Method of forming an abrasive nickel-based alloy on a turbine blade tip

Patent metadata

Field	Value
Publication number	US-2020078867-A1
Application number	US-201816126222-A
Country	US
Kind code	A1
Filing date	Sep 10, 2018
Priority date	Sep 10, 2018
Publication date	Mar 12, 2020
Grant date	—

Abstract

A method of forming an abrasive nickel-based alloy on a turbine blade tip includes producing or obtaining a metal powder that is mixed with a carbon powder to form a carbon-enriched metal powder. The metal powder includes a refractory element. The method further includes bonding the carbon-enriched metal powder to the turbine blade tip. The step of bonding includes raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles.

First claim

What is claimed is:

1 . A method of forming an abrasive nickel-based alloy on a turbine blade tip, comprising:
producing or obtaining a metal powder that is mixed with a carbon powder to form a carbon-enriched metal powder, wherein the metal powder comprises a refractory element; and bonding the carbon-enriched metal powder to the turbine blade tip, wherein the step of bonding comprises raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles.

2 . The method of claim 1 , wherein the metal powder is produced using an atomization process.

3 . The method of claim 1 , wherein the metal powder comprises a nickel-based superalloy.

4 . The method of claim 3 , wherein the refractory element is selected from the group consisting of: tungsten, tantalum, titanium, and a mixture of two or more thereof.

5 . The method of claim 3 , wherein the nickel-based superalloy comprises, by weight: about 1.5% to about 5.5% chromium, about 8% to about 12% aluminum, about 4% to about 8% tantalum, about 1.5% to about 5.5% tungsten, less than about 1% of one or more of elements selected from a group consisting of boron, zirconium, yttrium, hafnium, and silicon, and a balance of nickel

6 . The method of claim 3 , wherein the nickel-based superalloy comprises, by weight: about 5% to about 12% cobalt, about 3% to about 10% chromium, about 5.5% to about 6.3% aluminum, about 5% to about 10% tantalum, about 3% to about 10% rhenium, about 2% to about 5% of one or more of elements selected from a group consisting of platinum, ruthenium, palladium, and iridium, about 0.1% to about 1.0% hafnium, about 0.01% to about 0.4% yttrium, about 0.01% to about 0.15% silicon, and a balance of nickel.

7 . The method of claim 1 , wherein a variance between the mean particle size (d50) of the metal powder as compared with the mean particle size (d50) of the carbon powder is +/−25%.

8 . The method of claim 7 , wherein a variance between the mean particle size (d50) of the metal powder as compared with the mean particle size (d50) of the carbon powder is +/−10%.

9 . The method of claim 1 , wherein the metal and ceramic powder mixture has a weight ratio of metal powder to carbon powder of from about 100:1 to about 20:1, or

10 . The method of claim 9 , wherein the metal and ceramic powder mixture has a weight ratio of metal powder to carbon powder of from about 50:1 to about 25:1.

11 . The method of claim 1 , wherein bonding the carbon-enriched metal powder is performed using a laser deposition process.

12 . The method of claim 1 , wherein the laser deposition process produces a melted powder bead width of about 0.02 to about 0.100 inches.

13 . The method of claim 1 , wherein the laser deposition process produces a melted powder bead width of about 0.04 to about 0.06 inches in width.

14 . The method of claim 1 , wherein bonding the carbon-enriched metal powder is performed using an electron-beam welding process.

15 . The method of claim 1 , wherein the turbine blade comprises a nickel-based superalloy.

16 . The method of claim 1 , further comprising performing a finishing process on the turbine blade after the step of bonding, wherein the finishing process is selected from the group consisting of: heat treating, machining, surface finishing, polishing, and coating.

17 . A method of forming an abrasive nickel-based alloy on a turbine blade tip, comprising:
producing or obtaining a turbine blade comprising the turbine blade tip, wherein the turbine blade comprises a nickel-based superalloy; producing or obtaining a metal powder that is mixed with a carbon powder to form a carbon-enriched metal powder, wherein the metal powder comprises a nickel-based superalloy and further comprises a refractory element selected from the group consisting of tungsten, tantalum, titanium, and a mixture of two or more thereof, and wherein the metal and ceramic powder mixture has a weight ratio of metal powder to carbon powder of from about 100:1 to about 20:1; and bonding the carbon-enriched metal powder to the turbine blade tip, wherein the step of bonding comprises raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles, wherein bonding the carbon-enriched metal powder is performed using a laser deposition process or an electron-beam welding process.

18 . The method of claim 17 , wherein a variance between the mean particle size (d50) of the metal powder as compared with the mean particle size (d50) of the carbon powder is +/−25%.

19 . The method of claim 17 , wherein the metal and ceramic powder mixture has a weight ratio of metal powder to carbon powder of from about 50:1 to about 25:1.

20 . A method of forming an abrasive nickel-based alloy on a turbine blade tip, comprising:
producing or obtaining a turbine blade comprising the turbine blade tip, wherein the turbine blade comprises a nickel-based superalloy; producing or obtaining a metal powder that is mixed with a carbon powder to form a carbon-enriched metal powder, wherein the metal powder comprises a nickel-based superalloy and further comprises a refractory element selected from the group consisting of tungsten, tantalum, titanium, and a mixture of two or more thereof, wherein the metal and ceramic powder mixture has a weight ratio of metal powder to carbon powder of from about 50:1 to about 25:1, and wherein a variance between the mean particle size (d50) of the metal powder as compared with the mean particle size (d50) of the carbon powder is +/−25%; bonding the carbon-enriched metal powder to the turbine blade tip, wherein the step of bonding comprises raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles, wherein bonding the carbon-enriched metal powder is performed using a laser deposition process or an electron-beam welding process; and performing a finishing process on the turbine blade after the step of bonding, wherein the finishing process is selected from the group consisting of: heat treating, machining, surface finishing, polishing, and coating.

Assignees

• Honeywell Int Inc

Inventors

• Mittendorf Don
• Tolpygo Vladimir K

Classifications

• B22F5/04 Primary

  of turbine blades · CPC title

• B23K26/21

  by welding · CPC title

• B22F2301/15

  Nickel or cobalt · CPC title

• C22C19/057 Primary

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

• F05D2230/22

  by sintering · CPC title