Method of manufacturing a part comprising two different superalloys

Patent metadata

Field	Value
Publication number	US-10697324-B2
Application number	US-201816140096-A
Country	US
Kind code	B2
Filing date	Sep 24, 2018
Priority date	Sep 25, 2017
Publication date	Jun 30, 2020
Grant date	Jun 30, 2020

Abstract

A method of manufacturing a superalloy part including a first portion including a majority by weight of a first superalloy and a second portion including a majority by weight of a second superalloy, the second portion extending from the first portion, the method including depositing the second portion on the first portion by a direct metal deposition method, deposition of the second portion including depositing a first layer, then depositing a second layer on the first layer, the first layer including the first and second superalloys, the first layer presenting a content by weight of the first superalloy that is strictly greater than that content by weight of the second layer and strictly less than that content by weight of the first portion, the second layer presenting a content by weight of the second superalloy that is strictly greater than that content by weight of the first layer.

First claim

The invention claimed is:

1. A method of manufacturing a superalloy part, the part comprising a first portion comprising a majority by weight of a first superalloy and a second portion comprising a majority by weight of a second superalloy different from the first superalloy, the second portion extending from the first portion, the method comprising depositing the second portion on a surface of the first portion by a direct metal deposition method, deposition of the second portion comprising at least depositing a first layer on said surface, then depositing a second layer on the first layer, the first layer comprising the first and second superalloys, the first layer presenting a content by weight of the first superalloy that is strictly greater than that content by weight of the second layer and strictly less than that content by weight of the first portion, the second layer presenting a content by weight of the second superalloy that is strictly greater than that content by weight of the first layer;
wherein the first portion of the part constitutes at least a portion of a gas turbine casing and the second portion of the part constituting an attachment portion for attaching a ring sector or a sealing portion, the second portion extending radially towards the inside of said casing.

2. The method according to claim 1 , wherein depositing the second portion comprises depositing a third layer on the second layer, the third layer presenting a content by weight of the first superalloy that is zero or strictly less than that content by weight of the second layer, and a content by weight of the second superalloy that is strictly greater than that content by weight of the second layer.

3. The method according to claim 1 , wherein the first and second superalloys are nickel-based superalloys presenting nonzero contents by weight of titanium and of aluminum, the sum of the contents by weight of aluminum and of titanium in the first superalloy being strictly less than 3%, and the sum of the contents by weight of aluminum and of titanium in the second superalloy being greater than or equal to 3%.

4. The method according to claim 3 , wherein the first superalloy is a nickel-based superalloy presenting a content by weight of aluminum lying in the range 0.1% to 0.9% and a content by weight of titanium lying in the range 0.5% to 2.5%, and the second superalloy is a nickel-based superalloy presenting a content by weight of aluminum lying in the range 1% to 4.8% and a content by weight of titanium lying in the range 2.6% to 4%.

5. The method according to claim 1 , wherein during the step of depositing the second portion on the surface of the first portion of the part, said surface is heated to a temperature lying in the range 400° C. to 800° C.

6. The method according to claim 5 , wherein the surface of the first portion is heated by induction.

7. The method according to claim 1 , wherein the second portion is deposited by laser metal deposition or by electron beam metal deposition.

8. The method according to claim 1 , wherein the first portion of the part is obtained by casting or by additive manufacturing.

9. The method according to claim 1 , wherein the first portion of the part is obtained by forging.

10. The method according to claim 1 , wherein the second super-alloy is a nickel-based super-alloy presenting a content by weight of aluminum lying in the range 1% to 4.8% and a content by weight of titanium lying in the range 2.6% to 4%.

11. The method according to claim 1 , wherein the first super-alloy is a nickel-based super-alloy presenting a content by weight of aluminum lying in the range 0.1% to 0.9% and a content by weight of titanium lying in the range 0.5% to 2.5% and the second super-alloy is a nickel-based super-alloy presenting a content by weight of aluminum lying in the range 1% to 4.8% and a content by weight of titanium lying in the range 2.6% to 4%.

Assignees

• Safran Aircraft Engines

Inventors

• Pouzet Sébastien Yohann
• Seince Hervé Antoine Frédéric
• Castagne Jean-François

Classifications

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F12/58

  for changing the material composition, e.g. by mixing · CPC title

• B22F12/53

  Nozzles · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B22F10/00 Primary

  Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) · CPC title