• 专利附录
  • 专利说明
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    • 专利摘要:
    The invention relates to methods for repairing a superalloy article. In some embodiments, a method of repairing a nickel-based superalloy article includes providing a layered assembly over a damaged region of the nickel-based superalloy article, the assembly being layers comprising a nickel-based superalloy preform, an infiltration alloy preform and a melting point lowering component. The layered assembly is heated to form a metallurgically bonded nickel-based alloying alloy to the damaged region, the primary carbide and secondary carbide phases being present in the nickel-based alloying alloy in an amount combined 0.5 to 10% by volume.
    公开号:FR3065466A1
    申请号:FR1853354
    申请日:2018-04-17
    公开日:2018-10-26
    发明作者:Qingjun Zheng；Michael Meyer；Martin G. Perez；Abdelhakim Belhadjhamida
    申请人:Kennametal Inc；
    IPC主号:
    专利说明:

    Field
    The present invention relates to methods and compositions for repairing superalloy articles and, in particular, layered assemblies using nickel-based superalloy preforms in conjunction with infiltration alloy preforms.
    Background
    Gas turbine components, including blades and blades, are subjected to stringent operating conditions resulting in damage to the component by one or more mechanisms. Gas turbine components, for example, can suffer damage from cracks due to thermal fatigue, creep, surface degradation by oxidation, hot corrosion and damage. by foreign objects. If left unattended, such damage will necessarily jeopardize the efficiency of the gas turbine and potentially lead to further damage to the turbine.
    In light of such stringent operating conditions, turbine components are often made of a nickel-based or cobalt-based superalloy with high strength and high temperature resistance. The use of superalloy compositions in conjunction with complex design and shape requirements makes it expensive to manufacture a gas turbine. A single stage of blades for an aircraft turbine involves a cost of several tens of thousands of dollars. In addition, for industrial gas turbines, the cost can exceed $ 1 million. Given such a high capital investment, various methods have been developed to repair turbine components, thereby extending the life of the turbine. Solid state bonding, conventional soldering, transient liquid phase bonding (TLP) and wide slot repair processes have been employed in the repair of turbine components. However, each of these techniques is subject to one or more drawbacks. Solid state diffusion bonding, for example, requires costly templates for alignment, application of high pressure, and tight tolerances for assembly surfaces. Such requirements increase the cost and limit the appropriate turbine locations for repair by this method. Conventional brazing results in a weld with a significantly different composition than that of the superalloy component and is prone to the formation of brittle eutectic phases. On the other hand, the transient liquid phase bond (TLP) provides a soldering of composition and micro structure essentially indistinguishable from those of the superalloy component. However, the TLP is limited to damage or structural defects of 50 µm or less. As their name implies, the wide slot repair processes overcome the TLP free space limitations and deal with faults of more than 250 µm. However, the increases in scale offered by the repair of wide slits are counteracted by the use of filler alloy compositions incorporating elements forming brittle intermetallic species with the superalloy component. The wide slit processes further suffer from sintering shrinkage in which the filler alloy separates from the damaged area of the superalloy article. Such separation can produce cracking which is fatal to repair.
    summary
    In one aspect, methods using layered assemblies for repairing superalloy articles and / or an apparatus are described herein. In addition, superalloy items repaired by such layered assemblies are also provided. In some embodiments, for example, a nickel-based superalloy article includes a damaged region and a nickel-based filler alloy metallurgically bonded to the damaged region, the nickel-based filler alloy having a composition of 8 to 15% by weight of chromium, 7 to 14% by weight of cobalt, 0.1 to 5% by weight of molybdenum, 5 to 11% by weight of tungsten, 1 to 5% by weight of tantalum , 2 to 7% by weight of aluminum, 0.1 to 1.5% by weight of boron, 0.1 to 5% by weight of titanium, 0 to 2% by weight of hafnium, 0.05 to 1% by weight of carbon, 0 to 0.5% by weight of yttrium and the balance of nickel, in which primary carbide and secondary carbide phases are present in the nickel-based filler alloy in a combined amount of 0 , 5 to 10% by volume. In some embodiments, the filler alloy may exhibit mechanical properties comparable to the nickel-based superalloy of the article, including tensile strength, ductility and / or fatigue resistance.
    In some embodiments, a method of repairing a nickel-based superalloy article includes providing a layered assembly over a damaged region of the nickel-based superalloy article, the assembly layers comprising a nickel-based superalloy preform, an infiltration alloy preform and a melting point lowering component. The layered assembly is heated to form a nickel-based filler alloy metallurgically bonded to the damaged region, the primary carbide and secondary carbide phases being present in the nickel-based filler alloy in an amount combined from 0.5 to 10% by volume.
    These and other embodiments are further described in the following detailed description.
    Brief description of the drawings
    FIG. 1 is a scanning electron microscopy (SEM) image of the nickel-based filler alloy of Example 1 taken here at an angle of inclination of 70 ° for a diffraction analysis of the backscattered electrons ( EBSD).
    FIG. 2 is a diffraction analysis of the backscattered electrons quantifying the microstructural phases of the nickel-based filler alloy of FIG. 1.
    Figure 3 is a scanning electron microscope image of the nickel-based filler alloy of Example 2 taken here at a tilt angle of 70 ° for a diffraction analysis of the backscattered electrons EBSD.
    Figure 4 is a diffraction analysis of backscattered electrons quantifying the microstructural phases of the nickel-based filler alloy of Figure 3.
    detailed description
    The embodiments described here can be more easily understood with reference to the following detailed description and to the examples and to their preceding and following descriptions. The elements, apparatus and methods described herein, however, are not limited to the specific embodiments presented in the detailed description and the examples. It should be recognized that these embodiments are only given by way of illustration of the principles of the present invention. Numerous modifications and adaptations will be readily apparent to those skilled in the art without detracting from the spirit and scope of the invention.
    I. Repaired superalloy items
    In one aspect, nickel-based superalloy articles comprising one or more damaged regions repaired by a nickel-based filler alloy are described here. The nickel-based filler alloy may become a load-bearing component of the superalloy article and exhibit mechanical properties comparable to the nickel-based superalloy forming the article, including tensile strength, ductility and / or resistance to fatigue. In some embodiments, a nickel-based superalloy article includes a damaged region and a nickel-based filler alloy metallurgically bonded to the damaged region, the nickel-based filler alloy having a composition from 8 to 15% by weight of chromium, 7 to 14% by weight of cobalt, 0.1 to 5% by weight of molybdenum, 5 to 11% by weight of tungsten, 1 to 5% by weight of tantalum, 2 to 7% by weight of aluminum, 0.1 to 1.5% by weight of boron, 0.1 to 5% by weight of titanium, 0 to 2% by weight of hafnium, 0.05 to 1% by weight of carbon, 0 to 0.5% by weight of yttrium and the balance of nickel, in which primary carbide and secondary carbide phases are present in the nickel-based filler alloy in a combined amount of 0.5 to 10% by volume. In certain embodiments, the nickel-based filler alloy has a composition chosen from Table I.
    Table I - Composition of nickel-based filler alloy
    Alloyinput Ni (%inweight) Cr (% inweight) Co (% inweight) MB (%inweight) W (%inweight) Ta (%inweight) Al (%inweight) B (%inweight) Ti (%inweight) Hf (%inweight) C (% inweight) Y (%inweight) 1 Balance 9 to 13 8 to 12 0.1 to 1 6 to 10 1.5 to 4 3 to 6 0.4 to 0.9 0.3 to 1 0.3 to 2 0.05 to 0.5 0 to 0.3 2 Balance 10 to 12 9 to 11 0.3 to 0.5 5 to 7 2 to 3 4 to 5 0.5 to 0.8 0.5 to 0.8 0.6 to 1 0.05 to 0.2 0 to 0.1
    As described herein, the nickel-based filler alloy may include primary carbide and secondary carbide phases in a combined amount of 0.5 to 10% by volume. The percentage by volume of the primary and secondary carbide phases can be determined by backscattered electron diffraction (EBSD) and scanning electron microscopy (SEM). An energy dispersive X-ray analysis (EDS) can also be used for additional quantification of the primary and secondary carbide phases of the nickel-based filler alloy. In certain embodiments, secondary carbides M23C6 are present in the filler alloy in an amount of 0.1 to 5% by volume, in which M is one or more transition metals chosen from the group consisting of chromium, molybdenum and tungsten. Secondary M23C6 carbides may also be present in the nickel-based filler alloy in an amount selected from Table II.
    Table II - MnC (, of the Ni-based filler alloy (% by volume)
    M23C6 carbides are generally present at the grain boundaries of the nickel matrix and may have a globular morphology. In some embodiments, the M23C6 carbides are present as a chain of discontinuous globules along grain boundaries of the nickel matrix. In other embodiments, the M23C6 carbides may have other morphologies such as platelets, coverslips, sheets and / or cell structures. By being located at the grain boundaries, M23C6 carbides can be used to increase resistance to thermal creep by braking or preventing grain from sliding.
    Primary carbides may also be present in the nickel-based filler alloy. In certain embodiments, primary MeC carbides are present in an amount of 0.5 to 5% by volume, in which Me is selected from the group consisting of titanium, tantalum and hafnium. Primary MeC carbides may also be present in the nickel-based filler alloy in an amount selected from Table III.
    Table III- MC of Ni-based filler alloy (% by volume)
    Primary MeC carbides can be distributed heterogeneously over the entire nickel matrix, existing at the grain boundaries and / or within the grains of the nickel matrix. The metals (Me) of the primary carbides can be chosen to have a higher affinity for carbon by comparison with the metals (M) of the carbides M23C6. In such embodiments, the primary carbide metals can inhibit or prevent excessive precipitation of the grain boundaries of the M23C6 carbides. By regulating the precipitation of grain boundaries of M23C6 carbides, advantageous properties of tensile strength and ductility can be obtained. Depending on the infiltration conditions used to form the nickel-based filler alloy, the primary MeC carbides may be present in the nickel-based filler alloy in an amount greater than the secondary M23C6 carbides. Alternatively, the secondary M23C6 carbides are present in an amount greater than the primary MeC carbides. The nickel-based filler alloy, in certain embodiments, also includes a C2Cr3 phase. The C2Cr3 phase can exist at the grain boundaries and / or within the grains of the nickel matrix. The C2Cr3 phase can generally be present in the nickel-based filler alloy in an amount of 1 to 6% by volume. In some embodiments, the C2Cr3 phase is present in an amount of 3 to 5% by volume or 2 to 4% by volume. The microstructure of the nickel-based filler alloy can also be devoid or essentially devoid of brittle precipitates of metal boride, including various chromium borides [CrB, (Cr, W) B, Cr (B, C) , GyBs] and / or nickel borides such as N13B. In addition, the nickel-based filler alloy may be completely dense or substantially completely dense. By being substantially completely dense, the filler alloy may have less than 5 percent by volume of porosity.
    The nickel-based filler alloy, in some embodiments, has a tensile strength at break (ots) at elevated temperature of at least 30% of the ots for the nickel-based superalloy forming l 'article. In some embodiments, the ots of the nickel-based filler alloy is at least 50% or at least 60% of the ots of the superalloy article. For example, the ots of the nickel-based filler alloy can be 50 to 70% of the ots of the superalloy article. In addition, the nickel-based filler alloy, in certain embodiments, can have a% elongation of at least 2 at high temperature. In certain embodiments, the nickel-based filler alloy has a% elongation chosen in Table IV.
    Table IV -% elongation of the Ni-based filler alloy
    The ots and% elongation of the nickel-based filler alloy described here can be determined according to ASTM E21 - Standard test procedures for high temperature tensile testing of metallic materials.
    As described herein, the nickel-based filler alloy is metallurgically bonded to a damaged region of the nickel-based superalloy article. In some embodiments, the damaged region includes one or more dimensions exceeding 1 mm, 5 mm, or 10 mm. The damaged region, for example, can be a deep crater or a deep slit in a surface of the nickel-based superalloy article. In other embodiments, the damaged region may be a hole extending through a surface or wall of the nickel-based superalloy article. In some embodiments, an interfacial transition region can be established between the nickel-based filler alloy and the nickel-based superalloy article. The interfacial transition region may have a micro structure which differs from the filler alloy and the nickel-based superalloy article. The interfacial transition region, in some embodiments, is devoid or essentially devoid of brittle precipitates of metal boride, including the chromium boride and nickel boride species described above. For example, less than 0.5% by weight of metal boride precipitates is considered to be essentially free of such precipitates in the interfacial transition region. An interfacial transition region, in some embodiments, is 20 to 150 µm thick.
    Following metallurgical bonding of the nickel-based filler alloy over the damaged area, the repaired nickel-based superalloy article may be subjected to additional treatments, including dissolution and heat aging. In some embodiments, a protective refractory coating may be applied to the repaired nickel-based superalloy part. For example, a protective refractory coating may include one or more metallic elements chosen from the group consisting of aluminum and metallic elements from Groups IVB, VB and VIB of the periodic table and one or more non-metallic elements chosen from Groups ΠΙΑ, IVA, VA and VIA from the periodic table. A protective refractory layer may comprise a carbide, nitride, carbonitride, oxycarbonitride, oxide or boride of one or more metallic elements chosen from the group consisting of aluminum and metallic elements from Groups IVB, VB and VIB of the periodic table. For example, one or more protective layers can be chosen from the group consisting of titanium nitride, titanium carbonitride, titanium oxycarbonitride, titanium carbide, zirconium nitride, zirconium carbonitride, hafnium nitride, hafnium carbonitride, and alumina, and mixtures thereof.
    II. Superalloy article repair methods
    In another aspect, methods of repairing superalloy article are provided. A method of repairing a nickel-based superalloy article includes providing a layered assembly over a damaged region of the nickel-based superalloy article, the layered assembly comprising a superalloy preform based on nickel, an infiltration alloy preform and a melting point lowering component. The layered assembly is heated to form a nickel-based filler alloy metallurgically bonded to the damaged region, the primary carbide and secondary carbide phases being present in the nickel-based filler alloy in an amount combined from 0.5 to 10% by volume. The nickel-based filler alloy can have any composition, microstructure and / or properties described in Section I here.
    Turning now to the specific components, the nickel-based superalloy preform may include one or more nickel-based superalloy powders. For example, a suitable nickel-based superalloy powder may be of similar composition or compatible with one or more nickel-based superalloys employed in the manufacture of gas turbine components, such as blades and vanes. In certain embodiments, the nickel-based superalloy powders have composition parameters falling within the nickel-based superalloy classes of conventionally cast alloys, directionally solidified alloys, first generation monocrystalline alloys, second generation monocrystalline alloys, third generation monocrystalline alloys, forged superalloys and / or powder treated superalloys. In some embodiments, a nickel-based superalloy powder has a composition of 0.05 to 0.2% by weight of carbon, 7 to 9% by weight of chromium, 8 to 11% by weight of cobalt, 0 , 1 to 1% by weight of molybdenum, 9 to 11% by weight of tungsten, 3 to 4% by weight of tantalum, 5 to 6% by weight of aluminum, 0.5 to 1.5% by weight of titanium , less than 0.02% by weight of boron, less than 0.02% by weight of zirconium, less than 2% by weight of hafnium and the balance of nickel. In several specific embodiments, the nickel-based superalloy powder component can include an alloy powder selected from Table V.
    Table V - Composition of nickel-based superalloy powder (% by weight)
    Powderalloy Or VS Cr Co Mo W Your Al Ti B Zr Hf 1 Balance 0.05 to 0.1 7 to 9 8 to 10 0.1 to 1 9 to 11 3 to 4 5 to 6 0.5 to 1 0.01 to 0.02 0.005 to 0.02 1 to 2 2 Balance 0.1 to 0.2 8 to 9 9 to 11 0.5 to 1 9 to 11 3 to 4 5 to 6 0.5 to 1.5 0.01 to 0.02 0.01 to 0.1 1 to 2 3 Balance 0.1 to 0.2 12 to 15 8 to 11 3 to 5 3 to 5 - 2 to 4 4 to 6 0.01 to 0.03 0.02 to 0.04 - 4 Balance 0.1 to 0.2 14 to 17 9 to 11 8 to 10 - - 3 to 5 3 to 5 0.005 to 0.02 - - 5 Balance 0.05 to 0.15 11 to 14 8 to 10 1 to 3 3 to 5 3 to 5 3 to 5 3 to 5 0.01 to 0.03 0.05 to 0.07 0.5 to 2 6 Balance - 9 to 11 4 to 6 - 3 to 5 11 to 13 4 to 6 1 to 3 - - - 7 Balance 0.05 to 0.08 12 to 14 7 to 9 3 to 5 3 to 5 3 to 5 (Nb) * 3 to 5 2 to 4 0.01 to 0.02 0.04 to 0.06 - 8 Balance 0.02 to 0.04 15 to 17 12 to 14 3 to 5 3 to 5 0.6 to0.8(Nb) * 1 to 3 3 to 5 0.01 to 0.02
    * Nb replacing Ta
    A suitable nickel-based superalloy powder for the preform, in some embodiments, is commercially available from various gas turbine manufacturers. Additional commercially available nickel-based superalloy powder for use in a preform described herein may include Mar M247, Rene 108 or CM247 LC. In certain embodiments, the nickel-based superalloy powder of a preform has a composition chosen from Table 1 listed in Bouse et al, Optimizing Rene N4 Alloy for DS AFT-Stage Bucket Applications in Industrial Gas Turbines, Superalloys 2008 , TMS (The Minerais, Metals and Materials Society) 2008, pages 99 to 108.
    The nickel-based superalloy powder of the preform can have any desired particle size. The particle size can be chosen according to various criteria including, but not limited to, the dispersibility in a fibrous polymer matrix, the packing characteristics and / or the specific surface for interaction and / or reaction with the alloy component to be brazed. based on nickel. In some embodiments, for example, the nickel-based superalloy powder has an average particle size of 10 µm to 100 µm or 30 µm to 70 µm. In some embodiments, the nickel-based superalloy powder is present in the layered assembly in an amount of 45 to 95 percent by weight of the layered assembly. In some embodiments, the nickel-based superalloy powder is present in the layered assembly in an amount selected from Table VI.
    Table VI - Nickel-based superalloy powder in a layered assembly (% by weight)
    In addition to the nickel-based superalloy preform, a layered assembly includes an infiltration alloy preform. An infiltration alloy preform, in some embodiments, includes a nickel-based solder alloy powder. Any nickel-based brazing alloy powder which is not incompatible with the objectives of the present invention can be used. For example, a suitable nickel-based brazing alloy powder may have a lower melting point than the nickel-based superalloy powder of the layered assembly. In some embodiments, a nickel-based brazing alloy powder has a melting point at least 100 ° C lower than the nickel-based superalloy powder. In a specific embodiment, the nickel-based brazing alloy powder can include an alloy powder having the composition presented in Table VII.
    Table VII - Composition of nickel-based brazing alloy powder (% by weight)
    Powderalloy Or VS Cr Co Mo Fe Your Al Ti B Zr Mn 1 Balance 0.01at0.03 14 to 17 9 to 12 0.005 to 0.02 0.05 to 0.2 2 to 5 2 to5 0.005 to 0.02 1.5 to 3 0.05 to 0.2 0.005 to 0.02
    A nickel-based brazing alloy powder having the composition meeting the parameters of Table VII is commercially available under the trade designation Amdry D15.
    Additional suitable nickel-based brazing alloy powders can be selected from the Amdry range and other commercially available powders. In other embodiments, the nickel-based brazing alloy powder has the composition of Table VIII.
    Table VIII - Component of nickel brazing alloy
    Powderalloy Ni% by weight Co% by weight Cr% by weight B% by weight Ta% by weight Al% by weight Y% by weight 1 Balance 5 to 15 10 to 20 1 to 4 0 to 5 0 to 5 0 to 0.1 2 Balance 7 to 12 10 to 15 2 to 3 2 to 3 2.5 to 5 0 to 0.1
    A nickel-based brazing alloy powder having the composition meeting the parameters of Table VIII is commercially available under the trade designation DF4B. The nickel-based brazing alloy powder of the composite preform can have any desired particle size. The particle size can be chosen according to various criteria including, but not limited to, the dispersibility in a fibrous polymer matrix, the packing characteristics and / or the specific surface for interaction and / or reaction with the superalloy powder based on nickel. In some embodiments, for example, the nickel-based solder alloy powder has an average particle size of 10 µm to 150 µm or 40 µm to 125 µm. In addition, the nickel-based brazing alloy powder is generally present in an amount of 10 to 45 percent by weight of the layered assembly. In certain embodiments, the nickel-based brazing alloy powder is generally present in layers in an amount chosen from Table IX.
    Table IX - Nickel-based solder powder of the whole layer (% by weight) at 40 to 35 to 30
    A layered assembly can include any number of nickel-based superalloy preforms and infiltration alloy preforms. For example, a layered assembly may include two or more nickel-based superalloy preforms and / or two or more infiltration alloy preforms, arranged in any manner. The number of superalloy and / or infiltration alloy preforms can be chosen according to various considerations including the size and properties of the damaged area and the desired composition properties of the nickel-based filler alloy formed. heating the whole in layers.
    As described herein, the layered assembly includes a melting point lowering component in addition to the nickel-based superalloy preform and the nickel-based brazing alloy preform. Any melting point lowering agent which is not incompatible with the objectives of the present invention can be used. For example, a suitable melting point lowering agent can include boron, magnesium, hafnium, zirconium, MgNi 2 , silicon or combinations thereof. Generally, the melting point lowering component is present in an amount of 0.2 to 5 percent by weight of the layered assembly. In some embodiments, the melting point lowering component comprises boron in an amount of 0.2 to 2 percent by weight of the layered assembly. Boron, in some embodiments, is the only species of the melting point lowering component. Alternatively, boron can be combined with one or more additional species of melting point lowering agents. For example, boron can be combined with silicon, hafnium or MgNÎ2 to provide the melting point lowering component.
    The melting point lowering component, in some embodiments, is part of the nickel-based solder alloy powder and / or the nickel-based superalloy powder. The nickel-based brazing alloy and / or the nickel-based superalloy may incorporate the melting point lowering agent as part of the alloy composition. For example, the nickel-based brazing alloy powder can be chosen to contain boron, silicon and / or hafnium to serve as a melting point lowering component. In such embodiments, the nickel-based brazing alloy powder and the nickel-based superalloy powder are present in the layered assembly at a ratio to provide the desired amount of lowering agent melting point. For example, the nickel-based brazing alloy powder and the nickel-based superalloy powder may be present in the layered assembly at a ratio of 1: 1.5 to 1: 2. Alternatively, the melting point lowering component can be supplied to the layered assembly independently of the nickel-based superalloy powder and / or the nickel-based brazing alloy powder. For example, powder of melting point lowering agent can be added to the nickel-based brazing alloy preform and / or to the nickel-based superalloy preform.
    In addition, in certain embodiments, the nickel-based superalloy preform may also comprise an amount of nickel-based brazing alloy powder. For example, the nickel-based superalloy preform may comprise nickel-based solder alloy powder in an amount of 0.1 to 10 percent by weight of the layered assembly. Similarly, the nickel-based brazing alloy preform may include an amount of nickel-based superalloy powder. In some embodiments, the nickel-based brazing alloy preform may comprise a nickel-based superalloy powder in an amount of 0.1 to 10 percent by weight of the layered assembly.
    In some embodiments, preforms of nickel-based superalloy and infiltration alloy can be produced as follows. The desired powder alloy composition (for example Ni-based superalloy powder and / or Ni-based brazing alloy powder) can be combined with an organic support for application to one or more damaged surfaces of a superalloy item. Any organic support which is not incompatible with the objectives of the present invention can be used, including solid and liquid supports. In some embodiments, an organic carrier suitable for the powdered alloy composition comprises a fibrous polymer matrix. As detailed further in the examples below, the fibrous polymer matrix can form a flexible fabric in which the powdered alloy composition is dispersed. The flexible polymeric fabric can have any thickness which is not incompatible with the objectives of the present invention. For example, the flexible polymeric fabric can generally have a thickness of 0.2 to 4 mm or from 1 to 2 mm. Any polymer species which can be used to adopt a fiber or filament morphology can be used in the construction of the matrix. Suitable polymeric species can include fluoropoymers, polyamides, polyesters, polyolefins or mixtures thereof. In some embodiments, for example, the fibrous polymer matrix is formed of fibrillar polytetrafluoroethylene (PTLE). In such embodiments, the PTLE fibers or fibrils can provide an interconnected network matrix in which the powdered alloy composition is dispersed and trapped. In addition, the fibrillar PTLE can be combined with other polymeric fibers, such as polyamides and polyesters to modify or shape the properties of the fibrous matrix. The fibrous polymer matrix generally represents less than 1.5 percent by weight of the preform. In some embodiments, for example, the fibrous polymer matrix represents 1.0 to 1.5 percent by weight or 0.5 to 1.0 percent by weight of the nickel-based superalloy preform or the preform infiltration alloy.
    The preform can be manufactured by various techniques to disperse the powdered alloy composition in the fibrous polymer matrix. In certain embodiments, the preform is made by combining a polymer powder and a nickel-based superalloy powder and / or a nickel-based brazing alloy powder and mechanically working the mixture to fibrillate the polymer powder and trapping the alloy powder (s) in the resulting fibrous polymer matrix. In a specific embodiment, for example, the powdered alloy composition is mixed with 3 to 15% by volume of PTLE powder and mechanically worked to fibrillate the PTLE and trap the powdered alloy composition in a fibrous matrix of PTLE. As described here, the nickel-based superalloy powder may have a composition selected from Table IV here to produce a preform of nickel superalloy. Similarly, a nickel-based brazing alloy can have a composition chosen from Tables VI and VII here to produce a pre-forming alloy for infiltration. The mechanical work of the powder mixture can include ball milling, rolling, drawing, stretching, extruding, spreading or combinations thereof. In some embodiments, the resulting flexible composite PTFE preform fabric is subjected to cold isostatic pressing. A preform described herein can be produced in accordance with the description of one or more of U.S. patents 3,743,556, 3,864,124, 3,916,506, 4,194,040 and 5,352,526.
    In some embodiments, a nickel-based superalloy prefab described herein may have a raw density of at least 50 percent of the density of the superalloy article being repaired. In some embodiments, the raw density of the nickel-based superalloy preform is 50 to 75 percent or 60 to 70 percent of the density of the superalloy article.
    A layered assembly is formed by placing the preforms of nickel-based superalloy and infiltration alloy over the damaged region of the nickel-based superalloy article. In some embodiments, an infiltration alloy preform is disposed over the nickel-based superalloy preform so that the nickel-based brazing alloy infiltrates the superalloy-based particles. nickel during heating. In other embodiments, a nickel-based superalloy preform is disposed over an infiltration alloy preform. The surface of the nickel-based superalloy article can be cleaned by chemical and / or mechanical means before applying a layered assembly, for example, by fluoride ion cleaning and / or sanding. Additionally, one or more adhesives can be used to secure the preforms over the damaged area of the nickel-based superalloy article.
    Following application to the damaged area of the nickel-based superalloy article, the layered assembly is heated to form a filler alloy bonded metallurgically to the damaged area. Heating of the assembly decomposes the polymeric fibrous matrix, and the filler alloy is formed from the nickel-based superalloy powder and the nickel-based brazing alloy from the preforms. The assembly is generally heated to a temperature above the melting point of the nickel-based brazing alloy powder and below the melting point of the nickel-based superalloy powder. For this reason, the nickel-based brazing alloy powder is melted by forming the filler alloy with the nickel-based superalloy powder, the filler alloy being metallurgically bonded to the workpiece. nickel-based superalloy. The molten flow characteristics of the nickel-based brazing alloy can allow the formation of an interface devoid of empty spaces between the filler alloy and the nickel-based superalloy part. The heating temperature and the heating time period depend on the specific composition parameters of the nickel-based superalloy part and the layered assembly. In certain embodiments, for example, the assembly is heated under vacuum to a temperature of 1180 to 1250 ° C. for a period of time from 1 to 4 hours. In some embodiments, the assemblies can be held at 800 to 1000 ° C for a period of 0.5 to 5 hours following heating to the maximum temperature. The resulting filler alloy can have any composition, microstructural and / or mechanical properties described in Section I above. Following a metallurgical bonding of the filler alloy over the damaged area, the repaired nickel-based superalloy part can be subjected to additional treatments, including dissolution and aging. heat.
    These and other embodiments are further illustrated in the following nonlimiting examples.
    Example 1 - Nickel based filler alloy
    A nickel-based filler alloy plate was formed from a layered assembly described here as follows. A powder composition comprising nickel-based superalloy powder having the parameters of alloy powder 1 in Table V (René '108) and nickel-based brazing alloy powder having the parameters of Alloy powder 2 from Table VIII was provided. The nickel-based superalloy formed 99% by weight of the powder composition, the remaining amount of 1% by weight being formed by the nickel-based brazing alloy.
    The powder composition was mixed with 5 to 15% by volume of powdered PTFE. The resulting mixture was mechanically worked to fibrillate the PTFE and trap the nickel-based superalloy powder and the nickel-based brazing alloy powder, and then laminated, thereby forming the nickel-based superalloy preform as flexible sheet of fabric type, thickness 1 to 2 mm. This process was repeated to form the infiltration alloy preform, the difference being that the powder composition mixed with PTFE comprised 99% by weight of nickel-based brazing alloy powder and 1% by weight of nickel-based superalloy.
    The nickel-based superalloy preform was placed over a graphite base substrate. The infiltration alloy preform was placed on top of the nickel-based superalloy preform to complete the layered assembly. The nickel-based superalloy powder was present in the layered assembly in an amount of 66 to 68% by weight, and the nickel-based brazing alloy powder was present in the layered assembly in an amount from 32 to 34% by weight.
    The layered assembly was heated in a vacuum oven to 1190 to 1200 ° C for a period of 2 hours followed by heating to 1080 at 1090 ° C for two hours. Heating was subsequently maintained at 870-880 ° C for a period of 4 hours before cooling. The resulting nickel-based filler alloy plate was laser cut to 10 x 10 cm (4 x 4 inches) and disc ground to 0.102 cm (0.040 in). Figure 1 is a scanning electron microscope image of the plate taken at an angle of inclination of 70 ° for diffraction analysis of backscattered electrons. The arrows in the scanning electron microscope image correspond to the arrows detailing various microstructural phases in the diffraction image of the backscattered electrons in Figure 2. As shown in Figure 2, a primary carbide of TiC and a secondary carbide of C ^ Co were present along the grain boundaries of the nickel matrix. TiC has also been found within grains of the nickel matrix. The C 2 Cr 2 phase was also present within the grains of the nickel matrix and along the boundaries of the grains of the matrix. The volume percentages of the various phases are provided in Table X.
    Table X - Phases of the nickel-based filler alloy
    Phase % in volume Tic 3.38 Cr 26 C 3 2.39 C 2 Cr 3 3.15 Ni Matrix 86.5
    The nickel-based filler alloy plate was tested to determine the tensile strength and% elongation at elevated temperature [982 ° C (1800 ° F)] according to ASTM E21.
    The results are provided in Table XI.
    Table XI - Traction and% elongation
    Tensile strength at break (σ Τ8 ), MPa (ksi) Percentage of o TS de Rene '108 % elongation 210 (30.4) 37.2 3
    As shown in Table X, the ots of the nickel-based filler alloy was 37.2 percent of the ots for René '108.
    Example 2 - Nickel based filler alloy
    A nickel-based filler alloy plate was formed from a layered assembly described here as follows. A powder composition comprising nickel-based superalloy powder having the parameters of Alloy powder 2 in Table V (Mar M247) and nickel-based brazing alloy powder having the parameters of Powder alloy 2 of Table VIII was provided. The nickel-based superalloy formed 99% by weight of the powder composition, the remaining amount of 1% by weight being formed by the nickel-based brazing alloy.
    The powder composition was mixed with 5 to 15% by volume of powdered PTFE. The resulting mixture was mechanically worked to fibrillate the PTFE and trap the nickel-based superalloy powder and the nickel-based brazing alloy powder, and then laminated, thereby forming the nickel-based superalloy preform as flexible sheet of fabric type, thickness 1 to 2 mm. This process was repeated to form the infiltration alloy preform, the difference being that the powder composition mixed with PTFE comprised 99% by weight of nickel-based brazing alloy powder and 1% by weight of nickel-based superalloy.
    The nickel-based superalloy preform was placed over a graphite base substrate. The infiltration alloy preform was placed on top of the nickel-based superalloy preform to complete the assembly in layers. The nickel-based superalloy powder was present in the layered assembly in an amount of 66 to 68% by weight, and the nickel-based brazing alloy powder was present in the layered assembly in an amount from 32 to 34% by weight.
    The layered assembly was heated in a vacuum oven at 1190 to 1200 ° C for a period of 2 hours followed by heating at 1080 at 1090 ° C for two hours. The heating was subsequently maintained at 870-880 ° C for a period of 4 hours before cooling. The resulting nickel-based filler alloy plate was laser cut to 10 x 10 cm (4 x 4 inches) and disc ground to 0.102 cm (0.040 in). Fa Figure 3 is a scanning electron microscope image of the plate taken at an angle of inclination of 70 ° for analysis by diffraction of the backscattered electrons. The arrows in the scanning electron microscope image correspond to the arrows detailing various microstructural phases in the diffraction image of the backscattered electrons in Figure 4. As shown in Figure 4, a primary carbide of TiC and a secondary carbide of Ci ^ Cf, were present along the grain boundaries of the nickel matrix. TiC has also been found within grains of the nickel matrix. Fa CtCi'î phase was also present within the grains of the nickel matrix and along the joints of the grains of the matrix. The volume percentages of the various phases are provided in Table XII.
    Table XII - Phases of the nickel-based filler alloy
    Phase % in volume Tic 1.09 Cr 26 C 3 2.88 C 2 Cr 3 4.32 Ni Matrix 86.8
    The nickel-based filler alloy plate was tested to determine the tensile strength and% elongation at high temperature [982 ° C (1800 ° F)] according to ASTM E21. The results are provided in Table ΧΠΙ.
    Table XIII - Traction and% elongation
    Tensile strength at break (ots), MPa (ksi) Percentage of o r s of Mar M247 % elongation 220 (32) 35.3 8 to 10
    As shown in Table IX, the ots of the nickel-based filler alloy was 10 35.3 percent of the ots for Mar M247.
    Various embodiments of the invention have been described to satisfy the various objects of the invention. It should be recognized that these embodiments are only given by way of illustration of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without detracting from the spirit and scope of the invention.
    权利要求:
    Claims (10)
    [1" id="c-fr-0001]
    1. A nickel-based superalloy article comprising:
    a damaged area; and a nickel-based filler alloy metallurgically bonded to the damaged region, the nickel-based filler alloy having a composition of 8 to 15% by weight of chromium, 7 to 14% by weight of cobalt , 0.1 to 5% by weight of molybdenum, 5 to 11% by weight of tungsten, 1 to 5% by weight of tantalum, 2 to 7% by weight of aluminum, 0.1 to 1.5% by weight of boron, 0.1 to 5% by weight of titanium, 0 to 2% by weight of hafnium, 0.05 to 1% by weight of carbon, 0 to 0.5% by weight of yttrium and the balance of nickel , in which primary carbide and secondary carbide phases are present in the nickel-based filler alloy in a combined amount of 0.5 to 10% by volume.
    [2" id="c-fr-0002]
    2. A nickel-based superalloy article according to claim 1, wherein the nickel-based filler alloy is of composition 10 to 12% by weight of chromium, 9 to 11% by weight of cobalt, 0.3 to 0.5% by weight of molybdenum, 5 to 7% by weight of tungsten, 2 to 3% by weight of tantalum, 4 to 5% by weight of aluminum, 0.5 to 0.8% by weight of boron , 0.5 to 0.8% by weight of titanium, 0.6 to 1% by weight of hafnium, 0.05 to 0.2% by weight of carbon, 0 to 0.1% by weight of yttrium and the nickel balance.
    [3" id="c-fr-0003]
    3. A nickel-based superalloy article according to claim 1, wherein secondary M23C6 carbides are present in an amount of 1.5 to 4% by volume of the nickel-based filler alloy.
    [4" id="c-fr-0004]
    4. A nickel-based superalloy article according to claim 1, wherein secondary MzjCô carbides are present in an amount of 2 to 3% by volume of the nickel-based filler alloy.
    [5" id="c-fr-0005]
    5. A nickel-based superalloy article according to claim 3, wherein M is one or more transition metals selected from the group consisting of chromium, molybdenum and tungsten.
    [6" id="c-fr-0006]
    6. A nickel-based superalloy article according to claim 3, wherein primary MeC carbides are present in an amount of 0.5 to 5% by volume of the nickel-based filler alloy.
    5
    [7" id="c-fr-0007]
    7. A nickel-based superalloy article according to claim 6, wherein
    Me is chosen from the group consisting of titanium, tantalum and hafnium.
    [8" id="c-fr-0008]
    8. A nickel-based superalloy article according to claim 6, wherein the nickel-based filler alloy further comprises a C2Cr3 phase.
    [9" id="c-fr-0009]
    9. A nickel-based superalloy article according to claim 1, wherein the tensile strength of the nickel-based filler alloy is 50 to 70% of the tensile strength of the superalloy article nickel base according to ASTM E21 Standard test procedures for high temperature tensile testing of materials
    15 metallic.
    [10" id="c-fr-0010]
    10. A nickel-based superalloy article according to claim 9, wherein the nickel-based filler alloy has an elongation of at least 2 percent according to ASTM E21 - Standard test procedures for temperature tensile testing
    20 high metallic materials.
    1/4
    SEI733X 30 kV
    IM μτη
    2/4
    3/4
    SH'U31X30kV
    4/4
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    同族专利:
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    CA2991819A1|2018-10-20|
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    CN108728694A|2018-11-02|
    US20180304420A1|2018-10-25|
    DE102018108175A1|2018-10-25|
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    优先权:
    申请号 | 申请日 | 专利标题
    US15492413|2017-04-20|
    US15/492,413|US10967466B2|2017-04-20|2017-04-20|Layered assemblies for superalloy article repair|
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