Pre-sintered preform braze for joining alloy castings

Patent metadata

Field	Value
Publication number	US-2016339544-A1
Application number	US-201615151185-A
Country	US
Kind code	A1
Filing date	May 10, 2016
Priority date	May 20, 2015
Publication date	Nov 24, 2016
Grant date	—

Abstract

The disclosure describes techniques for joining a first component comprising a first metal or alloy and a second component comprising a second metal or alloy to each other. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component. The techniques also may include positioning a pre-sintered preform (PSP) braze material in the joint region, heating the PSP braze material to form a molten braze alloy, and cooling the molten braze alloy to join the first and second components. The PSP braze material may include a wide gap braze material.

First claim

What is claimed is:

1 . A method comprising:
positioning a first component comprising a first metal or alloy and a second component comprising a second metal or alloy to each other to define a joint region between adjacent portions of the first component and the second component; positioning a pre-sintered preform (PSP) braze material in the joint region, wherein the PSP braze material comprises a wide gap braze material; heating the PSP braze material to form a molten braze alloy; and cooling the molten braze alloy to join the first and second components.

2 . The method of claim 1 , wherein the PSP braze material comprises between about 50 wt. % and about 90 wt. % Ni, up to about 15 wt. % Cr, up to about 10 wt. % Ta, up to about 10 wt. % Co, up to about 7 wt. % Al, up to about 4 wt. % W, up to about 2 wt. % Re, up to about 1 wt. % Mo, up to about 1 wt. % Hf, up to about 0.5 wt. % Nb, up to about 3.0 wt. % Si, and up to about 3 wt. % B.

3 . The method of claim 2 , wherein the PSP braze material comprises about 58 wt. % Ni, about 11 wt. % Cr, about 9 wt. % Ta, about 9 wt. % Co, about 5 wt. % Al, about 3 wt. % W, about 1 wt. % Mo, about 1 wt. % Re, and about 1 wt. % Hf.

4 . The method of claim 2 , wherein the PSP braze material comprises between about 10.2 wt. % and about 11.3 wt. % Cr, between about 4.8 wt. % and about 5.1 wt. % Al, between about 9.1 wt. % and about 9.8 wt. % Co, between about 2.8 wt. % and about 3.3 wt. % W, between about 0.7 wt. % and about 0.9 wt. % Mo, about between about 8.2 wt. % and about 8.8 wt. % Ta, between about 0.6 wt. % and about 0.8 wt. % B, about 0.3 wt. % Si, between about 1.5 wt. % and about 1.8 wt. % Re, and between about 0.8 wt. % and about 0.9 wt. % Hf, and about 0.1 wt. % and about 0.2 wt. % Nb.

5 . The method of claim 2 , wherein the PSP braze material further comprises up to about 1 wt. % each of at least one of Ti, Nb, Pd, Pt, Ir, Ru, C, P, Mn, Fe, Ce, La, Y, or Zr.

6 . The method of claim 1 , wherein the PSP braze material comprises a low-melt powder composition and a high-melt powder composition, and wherein the low-melt powder composition comprises between about 50 wt. % and about 70 wt. % Ni, between about 8 wt. % and about 20 wt. % Cr, between about 8 wt. % and about 15 wt. % Ta, between about 4 wt. % and about 10 wt. % Co, between about 2 wt. % and about 7 wt. % Al, and up to about 2.25 wt. % B.

7 . The method of claim 6 , wherein the low-melt powder composition further comprises up to about 1 wt. % each of at least one of Ti, W, Mo, Re, Nb, Hf, Pd, Pt, Ir, Ru, C, Si, P, Mn, Fe, Ce, La, Y or Zr.

8 . The method of claim 1 , wherein the PSP braze material comprises a low-melt powder composition and a high-melt powder composition, and wherein the high-melt powder composition comprises between about 50 wt. % and about 70 wt. % Ni, between about 2 wt. % and about 10 wt. % Cr, between about 2 wt. % and about 10 wt. % Ta, between about 5 wt. % and about 15 wt. % Co, between about 2 wt. % and about 10 wt. % Al, between about 2 wt. % and about 10 wt. % W, up to about 3 wt. % Re, up to about 3 wt. % Mo, and up to about 3 wt. % Hf.

9 . The method of claim 1 , wherein the first metal or alloy comprises a Ni-based or a Co-based superalloy, and wherein the second metal or alloy comprises a Ni-based or a Co-based superalloy.

10 . The method of claim 1 , wherein heating the PSP braze material to form the molten braze alloy comprises heating the first component, the second component, and the PSP braze material in a vacuum furnace at a temperature between about 1093° C. and about 1260° C.

11 . The method of claim 1 , further comprising, after cooling the molten braze alloy to join the first and second components, heat treating the first and second components using a stepped diffusion cycle by at least heating the first and second components to about 1038° C. for about 1 hour to about 2 hours; heating the first and second components to about 1093° for about 1 hour to about 2 hours; heating the first and second components to about 1121° C. for about 1 hour to about 2 hours; heating the first and second components to about 1149° C. for about 1 hour to about 18 hours; and cooling the first and second components to room temperature.

12 . An assembly comprising:
a first component comprising a first metal or alloy; a second component comprising a second metal or alloy, wherein the first component and second component are positioned adjacent to each other to define a joint region between adjacent portions of the first component and the second component; a pre-sintered preform (PSP) braze material disposed in the joint region; and a heat source configured to heat the PSP braze material when the PSP braze material is disposed in the joint region.

13 . The assembly of claim 12 , wherein the PSP braze material comprises between about 50 wt. % and about 90 wt. % Ni, up to about 15 wt. % Cr, up to about 10 wt. % Ta, up to about 10 wt. % Co, up to about 7 wt. % Al, up to about 4 wt. % W, up to about 2 wt. % Re, up to about 1 wt. % Mo, up to about 1 wt. % Hf, up to about 0.5 wt. % Nb, up to about 3.0 wt. % Si, and up to about 3 wt. % B.

14 . The assembly of claim 13 , wherein the PSP braze material comprises about 58 wt. % Ni, about 11 wt. % Cr, about 9 wt. % Ta, about 9 wt. % Co, about 5 wt. % Al, about 3 wt. % W, about 1 wt. % Mo, about 1 wt. % Re, and about 1 wt. % Hf.

15 . The assembly of claim 13 , wherein the PSP braze material comprises between about 10.2 wt. % and about 11.3 wt. % Cr, between about 4.8 wt. % and about 5.1 wt. % Al, between about 9.1 wt. % and about 9.8 wt. % Co, between about 2.8 wt. % and about 3.3 wt. % W, between about 0.7 wt. % and about 0.9 wt. % Mo, about between about 8.2 wt. % and about 8.8 wt. % Ta, between about 0.6 wt. % and about 0.8 wt. % B, about 0.3 wt. % Si, between about 1.5 wt. % and about 1.8 wt. % Re, and between about 0.8 wt. % and about 0.9 wt. % Hf, and about 0.1 wt. % and about 0.2 wt. % Nb.

16 . The assembly of claim 13 , wherein the PSP braze material further comprises up to about 1 wt. % each of at least one of Ti, Nb, Pd, Pt, Ir, Ru, C, P, Mn, Fe, Ce, La, Y, or Zr.

17 . The assembly of claim 12 , wherein the PSP braze material comprises a low-melt powder composition and a high-melt powder composition, and wherein the low-melt powder composition comprises between about 50 wt. % and about 70 wt. % Ni, between about 8 wt. % and about 20 wt. % Cr, between about 8 wt. % and about 15 wt. % Ta, between about 4 wt. % and about 10 wt. % Co, between about 2 wt. % and about 7 wt. % Al, and up to about 2.25 wt. % B.

18 . The assembly of claim 17 , wherein the low-melt powder composition further comprises up to about 1 wt. % each of at least one of Ti, W, Mo, Re, Nb, Hf, Pd, Pt, Ir, Ru, C, Si, P, Mn, Fe, Ce, La, Y, or Zr.

19 . The assembly of claim 12 , wherein the PSP braze material comprises a low-melt powder composition and a high-melt powder composition, and wherein the high-melt powder composition comprises between about 50 wt. % and about 70 wt. % Ni, between about 2 wt. % and about 10 wt. % Cr, between about 2 wt. % and about 10 wt. % Ta, between about 5 wt. % and about 15 wt. % Co, between about 2 wt. % and about 10 wt. % Al, between about 2 wt. % and about 10 wt. % W, up to about 3 wt. % Re, up to about 3 wt. % Mo, and up to about 3 wt. % Hf.

20 . The assembly of claim 12 , wherein the first metal or alloy comprises a Ni-based or a Co-based superalloy, and wherein the second metal or alloy comprises a Ni-based or a Co-based sup

Assignees

• Rolls Royce Corp

Inventors

• Xu Raymond Ruiwen
• Nelson Scott

Classifications

• B23K35/0222

  for use in soldering or brazing (B23K35/0205 takes precedence) · CPC title

• B23K1/0018

  Brazing of turbine parts · CPC title

• C21D9/50

  for welded joints · CPC title

• C22C19/057

  with the maximum Cr content being less 10% · CPC title

• B23K35/304 Primary

  with Cr as the next major constituent · CPC title