Low heat flux mediated cladding of superalloys using cored feed material

Patent metadata

Field	Value
Publication number	US-2016144441-A1
Application number	US-201615008893-A
Country	US
Kind code	A1
Filing date	Jan 28, 2016
Priority date	Jan 31, 2013
Publication date	May 26, 2016
Grant date	—

Abstract

Methods are disclosed for melting a cored feed material ( 31 ) using a low heat input process. The feed material may be a sheath ( 34 ) consisting essentially of pure nickel, nickel-chromium, or nickel-chromium-cobalt, containing a powdered core material ( 36 ) having a powdered alloy material ( 42 ) and powdered flux material ( 38 ) which, when melted, form a desired superalloy material. Flux materials for use with the methods are disclosed. The process may be a cold metal transfer process wherein the feed material is oscillated at greater than 130 oscillations per second.

First claim

The invention claimed is:

1 . A method of depositing an alloy, the method comprising:
melting a cored feed material to form a melt pool using a heat input of 0.05 to 0.6 kJ/mm; and allowing the melt pool to cool and solidify to form deposited alloy.

2 . The method of claim 1 , further comprising:
melting flux material contained within a core of the feed material to form slag over the melt pool; allowing the melt pool to cool and solidify under and with the slag; and removing the solidified slag to reveal the deposited alloy.

3 . The method of claim 2 , further comprising:
melting the cored feed material with a cold metal transfer process; wherein the melted flux material and slag are effective to quiet weld pool oscillations.

4 . The method of claim 3 , wherein the cored feed material is oscillated at greater than 130 oscillations per second

5 . The method of claim 2 , further comprising:
selecting the feed material to comprise a sheath containing a powdered core material, the powdered core material comprising a powdered alloy material and a powdered flux material, the sheath consisting essentially of pure nickel, nickel-chromium, or nickel-chromium-cobalt; wherein: the powdered core material comprises constituents that complement the sheath to form the deposited alloy as a desired superalloy material when the sheath and powdered core material are melted together.

6 . The method of claim 5 , wherein the cored feed material is melted using a cold metal transfer process, a reciprocating wire feed gas metal arc welding process, a TIP TIG process, pulsed arc welding, or a low energy beam process.

7 . The method of claim 2 , wherein the flux material comprises:
5 to 85 percent by weight of a metal oxide, a metal silicate, or both; 10 to 70 percent by weight of a metal fluoride; and 1 to 30 percent by weight of a metal carbonate, relative to a total weight of the flux material, wherein:
the flux material does not contain substantial amounts of iron; and
the flux material does not contain substantial amounts of Li2O, Na2O or K2O.

8 . The method of claim 2 , wherein the flux material comprises:
at least one selected from a group consisting of a metal oxide, a metal silicate, a metal fluoride and a metal carbonate; and a metal carbide.

9 . The method of claim 2 , wherein the flux material comprises:
at least one selected from a group consisting of a metal oxide, a metal silicate and a metal fluoride; and at least two metal carbonates.

10 . The method of claim 2 , wherein the flux material comprises a metal hydride or hydrogen halide.

11 . The method of claim 2 , wherein the flux material melts to form a slag having a specific conductivity between 1 and 9 mho/cm.

12 . The method of claim 2 , wherein the powdered flux material comprises a cooling agent effective to remove heat from the melt pool.

13 . A method for depositing a desired superalloy composition, the method comprising:
melting a consumable electrode using a low heat input process in the presence of a flux material, wherein: the consumable electrode comprises a sheath consisting essentially of one of a group of nickel, nickel-chromium, and nickel-chromium-cobalt, the sheath containing a powdered core material; and the sheath and powdered core material comprising elements which, upon melting, form the desired superalloy composition.

14 . The method of claim 13 , wherein the low heat input process is cold metal transfer welding, a reciprocating wire feed gas metal arc welding process, a TIP TIG process, pulsed arc welding, or a low energy beam process.

15 . The method of claim 13 , wherein the flux material is a powdered flux material and the powdered core material comprises the powdered flux material and a powdered alloy material.

16 . The method of claim 13 , wherein the flux material comprises a flux composition comprising:
5 to 85 percent by weight of a metal oxide, a metal silicate, or both; 10 to 70 percent by weight of a metal fluoride; and 1 to 30 percent by weight of a metal carbonate, relative to a total weight of the flux composition, wherein:
the flux composition does not contain substantial amounts of iron; and
the flux composition does not contain substantial amounts of Li 2 O, Na 2 O or K 2 O.

17 . The method of claim 13 , wherein the flux material comprises a flux composition comprising:
at least one selected from the group consisting of a metal oxide, a metal silicate and a metal fluoride; and at least two metal carbonates.

18 . The method of claim 13 , wherein the flux material comprises a metal hydride or a hydrogen halide.

19 . The method of claim 13 , wherein the consumable electrode forms a fluidity enhanced alloy comprising greater than 1 wt. % silicon when melted.

20 . The method of claim 13 , wherein the low heat input process is a cold metal transfer process wherein the consumable electrode is oscillated axially relative to the substrate at a rate greater than 130 oscillations per second.

Assignees

• Siemens Energy Inc

Inventors

• Bruck Gerald J
• Kamel Ahmed

Classifications

• B23K35/3608

  Titania or titanates · CPC title

• B23K35/304

  with Cr as the next major constituent · CPC title

• B23K35/3605

  Fluorides · CPC title

• B23K35/3033

  Ni as the principal constituent · CPC title

• B23K35/368

  Selection of non-metallic compositions of core materials either alone or conjoint with selection of soldering or welding materials · CPC title