HIGH GAMMA PRIME NICKEL BASED SUPERALLOY, ITS USE, AND METHOD OF MANUFACTURING OF TURBINE ENGINE COMPONENTS

• US 20200131613A1
• Filed: 01/16/2019
• Published: 04/30/2020
• Est. Priority Date: 10/29/2018
• Status: Active Grant

• Current Assignee: Liburdi Engineering Limited
• Original Assignee: Liburdi Engineering Limited
• Inventors: GONCHAROV, Alexander B., LIBURDI, Joseph, LOWDEN, Paul
• Granted Patent: US 11,180,840 B2
• Time in Patent Office: Days
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• 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: B23K 2101/001 Turbines
• CPC Class Codes: B23K 2103/08 Non-ferrous metals or alloys
• CPC Class Codes: B23K 26/0093 combined with mechanical machining or metal-working covered by other subclasses than B23K combined welding or cutting procedures or apparatus B23K28/02
• CPC Class Codes: B23K 26/342 Build-up welding
• 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 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: Y02P 10/25 Process efficiency

Abstract

The invention is related to a high gamma prim nickel based superalloy, its use and a method of manufacturing of turbine engine components by welding, 3D additive manufacturing, casting and hot forming, and the superalloy comprises 9.0-10.5 wt. % Cr, 20-22 wt. % Co, 1.0-1.4 wt. % Mo, 5.0-5.8 wt. % W, 2.0-6.0 wt. % Ta, 3.0-6.5 wt. % Al, 0.2-0.5 wt. % Hf, 0.01-0.16 wt. % C, 1.5-3.5 wt. % Re, 0-1.0 Ge wt. %, 0-0.2 wt. % Y, 0-1 wt. % Si, 0-0.015 wt. % B and nickel with impurities to balance.

Claims

1. A high gamma prime nickel based superalloy, comprising by wt. %:

Chromium from 9.0 to 10.5%,

Cobalt from about 20 to 22%,

Molybdenum from 1.0 to 1.4%,

Tungsten from 5.0 to 5.8%,

Tantalum from 2.0 to 6.0%,

Aluminum from 3.0 to 6.5%,

Hafnium from 0.2 to 1.5%,

Germanium from 0 to 1.0%,

Yttrium from 0 to 0.2%,

Silicon form 0 to 1.0%,

Boron from 0 to 0.015%,

Carbon from 0.01 to 0.16%,

Rhenium from 1.5 to 3.5%, and

Nickel with impurities to balance.

2. The high gamma prime nickel based superalloy as per claim 1 wherein the total content of germanium and silicon is within 0.9-1.1 wt. %.

3. The use of the high gamma prime nickel based superalloy as per claim 1 as the material for a welding wire, welding powder, or turbine engine components.

4. A method of manufacturing a turbine engine component, wherein it comprises a step of using the high gamma prime nickel based superalloy as per claim 1.

5. The method of manufacturing a turbine engine component as per claim 4, wherein the method comprises one or more steps selected from among:

a) Casting,

b) Annealing at 2190-2290°

F. for 1-2 hours,

c) Hot forming by a plastic deformation at 1500-1800°

F.,

d) Primary aging at 1975-2050°

F. for 2-4 hours, and

e) Secondary aging at 1300-1500°

F. for 16-24 hours

6. The method of manufacturing a turbine engine component as per claim 5, wherein the method comprises a heat treatment selected from among an annealing within a temperature range from 2190°

F. to 2290°

F. for 1-2 hours, a primary aging within a temperature range from 1975°

F. to 2050°

F. for 2-4 hours, and a secondary aging within a temperature range from 1300°

F. to 1500°

F. for 16-24 hours.

7. The method of manufacturing a turbine engine component as per claim 5, wherein prior to the step of hot forming at the temperature of 1500-1800°

F., the method comprises an additional step of a hot isostatic pressure treatment at a temperature of 2200-2290°

F., pressure of 15-20 KSI for 2-6 hours.

8. The method of manufacturing a turbine engine component as per claim 5, wherein the method comprises the hot forming by the plastic deformation by 5-80%.

9. The method of manufacturing a turbine engine component as per claim 5, wherein the temperature of the primary aging is selected above the service temperature of the turbine engine component.

10. The method of manufacturing a turbine engine component as per claim 4, wherein the method comprises steps of:

a) a fusion welding by a melting in a welding pool and deposition of a powder mix comprising at least two dissimilar nickel and cobalt based powders in quantities of (70-80) wt. % and (20-30) wt. % respectively, wherein;

The nickel based powder comprises by wt. %;

Chromium form 6 to 8%,

Cobalt from 11 to 12%,

Molybdenum 1.3 to 1.6%,

Tungsten from 4.5 to 5%,

Tantalum from 2.0 to 6.4%,

Aluminum from 3.0 to 6.5%,

Hafnium from 0.2 to 1.5%,

Rhenium from 2.5 to 3%,

Germanium from 0 to 1.0%,

Silicon from 0 to 1%,

Yttrium for 0 to 0.2%,

Boron from 0 to 0.015%, and

Ni with impurities to balance, and

The cobalt based powder comprises by wt. %;

Nickel from 14 to 18%,

Chromium from 19 to 21%,

Tungsten from 8 to 10%,

Aluminum from 3 to 6.5%,

Germanium from 0 to 1.0%,

Silicon from 0 to 1%,

Yttrium form 0 to 0.45%,

Hafnium from 0 to 1.5%, and

Co with impurities to balance;

b) Progressively moving and solidifying the welding pool as per a preprogrammed welding path, forming welding beads with the same chemical composition as the high gamma prime nickel based superalloy of claim 1.

11. The method of manufacturing a turbine engine component as per claim 10, wherein the fusion welding is selected from among a laser beam, plasma arc, micro plasma, electron beam welding.

12. The method of manufacturing a turbine engine component as per claim 10, wherein the method further comprises a post weld heat treatment selected from among the high isostatic pressure, annealing, aging or combination of the annealing and aging.

13. The method of manufacturing a turbine engine component as per claim 12, wherein after post weld heat treatment, the method further comprises a step of machining to a required geometry.

14. The method of manufacturing a turbine engine component as per claim 13, wherein the method further comprises a step of non-destructive testing.

15. The method of manufacturing a turbine engine component as per claim 10, wherein the powder mix is in the form of a pre-alloyed powder blend comprising the nickel and cobalt based powders or in the form of the dissimilar nickel and cobalt based powders that are mixed in the welding pool directly during welding.

16. The method of manufacturing a turbine engine component as per claim 10, wherein the turbine engine component is manufactured by a 3D additive manufacturing method.

17. A turbine engine component as obtained by the method according to claim 4.