Presintered preform for repair of superalloy component

• US 10,279,438 B2
• Filed: 03/14/2014
• Issued: 05/07/2019
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Energy Incorporated (Siemens AG)
• Inventors: Ozbaysal, Kazim, Kamel, Ahmed
• Primary Examiner(s): Hoban, Matthew E.
• Application Number:
  US14/767,967
• Publication Number:
  US 20150367456A1
• Time in Patent Office: 1,880 Days
• CPC Class Codes: B22F 2007/068 repairing articles
• CPC Class Codes: B22F 2304/15 Millimeter size particles, i.e. above 500 micrometer
• CPC Class Codes: B22F 3/12 Both compacting and sintering by forging B22F3/17
• CPC Class Codes: B22F 5/009 of turbine components other than turbine blades of turbine blades B22F5/04
• CPC Class Codes: B22F 7/062 involving the connection or repairing of preformed parts
• CPC Class Codes: B23K 35/0222 for use in soldering, brazing B23K35/0205 takes precedence
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B23K 35/025 Pastes, creams, slurries
• CPC Class Codes: B23K 35/30 with the principal constituent melting at less than 1550 degrees C
• CPC Class Codes: B23K 35/3033 Ni as the principal constituent
• CPC Class Codes: B23K 35/304 with Cr as the next major constituent
• CPC Class Codes: B23K 35/325 Ti as the principal constituent
• CPC Class Codes: B23P 6/005 using only replacement pieces of a particular form
• CPC Class Codes: B23P 6/045 of turbine components, e.g. moving or stationary blades, rotors, etc.
• CPC Class Codes: C21D 9/50 for welded joints
• CPC Class Codes: C22C 1/0433 Nickel- or cobalt-based alloys
• CPC Class Codes: C22C 19/007 with a light metal (alkali metal Li, Na, K, Rb, Cs; earth alkali metal Be, Mg, Ca, Sr, Ba, Al Ga, Ge, Ti) or B, Si, Zr, Hf, Sc, Y, lanthanides, actinides, as the next major constituent
• 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%

Abstract

A method of making pre-sintered preforms using a mixture of base superalloy particles and titanium-containing boron and silicon free braze alloy particles, such as for the repair of superalloy gas turbine engine components. Alloy particles as large as 2 mm provide reduced shrinkage when compared to prior art preforms. Braze material compositions disclosed herein are boron and silicon free and may have melting temperature ranges as low as 10° C., and they include no element not already present in the composition of the superalloy component.

Claims

1. A method comprising:

forming a preform from a powder mixture comprising superalloy material particles and boron and silicon free braze material particles comprising titanium, a size range of the superalloy material particles comprising particles larger than 140 US mesh; and

sintering the preform at a temperature below solidus temperatures of the superalloy and braze material particles,

wherein a first size of the superalloy particles is larger than a second size of the braze material particles, and

wherein the powder mixture comprises from 5% to 50% by weight braze material particles.

2. The method of claim 1, further comprising joining the sintered preform to a superalloy component with a braze joint formed from braze material particles disposed on a periphery of the preform.

3. The method of claim 1, further comprising joining the sintered preform to a superalloy component with a braze joint formed from braze material applied between the preform and a surface of the component.

4. The method of claim 1, further comprising forming the preform from a powder mixture comprising superalloy material particles larger than 100 US mesh.

5. The method of claim 1, further comprising forming the preform from a powder mixture comprising superalloy material particles as large as 2,000 microns.

6. The method of claim 1, further comprising sintering the preform to a porosity of less than 5% by volume.

7. The method of claim 1, further comprising forming the preform from a powder mixture comprising braze material particles having a composition of Cr 15-25%;

Ti 15-25%;

balance Ni.

8. The method of claim 1, further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:

Cr 12-16%;

Ti 13-16%;

Al 0-2.5%

Co 2-4%

W 3-5%

Mo 0-2%;

Ta 0-2%;

Balance Ni.

9. The method of claim 1, further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:

Cr 15-18%;

Ti 10-15%;

Al 0-2.5%

Co 2-4%

W 3-5%

Mo 0-2%;

Ta 0-2%;

balance Ni.

10. The method of claim 1, further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:

Cr 15-19%;

Ti 8-10%;

Al 0-2.5%

Co 14-18%

Mo 12-16%;

balance Ni.

11. The method of claim 1, further comprising:

joining the sintered preform to a superalloy component with a braze joint; and

homogenizing the braze joint with a solution heat treatment applied to the component in order to rejuvenate material properties of the superalloy component.

12. The method of claim 1, further comprising selecting a composition of the braze material particles to include no element that is not part of a composition of the superalloy particles.

19. The method of claim 1, further comprising forming the preform with the braze material particles having a melting temperature range of less than 50°

C.

13. A method comprising:

forming a preform from a powder mixture comprising superalloy material particles and braze material particles, a size range of the superalloy material particles comprising particles larger than 140 US mesh, and a composition of the braze material particles having a melting temperature range of less than 50°

C.; and

sintering the preform at a temperature less than solidus temperatures of the superalloy material and braze material particles, under a pressure of minimum of 15 ksi and an inert atmosphere until the porosity is less than 5% by volume, wherein a first size of the superalloy particles is larger than a second size of the braze material particles, and

wherein the powder mixture comprises from 5% to 50% by weight braze material particles.

14. The method of claim 13, further comprising forming the preform from a powder mixture comprising braze material particles having a composition of Cr 15-25%;

Ti 15-25%;

balance Ni.

15. The method of claim 13, further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:

Cr 12-16%;

Ti 13-16%;

Al 0-2.5%;

Co 2-4%;

W 3-5%;

Mo 0-2%;

Ta 0-2%;

balance Ni.

16. The method of claim 13, further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:

Cr 15-18%;

Ti 10-15%;

Al 0-2.5%;

Co 2-4%;

W 3-5%;

Mo 0-2%;

Ta 0-2%;

balance Ni.

17. The method of claim 13, further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:

Cr 15-19%;

Ti 8-10%;

Al 0-2.5%

Co 14-18%

Mo 12-16%;

balance Ni.

18. The method of claim 13, further comprising:

joining the sintered preform to a superalloy component with a braze joint; and

homogenizing the braze joint with a solution heat treatment applied to the component in order to rejuvenate material properties of the superalloy component.