Method for preparation of a superalloy having a crystallographic texture controlled microstructure by electron beam melting

Patent metadata

Field	Value
Publication number	US-2016273079-A1
Application number	US-201415034063-A
Country	US
Kind code	A1
Filing date	Oct 28, 2014
Priority date	Nov 4, 2013
Publication date	Sep 22, 2016
Grant date	—

Abstract

The present disclosure provides a method of preparing superalloy metals having a crystallographic texture controlled micro structure by electron beam melting.

First claim

What is claimed is:

1 . A process for the preparation of a superalloy metal comprising the steps of
providing a metal alloy powder composition; providing a seed crystal; processing the metal alloy powder composition in the presence of the seed crystal to provide a superalloy metal having a highly textured or single crystal microstructure.

2 . The process for the preparation of a superalloy metal according to claim 1 , further comprising:
providing an inoculant prior to the processing step to provide a texture-free microstructure.

3 . The process for the preparation of a superalloy metal according to claim 1 , further comprising the step of:
subjecting the superalloy metal to heat treatment.

4 . The process for the preparation of a superalloy metal according to claim 1 , further comprising the step of:
subjecting the superalloy metal to hot isostatic pressing (HIP).

5 . The process for the preparation of a superalloy metal according to claim 1 , further comprising the steps of:
subjecting the superalloy metal to heat treatment, and subjecting the superalloy metal to hot isostatic pressing (HIP).

6 . The process for the preparation of a superalloy metal according to claim 1 , wherein the processing step is performed by electron beam melting, electron beam solid freeform fabrication, epitaxial laser beam formation, laser engineered net shaping, spray forming, three-dimensional printing, shaped metal deposition, or metal inert gas welding.

7 . The process for the preparation of a superalloy metal according to claim 6 , wherein the processing step is performed by electron beam melting.

8 . The process for the preparation of a superalloy metal according to claim 1 , wherein the metal alloy powder composition comprises iron, nickel, chromium, molybdenum, niobium, cobalt, manganese, copper, aluminum, titanium, silicon, carbon, sulfur, phosphorous, boron, tantalum, tungsten, or a combination thereof.

9 . The process for the preparation of a superalloy metal according to claim 8 , wherein the metal alloy powder composition comprises a combination of iron, nickel, titanium, aluminum, molybdenum, niobium, tantalum, carbon and chromium.

10 . The process for the preparation of a superalloy metal according to claim 8 , wherein the metal alloy powder composition comprises a combination of iron, nickel, and chromium.

11 . The process for the preparation of a superalloy metal according to claim 8 , wherein the iron powder comprises austenitic iron.

12 . The process for the preparation of a superalloy metal according to claim 8 , wherein the metal alloy powder composition comprises a powder of Inconel 718, Inconel 600, Inconel 625, Inconel X-750, or Inconel 100.

13 . The process for the preparation of a superalloy metal according to claim 1 , wherein the seed crystal has a (111), (110), or (100) textured gamma microstructure.

14 . The process for the preparation of a superalloy metal according to claim 2 , wherein the inoculant is Co 3 FeNb 2 , CrFeNb, CoAl 2 O 4 , or combinations thereof.

15 . A superalloy metal formed by the process according to claim 1 .

16 . An article comprising a superalloy metal formed by the process according to claim 1 .

17 . The article comprising a superalloy metal according to claim 16 , wherein the article comprises multiple layers of superalloy metal.

18 . The article comprising a superalloy metal according to claim 16 , wherein the article is a turbine blade, a vane, a stator, a diffuser case, a TOBI, or a rotor.

19 . The article comprising a superalloy metal according to claim 18 , wherein the article is a turbine blade, a vane, a stator, a diffuser case, a TOBI, or a rotor.

Assignees

• United Technologies Corp

Inventors

• Das Gopal
• Cernatescu Luliana
• Shah Dilip M

Classifications

• F01D5/28

  Selecting particular materials; {Particular measures relating thereto;} Measures against erosion or corrosion · CPC title

• C22C19/05

  with chromium · CPC title

• C22C19/055

  with the maximum Cr content being at least 20% but less than 30% · CPC title

• B23K9/044

  Built-up welding on three-dimensional surfaces · CPC title

• B23K15/0086

  welding for purposes other than joining, e.g. build-up welding · CPC title