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

Patent metadata

Field	Value
Publication number	US-2018347014-A1
Application number	US-201816059565-A
Country	US
Kind code	A1
Filing date	Aug 9, 2018
Priority date	Dec 16, 2014
Publication date	Dec 6, 2018
Grant date	—

Abstract

A nickel-based superalloy component includes a nickel-based superalloy metal. The nickel-based superalloy metal includes, 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. In some examples, the component includes a gas turbine engine component, such as a turbine blade or a turbine vane, and the metal form of the nickel-based superalloy may be used as a filler metal for welding a casting alloy, a wrought alloy, or a powder metal alloy or other wrought forms.

First claim

What is claimed is:

1 . 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; less than about 0.005% titanium; and a majority of nickel.

2 . The nickel-based superalloy component of claim 1 , wherein the component comprises a gas turbine engine component.

3 . The nickel-based superalloy component of claim 2 , wherein the component comprises a turbine blade.

4 . The nickel-based superalloy component of claim 2 , wherein the component comprises a turbine vane.

5 . The nickel-based superalloy component of claim 1 , wherein the nickel-based superalloy metal comprises silicon in an amount of less than about 0.005%.

6 . The nickel-based superalloy component of claim 1 , wherein the nickel-based superalloy metal comprises boron in an amount of less than about 0.005%.

7 . The nickel-based superalloy component of claim 1 , wherein the nickel-based superalloy metal comprises zirconium in an amount of less than about 0.005%.

8 . The nickel-based superalloy component of claim 1 , wherein the nickel-based superalloy metal comprises carbon in an amount of greater than about 0.02% but less than or equal to about 0.04%.

9 . The nickel-based superalloy component of claim 1 , wherein the nickel-based superalloy metal comprises phosphorous in an amount of less than about 0.005% and sulfur in an amount of less than about 0.002%.

10 . The nickel-based superalloy component of claim 1 , wherein the nickel-based superalloy metal comprises manganese, iron, copper, and niobium in amounts, individually, of less than about 0.1% each.

11 . The nickel-based superalloy component of claim 1 , wherein the nickel-based superalloy metal comprises inevitable/unavoidable impurities.

12 . A nickel-based superalloy component, wherein the nickel-based superalloy component is manufactured by a method 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;
less than about 0.005% titanium; 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.

13 . The nickel-based superalloy component of claim 12 , wherein the additive manufacturing process comprises direct metal laser sintering.

14 . The nickel-based superalloy component of claim 12 , wherein the finishing process comprises hot isostatic pressing or annealing.

15 . The nickel-based superalloy component of claim 14 , wherein the finishing process further comprises encapsulation.

16 . The nickel-based superalloy component of claim 12 , wherein the component comprises a gas turbine engine component.

17 . The nickel-based superalloy component of claim 16 , wherein the component comprises a turbine blade.

18 . The nickel-based superalloy component of claim 16 , wherein the component comprises a turbine vane.

19 . A nickel-based superalloy component comprising a nickel-based superalloy metal, wherein the nickel-based superalloy metal consists of, 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; less than about 0.005% titanium; less than about 0.005% silicon; less than about 0.005% boron; less than about 0.005% zirconium; less than about 0.005% phosphorous; less than about 0.002% sulfur; less than about 0.1%, each individually, of manganese, iron, copper, and niobium; and a majority of nickel, with the proviso that the nickel-based superalloy metal may have inevitable/unavoidable impurities.

20 . The nickel-based superalloy component of claim 19 , wherein the component comprises a gas turbine engine component.

Assignees

• Honeywell Int Inc

Inventors

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

Classifications

• B22F10/36

  of energy beam parameters · CPC title

• B22F12/49

  Scanners · CPC title

• B22F10/28

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

• B22F10/73

  of powder · CPC title

• B22F10/64

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