Method for forming hybrid article

Patent metadata

Field	Value
Publication number	US-2018043451-A1
Application number	US-201715793318-A
Country	US
Kind code	A1
Filing date	Oct 25, 2017
Priority date	Dec 11, 2015
Publication date	Feb 15, 2018
Grant date	—

Abstract

A hybrid article is disclosed including a coating disposed on and circumscribing the lateral surface of a core having a core material. The coating includes about 35% to about 95% of a first metallic material having a first melting point, and about 5% to about 65% of a second metallic material having a second melting point lower than the first melting point. A method for forming the hybrid article is disclosed including disposing the core in a die, forming a gap between the lateral surface and the die, introducing a slurry having the metallic materials into the gap, and sintering the slurry, forming the coating. A method for closing an aperture of an article is disclosed including inserting the hybrid article into the aperture. Closing the aperture includes brazing the hybrid article to the article, welding the aperture with the hybrid article serving as weld filler, or a combination thereof.

First claim

What is claimed is:

1 . A method for forming a hybrid article, comprising:
disposing a core in a die, the core including a lateral surface; forming a gap between the lateral surface and the die, the gap circumscribing the lateral surface; introducing a slurry into the gap, the slurry including a first metallic material having a first melting point, and a second metallic material having a second melting point, the first melting point being higher than the second melting point; coating the lateral surface with the slurry; and sintering the slurry to form a coating circumscribing the lateral surface, forming the hybrid article, the coating including about 35% to about 95% of the first metallic material and about 5% to about 65% of the second metallic material.

2 . The method of claim 1 , wherein disposing the core in the die includes passing the core through the die.

3 . The method of claim 2 , wherein passing the core through the die is a continuous process.

4 . The method of claim 1 , wherein disposing the core in the die includes disposing the core in a coating apparatus for the production of a welding electrode.

5 . The method of claim 1 , wherein disposing the core in the die includes disposing the core in an extrusion press.

6 . The method of claim 1 , wherein sintering the slurry to form the coating includes heating the slurry to a sintering temperature of from about 1,500° F. to about 2,375° F. for a sintering duration of from about 5 minutes to about 150 minutes.

7 . The method of claim 1 , wherein sintering the slurry to form the coating includes heating the slurry with a heating element.

8 . The method of claim 1 , wherein the slurry includes a viscosity sufficient to adhere to the core until the slurry is sintered to form the coating.

9 . The method of claim 1 , wherein disposing the core in the die includes disposing a wire as the core.

10 . The method of claim 1 , wherein introducing the slurry into the gap includes introducing the slurry under elevated pressure.

11 . The method of claim 1 , further including finishing the hybrid article.

12 . The method of claim 1 , further including sizing the hybrid article to a predetermined length.

13 . The method of claim 1 , wherein disposing the core in the die includes disposing the core having a core cross-sectional conformation selected from the group consisting of a circle, an ellipse, an oval, a triangle, a rounded triangle, a square, a rounded square, a rectangle, a rounded rectangle, a pentagon, a rounded pentagon, a hexagon, a rounded hexagon, and combinations thereof.

14 . The method of claim 1 , wherein coating the lateral surface with the slurry and sintering the slurry forms the hybrid article including an article cross-sectional conformation selected from the group consisting of a circle, an ellipse, an oval, a triangle, a rounded triangle, a square, a rounded square, a rectangle, a rounded rectangle, a pentagon, a rounded pentagon, a hexagon, a rounded hexagon, and combinations thereof.

15 . The method of claim 1 , wherein the core material is selected from the group consisting of at least one of a superalloy, a nickel-based superalloy, a cobalt-based superalloy, an iron-based superalloy, a hard-to-weld (HTW) alloy, a refractory alloy, GTD 111, GTD 444, HAYNES 188, INCONEL 738, MAR-M-247, Rene 108, Rene 142, Rene 195, and Rene N2.

16 . The method of claim 1 , wherein the first metallic material is selected from the group consisting of at least one of a superalloy, a nickel-based superalloy, a cobalt-based superalloy, an iron-based superalloy, a hard-to-weld (HTW) alloy, a refractory alloy, GTD 111, GTD 444, HAYNES 188, INCONEL 738, MAR-M-247, Rene 108, Rene 142, Rene 195, and Rene N2.

17 . The method of claim 1 , wherein the second metallic material is selected from the group consisting of at least one of a braze alloy, DF-4B, BNi-2, BNi-5, and BNi-9.

18 . The method of claim 1 , wherein the first melting point is from about 2,400° F. to about 2,600° F., and the second melting point is from about 1,400° F. to about 2,375° F.

19 . The method of claim 1 , wherein the coating further includes an average coating thickness of from about 0.5 mm to about 5 mm.

20 . The method of claim 1 , wherein the core further includes an average diameter of from about 0.5 mm to about 30 mm.

Assignees

• Gen Electric

Inventors

• Cui Yan
• Kottilingam Srikanth Chandrudu
• Tollison Brian Lee

Classifications

• B22F5/009 Primary

  of turbine components other than turbine blades (of turbine blades B22F5/04) · CPC title

• B23K15/0086

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

• B23K1/0018 Primary

  Brazing of turbine parts · CPC title

• B22F7/062

  involving the connection or repairing of preformed parts · CPC title

• B32B15/01

  all layers being exclusively metallic {(making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00)} · CPC title