Method for Manufacturing a Part Consisting at Least Partially of a Metal Alloy, and Optimisation Method

Abstract

The present invention concerns a method for manufacturing a part consisting at least partially of a metal alloy. The method includes a metallurgical manufacturing step a1) consisting of manufacturing the body of the part. The method subsequently includes a reinforcing step a2) consisting of forming a local reinforcement directly on the body, in an area of the part that is under stress. The invention also concerns a method for optimising a part.

1 . A manufacturing method for a part constituted at least partially of a metal alloy, wherein the method comprises a metallurgical manufacturing step a1) consisting of manufacturing the body of the part, wherein the method next comprises a reinforcement step a2) consisting of forming a local reinforcement directly on the body, in an area under stress of the part. 
     
     
         2 . The method according to  claim 1 , wherein the metallurgical manufacturing step a1) comprises a foundry operation a11) consisting of manufacturing a foundry preform, and then a forge operation a12) consisting of forging the foundry preform to obtain the body of the part. 
     
     
         3 . The method according to  claim 1 , wherein the metallurgical manufacturing step a1) comprises a foundry operation a11) or a forge operation a12) consisting of manufacturing the body of the part. 
     
     
         4 . The method according to  claim 1 , wherein the local reinforcement has a surface arranged at least 50% in contact with the body of the part. 
     
     
         5 . The method according to  claim 1 , wherein the local reinforcement substantially marries the body of the part. 
     
     
         6 . The method according to  claim 1 , wherein several local reinforcements are formed on the body, in one or more areas under stress of the part. 
     
     
         7 . The method according to  claim 1 , further comprising a step of preparation of the surface of the area to be reinforced, between the metallurgical manufacturing step a1) and the reinforcement step a2). 
     
     
         8 . The method according to  claim 1 , further comprising a step of finishing the part in the reinforced area, after the reinforcement step a2). 
     
     
         9 . The method according to  claim 1 , wherein the body and the local reinforcement are made of different metal alloys. 
     
     
         10 . The method according to  claim 1 , wherein the body is made of a metal alloy, whereas the local reinforcement is made of a composite material. 
     
     
         11 . The method according to  claim 9 , wherein the local reinforcement is formed by cold spraying. 
     
     
         12 . The method according to  claim 9 , wherein the local reinforcement is formed by micro-arc oxidation. 
     
     
         13 . The method according to  claim 10 , wherein the local reinforcement is formed by adhering a composite assembly taking the final shape thereof on the body of the part. 
     
     
         14 . The method according to  claim 10 , wherein the local reinforcement is formed by baking a resin. 
     
     
         15 . The method according to  claim 1 , wherein the local reinforcement is formed by additive manufacturing. 
     
     
         16 . A method for optimization of the design of an existing part, comprising a metal alloy body, wherein the optimization method comprises the following successive phases:
 b1) identifying an area under stress of the existing part;   b2) defining an optimized part comprising a modified body, by providing at least one local reinforcement formed on the body in the stressed area;   b3) defining metallurgical manufacturing tools conforming to the body of the optimized part;   b4) manufacturing the body of the optimized part with the tools; and   b5) forming the local reinforcement directly on the body, in the area under stress of the optimized part.   
     
     
         17 . The method according to  claim 16 , wherein the local reinforcement is substituted for an original portion of the body of the existing part. 
     
     
         18 . The method according to  claim 16 , wherein the local reinforcement is substituted for an insert fitted, overmolded or pressed on the body of the existing part. 
     
     
         19 . The method according to  claim 13 , wherein the local reinforcement is formed by baking a resin.