Composition for material for liquid metal deposition or additive manufacturing, method and product

Abstract

A composition of a nickel based alloy mixture which can be used for welding via especially liquid metal deposition or as a powder bed of an additive manufacturing method. A metallic powder mixture includes (in wt %): a cobalt (Co) or nickel (Ni) based super alloy with a content of 20% to 60%, a NiCoCrAlY-composition with a content of 70% to 30% and a metallic braze material with a content between 10% to 5%. The melting point of the braze material is at least 10K lower than the melting point of the nickel or cobalt based superalloy.

Claims

1. A metallic powder mixture, usable for build up via liquid metal deposition or any additive manufacturing method, comprising (in wt %): a nickel (Ni) based superalloy with a content of 20% to 60%, a NiCoCrAlY-composition with a content of 70% to 30% and a metallic braze material with a content between 10% to 5%, wherein the melting point of the braze material is at least 10K lower than the melting point of the nickel based superalloy, wherein the nickel (Ni) based superalloy comprises (in wt %): Cobalt (Co) 18.0%-19.0% wherein the NiCoCrAlY composition comprises (in wt %): 14%-22% Chromium (Cr) 9.0%-11.5% Aluminum (Al) 0.3%-0.5% Yttrium (Y) 11%-26% Cobalt (Co) 0%-1.0% Silicon (Si), 0%-2.5% Rhenium (Re) and remainder Nickel (Ni).

2. The metallic powder mixture according to claim 1, comprising (in wt %): TABLE-US-00006 Nickel (Ni) from 51.00% to 58.00%  Carbon (C) from 0.02% to 0.05% Chromium (Cr) from 11.00% to 15.00%  Molybdenum (Mo) from 0.05% to 0.35% Tungsten (W) from 1.80% to 5.80% Titanium (Ti) from 0.10% to 0.50% Aluminum (Al) from 6.50% to 8.50% Boron (B) from 0.05% to 0.10% Tantalum (Ta) from 0.80% to 2.20% Hafnium (Hf) from 0.20% to 0.80% Yttrium (Y) from 0.05% to 0.25% Rhenium (Re)  from 0.40% to 1.10%.

3. The metallic powder mixture according to claim 1, wherein the nickel (Ni) base superalloy further comprises (in wt %): TABLE-US-00007 Carbon (C) 0.05%-0.20% Chromium (Cr)  8.0%-23.0% Tungsten (W)  2.0%-10.0% Titanium (Ti) 0.6%-5.0% Aluminum (Al) 1.0%-6.0% Boron (B) 0.005%-0.02%  optionally Molybdenum (Mo) 0.0%-4.5% Tantalum (Ta) 0.0%-4.5% Hafnium (Hf) 0.6%-1.5% Zirconium (Zr) 0.02%-0.12% Niobium (Nb) 0.5%-1.0% no Yttrium (Y) and/or no Rhenium (Re), remainder Nickel (Ni).

4. A metallic powder mixture, usable for build up via liquid metal deposition or any additive manufacturing method, comprising (in wt %): a nickel (Ni) based superalloy with a content of 20% to 60%, a NiCoCrAlY-composition with a content of 70% to 30% and a metallic braze material with a content between 10% to 5%, wherein the melting point of the braze material is at least 10K lower than the melting point of the nickel based superalloy, wherein the nickel (Ni) based superalloy comprises (in wt %): TABLE-US-00008 Nickel (Ni) 61.6% Carbon (C) 0.08% Chromium (Cr) 8.25% Molybdenum (Mo) 0.50% Tungsten (W) 9.50% Titan (Ti) 0.75% Aluminum (Al) 5.55% Boron (B) 0.02% Tantalum (Ta) 3.20% Hafnium (Hf) 1.30%, no Yttrium (Y) and/or no Rhenium (Re) wherein the NiCoCrAlY composition comprises (in wt %): TABLE-US-00009 14%-22% Chromium (Cr) 9.0%-11.5% Aluminum (Al) 0.3%-0.5% Yttrium (Y) 11%-26% Cobalt (Co) 0%-1.0% Silicon (Si), 0%-2.5% Rhenium (Re) and remainder Nickel (Ni).

5. The metallic powder mixture according to claim 1, wherein the braze alloy comprises (in wt %): TABLE-US-00010 Nickel (Ni) 40%-70%  Chromium (Cr) 8.0%-23.0% Cobalt (Co) 5.0%-20.0% Aluminum (Al) 1.0%-10.0% Boron (B) 0.5%-4.00% optionally Tantalum (Ta) 1.0%-4.0% Molybdenum (Mo) 0.0%-5.0% Hafnium (Hf) 0.05%-0.09% Tungsten (W)  2.0%-10.0% Titanium (Ti) 0.5%-5.0% no Yttrium (Y), and/or no Rhenium (Re), and/or no Carbon (C).

6. The metallic powder mixture according to claim 1, wherein the braze alloy comprises (in wt %): TABLE-US-00011 Nickel (Ni) 69.2% Chromium (Cr) 14.0% Cobalt (Co) 10.0% Aluminum (Al)  3.5% Boron (B) 0.75% Tantalum (Ta)  2.5% Hafnium (Hf)  0.06%, no Yttrium (Y) and/or no Tungsten (W), and/or no Titanium (Ti), and/or no Molybdenum (Mo), and/or no Rhenium (Re), and/or no Carbon (C).

7. The metallic powder mixture according to claim 1, wherein the metallic braze material comprises: Silicon (Si) and/or Magnesium (Mg) and/or Manganese (Mn).

8. The metallic powder mixture according to claim 1, wherein the braze material is a nickel-based alloy with at least 0.5 wt % Boron (B), and/or at least 1.0 wt % Silicon (Si), and/or at least 2.0 wt % Magnesium (Mg).

9. The metallic powder mixture according to claim 1, wherein the NiCoCrAlY composition consists of NiCoCrAlY and optionally Tantalum (Ta), Rhenium (Re), Iron (Fe) and/or Silicon (Si).

10. The metallic powder mixture according to claim 1, wherein the NiCoCrALY composition comprises (in wt %): TABLE-US-00012 20%-22% Chromium (Cr) 10.5%-11.5% Aluminum (Al) 0.3%-0.5% Yttrium (Y) 1.5%-2.5% Rhenium (Re) 11%-13% Cobalt (Co) and remainder Nickel.

11. The metallic powder mixture according to claim 1, wherein the NiCoCrAlY composition comprises (in wt %): TABLE-US-00013 15%-21%  Chromium (Cr) 24%-26%  Cobalt (Co) 9.0%-11.5% Aluminum (Al) 0.05%-0.7%   Yttrium (Y) 0.5%-2.0%  Rhenium (Re) and remainder Nickel.

12. The metallic powder mixture according to claim 1, wherein the NiCoCrAlY composition comprises (in wt %): TABLE-US-00014 22%-24% Cobalt (Co) 14%-16% Chromium (Cr) 10.5%-11.5% Aluminum (Al) 0.2%-0.4% Yttrium (Y), optionally 0.3%-0.9% Tantalum (Ta) and remainder Nickel (Ni).

13. A method to build up metallic material, comprising: building up a metallic powder mixture of claim 1.

14. The method according to claim 13, wherein the building up of the metallic powder mixture is used for welding using powder cladding, wire welding or for additive manufacturing using powder beds.

15. A product, comprising: a metallic powder mixture according to claim 1.

16. The product according to claim 15, wherein first directly on a substrate a layer of a mixture consisting of a NiCoCrAlY, and a nickel or cobalt based superalloy is applied on the substrate, and then layers of the metallic powder mixture are applied.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a method how to apply the inventive material during welding and FIG. 2 shows a schematic arrangement to use the inventive powder for additive manufacturing, especially via laser. FIG. 3 lists further examples of alloys.

DETAILED DESCRIPTION OF INVENTION

(2) The description and the figures are only examples of the invention.

(3) This method and the material can be used to build up totally new component starting on a base plate or to repair an existing substrate 4 which both means a build up of material.

(4) The build up of material is necessary to erosion or cracks which have been removed. In this case, only for example, a blade tip is repaired by building up the material onto a blade tip 7. The surface 10 of the substrate 4 reveals the base on which the material is applied on. The material 16 is applied via a nozzle 13 which is connected to a powder supply 19 is an inventive material. The nozzle 13 also includes a laser which together with the powder 16 is used for welding by melting the powder via a laser beam (not shown).

(5) The inventive material can also be produced as a rod and or a wire and can be used via wire welding.

(6) In FIG. 2 another application of the inventive material is shown.

(7) Here a selective laser melting process (also electron beams can be used instead of a laser) wherein a powder bed 22 with the inventive powder mixture is used to create a totally new component or even to repair a substrate 4.

(8) The substrate 4 is totally inside the powder bed 22 and a laser 25 with a laser beam 28 is used to melt or to sinter partially a powder where a material build up onto the substrate 4 where it is needed or wanted.

(9) The inventive material is a metallic powder mixture of three different powders.

(10) Especially the powder mixture comprises alloy 247 or generally a nickel based super alloy and a NiCoCrAlY, a braze alloy which has at least a melting point at least 20K lower than the nickel based super alloy.

(11) Further examples for the nickel based super alloy are listed in FIG. 3.

(12) NiCoCrAlY can also comprise optionally additions like Rhenium (Re), Tantalum (Ta) and/or Silicon (Si), very especial only these ones.

(13) Another example is, wherein first direct on the substrate a layer of a mixture consisting of a NiCoCrAlY especially according to dependent claims and a nickel or cobalt based superalloy, especially according to dependent claims is applied and then layers of a mixture according to certain claims.