Nickel-based superalloys and additive manufacturing processes using nickel-based superalloys

Patent metadata

Field	Value
Publication number	US-2016348216-A1
Application number	US-201414571332-A
Country	US
Kind code	A1
Filing date	Dec 16, 2014
Priority date	Dec 16, 2014
Publication date	Dec 1, 2016
Grant date	—

Abstract

Nickel-based superalloys and additive manufacturing processes using nickel-based superalloys are disclosed herein. For example, a nickel-based superalloy includes, on a weight basis of the overall superalloy: about 9.5% to about 10.5% tungsten, about 9.0% to about 11.0% cobalt, about 8.0% to about 8.8% chromium, about 5.3% to about 5.7% aluminum, about 2.8% to about 3.3% tantalum, about 0.3% to about 1.6% hafnium, about 0.5% to about 0.8% molybdenum, about 0.005% to about 0.04% carbon, and a majority of nickel. Exemplary additive manufacturing processes include subjecting such a nickel-based superalloy in powdered build material form to a high energy density beam in an additive manufacturing process to selectively fuse portions of the build material to form a built component and subjecting the built component to a finishing process to precipitate a gamma-prime phase of the nickel-based superalloy.

First claim

What is claimed is:

1 . A nickel-based superalloy comprising, on a weight basis of the overall superalloy:
about 9.5% to about 10.5% tungsten; about 9.0% to about 11.0% cobalt; about 8.0% to about 8.8% chromium; about 5.3% to about 5.7% aluminum; about 2.8% to about 3.3% tantalum; about 0.3% to about 1.6% hafnium; about 0.5% to about 0.8% molybdenum; about 0.005% to about 0.04% carbon; and a majority of nickel.

2 . The nickel-based superalloy of claim 1 , further comprising silicon in an amount of less than about 0.005%.

3 . The nickel-based superalloy of claim 1 , further comprising boron in an amount of less than about 0.005%.

4 . The nickel-based superalloy of claim 1 , further comprising zirconium in an amount of less than about 0.005%.

5 . The nickel-based superalloy of claim 1 , further comprising titanium in an amount of less than about 0.005%.

6 . The nickel-based superalloy of claim 1 , wherein carbon is present in an amount of greater than about 0.02%.

7 . The nickel-based superalloy of claim 1 , further comprising phosphorous in an amount of less than about 0.005% and sulfur in an amount of less than about 0.002%.

8 . The nickel-based superalloy of claim 1 , further comprising manganese, iron, copper, and niobium in amounts of less than about 0.1% each.

9 . A method for manufacturing a nickel-based superalloy component comprising the steps of:
providing or obtaining, in a powdered form, a build material alloy comprising, on a weight basis of the overall build material alloy: about 9.5% to about 10.5% tungsten; about 9.0% to about 11.0% cobalt; about 8.0% to about 8.8% chromium; about 5.3% to about 5.7% aluminum; about 2.8% to about 3.3% tantalum; about 0.3% to about 1.6% hafnium; about 0.5% to about 0.8% molybdenum; about 0.005% to about 0.04% carbon; and a majority of nickel; subjecting the build material alloy to a high energy density beam in an additive manufacturing process to selectively fuse portions of the build material to form a built component; and subjecting the built component to a finishing process to precipitate a gamma-prime phase of the nickel-based superalloy.

10 . The method of claim 9 , wherein the additive manufacturing process comprises direct metal laser sintering.

11 . The method of claim 9 , wherein the finishing process comprises hot isostatic pressing or annealing.

12 . The method of claim 11 , wherein the finishing process further comprises encapsulation.

13 . The method of claim 9 , wherein silicon is present in the build material alloy in an amount of less than about 0.005%.

14 . The method of claim 9 , wherein boron is present in the build material alloy in an amount of less than about 0.005%.

15 . The method of claim 9 , wherein zirconium is present in the build material alloy in an amount of less than about 0.005%.

16 . The method of claim 9 , wherein titanium is present in the build material alloy in an amount of less than about 0.005%.

17 . A nickel-based superalloy component comprising a nickel-based superalloy metal, wherein the nickel-based superalloy metal comprises, on a weight basis of the overall superalloy metal:
about 9.5% to about 10.5% tungsten; about 9.0% to about 11.0% cobalt; about 8.0% to about 8.8% chromium; about 5.3% to about 5.7% aluminum; about 2.8% to about 3.3% tantalum; about 0.3% to about 1.6% hafnium; about 0.5% to about 0.8% molybdenum; about 0.005% to about 0.04% carbon; and a majority of nickel.

18 . The nickel-based superalloy component of claim 17 , wherein the component comprises a gas turbine engine component.

19 . The nickel-based superalloy component of claim 18 , wherein the component comprises a turbine blade.

20 . The nickel-based superalloy component of claim 18 , wherein the component comprises a turbine vane.

Assignees

• Honeywell Int Inc

Inventors

• Szuromi Andy
• Deutchman Hallee Zox
• Baughman Brian G
• Godfrey Donald G
• Kington Harry Lester
• Morris Mark C

Classifications

• B22F10/66

  by mechanical means · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F10/64

  by thermal means (control of energy beam parameters for post heating B22F10/364) · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F12/49

  Scanners · CPC title