Method of manufacturing a metal alloy component for a turbine engine

Abstract

The invention relates to a method of manufacturing a metal alloy part for an aircraft turbine engine, said method comprising the following steps: • a) producing a blank of the part by additive manufacturing by laser fusion on a powder bed, and • b) machine finishing the blank by immersion in an abrasive composition contained in a tank subjected to a vibratory motion to obtain the part, the abrasive composition comprising abrasive elements formed of alumina particles, carrier elements formed of copper particles.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing metal alloy components for aircraft turbine engines, the method comprising an additive manufacturing step of laser fusion on a powder bed. Background Technology

[0002] Background art specifically includes documents WO-A1-2015 / 055601, FR-A1-3 058 457, WO-A1-2012 / 0013624, US-A1-2014 / 235146 and US-A1-2016 / 346896.

[0003] In particular, in the aerospace industry, where components for aircraft turbine engines are produced, powder metallurgy forming methods (more specifically, additive manufacturing) have recently regained interest due to their competitiveness in terms of production costs, output, and processing efficiency.

[0004] While these manufacturing methods enable the production of parts with complex geometries approaching finish dimensions, the surface finish at the end of the process remains unacceptable. The roughness levels achieved after additive manufacturing are typically very coarse, with roughness Ra varying between 10 μm and 50 μm depending on the manufacturing strategy, the type of powder used, the manufacturing conditions implemented, and the orientation of the part during construction. These high roughness levels negatively impact the mechanical properties of the part and the performance of the turbine engine, particularly in areas through which airflow passes, such as in parts comprising at least one aerodynamic blade (wheel blade, distributor, rectifier, etc.).

[0005] Therefore, aerospace components produced through additive manufacturing must be systematically precision-machined, primarily to achieve acceptable levels of roughness.

[0006] Additive manufacturing is a manufacturing method that emerged in the 1990s. It is a manufacturing method that enables the production of physical objects layer by layer by adding materials based on digital files. These manufacturing methods make it possible to directly produce parts with finish dimensions close to those of the original components.

[0007] Components of aircraft turbine engines (such as rectifiers) can be manufactured using laser fusion technology (also known as selective laser melting (SLM) or laser beam melting (LBM)) on a powder bed.

[0008] The technology involves using a laser 12 to continuously fuse powder 10 in a bed until part 14 is obtained. Figure 1Furthermore, this technology is well-known to those skilled in the field of additive manufacturing of aerospace components.

[0009] A powder bed 10 of a certain thickness (20μm-60μm) is spread out, and the laser 12 fuses the powder according to the geometry of the part 14 to be produced (according to a defined scanning strategy). Unfused powder is removed, and a new powder bed 10 is spread out, allowing a new laser scanning cycle to be performed.

[0010] The surface condition of part 14 produced by additive manufacturing can be improved by vibratory finishing. Vibratory finishing encompasses all industrial grinding machining methods used to improve roughness or micro-roughness, trimming, scribing, polishing, or rust removal by moving an abrasive composition around the part in a jar.

[0011] From a scientific perspective, vibration finishing can include three phenomena: abrasion (especially used to reduce roughness), shearing (especially used for engraving and trimming), and impact (especially used for polishing).

[0012] There are various types of vibration finishing equipment, including:

[0013] a) Tumbling mill: A tumbling mill consists of a jar that rotates about a horizontal axis, the jar containing a grinding composition and components that are either fixed or free within the jar;

[0014] b) Linear vibrators and circular vibrators: Linear vibrators and circular vibrators consist of a vibrating jar that moves the grinding composition and houses the component, which can be stationary or moving.

[0015] c) Centrifugal machine: A centrifugal machine is a machine that uses kinetic energy in a tank to move a grinding composition, the tank including a plate that rotates at high speed at the bottom; this component is free in the tank;

[0016] d) Drag finishing machine: A drag finishing machine is a machine that moves parts in a rotary manner within a tank containing an abrasive composition; and

[0017] e) Surf finishing machine: The surf finishing machine consists of a tank that rotates around a vertical axis, containing a grinding composition and parts that can be fixed or free in the tank.

[0018] These techniques are insufficient when it comes to finishing parts produced through additive manufacturing, particularly because they cannot completely reduce the very high surface roughness of the original additively manufactured parts, and they are generally not suitable for working in hard-to-access, restricted areas. Therefore, alternative methods, such as polishing with abrasive paste, sandblasting, or chemical methods, must be employed before these techniques.

[0019] Therefore, many of these technologies need to be combined to finish parts with complex geometries obtained through additive manufacturing.

[0020] Therefore, there is a need for a vibration finishing solution that simplifies the manufacturing process for aerospace components, including additive manufacturing steps involving laser fusion on a powder bed. Summary of the Invention

[0021] This invention relates to a method for manufacturing metal alloy components for aircraft turbine engines, the method comprising the following steps:

[0022] a) Producing the blank of the part by additive manufacturing using laser fusion on a powder bed, and

[0023] b) The blank is machined by a grinding machine to obtain the part. This machining is performed by immersing the blank in a grinding composition and vibrating it for finishing. The grinding composition is contained in a jar subjected to vibratory motion.

[0024] The grinding composition includes an abrasive element formed of alumina particles, a bearing element formed of copper particles, and a liquid.

[0025] Step b) includes a first cycle of vibratory finishing of the blank in the grinding composition, and at least one additional cycle of vibratory finishing of the blank, at the beginning of at least one additional cycle, some or all of the grinding composition in the grinding composition is discharged and replaced by a new grinding composition having the same formulation, and between two successive cycles of vibratory finishing, the orientation of the part in the tank is changed.

[0026] Therefore, the present invention provides a specific grinding composition for vibratory finishing of metal blanks obtained by additive manufacturing. In the techniques described above, the present invention uses vibration or vibratory finishing.

[0027] In this application, "abrasive element" refers to an element having abrasive function (i.e., the function of performing surface treatment by abrasion of a component to change the roughness of the component (specifically, to reduce the roughness of the component in the case of this invention)). The hardness of the abrasive element is generally greater than the hardness of the component to be treated, and therefore greater than the hardness of the metal alloy in the case of this invention. According to the invention, the abrasive element is formed from alumina (Al2O3) particles. Alumina is a ceramic material with high hardness and chemical stability.

[0028] In this application, a carrier element refers to an element whose function is to facilitate the flow of the abrasive composition within the container. The carrier element is independent of and distinct from the abrasive element. When the container vibrates, the carrier element moves within the container and causes the abrasive element to move along with it. This creates a flow of the abrasive composition within the container, allowing the abrasive element to flow over and around the component, performing its abrasive machining function. The carrier element typically has a higher density than the abrasive element. According to the invention, the carrier element is formed of copper particles. Copper is so dense and hard that it will not bounce off the component as it moves through the container.

[0029] The liquid in the abrasive composition allows for fluidization of the composition's flow and facilitates the cleaning of parts and the removal of material from the parts through abrasion. The liquid also enables lubrication of the parts and prevents temperature rise due to friction.

[0030] The method according to the invention may include one or more of the following features, either individually or in combination:

[0031] - The grinding element is harder than the part being processed;

[0032] - The average diameter or average size of the alumina particles is between 5 μm and 100 μm, preferably between 10 μm and 70 μm; the alumina particles can have any shape;

[0033] - The density of the bearing element is greater than that of the grinding element;

[0034] - The average diameter or average size of the copper particles is between 0.5 mm and 5 mm, preferably between 1 mm and 4 mm; the copper particles can have any shape; for example, the copper particles can be in the form of parallelepiped plates and have a thickness of about 1 mm, for example.

[0035] - This component is made of titanium, nickel, or an iron-based alloy.

[0036] - The grinding composition comprises, by weight, 0.05% to 0.4% (preferably, 0.1% to 0.2%) of grinding elements and 95% to 99% (preferably, 96% to 98%) of carrier elements, the remainder of the grinding composition being formed of liquid;

[0037] - The ratio R1 = Q1 / Q2 is between 200 and 2000, preferably between 500 and 1000, where Q1 is the weight of the carrier element in the grinding composition and Q2 is the weight of the grinding element in the grinding composition;

[0038] - The grinding composition comprises a liquid of between 0.6% and 4.95% by weight (more preferably, between 1.8% and 3.9%);

[0039] - The ratio R2 = Q1 / Q3 is between 10 and 500, preferably between 30 and 300, where Q1 is the weight of the bearing element in the grinding composition and Q3 is the weight of the liquid in the grinding composition;

[0040] - The ratio R3 = Q3 / Q2 is between 5 and 50, preferably between 10 and 30, where Q3 is the weight of the liquid in the grinding composition and Q2 is the weight of the grinding element in the grinding composition;

[0041] - In step b), the blank is completely immersed in the grinding composition;

[0042] - The blank is located at a certain height in the can or extends to a maximum height in the can, which is at most 30%, preferably at most 15%, of the maximum height of the grinding composition in the can;

[0043] - The liquid used to grind the composition is an aqueous solution comprising at least one surfactant and possibly other additives;

[0044] - Step b) includes a first cycle of vibratory finishing of the blank in the grinding composition, and at least one additional cycle of vibratory finishing of the blank, wherein at the beginning of at least one additional cycle, the grinding composition is at least partially discharged and replaced by a new grinding composition having the same formulation, and the orientation of the part in the can may be changed between the two successive cycles.

[0045] - The vibration motion occurs at a frequency between 30Hz and 60Hz, preferably between 40Hz and 50Hz;

[0046] - The vibrational motion occurs along three axes of an orthogonal reference frame;

[0047] - The component includes at least one aerodynamic blade and, for example, multiple adjacent aerodynamic blades, which form an integrated assembly known as a rectifier;

[0048] - The component is held in the can by a tool, which includes clamps for holding the component and a flat ferromagnetic base arranged at the center of the can and at the bottom of the can, and is held in place by an electromagnetic field;

[0049] -The method includes, between step a) and step b), a step i) of heat treating the blank and / or a step ii) of machining the blank to remove the manufacturing support.

[0050] -The method includes, after step b), step x) to decontaminate the component by immersing it in a decontamination bath, or successive steps y) and z) to degrease and perform penetration testing on the component;

[0051] - The cleaning bath includes an aqueous solution containing at least one acid, such as nitric acid. Attached Figure Description

[0052] Other features and advantages will become apparent from the following description of non-limiting embodiments of the invention with reference to the accompanying drawings, in which:

[0053] [ Figure 1 ] Figure 1 This is a very schematic view of an additive manufacturing apparatus using laser fusion on a powder bed, and illustrates the first step of the method according to the invention;

[0054] [ Figure 2 ] Figure 2 This is a flowchart illustrating an embodiment of a method according to the invention for manufacturing metal alloy components for aircraft turbine engines;

[0055] [ Figure 3 ] Figure 3 This is a very schematic view of a vibrating jar containing an abrasive composition, with the workpiece to be treated immersed in the abrasive composition, and Figure 3 Another step in the method according to the invention is shown;

[0056] [ Figure 4 ] Figure 4 This is a larger-scale view of the component and its support within the tank, showing the direction of the grinding flow at the component to be treated within the tank;

[0057] [ Figure 5 ] Figure 5 This is a schematic perspective view of a tool used to attach and hold the component in a container, in which case the component is an aircraft turbine engine rectifier and is held in a first position; and

[0058] [ Figure 6 ] Figure 6 yes Figure 5 Another schematic perspective view of the components and tools, with a portion of the tool having been rotated about a horizontal axis to hold the components in a second position. Detailed Implementation

[0059] The above has been briefly described Figure 1 , Figure 1 Step a) of a method for additive manufacturing of a metal alloy component for an aircraft turbine engine according to the present invention is shown.

[0060] The component to be manufactured includes, for example, at least one aerodynamic blade and, for example, multiple adjacent aerodynamic blades. For example, in... Figure 5 and Figure 6 The rectifier 20 shown is an example of this, which includes a plurality of adjacent blades 22, the ends of which are connected to housings 24, 26.

[0061] The turbine engine rectifier 20 has an annular shape around the axis of rotation. Figure 5 and Figure 6 The component shown is actually a rectifier sector, which is an angled portion of the rectifier. Dividing the rectifier into sections makes it easier to manufacture and assemble.

[0062] exist Figure 5 and Figure 6 The rectifier sector shown is formed as an integral component produced by the method according to the invention.

[0063] Figure 2 A non-limiting embodiment of the method according to the present invention, having necessary and optional steps, is shown.

[0064] The two necessary steps are:

[0065] a) Use Figure 1 The apparatus 16 shown uses laser fusion on a powder bed to produce a blank 30 for the component via additive manufacturing, and

[0066] b) The blank 30 is machined by a grinding machine to obtain the component (e.g., rectifier 20 in the specific case described above). This machining is performed by immersing the blank 30 in a grinding composition 32 by vibration finishing, the grinding composition being contained in a tank 34 subjected to vibration.

[0067] Since additive manufacturing step a) is considered to be part of the common knowledge of those skilled in the art in the field under discussion, additive manufacturing step a) will not be described in detail below.

[0068] Preferably, the blank 30 is made of powder from a nickel-based alloy (e.g., Inconel 718), titanium, or iron. Unlike the figures showing the blank 30 as a simple specimen, the blank can have complex shapes, such as... Figure 5 and Figure 6 As shown. The resulting blank 30 has a high surface roughness, which is reduced by the vibration finishing step b).

[0069] This vibratory finishing is performed using a vibratory tank 34, such as... Figure 3As shown. The vibratory tank 34 has any conventional shape and contains an abrasive composition 32, in which the blank 30 to be treated is immersed. For example, the tank 34 has a cubic shape with sides of 40 cm.

[0070] Tank 34 forms part of a vibratory finishing apparatus, which is not shown in the accompanying drawings for clarity. The apparatus includes, for example, a motorized device 36 configured to apply vibratory motion to tank 32, and a control device 38 for controlling these motorized devices. For example, the apparatus is similar to that described in document US-A1-2014 / 235146.

[0071] According to the present invention, the grinding composition 32 contained in the tank 34 includes a grinding element formed of alumina particles, a bearing element formed of copper particles, and a liquid.

[0072] The abrasive composition 32 preferably comprises abrasive elements at a weight of between 0.05% and 0.4% and a bearing element at a weight of between 95% and 99%, the remainder of the abrasive composition being formed of liquid.

[0073] The liquid in the grinding composition preferably includes an additive at a weight of 2% to 8% (more preferably, 4% to 5% by weight). When the additive content is above a certain level, there is a risk of thermal corrosion of the component if trace amounts of additive remain on the component during use (in flight).

[0074] The average diameter or average size of the alumina particles is between 5 μm and 100 μm, preferably between 10 μm and 70 μm. The alumina particles can have any shape.

[0075] The average diameter or average size of the copper particles is between 0.5 mm and 5 mm, preferably between 1 mm and 4 mm. The copper particles can be of any shape, for example, they can be in the form of parallelepiped plates.

[0076] Q1, Q2, and Q3 are defined as the weight of the carrier element in the grinding composition 32, the weight of the grinding element in the grinding composition 32, and the weight of the liquid in the grinding composition 32, respectively. The inventors have discovered that increasing the amount of the grinding element in the composition leads to an improvement in the final surface condition of the part, and that increasing the amount of the carrier element in the composition also leads to an improvement in the final surface condition of the part.

[0077] Advantageous:

[0078] - The ratio R1 = Q1 / Q2 is between 200 and 2000, preferably between 500 and 1000, and / or

[0079] - The ratio R2 = Q1 / Q3 is between 10 and 500, preferably between 30 and 300, and / or

[0080] - The ratio R3 = Q3 / Q2 is between 5 and 50, preferably between 10 and 30.

[0081] Depending on the capacity of the can, Q1 is preferably greater than 300 kg.

[0082] Q2 is preferably between 300g and 600g.

[0083] Q3 is preferably between 3 kg and 10 kg, and more preferably between 5 kg and 9 kg.

[0084] The grinding element is, for example, made of SPM. The grinding element is sold under the name 860G.

[0085] The purity of the carrier element is, for example, 99.9%. Therefore, the carrier element is mainly composed of copper.

[0086] The liquid in the grinding composition 32 is preferably an aqueous solution comprising at least one surfactant and possibly other additives. This liquid may be produced by SPM. Aquatic blend products sold under the names A320R and FAM 521.

[0087] The vibration occurs along the axes x, y, and z. This vibration occurs, for example, at a frequency between 30 Hz and 60 Hz (preferably between 40 Hz and 50 Hz).

[0088] This vibrational motion displaces the bearing element, thereby displacing the copper particles in the can 34. The displacement of the copper particles causes the alumina particles to move, and thus all the particles in the can move. Therefore, the vibrating composition vibrates in the can along three directions x, y, and z, and the vibrating composition moves primarily in one direction within the can, specifically along the axis Y. This direction of movement is horizontal and parallel to the bottom 34a of the can 34, to which the blank 30 is attached. Liquid helps to fluidize this motion and forms a grinding flow within the can 34, which is generated by… Figure 4 The double arrow F is schematically shown in the diagram. Therefore, the grinding flow depends on the vibratory motion of the tank 34.

[0089] The motion applied to the tank 34 can be linear, circular, etc. For example, the motor 36 can rotate clockwise or counterclockwise, alternating between the two modes. This has the effect of changing the flow orientation of the grinding flow F while maintaining the same direction, and making the vibration finishing of the parts as uniform as possible.

[0090] The blank 30 is immersed in the composition 32, and preferably completely immersed in the composition 32, such as... Figure 3 As shown. The blank 30 is located at height H1 in the tank 34, or extends to the maximum height H1 in the tank.

[0091] The height H1 is preferably as low as possible so that the blank 30 is positioned as close as possible to the bottom of the tank, which makes it possible to improve wear during vibration finishing.

[0092] The height H1 can represent up to 30%, preferably up to 15%, of the maximum height H2 of the grinding composition 32 in the jar.

[0093] H1 is preferably between 5cm and 10cm.

[0094] In other words, preferably, the upper limit N of the grinding composition 32 in the jar 34 is much higher than the blank 30 or the upper end of the blank.

[0095] The grinding flow F allows the grinding elements in contact with the blank 30 to circulate for vibratory finishing. It should be understood that the blank 30 can be arranged in the container 34 according to the direction of the flow F. For example, the flat surface 30a of the blank 30 will preferably be arranged parallel to the flow F to ensure that alumina particles circulate on this surface and wear it down through friction. Figure 4 The inventors also discovered that abrasion was better when the surface to be treated 30a was positioned toward the top of the tank.

[0096] During step b), the orientation of the blank 30 in the tank 34 can be changed to ensure that all surfaces of the blank 30 are well treated by vibration finishing.

[0097] Therefore, step b) may include multiple vibratory finishing cycles. The duration of the vibratory finishing cycle depends particularly on the desired surface condition of the part. The inventors have found that increasing this time leads to an improvement in the surface condition. It should be noted that after a certain vibratory finishing time, the wear is no longer as effective as at the start of the cycle, and the surface condition no longer improves. Therefore, it may be necessary to restart a new vibratory finishing cycle.

[0098] The longest duration of a vibration finishing cycle is 8 hours.

[0099] Step b) includes, for example, a first cycle of vibratory finishing of the blank 30 in the grinding composition 32, during which the tank 34 is set to vibrate motion.

[0100] The movement of the can 34 is stopped, and the orientation of the blank 30 in the can 34 can be changed, for example, by rotating the blank 30 about the vertical axis z (arrow F2). An additional amount of abrasive elements is preferably added to the can, and some of the abrasive composition 32 can be removed or discharged from the can so that the composition can be recycled and ensures that the composition still maintains good abrasive properties. All of the abrasive composition can be discharged and replaced with a new abrasive composition of the same formulation. Then, step b) includes a second cycle of vibratory finishing of the blank 30 in the abrasive composition 32, during which the can 34 is set to vibrate motion.

[0101] The movement of the can 34 is stopped, and the orientation of the blank 30 in the can 34 can be changed again, for example, by rotating the blank 30 about the horizontal axis x (arrow F3), which is perpendicular to axes y and z. A further amount of abrasive elements is preferably added back to the can 34, and some of the abrasive composition in the abrasive composition 32 can be removed or discharged from the can. All the abrasive composition can be emptied and replaced with a new abrasive composition of the same formulation. Then, step b) includes a third cycle of vibratory finishing of the blank 30 in the abrasive composition 32, during which the can is set to vibrate motion.

[0102] There is no limit to the number of vibration finishing cycles, and it depends particularly on the shape of the part to be processed.

[0103] exist Figure 3 and Figure 4 The blank 30 is schematically held in the container 34 by means of a tool 40. The tool includes means 42 for attaching the blank 30 and means 44 for attaching the blank to the bottom 32 of the container 32. The tool 40 is also configured to allow the position and orientation of the blank within the container 32 to be changed, as described above.

[0104] Figure 5 and Figure 6 A more specific example is shown of how tool 40 can be used for vibratory finishing of rectifier 20 or rectifier sector.

[0105] The device 44 for attachment to the bottom 34a of the can 34 includes a flat ferromagnetic base configured to be disposed at the center of the can 34 and on the bottom of the can 34, and held in place by an electromagnetic field, as described in document US-A1-2014 / 235146. The inventors have discovered that the optimal location for the component is at the center of the can to avoid placing the component in a “dead zone,” such as near the edge or wedge of the can, where grinding flow may be weak and vibration finishing efficiency may be low.

[0106] In this case, the base is typically disc-shaped, allowing it to be inserted into and positioned at the bottom of a generally cubic can 34. The base is made of a ferromagnetic material, ensuring it is firmly held at the bottom of the can by magnetic field alone. Therefore, the vibratory finishing apparatus includes a magnet or similar object configured to generate a magnetic field to hold the base at the bottom of the can. This method of holding the tool 40 implies the absence of any means of attaching the tool to the can or its bottom, and the unimpeded flow of the abrasive composition F within the can.

[0107] Alternatively, tool 40 can be held at the bottom of the can by a mechanical device.

[0108] The device 42 for attaching the rectifier 20 includes clamping clamps. These clamping clamps may be formed by two parts 42a, 42b, which are clamped together by a suitable means (e.g., screws 44).

[0109] In the example shown, rectifier 20 is held in place at rectifier housings 24, 26. Components 42a, 42b include first sides shaped like convex arcs to receive and clamp the inner housing 26 between components 42a, 42b. Figure 5 ). Components 42a, 42b include opposing second sides shaped like concave arcs to receive and clamp the housing 24 between components 42a, 42b. Figure 5 ).

[0110] The tool also includes means 46 for attaching the clamps to the base. These attachment means 46 include two supports attached to the upper surface of the base, which is opposite to the bottom of the can, and an attachment means 42 extending between the two supports.

[0111] The attachment device 42 can rotate and move about an axis relative to the connecting device 46. Figure 4 In this case, the axis is axis x. The attachment device 42 can be adopted as follows: Figure 5 The first position shown is in which the first convex side of the attachment device is oriented upwards and receives the inner housing 26 of the rectifier 20. The attachment device 42 can be adopted as follows: Figure 6 The second position shown is in which the second concave side of the attachment device is oriented upwards and receives the outer housing 24 of the rectifier 20. Therefore, moving the attachment device 42 between these two positions allows the rectifier 42 to be positioned in two locations 180° apart from each other about the axis x. The attachment device 42 can be secured in a specific position relative to the connecting device 46 by screws 48 or the like.

[0112] By stopping the magnetic field, rotating the base in the tank around axis z by a quarter turn, and reactivating the magnetic field, the rectifier can move around axis z.

[0113] Tool 40 is preferably made of a material suitable for resisting wear and corrosion during vibratory finishing. For example, the tool is made of nitrided or coated stainless steel with a protective polymer coating.

[0114] As in Figure 2 As schematically shown in the flowchart, the method according to the invention may include step i) of heat treatment of the blank and / or step ii) of machining the blank to remove the support portion, which is formed during additive manufacturing in step a). The machining in step ii) may be performed by EDM (Electro Discharge Machining).

[0115] The method according to the invention may include, after step b), step x) to decontaminate the component by immersing it in a decontamination bath, or successive steps y) and z) to degrease and perform penetration testing on the component.

[0116] The decontamination of the component in step x) is particularly beneficial in ensuring that the component is not contaminated by the abrasive composition, especially by any copper particles that may remain attached to the component. During engine operation, these copper particles can cause copper to diffuse or be released into the component. These particles can also mask potential cracks in the component that cannot be detected during the control processes performed at the end of the manufacturing process via penetrant testing.

[0117] The cleaning bath preferably comprises an aqueous solution containing at least one acid (e.g., nitric acid (HNO3)). The purpose of the acid is to dissolve the copper in the solution, thereby removing copper particles adhering to the component. The aqueous solution contains, for example, 510 ml / L of HNO3, and the component can be immersed in the bath for a certain period of time, such as 15 minutes.

Claims

1. A method for manufacturing a metal alloy component (14) for an aircraft turbine engine, the method comprising the following steps: a) Producing blanks (30) of the metal alloy parts by additive manufacturing using laser fusion on a powder bed, and b) The blank is subjected to grinding to obtain the metal alloy part by immersing the blank in a grinding composition (32) and vibrating to finish it. The grinding composition is contained in a tank (34) subjected to vibration. The grinding composition includes a grinding element formed of alumina particles, a bearing element formed of copper particles, and a liquid. Step b) includes a first cycle of vibratory finishing of the blank (30) in the grinding composition, and at least one additional cycle of vibratory finishing of the blank (30), at the beginning of the at least one additional cycle, some or all of the grinding composition (32) in the grinding composition (32) is discharged and replaced by a new grinding composition (32) having the same formulation, and the orientation of the metal alloy component in the can is changed between two successive cycles of vibratory finishing.

2. The method according to claim 1, wherein, The metal alloy component (14) is made of titanium, nickel or iron-based alloy.

3. The method according to claim 1 or 2, wherein, The abrasive composition (32) comprises abrasive elements comprising between 0.05% and 0.4% by weight, and a bearing element comprising between 95% and 99% by weight, the remainder of the abrasive composition being formed of liquid.

4. The method according to claim 1 or 2, wherein, The liquid in the grinding composition (32) is an aqueous solution comprising at least one surfactant and possibly other additives.

5. The method according to claim 1 or 2, wherein, The vibration occurs at a frequency between 30 Hz and 60 Hz.

6. The method according to claim 1 or 2, wherein, The metal alloy component (14) includes at least one aerodynamic blade (22).

7. The method according to claim 1 or 2, wherein, The metal alloy component (14) is held in the can (34) by a tool (40) comprising clamps for holding the metal alloy component and a flat ferromagnetic base disposed at the center of the can (34) and at the bottom of the can, and held in place by an electromagnetic field.

8. The method according to claim 1 or 2, wherein, The method, following step b), includes step x) to decontaminate the metal alloy component by immersing it in a decontamination bath, or a series of steps y) and z) to degrease and perform penetration testing on the metal alloy component.

9. The method according to claim 8, wherein, The cleaning bath comprises an aqueous solution containing at least one acid.

10. The method according to claim 1 or 2, wherein, The hardness of the grinding element is greater than the hardness of the metal alloy component to be processed.

11. The method according to claim 1 or 2, wherein, The density of the bearing element is greater than that of the grinding element.

12. The method according to claim 1 or 2, wherein, The grinding composition comprises between 1.8% and 3.9% liquid by weight.

13. The method according to claim 1 or 2, wherein, The blank is located at a certain height in the tank.

14. The method according to claim 1 or 2, wherein, The vibrational motion occurs along three axes of an orthogonal reference frame.

15. The method according to claim 1 or 2, wherein, The method includes, between step a) and step b), a step i) of heat treating the blank and / or a step ii) of machining the blank to remove the manufacturing support.

16. The method according to claim 5, wherein, The vibration occurs at a frequency between 40 Hz and 50 Hz.

17. The method according to claim 6, wherein, The metal alloy component (14) includes a plurality of adjacent aerodynamic blades that form an integral assembly called a rectifier (20).

18. The method according to claim 9, wherein, The cleaning bath includes an aqueous solution containing nitric acid.

19. The method according to claim 13, wherein, The blank extends to a maximum height in the jar, the maximum height being up to 30% of the maximum height of the grinding composition in the jar.

20. The method according to claim 13, wherein, The blank extends to a maximum height in the jar, the maximum height being up to 15% of the maximum height of the grinding composition in the jar.

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