Additively manufactured articles having a microstructure with a high gamma-prime volume fraction

Patent metadata

Field	Value
Publication number	US-2025163811-A1
Application number	US-202318511534-A
Country	US
Kind code	A1
Filing date	Nov 16, 2023
Priority date	Nov 16, 2023
Publication date	May 22, 2025
Grant date	—

Abstract

An additively manufactured article comprises a superalloy composition and a microstructure. The microstructure comprises a gamma-prime phase greater than or equal to 35% by volume of the microstructure. The microstructure comprises grains having an average aspect ratio of greater than or equal to 5.

First claim

What is claimed is:

1 . An additively manufactured article comprising:
a superalloy composition; and a microstructure comprising:
a gamma-prime phase, wherein the gamma-prime phase is greater than or equal to 35% by volume of the microstructure; and
grains, the grains having an average aspect ratio of greater than or equal to 5.

2 . The additively manufactured article of claim 1 , wherein the additively manufactured article is manufactured using an electron beam melting process.

3 . The additively manufactured article of claim 2 , wherein the additively manufactured article comprises a build direction height of greater than or equal to 20 mm.

4 . The additively manufactured article of claim 1 , wherein the superalloy composition is a Ni-based superalloy composition or a Co-based superalloy composition.

5 . The additively manufactured article of claim 4 , wherein the superalloy composition comprises a titanium content and an aluminum content such that w Al +w Ti >=4.0 wt. %, where w Al corresponds to a weight percentage of aluminum in the superalloy composition and w Ti corresponds to a weight percentage of titanium in the superalloy composition.

6 . The additively manufactured article of claim 1 , wherein the superalloy composition comprises less than or equal to 13.5 wt % chromium.

7 . The additively manufactured article of claim 1 , wherein the additively manufactured article comprises a rupture life at 980° C. and 200 MPa of at least 10 hours measured in accordance with ISO 204:2009.

8 . The additively manufactured article of claim 1 , wherein the additively manufactured article comprises a rupture strain at 980° C. and 200 MPa of at least 4% measured in accordance with ISO 204:2009.

9 . An additively manufactured article comprising:
a superalloy composition; and a graded microstructure comprising:
a gamma-prime phase, wherein the gamma-prime phase is greater than or equal to 35% by volume of the graded microstructure;
a first section comprising first grains with a first average aspect ratio of greater than or equal to 5; and
a second section comprising second grains with a second average aspect ratio of less than 5.

10 . The additively manufactured article of claim 9 , wherein the additively manufactured article is manufactured using an electron beam melting process.

11 . The additively manufactured article of claim 10 , wherein the additively manufactured article comprises a build direction height of greater than or equal to 20 mm.

12 . The additively manufactured article of claim 9 , wherein the superalloy composition is a Ni-based superalloy composition or a Co-based superalloy composition.

13 . The additively manufactured article of claim 12 , wherein the superalloy composition comprises a titanium content and an aluminum content such that w Al +w Ti >=4.0 wt. %, where w Al corresponds to a weight percentage of aluminum in the superalloy composition and w Ti corresponds to a weight percentage of titanium in the superalloy composition.

14 . The additively manufactured article of claim 12 , wherein the superalloy composition comprises less than or equal to 13.5 wt % chromium.

15 . The additively manufactured article of claim 9 , wherein the first section comprises a core of the additively manufactured article and the second section comprises an outer shell of the additively manufactured article.

16 . An additively manufactured turbine blade comprising:
an airfoil connected to a shank; a superalloy composition; and a graded microstructure comprising:
a gamma-prime phase, wherein the gamma-prime phase is greater than or equal to 35% by volume of the graded microstructure;
a first section comprising first grains with a first average aspect ratio; and
a second section comprising second grains with a second average aspect ratio, wherein the second average aspect ratio is different than the first average aspect ratio.

17 . The additively manufactured turbine blade of claim 16 , wherein:
the airfoil comprises the first section, wherein the first average aspect ratio is greater than or equal to 5; and the shank comprises the second section, wherein the second average aspect ratio is less than or equal to 5.

18 . The additively manufactured turbine blade of claim 16 , further comprising a third section comprising third grains with a third average aspect ratio different from the first average aspect ratio and the second average aspect ratio, wherein:
the airfoil comprises a core and an outer shell surrounding the core, wherein:
the core comprises the first section, wherein the first average aspect ratio is greater than or equal to 5; and
the outer shell comprises the third section, wherein the third average aspect ratio is less than or equal to 3; and
the shank comprises the second section, wherein the second average aspect ratio is less than or equal to 5.

19 . The additively manufactured turbine blade of claim 16 , wherein:
the airfoil comprises a core and an outer shell surrounding the core, wherein:
the core comprises a single crystal; and
the outer shell comprises the second section, wherein the second average aspect ratio is less than or equal to 3; and
the shank comprises the first section, wherein the first average aspect ratio is less than or equal to 5.

20 . The additively manufactured turbine blade of claim 16 , wherein:
the airfoil comprises an airfoil core and an airfoil shell surrounding the airfoil core; the shank comprises a shank core and a shank shell surrounding the shank core; the airfoil core and the shank core comprise the first section, wherein the first average aspect ratio is greater than or equal to 5; and the airfoil shell and the shank shell comprise the second section, wherein the second average aspect ratio is less than or equal to 5.

Assignees

• Arcam Ab
• Concept Laser Gmbh

Inventors

• Ramsperger Markus
• Eichler Simon

Classifications

• F01D5/28

  Selecting particular materials; {Particular measures relating thereto;} Measures against erosion or corrosion · CPC title

• F01D5/12

  Blades ({specially adapted for radial flow machines or engines F01D5/04}; blade roots F01D5/30; rotors with blades adjustable in operation F01D7/00; stator blades F01D9/02) · CPC title

• B22F3/15

  Hot isostatic pressing · CPC title

• C22C19/058

  without Mo and W · CPC title

• C22C19/057

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