Method For Producing A Structural Component From A High-Strength Alloy Material

Abstract

A method for producing a structural component, which has different component sections, from a high-strength alloy material. The structural component to be produced is divided into at least two component sections which differ with respect to their requirement profiles when the structural component is later used, wherein one component section must meet a higher requirement profile with respect to occurring loads, and the at least one other component section must meet a lower requirement profile. In a first production step for producing the component section with the higher requirements, a blank is brought to near-net-shape or net-shape by a massive forming process in some regions. To form the at least one component section with the lower requirement profile, a body in the form of a pre-manufactured part, which corresponds to said component section, is arranged on at least one surface region in the form of a substrate, which has not yet been brought into its near-net-shape or net-shape by the massive forming process, and is bonded to the blank in at least one following step, and/or said component section is attached to the provided surface region of the blank by a generative production method in order to also bring the aforementioned regions of the massive-formed component section to a near-net-shape. The semi-finished product produced in this manner, as a completed preform, is then brought to its net-shape in one or more steps.

1 - 14 . (canceled) 
     
     
         15 . Method for producing a one-piece structural component for constructing a larger structure typically used in aerospace technology, which has different component sections, from a high-strength alloy material, comprising:
 the structural component to be produced is divided into at least two component sections which differ with respect to their requirement profiles when the structural component is later used, wherein one component section as a core segment must meet a higher requirement profile with respect to occurring loads when the structural component is used, and at least one other component section must meet a lower requirement profile,   in a first production step for producing the core segment with the higher requirement profile, a blank is brought to near-net-shape or net-shape by a massive forming process in some regions,   in at least one further production step in order to form the at least one component section with the lower requirement profile, said at least one component section is manufactured by a generative production method onto at least one surface region not yet brought into its net-shape or near net-shape of the core segment used as a substrate, in order to also bring said at least one surface region of the massive-formed core segment into a more near-net-shape, and   the semi-finished product produced in this manner, as a completed preform, is then brought to its net-shape in one or more steps.   
     
     
         16 . Method of  claim 15 , wherein the requirement profile of the core segment with the higher requirement profile and that of the component section with the lower requirement profile differ with regard to the respective mechanical resilience. 
     
     
         17 . Method of  claim 15 , wherein the structural component is made of a titanium alloy, an aluminum alloy, a cobalt-based alloy, or a nickel-based alloy. 
     
     
         18 . Method of  claim 17 , wherein an (α+β) titanium alloy is used as the titanium alloy. 
     
     
         19 . Method of  claim 18 , wherein a Ti-6Al-4V alloy is used as the titanium alloy. 
     
     
         20 . Method of  claim 15 , wherein the generative production method, with which the component section with the lower requirement profile is created, is carried out as laser deposition welding using solid particles or wire, or by arc deposition welding, or by electron beam deposition welding. 
     
     
         21 . Method of  claim 15 , wherein the same alloy, from which the core segment is made, is also used for the generative production step for forming the component section with the lower requirement profile. 
     
     
         22 . Method of  claim 15 , wherein an alloy different from the alloy of the core segment is used for the generative production step for forming the component section with the lower requirement profile. 
     
     
         23 . Method of  claim 15 , wherein a plurality of generative production steps is carried out for the near-net-shape forming of the component sections which have not yet been brought to near-net-shape or net-shape by the forging step. 
     
     
         24 . Method of  claim 23 , wherein, between two generative production steps, the generatively formed component sections are formed by forging into a nearer-net-shape, and the subsequent generative production step is carried out on the formed material of the preceding production step. 
     
     
         25 . Method of  claim 15 , wherein, prior to carrying out a generative production step, the application surface of the core segment serving as substrate is pretreated for the generative production step. 
     
     
         26 . Method of  claim 15 , wherein the at least one component section with the lower requirement profile of the completed preform is brought into its net-shape by forging and/or by machining. 
     
     
         27 . Method of  claim 15 , wherein the core segment is created by forging as a massive forming step. 
     
     
         28 . Method of  claim 15 , wherein one of several variations of the structural component is produced as the structural component, and wherein, with the step of massive forming to form the core segment, said core segment is produced as a common part for the several variations, and the several variations are provided by the at least one component section with the lower requirement profile formed by generative production.