Nickel-base superalloy and use thereof

Abstract

The novel nickel-base superalloy useful in an additive manufacturing process or a powder-based manufacturing process includes the following composition in wt %: Cr 8.0-8.5; Co 9.0-9.5; Mo 0.4-0.6; W 9.3-9.7; Ta 2.9-3.6; Al 4.9-5.6; Ti 0.2-1.0; Hf 0-0.05; C 0.005-0.03; B 0.005-0.02; Zr 0.005-0.1; Nb 0.2-1; Mn 0-0.6; and S 0-0.002 (20 ppm); the balance nickel and incidental elements and unavoidable impurities.

Claims

1. A nickel-base superalloy comprising the following composition in wt %: TABLE-US-00006 Cr 8.0-8.5 Co 9.0-9.5 Mo 0.4-0.6 W 9.3-9.7 Ta 2.9-3.6 Al 4.9-5.6 Ti 0.2-1.0 Hf 0-0.05 C 0.005-0.03 B 0.005-0.02 Zr 0.005-0.1 Nb 0.2-1 Mn 0-0.6 S 0-0.002 (20 ppm) the balance nickel and incidental elements and unavoidable impurities.

2. A nickel-base superalloy as claimed in claim 1, comprising the following composition in wt %: TABLE-US-00007 Cr 8.0-8.5 Co 9.0-9.5 Mo 0.4-0.6 W 9.3-9.7 Ta 3.1-3.5 Al 5.1-5.5 Ti 0.5-0.9 Hf 0-0.05 C 0.005-0.02 B 0.005-0.02 Zr 0.005-0.02 Nb 0.6-1 S 0-0.0005 (5 ppm) the balance nickel and incidental elements and unavoidable impurities.

3. A nickel-base superalloy as claimed in claim 1, comprising the following composition in wt %: TABLE-US-00008 Cr 8.00-8.50 Co 9.00-9.50 Mo 0.40-0.60 W 9.30-9.70 Ta 3.10-3.50 Al 5.10-5.50 Ti 0.50-0.90 Hf 0-0.05 C 0.005-0.015 B 0.005-0.015 Zr 0.005-0.015 Nb 0.6-1.0 S 0-0.0005 (5 ppm) the balance nickel and incidental elements and unavoidable impurities.

4. A nickel-base superalloy as claimed in claim 1, wherein the incidental elements are one or more element selected from the following (wt % unless indicated to be ppm): TABLE-US-00009 V 0.10 max Fe 0.05 max Si 0.05 max P 0.005 max Mg 0.005 max Cu 0.01 max N 60 ppm max O 250 ppm max Ag 1 ppm max As 5 ppm max Bi 0.1 ppm max. Cd 2 ppm max Ga 25 ppm In 0.2 ppm max Pb 2 ppm max Sb 2 ppm max Se 1 ppm max Sn 10 ppm max Te 0.1 ppm max Tl 0.2 ppm max Zn 5 ppm max.

5. A nickel-base superalloy as claimed in claim 2, wherein the incidental elements are one or more element selected from the following (wt % unless indicated to be ppm): TABLE-US-00010 V 0.10 max Fe 0.05 max Si 0.05 max P 0.005 max Mg 0.005 max Cu 0.01 max N 60 ppm max O 250 ppm max Ag 1 ppm max As 5 ppm max Bi 0.1 ppm max. Cd 2 ppm max Ga 25 ppm In 0.2 ppm max Pb 2 ppm max Sb 2 ppm max Se 1 ppm max Sn 10 ppm max Te 0.1 ppm max Tl 0.2 ppm max Zn 5 ppm max.

6. A nickel-base superalloy as claimed in claim 3, wherein the incidental elements are one or more element selected from the following (wt % unless indicated to be ppm): TABLE-US-00011 V 0.10 max Fe 0.05 max Si 0.05 max P 0.005 max Mg 0.005 max Cu 0.01 max N 60 ppm max O 250 ppm max Ag 1 ppm max As 5 ppm max Bi 0.1 ppm max. Cd 2 ppm max Ga 25 ppm In 0.2 ppm max Pb 2 ppm max Sb 2 ppm max Se 1 ppm max Sn 10 ppm max Te 0.1 ppm max Tl 0.2 ppm max Zn 5 ppm max.

7. A nickel-base superalloy as claimed in claim 1, in a physical form which is adapted for use in an additive manufacturing process.

8. A nickel-base superalloy as claimed in claim 1, in the form of a wire, rod or powder adapted for use in an additive manufacturing process.

9. A nickel-base superalloy as claimed in claim 1, in the form of a wire, rod or powder adapted for use in a directed energy deposition (DED) additive manufacturing process.

10. A nickel-base superalloy as claimed in claim 7, wherein the physical form is adapted for use in a manufacturing process selected from laser-based additive manufacturing (LBAM), direct laser deposition (DLD), electron beam additive manufacturing (EBAM), laser engineered net shaping (LENS), selective laser melting (SLM), SLM three-dimensional printing (SLM 3D printing), direct metal laser sintering (DMLS), direct metal laser sintering three-dimensional printing (DML 3D printing), electron beam melting (EBM), direct metal deposition (DMD), direct metal tooling (DMT), direct metal tooling three-dimensional printing (DMT 3D printing), construction laser additive direct (CLAD) and ion fusion formation (IFF).

11. A nickel-base superalloy as claimed in claim 1, in a physical form which is adapted for use in a powder-based manufacturing process.

12. A nickel-base superalloy as claimed in claim 11, in the form of a powder adapted for use in a powder-based manufacturing process.

13. A nickel-base superalloy as claimed in claim 11, in the form of a powder adapted for use in hot isostatic pressing (HIP).

14. A metal article, component or structure comprising a nickel-base superalloy comprising the following composition in wt %: TABLE-US-00012 Cr 8.0-8.5 Co 9.0-9.5 Mo 0.4-0.6 W 9.3-9.7 Ta 2.9-3.6 Al 4.9-5.6 Ti 0.2-1.0 Hf 0-0.05 C 0.005-0.03 B 0.005-0.02 Zr 0.005-0.1 Nb 0.2-1 Mn 0-0.6 S 0-0.002 (20 ppm) the balance nickel and incidental elements and unavoidable impurities.

15. A metal article, component or structure as claimed in claim 14, wherein the article, component or structure is an article, component or structure for use in the aerospace industry.

16. A metal article, component or structure as claimed in claim 14, which is selected from statics, turbine blades, other turbine components, and combustor components for use in the aerospace industry.

17. A method of manufacturing a metal article, component or structure which is selected from statics, turbine blades, other turbine components, and combustor components for use in the aerospace industry, which comprises applying energy to melt a nickel-base superalloy comprising the following composition in wt %: TABLE-US-00013 Cr 8.0-8.5 Co 9.0-9.5 Mo 0.4-0.6 W 9.3-9.7 Ta 2.9-3.6 Al 4.9-5.6 Ti 0.2-1.0 Hf 0-0.05 C 0.005-0.03 B 0.005-0.02 Zr 0.005-0.1 Nb 0.2-1 Mn 0-0.6 S 0-0.002 (20 ppm) the balance nickel and incidental elements and unavoidable impurities.

18. A method as claimed in claim 17, wherein the nickel-base superalloy is in the physical form of a powder and the energy is applied in a powder-based manufacturing process, or the nickel-base superalloy is in the form of a metal body or a powder as a metal feed and the energy is applied in an additive manufacturing process.

19. A method of manufacturing a nickel-base superalloy as defined in claim 1, the method comprising mixing the components of the superalloy in the required proportions at an elevated temperature in a melt, and allowing the molten mixture to cool to provide the superalloy.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be described in more detail, for further illustration and without any limiting effect on the scope of the invention, with reference to the accompanying drawings, in which:

(2) FIG. 1 a backscattered electron image of as-deposited CM247LC (prior art). The bright particles are Hf-rich oxides, predominantly Hf- and Ta-rich MC carbides and W- and Cr-rich M.sub.6C carbides;

(3) FIG. 2 shows a backscattered electron image of a fracture surface from deposited CM247LC (prior art) that cracked after hot isostatic pressing (HIP). The small bright particles are Hf-rich oxides, carbides and oxy-carbides.

DETAILED DESCRIPTION OF THE DRAWINGS

(4) Referring to FIG. 1, an electron image of the as-deposited prior art nickel-base superalloy CM247CL is shown. Many bright particles are visible that are aligned and reside at interfaces and interdentritic regions. The bright appearance of the particles indicates high atomic number contrast, which suggests that they are rich in hafnium (Hf) and tantalum (Ta).

(5) Energy dispersive X-ray spectroscopy from scanning electron microscopy and transmission electron microscopy have shown that the particles consist of hafnium-rich oxides, Hf- and Ta-rich MC carbides and W- and Cr-rich M.sub.6C carbides.

(6) FIG. 2 shows an alternative backscattered electron image of deposited CM247LC that was subsequently hot isostatic pressed before the image was obtained.

(7) The presence and location of these carbide particles suggest that they contribute to the low ductility values that have been observed in as-deposited CM247LC.

(8) The new alloy of the present disclosure is expected to largely retain the morphology of as-deposited CM247LC, by reason of the control of the formation of niobium, tantalum, tungsten, chromium and (if present) hafnium oxides, carbides and oxy-carbides as described above.

(9) The present invention has been broadly described without limitation to any particular form or embodiment. Variations and modifications as will be readily apparent to those skilled in this art are intended to be within the scope of the patent application and subsequent patent.