Presintered preform for repair of superalloy component

Patent metadata

Field	Value
Publication number	US-10279438-B2
Application number	US-201414767967-A
Country	US
Kind code	B2
Filing date	Mar 14, 2014
Priority date	Mar 15, 2013
Publication date	May 7, 2019
Grant date	May 7, 2019

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.

First claim

The invention claimed is:

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.

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.

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.

Assignees

• Siemens Energy Inc

Inventors

• Ozbaysal Kazim
• Kamel Ahmed

Classifications

• B23K35/304

  with Cr as the next major constituent · CPC title

• C22C19/007

  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 title

• B23K35/3033 Primary

  Ni as the principal constituent · CPC title

• B22F2304/15

  Millimeter size particles, i.e. above 500 micrometer · CPC title

• C21D9/50

  for welded joints · CPC title