POWDER ALLOY COMPOSITION, GAS TURBINE ENGINE COMPONENT AND METHOD FOR MANUFACTURE OF THE SAME

• US 20200131604A1
• Filed: 09/25/2019
• Published: 04/30/2020
• Est. Priority Date: 10/25/2018
• Status: Abandoned Application

• Current Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Inventors: CHRISTOFIDOU, Katerina, STONE, Howard J., JONES, Nicholas G., PARDHI, Yogiraj, JONES, Colin N.
• Application Number:
  US16/581,882
• Publication Number:
  US 20200131604A1
• Time in Patent Office: Days
• CPC Class Codes: B22F 1/05 Metallic powder characterised by the size or surface area of the particles
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/34 of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B22F 10/66 by mechanical means
• CPC Class Codes: B22F 2301/15 Nickel or cobalt
• 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 26/342 Build-up welding
• CPC Class Codes: B23K 9/042 Built-up welding on planar surfaces
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• 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 1/0433 Nickel- or cobalt-based alloys
• CPC Class Codes: C22C 19/05 with chromium
• 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: C22F 1/10 of nickel or cobalt or alloys based thereon
• CPC Class Codes: F01D 5/005 Repairing methods or devices
• CPC Class Codes: F01D 5/28 Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
• CPC Class Codes: F05D 2220/32 : in gas turbines
• CPC Class Codes: F05D 2230/22 : by sintering
• CPC Class Codes: F05D 2230/31 : Layer deposition
• CPC Class Codes: F05D 2300/175 : Superalloys
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y02T 50/60 : Efficient propulsion technologies, e.g. for aircraft

Abstract

A Ni-based superalloy powder having a freezing range of not more than 80° C. is disclosed, with a composition, expressed in weight percent, of: Ni; 9-25 Co; 3-15 Cr; 0-5 Mo; 0-12 W; 3-9 Al; 0-6.5 Nb; 0.3-1 C; 0-6.5 Ta; 0-3 Ti, and incidental impurities. It is disclosed in methods for manufacturing or repair of gas turbine engine components such as gas turbine blades using additive layer manufacturing techniques.

Claims

1. A Ni-based superalloy powder having a freezing range of not more than 80°

C., the freezing range being defined as the temperature difference between the liquidus and solidus determined by differential scanning calorimetry (DSC) on cooling, the powder having a composition, expressed in weight percent, of;

2. The Ni-based superalloy powder of claim 1, wherein the powder has a composition, expressed in weight percent, of:

3. The Ni-based superalloy powder of claim 1, wherein the powder has an average (d₅₀) particle size in the range 10-150 μ

m.

4. The Ni-based superalloy powder of claim 1, wherein the powder has a particle size distribution such that d₁₀ and d₉₀ are in the range 10-150 μ

m.

5. The Ni-based superalloy powder of claim 1, wherein the powder has an average (d₅₀) particle size in the range 15-45 μ

m.

6. The Ni-based superalloy powder of claim 1, wherein the powder has a particle size distribution such that d₁₀ and d₉₀ are in the range 15-45 μ

m.

7. The Ni-based superalloy powder of claim 1, wherein the powder has an average (d₅₀) particle size in the range 45-110 μ

m.

8. The Ni-based superalloy powder of claim 1, wherein the powder has a particle size distribution such that d₁₀ and d₉₀ are in the range 45-110 μ

m.

9. A method of manufacturing a component, the method comprising the steps of:

providing a Ni-based superalloy powder; and

performing additive layer manufacturing by melting and solidifying the Ni-based superalloy powder to form one layer of the Ni-based superalloy powder in a predetermined shape, disposing a further layer of the Ni-based superalloy powder over said one layer and melting and solidifying said further layer of the Ni-based superalloy powder in a predetermined shape, and repeating as needed to form the component, wherein the Ni-based superalloy powder is according to claim 1.

10. The method of claim 9, wherein the component is a gas turbine engine component.

11. The method of claim 10, further comprising a step of subjecting the component to a thermal treatment and/or finishing treatment.

12. A method of repairing a component, the method comprising the steps of:

providing a Ni-based superalloy powder; and

performing additive layer deposition by melting and solidifying the Ni-based superalloy powder to form one layer of the Ni-based superalloy powder in a predetermined shape on a component to be repaired, disposing a further layer of the Ni-based superalloy powder over said one layer and melting and solidifying said further layer of the Ni-based superalloy powder in a predetermined shape, and repeating a suitable number of times to repair the component,

wherein the Ni-based superalloy powder is according to claim 1.

13. The method of claim 12, wherein the component is a gas turbine engine component.

14. The method of claim 12, further comprising a step of subjecting the component to a thermal treatment and/or finishing treatment.

15. A component formed of a Ni-based superalloy by additive layer manufacturing using a Ni-based superalloy powder according to claim 1.

16. The component of claim 15, wherein the component is a gas turbine engine component.

17. The component of claim 15, wherein the component has a γ

′

volume fraction in excess of 50% by volume.

18. The component of claim 15, wherein the component has a refractory element carbide present in a volume fraction of at least 0.5% by volume.

19. The component of claim 15, wherein the component is a turbine blade, vane or a component of a combustor of a gas turbine engine.