Superalloy composite preforms and applications thereof

Patent metadata

Field	Value
Publication number	US-2016303689-A1
Application number	US-201514686423-A
Country	US
Kind code	A1
Filing date	Apr 14, 2015
Priority date	Apr 14, 2015
Publication date	Oct 20, 2016
Grant date	—

Abstract

In one aspect, composite preforms for the repair of superalloy parts and/or apparatus are described herein. For example, a composite preform comprises a nickel-based superalloy powder component, a nickel-based braze alloy powder component and a melting point depressant component disposed in a fibrous polymeric matrix. The fibrous polymeric matrix can form a flexible cloth in which the nickel-based superalloy powder component, nickel-based braze alloy powder component and melting point depressant component are dispersed.

First claim

1 . A composite preform comprising:
a nickel-based superalloy powder component, a nickel-based braze alloy powder component and a melting point depressant component disposed in a fibrous polymeric matrix.

2 . The composite preform of claim 1 , wherein the fibrous polymeric matrix is cloth-like having a thickness of 0.2-4 mm.

3 . The composite preform of claim 2 , wherein the nickel-based superalloy powder component, nickel-based braze alloy powder component and melting point depressant component are dispersed throughout the fibrous polymeric matrix.

4 . The composite preform of claim 2 , wherein the fibrous polymeric matrix comprises fibrillated polytetrafluoroethylene.

5 . The composite preform of claim 1 , wherein the melting point depressant component is present in an amount of 0.2 to 20 weight percent of the composite preform.

6 . The composite preform of claim 5 , wherein the melting point depressant component comprises boron in an amount of 0.2 to 2 weight percent of the composite preform.

7 . The composite preform of claim 5 , wherein the melting point depressant component comprises boron in an amount of 0.2 to 0.95 weight percent of the composite preform.

8 . The composite preform of claim 5 , wherein the melting point depressant component comprises boron in an amount of 0.7 to 0.8 weight percent of the composite preform.

9 . The composite preform of claim 6 , wherein the melting point depressant component further comprises at least one of magnesium, hafnium, zirconium, MgNi 2 and silicon.

10 . The composite preform of claim 6 , wherein the boron is provided by the nickel-based braze alloy powder, the nickel-based superalloy powder or combinations thereof.

11 . The composite preform of claim 1 , wherein the nickel-based superalloy powder is of composition of 0.05-0.2 wt. % carbon, 7-9 wt. % chromium, 8-11 wt. % cobalt, 0.1-1 wt. % molybdenum, 9-11 wt. % tungsten, 3-4 wt. % tantalum, 5-6 wt. % aluminum, 0.5-1.5 wt. % titanium, less than 0.02 wt. % boron, less than 0.02 wt. % zirconium, less than 2 wt. % hafnium and the balance nickel.

12 . The composite preform of claim 11 , wherein the nickel-based braze alloy powder is of composition 0.01-0.03 wt. % carbon, 14-17 wt. % chromium, 9-12 wt. % cobalt, less than 0.02 wt. % molybdenum, 0.05-0.2 wt. % iron, 2-5 wt. % tantalum, 2-5 wt. % aluminum, less than 0.02 wt. % titanium, 1.5-2.5 wt. % boron, 0.05-0.2 wt. % zirconium, less than 0.02 wt. % manganese and the balance nickel.

13 . The composite preform of claim 1 , wherein a ratio of the nickel-based superalloy powder component to the nickel-based braze alloy powder component ranges from 2-3.

14 . A method of repairing a nickel-based superalloy part comprising:
providing an assembly by application of at least one composite preform to a damaged area of the nickel-based superalloy part, the composite preform including a nickel-based superalloy powder component, a nickel-based braze alloy powder component and a melting point depressant component disposed in a fibrous polymeric matrix; and heating the assembly to form a filler alloy metallurgically bonded to the damaged area, the filler alloy formed from the nickel-based superalloy powder component and nickel-based braze alloy powder component.

15 . The method of claim 14 , wherein the nickel-based braze alloy powder component has a melting point lower than the nickel-based superalloy powder component.

16 . The method of claim 15 , wherein the assembly is heated to a temperature greater than the melting point of the nickel-based braze alloy powder component and less than the melting point of the nickel-based superalloy powder component.

17 . The method of claim 16 , wherein the filler alloy is substantially fully dense.

18 . The method of claim 16 , wherein the filler alloy forms a void-free interface with the nickel-based superalloy part.

19 . The method of claim 14 , wherein an interfacial transition region is established between the filler alloy and the nickel-based superalloy part.

20 . The method of claim 19 , wherein the interfacial transition region is free of brittle metal boride precipitates.

21 . The method of claim 14 , wherein the fibrous polymeric matrix is cloth-like having a thickness of 0.2-4 mm.

22 . The method of claim 14 , wherein the melting point depressant component is present in an amount of 0.2 to 20 weight percent of the composite preform.

23 . The method of claim 22 , wherein the melting point depressant component comprises boron in an amount of 0.2 to 1.2 weight percent of the composite preform.

24 . The method of claim 23 , wherein the melting point depressant component further comprises at least one of magnesium, hafnium, zirconium, MgNi 2 and silicon.

25 . The method of claim 23 , wherein the boron is provided by the nickel-based braze alloy powder, the nickel-based superalloy powder or combinations thereof.

26 . The method of claim 14 , wherein the nickel-based superalloy powder is of composition of 0.05-0.2 wt. % carbon, 7-9 wt. % chromium, 8-11 wt. % cobalt, 0.1-1 wt. % molybdenum, 9-11 wt. % tungsten, 3-4 wt. % tantalum, 5-6 wt. % aluminum, 0.5-1.5 wt. % titanium, less than 0.02 wt. % boron, less than 0.02 wt. % zirconium, less than 2 wt % hafnium and the balance nickel.

27 . The method of claim 26 , wherein the nickel-based braze alloy powder is of composition 0.01-0.03 wt. % carbon, 14-17 wt. % chromium, 9-12 wt. % cobalt, less than 0.02 wt. % molybdenum, 0.05-0.2 wt. % iron, 2-5 wt. % tantalum, 2-5 wt. % aluminum, less than 0.02 wt. % titanium, 1.5-2.5 wt. % boron, 0.05-0.2 wt. % zirconium, less than 0.02 wt. % manganese and the balance nickel.

28 . The method of claim 14 , wherein the damaged nickel-based superalloy part is a component of a gas turbine.

29 . The method of claim 28 , wherein the component is a turbine blade or vane.

Assignees

• Kennametal Inc

Inventors

• Perez Martin Gerardo
• De Wet Daniel J
• Dawson Joel
• Monds Bob

Classifications

• B23P6/005

  using only replacement pieces of a particular form · CPC title

• C22C19/058

  without Mo and W · CPC title

• B23P6/045

  of turbine components, e.g. moving or stationary blades, rotors, etc. · CPC title

• B23K35/0233

  Sheets or foils (B23K35/0244 takes precedence) · CPC title

• C08K3/08

  Metals · CPC title