Fcc materials of aluminum, cobalt, iron and nickel, and products made therefrom

Patent metadata

Field	Value
Publication number	US-2017306458-A1
Application number	US-201715493012-A
Country	US
Kind code	A1
Filing date	Apr 20, 2017
Priority date	Apr 20, 2016
Publication date	Oct 26, 2017
Grant date	—

Abstract

The present disclosure relates to new materials comprising Al, Co, Fe, and Ni. The new materials may realize a single phase field of a face-centered cubic (fcc) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1000° C. The new materials may include 4.4-11.4 wt. % Al, 4.9-42.2 wt. % Co, 4.6-28.9 wt. % Fe, and 44.1-86.1 wt. % Ni. In one embodiment, the precipitate is selected from the group consisting of the L1 2 phase, the B2 phase, and combinations thereof. The new alloys may realize improved high temperature properties.

First claim

What is claimed is:

1 . A composition of matter comprising:
4.4-11.4 wt. % Al; 4.9-42.2 wt. % Co; 4.6-28.9 wt. % Fe; and 44.1-86.1 wt. % Ni; the balance being any optional incidental elements and impurities.

2 . The composition of matter of claim 1 , wherein the incidental elements comprise up to 0.15 wt. % C, up to 0.15 wt. % B, up to 0.5 wt. % Hf and up to 0.5 wt. % Zr.

3 . The composition of matter of claim 1 , wherein the composition of matter comprises 4.9-18.2 wt. % Co, 4.6-17.3 wt. % Fe, and 57.4-86.1 wt. % Ni.

4 . The composition of matter of claim 1 , wherein the composition of matter comprises 6.8-11.4 wt. % Al, 4.9-12.5 wt. % Co, 4.8-17.3 wt. % Fe, and 64.1-83.5 wt. % Ni.

5 . The composition of matter of claim 1 , wherein the composition of matter comprises 4.8-10.4 wt. % Al, 5.4-38.3 wt. % Co, 5.1-26.3 wt. % Fe, and 49.0-81.9 wt. % Ni.

6 . The composition of matter of claim 5 , wherein the composition of matter comprises 5.4-16.5 wt. % Co, 5.1-15.7 wt. % Fe, and 63.8-81.9 wt. % Ni.

7 . The composition of matter of claim 1 , wherein the composition of matter comprises 7.5-10.4 wt. % Al, 5.5-11.3 wt. % Co, 5.3-15.7 wt. % Fe, and 71.2-78.7 wt. % Ni.

8 . An alloy body comprising:
4.4-11.4 wt. % Al; 4.9-42.2 wt. % Co; 4.6-28.9 wt. % Fe; and 44.1-86.1 wt. % Ni; the balance being any optional incidental elements and impurities.

9 . The alloy body of claim 8 , wherein the alloy body is in the form of an aerospace or automotive component.

10 . The aerospace component of claim 9 , wherein the aerospace or automotive component is a turbine.

11 . A method comprising:
(a) using a feedstock in an additive manufacturing apparatus, wherein the feedstock comprises: 4.4-11.4 wt. % Al; 4.9-42.2 wt. % Co; 4.6-28.9 wt. % Fe; and 44.1-86.1 wt. % Ni; (b) producing a metal product in the additive manufacturing apparatus using the feedstock.

12 . The method of claim 11 , wherein the feedstock comprises a powder feedstock, wherein the method comprises:
(a) dispersing a metal powder of the powder feedstock in a bed and/or spraying a metal powder of the powder feedstock towards or on a substrate; (b) selectively heating a portion of the metal powder above its liquidus temperature, thereby forming a molten pool; (c) cooling the molten pool, thereby forming a portion of the metal product, wherein the cooling comprises cooling at a cooling rate of at least 100° C. per second; and (d) repeating steps (a)-(c) until the metal product is completed, wherein the metal product comprises a metal matrix, wherein the Al, Co, Fe, and Ni make-up the matrix.

13 . The method of claim 11 , wherein the feedstock comprises a wire feedstock, wherein the method comprises:
(a) using a radiation source to heat the wire feedstock above its liquidus point, thereby creating a molten pool, wherein the molten pool comprises Al, Co, Fe, and Ni; (b) cooling the molten pool at a cooling rate of at least 1000° C. per second; and (c) repeating steps (a)-(b) until the metal product is completed, wherein the metal product comprises a metal matrix, wherein the Al, Co, Fe, and Ni make-up the matrix.

14 . The method of claim 11 , comprising: cooling at a rate sufficient to form at least one precipitate phase.

15 . The method of claim 14 , wherein the at least one precipitate phase comprises at least one of L1 2 and B2.

16 . The method of claim 15 , wherein the metal product comprises at least 0.5 vol. % of the precipitate phase.

17 . The method of claim 11 , comprising:
working the metal product.

18 . The method of claim 17 , wherein the producing step comprises:
first producing a portion of the metal product using the feedstock; second producing another portion of the metal product using the feedstock; wherein the working occurs at least after the first or second producing steps.

19 . The method of claim 18 , wherein the working occurs between the first producing step and the second producing step.

20 . The method of claim 18 , wherein the working comprises one or more of rolling, forging, extrusion and hot isostatic pressing.

Assignees

• Arconic Inc

Inventors

• Lin Jen
• Yan Xinyan

Classifications

• B22F1/00

  Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties · CPC title

• B22F10/28

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

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B23K35/3033

  Ni as the principal constituent · CPC title

• B23K26/0006

  taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence) · CPC title