A casting method includes forming a seed. The seed has a first end and a second end. The forming includes bending a seed precursor. The seed second end is placed in contact or spaced facing relation a chill plate. The first end is contacted with molten material. The molten material is cooled and solidifies so that a crystalline structure of the seed propagates into the solidifying material. The forming further includes inserting the bent seed precursor into a sleeve leaving the bent seed precursor protruding from a first end of the sleeve.

A superalloy powder mixture is provided for use with additive manufacturing or welding metal components or portions thereof. The superalloy powder mixture includes at least 51% by weight a high melt superalloy powder and at least 5% by weight a low melt superalloy powder. The low melt superalloy powder may have a solidus temperature lower than the solidus temperature of the high melt superalloy powder by between 50° C. and 220° C. Each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture may have a nickel content by weight greater than 40% and may have an aluminum content by weight of greater than 1.5%. The low melt superalloy powder may include at least 5% by weight of tantalum, and the high melt superalloy powder may include less than half the content by weight percent of tantalum compared to the content by weight percent of tantalum in the low melt superalloy powder.

A method is provided that facilitates additive manufacturing a superalloy component using a liquid assisted additive manufacturing process. The method includes successively depositing and fusing together layers of a superalloy powder mixture comprising a high melt superalloy powder and a low melt superalloy powder to build up an additive portion of the superalloy component. The method may further include heat treating the additive portion to form a homogenized base alloy of which the additive portion is comprised, which base alloy has a chemistry defined by the superalloy powder mixture. Each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture may have a nickel content by weight greater than 40% and have an aluminum content by weight of greater than 1.5%. The low melt superalloy powder may include at least 5% by weight of tantalum, and the high melt superalloy powder may include less than half the content by weight percent of tantalum compared to the content by weight percent of tantalum in the low melt superalloy powder.

A high melt superalloy powder mixture is provided for use with additive manufacturing or welding metal components or portions thereof. The high melt superalloy powder may include by weight about 7.7% to about 18% chromium, about 10.6% to about 11% cobalt, about 4.5% to about 6.5% aluminum, about 10.6% to about 11% tungsten, about 0.3% to about 0.55% molybdenum, about 0.05% to about 0.08% carbon, and at least 40% nickel.

A wire is provided for additive manufacturing a superalloy component using a liquid assisted additive manufacturing process. The wire has an elongated body that includes therein a superalloy powder mixture including at least 51% by weight a high melt superalloy powder and at least 5% by weight a low melt superalloy powder. The low melt superalloy powder may have a solidus temperature lower than the solidus temperature of the high melt superalloy powder by between 50° C. and 220° C. Each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture may have an aluminum content by weight of greater than 1.5%. The low melt superalloy powder may include at least 5% by weight of tantalum, and the high melt superalloy powder may include less than half the content by weight percent of tantalum compared to the content by weight percent of tantalum in the low melt superalloy powder.

A nickel-based superalloy composition including by weight percent: Cobalt 7.5; Chromium 9.75; Aluminum 5.45; Titanium 1.0; Niobium 3.5; Tungsten 6.0; Molybdenum 1.5; Carbon 0.08; Hafnium 0.15; Boron 0.01; and Nickel 65.0; and incidental impurities.

A nickel-based alloy composition consisting, in weight percent, of: between 5.0% and 6.9% aluminium, between 0.0% and 11.0% cobalt, between 6.0% and 11.6% chromium, between 0.0% and 4.0% molybdenum, between 0.0% and 2.0% niobium, between 0.6 and 8.6% tantalum, between 0.0% and 3.0% titanium, between 8.4% and 15.2% tungsten, between 0.02 wt. % and 0.35 wt. % carbon, between 0.001 and 0.2 wt. % boron, between 0.001 wt. % and 0.5 wt. %. zirconium, between 0.0 and 0.5% silicon, between 0.0 and 0.1% yttrium, between 0.0 and 0.1% lanthanum, between 0.0 and 0.1% cerium, between 0.0 and 0.003% sulphur, between 0.0 and 0.25% manganese, between 0.0 and 0.5% copper, between 0.0 and 2.0% hafnium, between 0.0 and 1.0% vanadium, between 0.0 and 4.0% iron, between 0.0 and 1.0% rhenium, the balance being nickel and incidental impurities, wherein the following equations are satisfied in which W.sub.Nb, W.sub.Ta, W.sub.Ti, W.sub.Cr, W.sub.Mo, W.sub.W and W.sub.Re are the weight percent of niobium, tantalum, titanium, chromium, molybdenum, tungsten and rhenium in the alloy respectively 6.6≤2W.sub.Ti+W.sub.Ta+1.44W.sub.Nb, 22.2≥W.sub.W+W.sub.Re+1.16 W.sub.Cr+1.7W.sub.Mo, 13.9≤W.sub.Mo+1.17(W.sub.W+3.3W.sub.Re).

A turbine component includes a substrate made from monocrystalline nickel-based superalloy including rhenium, which has a γ-γ′ Ni phase, and an average weight faction of chromium of less than 0.08, a sublayer made from nickel-based metal superalloy covering the substrate, in which the sublayer made from metal superalloy includes at least aluminium, nickel, chromium, silicon, hafnium and has, predominantly by volume, a γ′-Ni 3 Al phase.

A nickel-based superalloy includes, in weight percent, 6 to 8% aluminum, 12 to 15% cobalt, 4 to 8% chromium, 0 to 0.2% hafnium, 0.5 to 4% molybdenum, 3.5 to 6% rhenium, 4 to 6% tantalum, 1 to 3% titanium, 0 to 2% tungsten, 0 to 0.1% silicon, the balance being nickel and unavoidable impurities.

A nickel-based superalloy includes, in weight percent, 4 to 6% aluminum, 5 to 8% cobalt, 6 to 9% chromium, 0.1 to 0.9% hafnium, 2 to 4% molybdenum, 5 to 7% rhenium, 5 to 7% tantalum, 2 to 5% tungsten, 0 to 0.1% silicon, the balance being of nickel and unavoidable impurities.