fiber 2 is fitted in the grooves 93, 102 to form a spiral shape of the reinforcing fiber 2, and a disc 6 is placed and fixed via a matrix metal foil 3 as shown in Fig. 3(B). Then, the fit mold 10 fitted in the borings 92 of the disc 9 is taken off, a low pressure plasma spraying with matrix metal powder is applied to the spiral fiber from the direction of the face where the borings are provided, the reinforcing fiber 2 of a spiral shape is fixed and adhered (with adhesive) to the matrix metal foil 3 by a spray coating 7. Finally, discs 6, 9 are taken off and an FRM disc preform is made. Incidentally, the reinforcing fiber 2 and the matrix metal used in the third preferred embodiment are of same materials as those of the first preferred embodiment. According to the third preferred embodiment, by changing the spaces of the grooves 93 provided on the spokes 91 and of the grooves 102 provided on the fit mold 10 in the direction of radius, the volumetric containing ratio V f distribution of the reinforcing fiber 2 within an FRM disc preform can be freely changed. And the matrix metal wire 8 or the matrix metal ribbon made of a Ti alloy becomes unnecessary and there is an advantage that an FRM disc preform can be manufactured at a lower cost. As described above, according to the FRM disc preform structured as set out above and being obtainable in the manufacturing method of the present invention, as the spiral shape of a reinforcing fiber forming an FRM disc preform can be fixed and adhered (with adhesive) by a spray coating of a matrix metal formed on the flat face of the spiral shape, the spiral shape does not easily collapse and handling thereof becomes extremely simplified and the FRM manufacturing work included in the post-processes such as a laminating process becomes extremely simplified and the manufacturing efficiency and the manufacturing accuracy of FRM discs can be enhanced. While the preferred forms of the present invention have been described, variations thereto will occur to those skilled in the art within the scope of the present inventive concepts which are delineated by the following claims.

Claims: A manufacturing method of an FRM disc preform comprising the step of winding a reinforcing fiber (2) between two oppositely disposed discs (5, 6) in the direction of radius so as to form a preform (1) of a spiral shape having flat faces on its both sides, characterized in that at least one of said discs is a disc (5) with borings (52) forming blank places in the direction of radius, said method further comprising the steps of spraying a matrix metal on one of said flat faces of the preform (1) from the direction of said blank places provided on the disc (5) with borings (52) to form a spray coating (7) to hold the spiral shape; and taking out said preform (1) with the spray coating (7) from between said discs (5, 6). A manufacturing method of an FRM disc preform set out in Claim 1 characterized in that said process of forming the preform (1) is such that said reinforcing fiber (2) is wound and laminated in the direction of radius with spacing elements interposed inbetween, said spacing elements consisting of a matrix metal wire (4) made of a same material as that of a matrix metal, and the preform (1) is formed. A manufacturing method of,an FRM disc preform set out in Claim 2 characterized in comprising a process in which said spacing elements are taken out from between the reinforcing fibers (2). A manufacturing method of an FRM disc preform set out in Claim 1 characterized in that said process of forming the preform (1) is such that said reinforcing fiber (2) is fitted in grooves (93, 102) of a spiral shape provided on one of the flat faces of said disc (9) with borings (92) and the preform (1) of a spiral shape having flat faces on its both sides is formed.

Inventors: FUJIWARA CHIKARA, FUJIWARA, CHIKARA, Fujiwara, Chikara, c/o AMG Co., Ltd.
Applicants: RES INST OF ADVANCED MATERIAL, RESEARCH INSTITUTE OF ADVANCED MATERIAL GAS-GENERATOR CO., LTD ( AMG)
Application year: 1995
Main classification: C22C47
IPC codes: C22C47, F04D29, F01D5, C23C4, F01D21, C22C49, F02C7