METHOD FOR PREPARATION OF A SUPERALLOY HAVING A CRYSTALLOGRAPHIC TEXTURE CONTROLLED MICROSTRUCTURE BY ELECTRON BEAM MELTING

• US 20160273079A1
• Filed: 10/28/2014
• Published: 09/22/2016
• Est. Priority Date: 11/04/2013
• Status: Abandoned Application

• Current Assignee: Raytheon Technologies Corporation d/b/a RTX (Rtx Corporation)
• Original Assignee: United Technologies Corporation (Rtx Corporation)
• Inventors: Cernatescu, Luliana, Das, Gopal, Shah, Dilip M.
• Application Number:
  US15/034,063
• Publication Number:
  US 20160273079A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/15 Hot isostatic pressing
• CPC Class Codes: B22F 5/009 of turbine components other than turbine blades of turbine blades B22F5/04
• CPC Class Codes: B22F 5/04 of turbine blades
• CPC Class Codes: B23K 15/002 Devices involving relative movement between electronbeam and workpiece
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 15/0093 characterised by the properties of the materials to be welded
• CPC Class Codes: B23K 2101/001 Turbines
• CPC Class Codes: B23K 2103/08 Non-ferrous metals or alloys
• CPC Class Codes: B23K 2103/26 Alloys of Nickel and Cobalt and Chromium
• CPC Class Codes: B23K 26/0006 taking account of the properties of the material involved B23K26/32, B23K26/40 take precedence
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 9/042 Built-up welding on planar surfaces
• CPC Class Codes: B23K 9/044 Built-up welding on three-dimensional surfaces
• CPC Class Codes: B23K 9/046 on surfaces of revolution
• CPC Class Codes: B23K 9/23 taking account of the properties of the materials to be welded
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: C22C 1/023 : Alloys based on nickel
• CPC Class Codes: C22C 1/0433 : Nickel- or cobalt-based alloys
• CPC Class Codes: C22C 19/05 : with chromium
• CPC Class Codes: C22C 19/055 : with the maximum Cr content being at least 20% but less than 30%
• CPC Class Codes: C22C 19/056 : with the maximum Cr content being at least 10% but less than 20%
• CPC Class Codes: C22C 19/057 : with the maximum Cr content being less 10%
• CPC Class Codes: C22C 33/0257 : characterised by the range of the alloying elements
• CPC Class Codes: C22F 1/10 : of nickel or cobalt or alloys based thereon
• CPC Class Codes: C30B 11/007 : Mechanisms for moving either the charge or the heater
• CPC Class Codes: C30B 29/52 : Alloys
• CPC Class Codes: F01D 25/005 : Selecting particular materials
• CPC Class Codes: F01D 5/28 : Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
• CPC Class Codes: F01D 5/286 : Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion F01D5/288 takes precedence
• CPC Class Codes: F05D 2300/175 : Superalloys
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

The present disclosure provides a method of preparing superalloy metals having a crystallographic texture controlled micro structure by electron beam melting.

Claims

1. A process for the preparation of a superalloy metal comprising the steps of

providing a metal alloy powder composition;

providing a seed crystal;

processing the metal alloy powder composition in the presence of the seed crystal to

provide a superalloy metal having a highly textured or single crystal microstructure.

2. The process for the preparation of a superalloy metal according to claim 1, further comprising:

providing an inoculant prior to the processing step to provide a texture-free microstructure.

3. The process for the preparation of a superalloy metal according to claim 1, further comprising the step of:

subjecting the superalloy metal to heat treatment.

4. The process for the preparation of a superalloy metal according to claim 1, further comprising the step of:

subjecting the superalloy metal to hot isostatic pressing (HIP).

5. The process for the preparation of a superalloy metal according to claim 1, further comprising the steps of:

subjecting the superalloy metal to heat treatment, and

subjecting the superalloy metal to hot isostatic pressing (HIP).

6. The process for the preparation of a superalloy metal according to claim 1, wherein the processing step is performed by electron beam melting, electron beam solid freeform fabrication, epitaxial laser beam formation, laser engineered net shaping, spray forming, three-dimensional printing, shaped metal deposition, or metal inert gas welding.

7. The process for the preparation of a superalloy metal according to claim 6, wherein the processing step is performed by electron beam melting.

8. The process for the preparation of a superalloy metal according to claim 1, wherein the metal alloy powder composition comprises iron, nickel, chromium, molybdenum, niobium, cobalt, manganese, copper, aluminum, titanium, silicon, carbon, sulfur, phosphorous, boron, tantalum, tungsten, or a combination thereof.

9. The process for the preparation of a superalloy metal according to claim 8, wherein the metal alloy powder composition comprises a combination of iron, nickel, titanium, aluminum, molybdenum, niobium, tantalum, carbon and chromium.

10. The process for the preparation of a superalloy metal according to claim 8, wherein the metal alloy powder composition comprises a combination of iron, nickel, and chromium.

11. The process for the preparation of a superalloy metal according to claim 8, wherein the iron powder comprises austenitic iron.

12. The process for the preparation of a superalloy metal according to claim 8, wherein the metal alloy powder composition comprises a powder of Inconel 718, Inconel 600, Inconel 625, Inconel X-750, or Inconel 100.

13. The process for the preparation of a superalloy metal according to claim 1, wherein the seed crystal has a (111), (110), or (100) textured gamma microstructure.

14. The process for the preparation of a superalloy metal according to claim 2, wherein the inoculant is Co₃FeNb₂, CrFeNb, CoAl₂O₄, or combinations thereof.

15. A superalloy metal formed by the process according to claim 1.

16. An article comprising a superalloy metal formed by the process according to claim 1.

17. The article comprising a superalloy metal according to claim 16, wherein the article comprises multiple layers of superalloy metal.

18. The article comprising a superalloy metal according to claim 16, wherein the article is a turbine blade, a vane, a stator, a diffuser case, a TOBI, or a rotor.

19. The article comprising a superalloy metal according to claim 18, wherein the article is a turbine blade, a vane, a stator, a diffuser case, a TOBI, or a rotor.