• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    An article and a method for producing a single crystal casting are disclosed. The article contains a nickel-based single crystal superalloy having a composition comprising greater than about 80 ppm boron (B) and a substantially single crystal microstructure having at least one grain boundary. A creep rupture strength of the article is largely preserved up to a grain boundary mismatch of about 40 degrees. The method of manufacturing a single crystal casting includes positioning a mold on a cooling plate, the mold having a single crystal selector, providing a molten nickel base superalloy composition in the mold, wherein the molten composition contains greater than about 80 ppm boron (B), cooling the molten one Assembling with the cooling plate and forming a unidirectional temperature gradient by extracting the mold from within a heat source to produce the single crystal casting having a substantially single crystalline microstructure with at least one grain boundary.
    公开号:CH710105B1
    申请号:CH01233/15
    申请日:2015-08-27
    公开日:2019-10-15
    发明作者:S Peck Arthur；Tan King Warren；Conrad Schaeffer Jon
    申请人:Gen Electric；
    IPC主号:
    专利说明:

    Description: The present invention is directed to a single crystal superalloy article and a corresponding manufacturing method.
    Background of the Invention Hot gas path components of gas turbines and aircraft engines, particularly turbine blades, vanes, nozzles, and stationary jackets, operate at elevated temperatures, often in excess of 1093.3 ° C (2000 ° F). The superalloy compositions used to make hot gas path components are often single crystal, nickel-based superalloy compositions.
    The strength of the hot gas path components is often measured on the basis of the grain boundary strength of the component. Today's acceptance criteria at grain boundaries of industrial gas turbine blades typically include a mismatch of at most 12 degrees in one airfoil and a mismatch of up to 18 degrees at other locations. Due to the grain boundary acceptance criteria, the casting process yield on hot gas path components is low, which leads to increased production costs and more rejects.
    One method of increasing yield involves adding elements such as boron and / or carbon to increase the grain boundary strength of directionally solidified (DS) superalloys. Although boron and / or carbon can increase the grain boundary strength of the DS superalloys, they also act as melting point depressants. Lowering the melting point lowers the melting start temperature and limits the heat treatment of the DS superalloys, thereby reducing the development of maximum strengths within the component. Due to the lowering of the melting point, the addition of boron and / or carbon is avoided.
    Another method of increasing yield involves modifying the manufacturing process to produce hot gas path components with reduced grain boundary mismatch, such as single crystal components. However, many components that are manufactured using today's single crystal manufacturing processes still have grain boundaries. Similar to DS super alloys, the addition of boron and / or carbon to single crystal components lowers the melting point. In addition, increasing the proportion of boron and / or carbon makes it difficult to manufacture single-crystal components. It is also desirable that single crystal components have no grain boundaries, and therefore the addition of boron and / or carbon is often limited in the manufacture of single crystal components. Since the grain boundary mismatch in single crystal components often does not meet the acceptance criteria during their manufacture, many single crystal components are scrapped, which increases the production costs.
    [0006] There is a need in the art for articles and methods with improvements in the properties of the components produced.
    Brief Description of the Invention The invention includes a single crystal superalloy article with a nickel base superalloy having a composition containing more than about 80 ppm boron (B). The article includes an essentially single-crystalline microstructure that has at least one grain boundary, the article having a creep rupture strength that is essentially preserved up to a grain boundary mismatch of about 40 degrees.
    [0008] The aforementioned article may further comprise between about 80 ppm and about 130 ppm boron (B).
    In particular, the article may preferably comprise between about 80 ppm and about 100 ppm boron (B).
    [0010] In one embodiment of the article, the composition, in weight percent, may include: about 5.75% to about 6.25% chromium (Cr); about 7.0% to about 8.0% cobalt (Co); about 6.2% to about 6.7% aluminum (AI); up to about 0.04% titanium (Ti); about 6.4% to about 6.8% tantalum (Ta); about 6.0% to about 6.5% tungsten (W); about 1.3% to about 1.7% molybdenum (Mo); about 0.03% to about 0.11% carbon (C); about 0.008% to about 0.013% boron (B); about 0.12% to about 0.18% hafnium (Hf); and the rest nickel (Ni) and accidental impurities.
    [0011] In a further embodiment of the article, the composition, in weight percent, may include: about 9.5% to about 10.0% chromium (Cr); about 7.0% to about 8.0% cobalt (Co); about 4.1% to about 4.3% aluminum (AI); about 3.35% to about 3.65% titanium (Ti); about 5.75% to about 6.25% tungsten (W); about 1.3% to about 1.7% molybdenum (Mo); about 4.6% to about 5.0% tantalum (Ta); about 0.03% to about 0.11% carbon (C); about 0.008% to about 0.013% boron (B); about 0.04% to about 0.6% niobium (Nb), about 0.1% to about 0.2% hafnium (Hf); and the rest nickel (Ni) and accidental impurities.
    [0012] The subject of any of the types mentioned above may be a hot gas path component of a gas turbine or an aircraft engine, the hot gas path component being capable of being exposed to temperatures of at least about 1093.3 ° C (2000 ° F).
    In particular, the hot gas path component can be selected from the group consisting of a moving blade, a guide blade, a nozzle, a nozzle and a stationary jacket.
    [0014] The subject of any of the types mentioned above may also have a mismatch angle of up to 40 degrees as an acceptance criterion.
    [0015] In particular, the last-mentioned object can further include small-angle boundaries that contain up to 10 degrees of mismatch.
    [0016] Additionally or alternatively, the object can also have large-angle boundaries that contain more than 10 degrees of mismatch.
    The object of each of the types mentioned above can be directionally solidified.
    [0018] In another embodiment, a single crystalline superalloy article includes a nickel-based superalloy that has a composition that, in weight percent, comprises: between about 5.75% and about 6.25% chromium (Cr); between about 7.0% and about 8.0% cobalt (Co); between about 6.2% and about 6.7% aluminum (AI); up to about 0.04% titanium (Ti); between about 6.4% and about 6.8% tantalum (Ta); between about 6.0% and about 6.5% tungsten (W); between about 1.3% and about 1.7% molybdenum (Mo); between about 0.03% and about 0.11% carbon (C); between about 0.008% and about 0.013% boron (B); between about 0.12% and about 0.18% hafnium (Hf); and the rest nickel (Ni) and accidental impurities. The object is solidified in a directional manner and contains an essentially single-crystalline microstructure which has at least one grain boundary, the object having a creep rupture strength which is essentially preserved up to a grain boundary mismatch of approximately 40 degrees.
    In another embodiment, a method of making a single crystal superalloy article from a nickel based superalloy composition describes positioning a mold on a cooling plate, the mold having a single crystal selector, providing the mold within a heat source, providing a molten superalloy composition Nickel-based in the mold, wherein the molten nickel-based superalloy composition contains more than about 80 ppm boron (B), cooling the molten nickel-based superalloy composition with the cooling plate to form crystal nuclei, and forming a unidirectional temperature gradient by pulling the mold out of the mold Inside the heat source. The unidirectional temperature causes stem crystals to grow from the seed crystals, and only one of the stem crystals is let into a body portion of the mold by the single crystal selector to form a single crystal casting. The single crystal casting includes an essentially single crystalline microstructure that has at least one grain boundary, the casting having a creep rupture strength that is essentially preserved up to a grain boundary mismatch of about 40 degrees.
    The aforementioned method may further comprise more than about 100 ppm boron (B).
    In any of the above-mentioned methods, the mold may further include a starting block between the cooling plate and the single crystal selector.
    In particular, the starting block can comprise a columnar starting block.
    [0023] In the method of any of the above-mentioned types, the single crystal selector may further comprise a helical single crystal selector.
    Additionally or alternatively, the single crystal casting may comprise a hot gas path component of a gas turbine or an aircraft engine, the hot gas path component being selected from the group consisting of a moving blade, a guide blade, a nozzle, a seal and a stationary jacket.
    In one embodiment of the method, the creep rupture strength, which is essentially preserved up to a grain boundary mismatch of approximately 40 degrees, can enable an increased yield of single-crystal castings.
    [0026] The method of any of the types mentioned above may further include heating the mold to a temperature between about 1500 and about 1700 ° C.
    Other features and advantages of the present invention will become more apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate by way of example the principles of the invention.
    Brief Description of the Drawings
    1 shows a perspective illustration of a turbine rotor blade according to an embodiment of the invention.
    Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.
    Detailed Description of the Invention An article and method of making an article is provided. Compared to methods and articles that do not use one or more of the features disclosed herein, embodiments of the present disclosure meet higher grain boundary acceptance criteria, lower manufacturing costs, increase casting process yield, increase grain boundary strength, decrease grain boundary life, or afford a combination of these.
    [0030] When introducing elements of various embodiments of the present invention, the articles "a, one" and "the one that means" are intended to mean that at least one of the elements is present. The terms “include”, “include” and “exhibit” are intended to be inclusive and mean that additional elements besides the elements listed may be present.
    In one embodiment, an article includes a substantially single crystalline article, such as, but not limited to, a hot gas path component of a gas turbine or an aircraft engine. In another embodiment, the hot gas path component includes any component that is exposed to temperatures of at least about 2000 ° F. In a further embodiment, the essentially single-crystalline object is produced using a single-crystal process. As shown in FIG. 1, a suitable object includes, for example, a turbine blade or turbine blade 100. The turbine blade 100 includes an airfoil portion 101, a platform portion 103, and a foot portion 105. Other suitable objects include, but are not limited to, a vane , a nozzle, a seal, a stationary jacket, other rotating machine parts, or a combination thereof.
    The person skilled in the art knows that a really “single-crystalline object” is formed from a single grain, which ensures single-crystallinity through the entire object. The single grain has no grain boundaries, i.e. Regions with undirected structure between adjacent grains with different crystallographic alignment or mismatch. As used herein, "substantially single crystalline article" and "substantially single crystalline microstructure" include articles and microstructures, at least a portion of which is single crystalline and a portion of which may include grain boundaries. In addition, the terms "bicrystalline object" and "essentially single-crystal object" can be used interchangeably to refer to an object at least a portion of which is single-crystal. If there are grain boundaries, which are also referred to as critical angle mismatch, they contain low angle boundaries (LAB) and / or large angle boundaries (HAB). Small angle boundaries generally include boundaries between adjacent grains with different crystallographic orientations or with a mismatch of up to 10 degrees, while large angle boundaries include boundaries between adjacent grains with different crystallographic orientations or with a mismatch of more than about 10 degrees. The division into small and large angle boundaries may be carried out differently by the individual and by organizations, but it should be clarified that such division variants are taken into account by the present disclosure.
    The single crystal process includes, but is not limited to, providing a superalloy melt in a mold that rests on a cooling plate and taking the mold out of the interior of a heat source. Providing the superalloy melt in the mold includes, for example, pouring the superalloy melt into the mold, heating the superalloy melt within the heat source, or a combination thereof. The shape includes a starting block, a single crystal selector, and a body portion that corresponds to a shape of the single crystal object. In one embodiment, the starting block includes, but is not limited to, a columnar starting block located on or adjacent to the cooling plate. The cooling plate provides a reduced temperature which cools the superalloy melt in the starting block and forms crystal nuclei adjacent to the cooling plate. Extracting the mold from the interior of the heat source provides radiation cooling of the superalloy melt in the mold, the radiation cooling providing a unidirectional temperature gradient that produces stem crystal growth from the crystal seed grains adjacent to the cooling plate. In another embodiment, the single crystal selector includes, but is not limited to, a helical grain selector disposed between the starting block and the body portion. The stem crystals enter the grain selector at the bottom while the mold is being removed, and a single grain emerges at the grain selector at the top. The single grain that emerges from the top of the grain selector fills the body portion of the mold to form the single crystal article.
    [0034] In a further embodiment, the process also contains any suitable metal temperature for forming the single-crystalline object. For example, suitable, but not limited to, suitable metal temperatures include between about 1450 and about 1700 ° C, between about 1500 and about 1700 ° C, between about 1500 and about 1650 ° C, between about 1500 and about 1600 ° C, between about 1525 and 1575 ° C or any combination, sub-combination, range or sub-range thereof. In another example, suitable temperatures include a mold temperature that is between about 25 and about 200 ° C higher than that of a stem crystal growth process that is between about 25 and about 150 ° C higher than that of a stem crystal growth process that is between about 15 and about 100 ° C higher than that of a stem crystal growth process, or any combination, sub-combination, range or sub-range thereof. The increased temperature of the process compared to a stem crystal growth process reduces or eliminates nucleation of false grains during the provision of the superalloy melt.
    The substantially single-crystalline article contains a nickel-based superalloy. The superalloy of the essentially single-crystalline article contains an increased proportion of boron (B) compared to today's single-crystal articles, which have up to 50 ppm B. The increased B content includes, but is not limited to, at least about 80 ppm B, at least about 90 ppm B, at least about 100 ppm B, between about 80 ppm and about 130 ppm B, between about 80 ppm and about 100 ppm B or any combination, sub-combination, range, or sub-range thereof. For example, the superalloy of a substantially single crystalline article contains a composition, in weight percent, of between about 5.75% and about 6.25% chromium (Cr); between about 7.0% and about 8.0% cobalt (Co); between about 6.2% and about 6.7% aluminum (AI); up to about 0.04% titanium (Ti); between about 6.4% and about 6.8% tantalum (Ta); between about 6.0% and about 6.5% tungsten (W); between about 1.3% and about 1.7% molybdenum (Mo); between about 0.03% and about 0.11% carbon (C); between about 0.008% and about 0.013% boron (B); between about 0.12% and about 0.18% hafnium (Hf); and the rest nickel (Ni) and accidental impurities. [0036] In another example, the superalloy contains a composition, in weight percent, of between about 9.5% and about 10.0% chromium (Cr); between about 7.0% and about 8.0% cobalt (Co); between about 4.1% and about 4.3% aluminum (AI); between about 3.35% and about 3.65% titanium (Ti); between about 5.75% and about 6.25% tungsten (W); between about 1.3% and about 1.7% molybdenum (Mo); between about 4.6% and about 5.0% tantalum (Ta); between about 0.03% and about 0.11% carbon (C); between about 0.008% and about 0.013% boron (B); between about 0.04% and about 0.6% niobium (Nb), between about 0.1% and about 0.2% hafnium (Hf); and the rest nickel (Ni) and accidental impurities.
    The increased boron content improves the fracture properties of the essentially single-crystalline article. The improvement in fracture properties includes, but is not limited to, increasing the grain boundary strength, increasing creep rupture strength, reducing or eliminating a shortening of the life associated with increased grain boundary mismatch, or a combination thereof. In one embodiment, the improved fracture properties meet higher requirements for the essentially single-crystalline article. The improved fracture properties due to the increased boron content meet higher acceptance criteria due to a higher tolerance of the essentially single-crystalline object to large-angle limits. For example, the substantially single-crystal article with the increased boron content contains a substantially single-crystal microstructure that retains or substantially retains fracture toughness (i.e. grain boundary strength and / or creep rupture strength) as the mismatch angle increases.
    In one embodiment, the substantially single-crystalline microstructure of the substantially single-crystal article having the increased boron content retains or substantially retains creep rupture at a grain boundary mismatch of up to 40 degrees. The creep rupture strength of a bicrystalline article containing 90 ppm boron is preserved up to a mismatch of 40 degrees, which proves a reduction or elimination of the shortening of the lifespan with increasing mismatch angle. In contrast, the creep rupture strength of a bicrystalline object without boron increases with an increasing mismatch angle, which proves an increase in the shortening of the tool life. The mismatch angle acceptance criterion of up to 40 degrees is a significant increase compared to today's acceptance criteria, which include, for example, a mismatch of 12 degrees for grain boundaries of an airfoil and a mismatch of up to 18 degrees at other locations on the turbine blade with between 30 and 50 ppm boron.
    The increased mismatch angle acceptance criteria made possible by the increased boron content increases a yield of the substantially single crystalline article by reducing or eliminating scrap of the substantially single crystalline article with up to 40 degree grain boundary mismatch. The increased yield of the substantially single crystalline article increases efficiency and / or lowers manufacturing costs.
    While the invention has been described with reference to one or more embodiments, those skilled in the art will recognize that various changes can be made therein and equivalents for elements thereof can be exchanged without departing from the scope of the invention. In addition, numerous modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the spirit and scope thereof. Therefore, the invention should not be limited to the particular embodiment considered the best mode for carrying out the invention, but the invention includes all embodiments which are within the scope of the appended claims.
    An object and a method for producing a single crystal casting are disclosed. The article contains a single crystal nickel-based superalloy with a composition greater than about 80 ppm boron (B) and a substantially single crystal microstructure with at least one grain boundary. A creep rupture strength of the object is largely preserved up to a grain boundary mismatch of approximately 40 degrees. The method of making a single crystal casting includes positioning a mold on a cooling plate, the mold having a single crystal selector, providing a molten nickel-based superalloy composition in the mold, the molten composition containing more than about 80 ppm boron (B), cooling the molten Composition with the cooling plate and forming a unidirectional temperature gradient by taking the mold from inside a heat source to produce the single crystal casting, which has a substantially single crystal microstructure with at least one grain boundary.
    权利要求:
    Claims (14)
    [1]
    Claims
    1. A single crystal superalloy article comprising:
    a nickel-based superalloy with a composition containing more than 80 ppm boron B;
    wherein the article has a substantially single-crystalline microstructure that has at least one grain boundary, the article has a creep rupture strength that is essentially preserved up to a grain boundary mismatch of 40 degrees.
    [2]
    2. A single crystal superalloy article according to claim 1, further comprising between 80 ppm and 130 ppm boron B, preferably between 80 ppm and 100 ppm boron B.
    [3]
    3. A single crystal superalloy article according to claim 1 or 2, wherein the composition, in weight percent, comprises:
    5.75% to 6.25% chromium Cr;
    7.0% to 8.0% cobalt Co;
    6.2% to 6.7% aluminum AI;
    up to 0.04% titanium Ti;
    6.4% to 6.8% tantalum Ta;
    6.0% to 6.5% Tungsten W;
    1.3% to 1.7% molybdenum Mo;
    0.03% to 0.11% carbon C;
    0.008% to 0.013% boron B;
    0.12% to 0.18% hafnium Hf; and the rest nickel nickel and accidental impurities.
    [4]
    4. The single crystal superalloy article of claim 1 or 2, wherein the composition, in weight percent, comprises:
    9.5% to 10.0% chromium Cr;
    7.0% to 8.0% cobalt Co;
    4.1% to 4.3% aluminum AI;
    3.35% to 3.65% titanium Ti;
    [5]
    5.75% to 6.25% tungsten W;
    1.3% to 1.7% molybdenum Mo;
    4.6% to 5.0% tantalum Ta;
    0.03% to 0.11% carbon C;
    0.008% to 0.013% boron B;
    0.4% to 0.6% niobium Nb;
    0.1% to 0.2% hafnium Hf; and the rest nickel nickel and accidental impurities.
    5. A single crystal superalloy article according to any one of the preceding claims, wherein the article is a hot gas path component of a gas turbine or an aircraft engine and wherein the hot gas path component withstands temperatures of at least 1093.3 ° C, 2000 ° F;
    wherein the hot gas path component can be selected from the group consisting of a moving blade, a guide blade, a nozzle, a seal and a stationary jacket.
    [6]
    6. A single crystal superalloy article according to any one of the preceding claims, further comprising a mismatch angle of grain boundary mismatch of up to 40 degrees.
    [7]
    7. The single crystal superalloy article of claim 6, further comprising small angle boundaries that include up to 10 degrees of mismatch and / or further comprising large angle boundaries that include more than 10 degrees of mismatch.
    [8]
    8. A single crystal superalloy article according to claim 1, wherein the article is directionally solidified.
    [9]
    9. A method of manufacturing a single crystal superalloy article according to claim 1, the method comprising:
    Positioning a mold on a cooling plate, the mold having a single crystal selector;
    Providing the mold inside a heat source;
    Providing the molten nickel-based superalloy composition in the mold;
    Cooling the molten nickel-based superalloy composition with the cooling plate to form crystal nuclei; and
    Forming a unidirectional temperature gradient by taking the shape out of the interior of the heat source;
    the unidirectional temperature causing stem crystals to grow from the crystal seed grains and only one of the stem crystals passes through the single crystal selector into a body portion of the mold to form the single crystal casting.
    [10]
    10. The method of claim 9, wherein more than 100 ppm boron B are provided.
    [11]
    11. The method of claim 9 or 10, wherein the shape is further formed with a starting block between the cooling plate and the single crystal selector, wherein the starting block is columnar.
    [12]
    12. The method according to any one of claims 9-11, wherein the single crystal selector is also formed helically; and / or wherein the single crystal casting is designed as a hot gas path component of a gas turbine or an aircraft engine, the hot gas path component being selected from the group consisting of a moving blade, a guide blade, a nozzle, a seal and a stationary jacket.
    [13]
    13. The method according to any one of claims 9-12, wherein the creep rupture strength, which is substantially preserved up to a grain boundary mismatch of 40 degrees, enables an increased yield of single crystal castings.
    [14]
    14. The method of any one of claims 9-13, further comprising heating the mold to a temperature between 1500 and 1700 ° C.
    类似技术:
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    同族专利:
    公开号 | 公开日
    CH710105A2|2016-03-15|
    JP2016056448A|2016-04-21|
    US20160184888A1|2016-06-30|
    CN105714381A|2016-06-29|
    DE102015114158A1|2016-03-10|
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    法律状态:
    2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/478,258|US20160184888A1|2014-09-05|2014-09-05|Nickel based superalloy article and method for forming an article|
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