Abrasive coating and manufacture and use methods

Patent metadata

Field	Value
Publication number	US-10012095-B2
Application number	US-201514750324-A
Country	US
Kind code	B2
Filing date	Jun 25, 2015
Priority date	Jul 2, 2014
Publication date	Jul 3, 2018
Grant date	Jul 3, 2018

Abstract

A method for applying an abrasive comprises: applying, to a substrate, the integral combination of: a self-braze material; an abrasive; and a matrix in which the abrasive is at least partially embedded; and heating to cause the self-braze material to braze to the substrate. The heating leaves at least a portion of the self-braze material with a composition comprising, in weight percent: cobalt 2.5-13.5; chromium 12-27; aluminum 5-7; yttrium 0.0-1.0; hafnium 0.0-1.0; silicon 1.0-3.0; tantalum 0.0-4.5; tungsten 0.0-6.5; rhenium 0.0-2.0; molybdenum 0.1-1.0; and the balance nickel.

First claim

What is claimed is:

1. A method for applying an abrasive, the method comprising:
applying, to a substrate, the integral combination of:
a self-braze material;
an abrasive; and
a matrix in which the abrasive is at least partially embedded; and

heating to cause the self-braze material to braze to the substrate, the heating leaving at least a portion of the self-braze material with a composition comprising, in weight percent:
cobalt 2.5-13.5;
chromium 12-27;
aluminum 5-7;
yttrium 0.0-1.0;
hafnium 0.0-1.0;
silicon 1.0-3.0;
tantalum 0.0-4.5;
tungsten 0.0-6.5;
rhenium 0.0-2.0;
molybdenum 0.1-1.0; and
the balance nickel.

2. The method of claim 1 wherein:
said portion of the self-braze material has said composition comprising, in weight percent:
cobalt 2.5-13.5;
chromium 12-27;
aluminum 5-7;
yttrium 0.0-1.0;
hafnium 0.0-1.0;
silicon 1.0-3.0;
tantalum 2.0-4.5;
tungsten 2.0-6.5;
rhenium 0.0-2.0;
molybdenum 0.1-1.0; and
the balance nickel.

3. The method of claim 1 wherein:
said composition has no more than 1.0 weight percent of any other individual element.

4. The method of claim 1 wherein:
said composition has no more than 3.0 weight percent of all other individual elements combined.

5. The method of claim 1 wherein:
the matrix comprises an MCrAlY; and
the abrasive comprises cubic boron nitride.

6. The method of claim 1 wherein the self-braze material comprises a sintered sheet of:
at least one first alloy of low melting point relative to the melting point of the substrate; and
at least one second alloy of high melting point relative to the melting point of the first alloy.

7. The method of claim 6 wherein:
the at least one first alloy comprises about 21.25-22.75 chromium, about 5.7-6.3 aluminum, about 11.5-12.5 cobalt, about 5.7-6.3 silicon, boron in an amount no greater than 1.0 weight percent, and a balance of nickel plus impurities if any; and
the at least one second alloy comprises about 4.75-10.5 chromium, about 5.5-6.7 aluminum, up to about 13 weight percent cobalt, about 3.75-9.0 tantalum, about 1.3-2.25 molybdenum, about 3.0-6.8 tungsten, about 2.6-3.25 rhenium, up to about 0.02 boron, about 0.05-2.0 hafnium, up to about 0.14 carbon, up to about 0.35 zirconium, and a balance of nickel plus impurities if any.

8. The method of claim 7 wherein:
a boron content of the first alloy is at least 0.30 weight percent greater than a boron content, if any, of the second alloy.

9. The method of claim 7 wherein:
the at least one first alloy comprises no more than 1.0 weight percent of any other individual element; and
the at least one second alloy comprises no more than 1.0 weight percent of any other individual element.

10. The method of claim 1 wherein:
the matrix has a characteristic thickness T 2 of 0.10-0.50 millimeters; and
the self-braze material has a characteristic thickness T 1 of 0.20-2.5 millimeters.

11. The method of claim 1 wherein:
the applied combination consists of the self-braze material, the abrasive, and the matrix.

12. The method of claim 1 further comprising forming the combination by:
slurry plating the abrasive and one or more components of the matrix to a first face of a sheet of the self-braze material; and
cutting the plated sheet.

13. The method of claim 12 further comprising forming the sheet by:
mixing powders of at least two different alloys; and
sintering the mixture.

14. The method of claim 12 wherein:
the slurry plating comprises:
nickel and/or cobalt entrapment plating of CrAlY particulate; and
nickel and/or cobalt entrapment plating of the abrasive.

15. The method of claim 1 wherein the substrate is a substrate of a turbine blade and wherein the combination is applied at a tip surface of an airfoil of the turbine blade.

16. The method of claim 1 wherein the matrix is metallic.

17. The method of claim 12 further comprising heat treatment to at least partially homogenize the matrix and bond it to the self-braze material prior to the cutting.

18. The method of claim 14 further comprising, after the nickel and/or cobalt entrapment plating of the abrasive:
nickel and/or cobalt entrapment plating of further CrAlY particulate around the plated abrasive.

Assignees

• United Technologies Corp

Inventors

• Stratton Eric W
• Minor Michael J

Classifications

• B23K35/0238

  layered · CPC title

• F05D2300/132

  Chromium · CPC title

• C09K3/1409

  Abrasive particles per se (preparation of diamond C01B32/25) · CPC title

• B23K35/30

  with the principal constituent melting at less than 1550°C · CPC title

• B23K35/0244

  Powders, particles or spheres; Preforms made therefrom · CPC title