Process for manufacturing a metal part, such as turbine engine blade reinforcement

1. A process for manufacturing a metal part, comprising:

positioning a plurality of metal staples in a forming tool presenting a die and a punch with said plurality of metal staples being metal sections in a rectilinear shape bended in a shape of a U or a V;

after positioning the plurality of metal staples in the forming tool, hot isostatic pressing said plurality of metal staples causing agglomeration of the plurality of metal staples so as to obtain a compact metal part,

wherein the positioning of said plurality of metal staples is achieved by placing at least two metal staples of said plurality of metal staples at different times in the die or on the punch of said forming tool.

2. The process for manufacturing a metal part according to claim 1 , wherein the positioning of said plurality of metal staples includes a first sub-step for pre-positioning of said plurality of metal staples on to a detachable frame so that said plurality of metal staples are suspended in said detachable frame and a second sub-step of positioning of the detachable frame, including the plurality of staples, in a groove arranged in the forming tool.

3. The process for manufacturing a metal part in accordance with claim 2 , wherein said detachable frame is formed of two rails so that during the second sub-step of positioning said detachable frame, each of said rails of said detachable frame is capable of being inserted into a notch arranged in said forming tool with said notches forming said groove of said forming tool.

4. The process for manufacturing a metal part according to claim 3 , wherein said notches are arranged in the die of said forming tool so that said detachable frame is placed in said die during said positioning.

5. The process for manufacturing a metal part according to claim 1 , wherein said positioning of said plurality of metal staples includes a first sub-step for manufacturing a metal structure formed by an assembly of said plurality of metal staples presenting a crossing hole and by at least one metal wire introduced in said crossing hole of each metal staple of said plurality of metal staples and by a second sub-step for positioning said metal structure in the forming tool.

6. The process for manufacturing a metal part according to claim 5 , comprising manufacturing said crossing hole of each metal staple.

7. The process for manufacturing a metal part according to claim 6 , wherein said crossing hole is achieved by laser drilling, at a time of said manufacturing of said crossing hole.

8. The process for manufacturing a metal part according to claim 1 , wherein, prior to the positioning, the process further comprises manufacturing said plurality of metal staples by bending the metal sections of rectilinear shape.

9. The process for manufacturing a metal part according to claim 8 , wherein the metal sections are metal wires.

10. The process for manufacturing a metal part according to claim 9 , wherein the metal wires have a circular section, a square section, a rectangular section or a hexagonal section.

11. The process for manufacturing a metal part according to claim 1 , wherein the positioning of said plurality of metal staples includes a first sub-step for manufacturing multiple three dimensional metal structures by fixing the plurality of metal staples, each of said three dimensional metal structures forming a portion of a preform of said metal part to be achieved and a second sub-step for positioning said three dimensional metal structures in the forming tool.

12. The process for manufacturing a metal part according to claim 1 , wherein said sub-step for manufacturing the multiple three dimensional metal structures is achieved by welding or by lamination of said plurality of metal staples.

13. The process for manufacturing a metal part according to claim 11 , wherein said sub-step for manufacturing the multiple three dimensional metal structures is achieved by welding or lamination of a metal foil on said plurality of metal staples forming the three dimensional metal structure with said metal foil linking each said plurality of metal staple of the three dimensional metal structure.

14. The process for manufacturing a metal part according to claim 1 , wherein the metal staples of said plurality of metal staples are placed, metal staple by metal staple, in the die of said forming tool or are placed, metal staple by metal staple, on the punch of said forming tool.

15. The process for manufacturing a metal part according to claim 14 , wherein said positioning of said plurality of metal staples is achieved by clamping arms of said metal staples in clamping means arranged in said punch, said clamping being achieved by elastic deformation of said arms.

16. The process for manufacturing a metal part according to claim 1 , wherein said process is a process for manufacturing a metal reinforcement for leading edge or trailing edge of a turbine blade or a metal reinforcement for a propeller so that said metal part obtained in said isostatic pressing is a metal reinforcement.

17. The process for manufacturing a metal part according to claim 1 , wherein said positioning of said plurality of metal staples includes a first sub-step for pre-positioning the plurality of metal staples, metal staple by metal staple, on a moulding template and a second sub-step for positioning of said plurality of metal staples, pre-positioned on said moulding template, in said forming tool.

18. The process for manufacturing a metal part according to claim 1 , comprising manufacturing said plurality of metal staples by bending metal sections, of a rectilinear shape, by cold forming.

19. The process for manufacturing a metal part according to claim 1 , wherein said metal part is a metal reinforcement for turbine engine blade.