Method for manufacturing a metal part, and associated use

Abstract

The present invention relates to a method for manufacturing a metal part comprising a peripheral part delimiting at least one through-opening, the method comprising the following steps: - providing a metal blank (20); - introducing the metal blank (20) and at least one sacrificial metal compact (22) into a forging tool (40); - jointly forging, in the forging tool (40), the blank (20) and the at least one sacrificial metal compact (22) so as to form a forged part (34) comprising a peripheral region (38) formed exclusively of material of the metal blank (20) and a web (36) formed at least partially from material of the at least one sacrificial metal compact (22); - removing the forged part (34); and - removing the web (36) so as to form the through-opening (16).

Description

[0001] TITLE: Manufacturing process for a metal part and associated use

[0002] The present invention relates to a method for manufacturing a metal part, said part comprising a peripheral part delimiting at least one through opening.

[0003] The metal part is intended, for example, to form a structural part of a vehicle, particularly an aircraft, in particular a window frame, or a part or a rough part of a turbine, for example a turbine disc.

[0004] The metal part is made in particular of a titanium alloy, an aluminum alloy, for example an aluminum-lithium alloy, or a nickel alloy.

[0005] Structural components, particularly those used in aeronautics, or turbine parts are typically manufactured by hot forming using a die-forging process. To create a through-hole in these parts, their geometry necessitates the removal of the central portion of the forged piece after forging, for example, by cutting or machining. This metal loss significantly reduces the efficiency of these operations, as the amount of metal required is considerably greater than the mass of the final part produced.

[0006] To improve this efficiency, the thickness in the central part is reduced, in order to decrease the amount of metal that needs to be removed. The central part thus forms a thinned region, commonly called a web.

[0007] However, this solution is not entirely satisfactory. It requires significant effort during the die-forging process. Furthermore, there is a minimum fabric thickness that cannot be exceeded due to the capabilities of the forging machines used and the risk of damage to these machines or the tooling involved.

[0008] Another solution is to prepare a smaller metal blank, limiting the loss of metal in the center, and then stretch it after forging to the final shape of larger dimensions.

[0009] However, such a process is complex to implement for parts that are not axisymmetric. Furthermore, it involves additional hot forming operations.

[0010] One object of the invention is to obtain a method for manufacturing a metal part having a through-hole, the method being simple to implement, while allowing for satisfactory material yield and thus good productivity. To this end, the invention relates to a method for manufacturing a metal part, said part comprising a peripheral portion defining at least one through-hole, the method comprising the following steps:

[0011] - supply of a metal blank;

[0012] - introduction of the metal blank and at least one sacrificial metal compact into a forging tool comprising an upper die and a lower die defining between them a forging cavity, the upper die and the lower die being movable relative to each other along an axis of movement between an open position for inserting material into the forging cavity and a closed forging position in which the forging cavity defines a final volume of a forged part, the forged part comprising at least one thinned region forming a web and a peripheral region disposed around the periphery of the thinned region and intended to form the peripheral part of the metal part;

[0013] - joint die-casting in the die-casting tool of the blank and at least one sacrificial metal compact so as to form the die-cast part, the peripheral region of the die-cast part being formed exclusively of material from the metal blank and the web being formed at least in part of material from the at least one sacrificial metal compact;

[0014] - deposit of the stamped part; and

[0015] - removal of the canvas in such a way as to form the through opening.

[0016] The use of one or more sacrificial metal compacts significantly improves material yield during part manufacturing. This is because the metal that is normally lost in the central portion of the part is replaced with lower-grade metal, such as compacted chips. Typically, unlike the metal of the final part, this lower-grade metal lacks traceability guaranteeing compliance with required specifications, for example, in terms of microstructure or manufacturing process. The central portion to be removed therefore largely consists of metal of considerably lower value than the metal used in the final part.

[0017] The process according to the invention is easy to implement and allows the recycling of scrap material already used, to form the metallic compact, thus allowing the recovery of metallic waste.

[0018] According to other advantageous aspects of the invention, the process includes one or more of the following features, taken individually or in all technically possible combinations: - at least one of the lower and upper dies comprises a core projecting towards the die-forming cavity and intended to form the thinned region, the sacrificial metal compact coming into contact with said core during the die-forming step;

[0019] - the metal compact is made of the same material as the metal blank; - the process includes a preliminary step of compacting metal chips to form the metal compact;

[0020] - the metallic compact is produced by mechanical compaction of metallic chips from the machining of a second metallic part;

[0021] - at the end of the die-casting, the fabric is formed of at least 60% by volume, preferably at least 70% by volume, of material from the metallic compact;

[0022] - the metal blank introduced into the die-forming tool has means for positioning the metal compact relative to the metal blank;

[0023] - the positioning means include a housing provided on one face of the metal blank and intended to receive at least part of the metal compact;

[0024] - the removal of the canvas is carried out by cutting, for example by plasma cutting, by water jet cutting or by hot cutting, preferably using a mechanical or hydraulic press, or by machining;

[0025] - the metal blank is made of a titanium alloy, an aluminum alloy, for example an aluminum-lithium alloy, or a nickel alloy;

[0026] - the process includes a preliminary step of upsetting the metal blank before its introduction into the forging tool, said upsetting being preferably carried out in an upsetting die;

[0027] - the process includes a final machining step of the metal part;

[0028] - the process includes a step of recycling the metallic waste formed during the final machining step of the metallic part, at least a part of said metallic waste being advantageously used to form a metallic compact.

[0029] The invention also relates to a forged part comprising at least one thinned region forming a web and a peripheral region disposed on the periphery of the thinned region and intended to form a peripheral part of a metal part, the forged part being obtained by joint forging of a metal blank and at least one sacrificial metal compact in a forging tool comprising an upper die and a lower die defining between them a forging cavity, the upper die and the lower die being movable relative to each other along an axis of displacement between an open position for inserting material into the forging cavity and a closed forging position in which the forging cavity defines a final volume of the forged part,the peripheral region of the forged part being formed exclusively from the metal blank material and the fabric being formed at least in part from the material of at least one sacrificial metal compact.

[0030] The invention also relates to the use of a metal part produced by a manufacturing process of the aforementioned type, as a structural part of a vehicle, in particular an aircraft, for example as a window frame.

[0031] The invention also relates to the use of a metal part produced by a manufacturing process of the aforementioned type, as a part or part blank of a turbine, for example as a turbine disc.

[0032] The invention will be better understood upon reading the following description, given solely by way of example, and made with reference to the attached drawings, in which:

[0033] [Fig. 1] Figure 1 is a schematic cross-sectional view of a preparation step for a metal blank intended for the implementation of a manufacturing process for a metal part according to the invention.

[0034] [Fig. 2] Figure 2 is a schematic cross-sectional view illustrating the joint die-making of the blank in Figure 1 and a sacrificial metal compact, to obtain a die-cast part;

[0035] [Fig. 3] Figure 3 is a schematic cross-sectional view illustrating the preparation of the metal part from the die-cast part in Figure 2.

[0036] Figures 1 to 3 illustrate a method for manufacturing a metal part 10 according to the invention.

[0037] Part 10, for example, is intended to form a structural component of a vehicle, in particular an aircraft structural component. For example, part 10 is intended to form a window frame.

[0038] Alternatively, part 10 is intended to form a part or a rough part of a turbine, for example a turbine disc.

[0039] Part 10 is made of metal. Preferably, part 10 is made of titanium alloy, aluminum alloy, for example aluminum-lithium alloy, or nickel alloy.

[0040] Preferably, the titanium alloy is chosen from TA6V, Ti5553, Ti10-2-3, Ti6246 and Ti17.

[0041] Preferably, the aluminum alloy is chosen from the 2XXX alloys, for example alloy 2050. Preferably, the nickel alloy is chosen from Inconel®718, René®65 and AD730®.

[0042] In the example in Figure 3, the metal part 10 extends substantially along a longitudinal plane perpendicular to a transverse axis A.

[0043] The metallic part 10 has a peripheral part 14 delimiting at least one through opening 16.

[0044] Part 10 can take various forms.

[0045] According to one embodiment, part 10 is axisymmetric, that is to say, it has a symmetry of revolution around the transverse axis A which passes through the through opening 16 in its center.

[0046] According to another embodiment, part 10 is non-axissymmetric and includes, for example, radial protrusions.

[0047] In the example in Figure 3, the peripheral part 14 has a cross-section, taken along a plane perpendicular to the longitudinal plane, which is substantially constant.

[0048] For example, the peripheral part 14 has a C-shaped, U-shaped or L-shaped cross-section. Other geometries are possible.

[0049] For example, the peripheral part 14 has a width, measured in the longitudinal plane between an outer edge 140 and an inner edge 141, of at least 50 mm, preferably at least 100 mm, and at most 500 mm, preferably at most 300 mm. Most preferably, the peripheral part 14 has a width between 100 mm and 300 mm.

[0050] The inner edge 141 of the peripheral part 14 delimits the through opening 16 over its entire periphery.

[0051] The through opening 16 is, for example, circular, oval, polygonal or irregularly shaped.

[0052] The through opening 16, for example, has a maximum dimension, measured in the longitudinal plane, between 200 mm and 800 mm, for example between 400 mm and 600 mm.

[0053] In projection in the longitudinal plane, the through opening 16 defines a projected surface area preferably between 30% and 90%, preferably between 50% and 85%, of the total area of ​​the surface projected by the part 10.

[0054] With reference to figures 1 to 3, part 10 is obtained from a metal blank 20. Part 10 is for example produced in a manufacturing set (located on a single site or on several sites) which includes a station 80 for supplying the metal blank 20 (see figure 1), a station 82 for forging the metal blank 20 and at least one sacrificial metal compact 22 in order to form a forged part 34 (see figure 2) and a station 84 for finishing the part to bring the forged part 34 to the final shape of part 10 (see figure 3), said part 10 having a through opening 16 and being machined or capable of being machined.

[0055] According to a particular embodiment, the manufacturing assembly further includes a station (not shown) for supplying at least one sacrificial metallic compact 22.

[0056] Item 80 for the supply of the metal blank 20 is intended to manufacture or supply a metal blank 20.

[0057] In the example in Figure 1, the metallic blank 20 extends around a central axis X.

[0058] The metallic blank 20, for example, has roughly the shape of a rectangular block. It has a longitudinal section, perpendicular to the central axis X, which is generally rectangular with rounded corners.

[0059] In the example in Figure 1, the metallic blank 20 is flat in shape and has a first face 24 and a second face 26 opposite the first face 24.

[0060] The metal blank 20 typically has a thickness, measured between the first face 24 and the second face 26, of between 20 mm and 300 mm, preferably between 20 mm and 200 mm.

[0061] The blank 20 is made of a titanium alloy, an aluminum alloy, for example an aluminum-lithium alloy, or a nickel alloy.

[0062] Preferably, the titanium alloy is chosen from TA6V, Ti5553, Ti10-2-3, Ti6246 and Ti17.

[0063] Preferably, the aluminum alloy is chosen from the 2XXX alloys, for example alloy 2050.

[0064] Preferably, the nickel alloy is chosen from Inconel®718, René®65 and AD730®.

[0065] The metallic blank 20 is obtained in this example from a volume 28 of metallic material, for example a billet, a slab or a long product of a given section, for example of a square or round section.

[0066] For example, the metal blank 20 is obtained by upsetting the block 28 of metallic material. Preferably, the blank 20 supply station 80 includes an upsetting die (not shown) in which the upsetting of the blank 20 takes place. The upsetting is carried out, for example, under a hydraulic press. Preferably, the metal blank 20 has means 30 for positioning the metal block or blocks 22 relative to the metal blank 20.

[0067] The said means 30 facilitate the positioning of the or each metallic compact 22 vis-à-vis the metallic blank 20 in a die-making tool 40, as will be described later.

[0068] The said positioning means 30 are for example arranged on the first face 24 and / or on the second face 26 of the blank 20.

[0069] The said positioning means 30 are configured to cooperate with the metallic compact(s) 22.

[0070] The positioning means 30 are for example made by machining or punching, preferably hot, of the metal blank 20.

[0071] In the example of Figures 1 and 2, the positioning means 30 include a housing 32 formed on the first face 24 of the metallic blank 20. Said housing 32 is intended to receive at least part of a metallic compact 22.

[0072] Housing 32, for example, has a depth p between 1 mm and 5 mm.

[0073] Housing 32 here plays the role of positioning support for the metallic compact 22.

[0074] Alternatively or in addition, the positioning means 30 include one or more recesses formed on a face 24, 26 of the metallic blank 20 and intended to receive one or more pins of complementary shape formed on the metallic compact 22. These recesses allow the positioning of compacts of different geometries.

[0075] Alternatively or in addition, the positioning means 30 include one or more pins provided on a face 24, 26 of the metallic blank 20 and intended to be received in one or more impressions of complementary shape provided in the metallic compact 22.

[0076] In the example in Figure 1, the positioning means 30 are centered with respect to the central axis X. Alternatively, said means 30 are offset with respect to the central axis X.

[0077] The sacrificial metallic compact 22 is preferably made of a material having a flow stress close to that of the metallic blank 20 material, for a given strain rate at the temperatures at which the various forming steps are carried out (these temperatures are not necessarily identical for all steps). By "close", we mean here a difference of less than 20% in absolute value, preferably less than 10% in absolute value.

[0078] Advantageously, the compact 22 metallic is made of the same material as the blank 20 metallic.

[0079] The dimensions of the compact 22 and its positioning relative to the blank 20 are chosen so that the compact 22 remains confined outside the peripheral part 14, as will be explained later.

[0080] The supply station for at least one sacrificial metal compact 22 preferably includes a compaction tool suitable for compacting metal chips to form the sacrificial metal compact 22. The compaction tool is, for example, capable of mechanically compacting the metal chips, with or without heating.

[0081] The said metal chips preferably have a typical minimum size of at least 1 mm, so as not to be powdery for handling reasons and for Hygiene, Safety and Environment (HSE) reasons.

[0082] Advantageously, the metal chips were obtained during the machining of another previously manufactured metal part.

[0083] The forging station 82 is intended for the joint forging of the metallic blank 20 and the sacrificial metallic compact 22, in order to form a forged part 34 (see figures 2 and 3).

[0084] As can be seen in particular on the left in figure 3, the die-cast piece 34 includes at least one thinned region 36 forming a web 36 and a peripheral region 38 arranged on the periphery of the thinned region 36.

[0085] The thinned region 36 is intended to be removed in order to form the through opening 16 of part 10.

[0086] The peripheral region 38 is intended to form the metallic part 10.

[0087] The thinned region 36 has a substantially constant thickness. Preferably, the thinned region 36 has a thickness between 10 mm and 50 mm.

[0088] The peripheral region 38 has a thickness at least equal to the thickness of the fabric 36. Preferably, as seen in figure 3, the peripheral region 38 forms a relief surrounding the thinned region 36 at its periphery.

[0089] Preferably, the peripheral region 38 has a maximum thickness at least twice the thickness of the fabric. Preferably, the peripheral region 38 has a maximum thickness between 40 mm and 200 mm. The peripheral region 38 of the die-cast part 34 is formed exclusively from the metallic blank 20 material. In other words, the peripheral region 38 does not include any material from the sacrificial metallic compact 22.

[0090] The fabric 36 is formed at least in part from material of the sacrificial metallic compact 22. Preferably, the fabric 36 comprises at least 60% by volume, preferably at least 70% by volume, of material from the metallic compact 22.

[0091] The die-making station 82 includes a die-making tool 40 comprising an upper die 42 and a lower die 44 defining between them a die-making cavity 46.

[0092] The upper die 42 and the lower die 44 are mobile relative to each other along a displacement axis Z between an open position of material insertion in the die cavity 46 (left in Figure 2) and a closed die position (right in Figure 2) in which the die cavity 46 has a shape complementary to that of the die-cast part 34.

[0093] In other words, in the closed position, the die cavity 46 defines a volume corresponding to the final volume of the die-cast part 34.

[0094] The upper die 42 and the lower die 44 each define a contact surface 48, 50 delimiting the die cavity 46. Said contact surfaces 48, 50 are intended to come into contact with the metallic blank 20 and / or the metallic compact 22 during their die-making.

[0095] Preferably, as seen in Figure 2, at least one of the upper matrix 42 and of the lower matrix 44 includes a core 52 projecting towards the forging cavity 46.

[0096] The said core 52 is intended to form the thinned region 36 of the die-cast part 34. In the closed position of the die-casting tool 40, the die-casting cavity 46 thus presents a narrow region, complementary to the thinned region 36 of the die-cast part 34 and delimited along the axis of movement Z at least in part by the core 52, and a widened region at the periphery of the narrow region, which is complementary to the peripheral region 38 of the die-cast part 34.

[0097] The core 52 is intended to come into contact with the sacrificial metallic compact 22 during the forging step.

[0098] In the example of Figure 2, the upper die 42 comprising the core 52 defines, around said core 52, a concave peripheral region 54, intended to be filled with material coming exclusively from the metal blank 20. With reference to Figure 3, the part finishing station 84 is intended to bring the die-cast part 34 to its final shape (represented by dotted lines on the part on the left), corresponding to the shape of the metal part 10.

[0099] The finishing station 84 includes a tool for removing the fabric 36, designed to form the through opening 16. This tool is, for example, a cutting tool, such as a plasma cutting tool, a waterjet cutting tool, or a hot cutting tool, preferably comprising a mechanical or hydraulic press. Alternatively, the removal tool is a machining tool.

[0100] Advantageously, the finishing station 84 further includes a machining tool configured to machine the peripheral region 38 of the die-cast part 34, to form the peripheral part 14 of the part 10.

[0101] Advantageously, the finalization station 84 further includes a recovery and sorting installation (not shown) for the metallic waste 60 formed during the machining of the part 10 (for example in the form of metal chips) and / or the removal of the fabric 36. The recycling installation is suitable for recovering said metallic waste 60, possibly forming it into chips, and forming a metallic compact, said compact being suitable for use in the manufacture of another metallic part.

[0102] A manufacturing process for the metal part 10 will now be described.

[0103] Initially, a 10-piece metal blank is provided.

[0104] As illustrated in Figure 1, the said metallic blank 20 is for example manufactured by shaping a block 28 of metallic material.

[0105] The process preferably includes a preliminary step of upsetting the metallic blank 20, preferably in an upsetting die.

[0106] Positioning means 30 are advantageously implemented on the blank 20, for example by machining or punching. For example, a housing is managed on one face of the metal blank 20.

[0107] The process further includes a step of supplying a sacrificial metallic compact 22.

[0108] Preferably, the metallic compact 22 is produced by compacting, in particular mechanically compacting, metal chips. These chips advantageously originate from the machining of another metal part.

[0109] Then, the blank 20 and the compact 22 are inserted into the die-making tool 40, which is in its open position. The compact 22 is advantageously positioned on the blank 20 using the positioning means 30. For example, in the embodiment shown in Figure 2, the compact 22 is positioned at the level of the housing 32, which then serves as a positioning support.

[0110] Preferably, the rough 20 and the compact 22 are at the same temperature.

[0111] Alternatively, the blank 20 and the compact 22 are at different temperatures, with the compact 22 preferably being at a lower temperature than the blank 20.

[0112] The assembly formed by the metallic blank 20 and the metallic compact 22 is positioned between the upper die 42 and the lower die 44.

[0113] In the example shown in Figure 2, the assembly formed by the metallic blank 20 and the metallic compact 22 is arranged on the contact surface 50 of the lower die 44. The metallic compact 22 is located opposite the core 52 and the metallic blank 20 is located at least partly opposite the concave peripheral region 54.

[0114] In projection into a plane perpendicular to the Z displacement axis of the upper matrix 42 with respect to the lower matrix 44, a projection of the sketch 20 is at least partially in superposition with a projection of the concave peripheral region 54.

[0115] In projection into a plane perpendicular to the Z displacement axis of the upper matrix 42 with respect to the lower matrix 44, a projection of the metallic compact 22 is entirely superimposed with a projection of the nucleus 52.

[0116] Thus, when the die-making tool 40 closes, the sacrificial metal compact 22 comes into contact with the core 52. The material of the metal compact 22 remains confined in the narrow region of the die-making cavity 46 and causes the material of the metal blank 20 to move at least in part into the enlarged region of the die-making cavity 46.

[0117] To achieve this, the die-forming tool 40 is moved to the closed position. The upper die 42 moves closer to the lower die 44 so that the die-forming cavity 46 adopts a shape complementary to that of the die-formed part 34.

[0118] The metallic blank 20 and the metallic compact 22 then deform plastically to fill the die-making cavity 46.

[0119] During this step, the enlarged region is filled exclusively with material from the metallic blank 20, to form the peripheral region 38 of the die-cast part 34.

[0120] The narrow region is filled with material from the metallic compact 22, and possibly with material from the metallic blank 20, to form the web 36. Preferably, after forging, the web 36 comprises at least 60% by volume, preferably at least 70% by volume, of material from the metallic compact. Then, the forging tool 40 is returned to the open position and the resulting forged part 34 is deposited. The forged part 34 thus has a web 36 and a peripheral region 38 surrounding the web.

[0121] The fabric 36 is then removed to form the through opening 16. Preferably, the fabric 36 is removed by cutting or machining. For example, the fabric 36 is removed by plasma cutting, waterjet cutting, or hot cutting, preferably using a mechanical or hydraulic press.

[0122] Advantageously, as can be seen in Figure 3, the part is then machined to give it its final shape. For example, grooves are made.

[0123] The resulting metallic part 10 has a peripheral region 14 delimiting a through opening 16.

[0124] During the steps of removing the canvas 36 and machining the part 10, metallic waste 60 is generated, for example massive waste.

[0125] Advantageously, the waste 60 is recycled to form a new sacrificial metallic compact 22 that can be used to manufacture another metal part. The waste is, for example, collected, possibly sorted, and ground into chips, then compacted together.

[0126] The manufacturing process according to the invention is thus simple to implement and allows, by substituting the metal which would ordinarily be lost during the formation of the through opening 16 with lower quality metal, to significantly improve the material yield of the manufacture of the part 10. Indeed, it is thus possible to use a smaller size metal blank 20, the fabric 36 being formed largely from material from the metal compact 22.

[0127] Since the compact 22 is produced, for example, by compacting chips from previous machining operations, it is inexpensive to manufacture. The manufacturing process according to the invention thus makes it possible to produce metal parts 10 using a smaller quantity of expensive metal.

[0128] According to an unshown variant, several metallic compacts 22 are used during the forging step. These compacts 22 are, for example, arranged on opposite faces 24, 26 or on the same face of the blank 20.

[0129] According to one variant, the part obtained at the end of the canvas removal step 36 is in its final shape and corresponds to the finished metal part 10.

Claims

DEMANDS 1. A method for manufacturing a metallic part (10), said part (10) comprising a peripheral portion (14) defining at least one through opening (16), the method comprising the following steps: supply of a metal blank (20); introduction of the metallic blank (20) and at least one sacrificial metallic compact (22) into a forging tool (40) comprising an upper die (42) and a lower die (44) defining between them a forging cavity (46), the upper die (42) and the lower die (44) being movable relative to each other along a displacement axis (Z) between an open position for inserting material into the forging cavity (46) and a closed forging position in which the forging cavity (46) defines a final volume of a forged part (34), the forged part (34) comprising at least one thinned region (36) forming a web and a peripheral region (38) disposed on the periphery of the thinned region (36) and intended to form the peripheral part (14) of the metallic part (10); joint die-forging in the die-forging tool (40) of the blank (20) and at least one sacrificial metallic compact (22) so as to form the die-forged part (34), the peripheral region (38) of the die-forged part (34) being formed exclusively of material from the metallic blank (20) and the web (36) being formed at least in part of material from the at least one sacrificial metallic compact (22); deposit of the stamped part (34); and removal of the canvas (36) so as to form the through opening (16).

2. A method according to claim 1, wherein at least one of the lower die (44) and the upper die (42) comprises a core (52) projecting towards the die-forming cavity (46) and intended to form the thinned region (36), the sacrificial metallic compact (22) coming into contact with said core (52) during the die-forming step.

3. A method according to any one of the preceding claims, wherein the metallic compact (22) is made of the same material as the metallic blank (20).

4. A method according to any one of the preceding claims, comprising a preliminary step of compacting metallic chips to form the metallic compact (22).

5. Method according to claim 4, wherein the metallic compact (22) is made by mechanical compaction of metallic chips from the machining of a second metallic part.

6. A method according to any one of the preceding claims, wherein, after forging, the fabric (36) is formed of at least 60% by volume, preferably at least 70% by volume, of material from the metallic compact (22).

7. A method according to any one of the preceding claims, wherein the metal blank (20) introduced into the die-making tool (40) has means (30) for positioning the metal compact (22) vis-à-vis the metal blank (20).

8. Method according to claim 7, wherein the positioning means (30) comprise a housing (32) formed on a face (24, 26) of the metallic blank (20) and intended to receive at least part of the metallic compact (22).

9. A method according to any one of the preceding claims, wherein the removal of the fabric (36) is carried out by cutting, for example by plasma cutting, by water jet cutting or by hot cutting, preferably using a mechanical or hydraulic press, or by machining.

10. A method according to any one of the preceding claims, wherein the metal blank (20) is made of a titanium alloy, an aluminum alloy, for example an aluminum-lithium alloy, or a nickel alloy.

11. A method according to any one of the preceding claims, comprising a preliminary step of upsetting the metal blank (20) before its introduction into the die-forming tool, said upsetting being preferably carried out in an upsetting die.15 12. A method according to any one of the preceding claims, comprising a final machining step of the metal part (10).

13. A method according to claim 12 comprising a step of recycling the metallic waste (60) formed during the final machining step of the metallic part (10), at least a part of said metallic waste (60) being advantageously used to form a metallic compact (22).

14. A die-cast part (34) comprising at least one thinned region (36) forming a web and a peripheral region (38) disposed on the periphery of the thinned region (36) and intended to form a peripheral part (14) of a metallic part (10), the die-cast part (34) being obtained by joint die-casting of a metallic blank (20) and at least one sacrificial metallic compact (22) in a die-casting tool (40) comprising an upper die (42) and a lower die (44) defining between them a die-casting cavity (46), the upper die (42) and the lower die (44) being movable relative to each other along a displacement axis (Z) between an open position for inserting material into the die-casting cavity (46) and a closed die-casting position in which the die-casting cavity (46) defines a final volume of the die-cast part (34), the peripheral region (38) of the die-cast part (34) being formed exclusively of material from the metallic blank (20) and the web (36) being formed at least in part of material from at least one sacrificial metallic compact (22).

15. Use of a metal part (10) produced by a manufacturing process according to any one of claims 1 to 13, as a structural part of a vehicle, in particular an aircraft, for example as a window frame.

16. Use of a metallic part (10) produced by a manufacturing process according to any one of claims 1 to 13, as a turbine part or part blank, for example as a turbine disc.

Images