Method for preparing nano-phase reinforced nickel-based high-temperature alloy using micron ceramic particles

Patent metadata

Field	Value
Publication number	US-12497672-B2
Application number	US-202018023731-A
Country	US
Kind code	B2
Filing date	Aug 31, 2020
Priority date	Aug 30, 2020
Publication date	Dec 16, 2025
Grant date	Dec 16, 2025

Abstract

A method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles is provided. In the method, a nickel-based superalloy is used as a matrix, and one or more of TiC, TiB 2 , WC and Al 2 O 3 are used as a strengthening phase. A ceramic particle raw material used as the strengthening phase has a particle size of 1-5 μm and is added in an amount of 1-5 wt. %. A nickel-based superalloy composite powder having homogeneously distributed nano-scale ceramic is prepared by mechanical milling. A nano-scale ceramic phase strengthened nickel-based superalloy is prepared by 3D printing technology, which has a homogeneously distributed nano-scale ceramic phase and excellent mechanical properties.

First claim

What is claimed is:

1 . A method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles, comprising:
(1) using micron-scale ceramic particles as a first raw material, and using a nickel-based superalloy powder as a second raw material; wet milling and then dry milling the first raw material and part of the second raw material to obtain a composite powder with homogeneous distribution of nano-scale ceramic particles; (2) mixing the composite powder and the remaining second raw material uniformly to obtain a mixed powder; and (3) 3D printing the mixed powder to obtain a 3D printed product, wherein a weight ratio of the first raw material to the second raw material is: (1-5):(99-95).

2 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 1 , wherein
a particle size of the nickel-based superalloy powder is 15-53 μm or 53-106 μm; the micron-scale ceramic particles are selected from at least one of TiC, TiB 2 , WC and Al 2 O 3 ; a particle size of the micron-scale ceramic particles is 1-5 μm; and the 3D printing is selected from one of selective laser melting (SLM), electron beam melting (EBM) and laser engineered net shaping (LENS).

3 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 1 , wherein the steps further comprise:
in step (1) the weight ratio of the first raw material to the second raw material is (1-5):(99-95); in step (2) putting the composite powder prepared in the step (1) and the remaining second raw material into a V-type mixer for uniform mixing to obtain the mixed powder, wherein an inert atmosphere is used for protection during mixing; and in step (3) building a 3D CAD model on a computer according to a part shape; slicing and layering the model using software and then importing it into an additive manufacturing system; then performing repeated laying, scanning, and melting of the uniformly mixed powder prepared in the step (2) layer by layer according to a determined scanning route through a digital control system by using a focused high-energy laser beam, and solidifying the melt, until a 3D part of the 3D printed product is built.

4 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 3 , wherein in step (1), the ceramic particles and part of the nickel-based superalloy powder are mixed first, and the weight ratio is 1:1-1:5.

5 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 3 , wherein the wet milling process in step (1) uses ethanol as a milling medium, and wet milling parameters comprise: a ball-to-material ratio of 10:1-5:1, a milling rotation speed of 150-300 rpm, and a milling time of 5-20 h; and the dry milling process is conducted in inert gas, and dry milling parameters comprise: a ball-to-material ratio of 5:1-1:1, a milling rotation speed of 100-200 rpm, and a milling time of 4-10 h.

6 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 3 , wherein before the 3D printing in step (3), the mixed powder obtained in the step (2) is dried in inert gas at 60-150° C. for 2-12 h.

7 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 3 , wherein the nickel-based superalloy is a René 104 nickel-based superalloy.

8 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 3 , wherein a substrate used for the 3D printing in step (3) is a stainless steel or a nickel-based superalloy.

9 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 3 , wherein laser process parameters in step (3) comprise: a laser spot diameter of 70-110 μm, a laser power of 150-300 W, a laser scanning speed of 500-1100 mm/s, a laser scanning spacing of 60-120 μm, and a powder layer thickness of 30-50 μm.

10 . The method for preparing a nano-phase strengthened nickel-based superalloy using micron-scale ceramic particles according to claim 3 , wherein the inert gas is helium, argon, or a mixture thereof, with a purity of 99.99 wt. % and an oxygen content of less than 0.0001 wt. %.

Assignees

• Univ Central South

Inventors

• Liu Zuming
• Wei Bing
• Nong Bizhong
• Lv Xueqian
• Ren Yake
• Cao Bin
• Ai Yongkang

Classifications

• C22C19/03

  based on nickel · CPC title

• C22C1/1084

  by mechanical alloying (blending, milling) · CPC title

• C22C1/0433

  Nickel- or cobalt-based alloys · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title