Method of making a Ni—based single crystal superalloy and turbine blade incorporating same
09932657 · 2018-04-03
Assignee
Inventors
Cpc classification
F05D2300/131
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C22C19/056
CHEMISTRY; METALLURGY
F05D2300/177
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/135
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2230/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/132
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/607
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C30B11/00
CHEMISTRY; METALLURGY
F05D2300/175
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/133
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D5/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The present invention provides a Ni-based single crystal superalloy which has the following composition by weight: 0.1 wt % or more and 9.9 wt % or less of Co, 5.1 wt % or more and 10.0 wt % or less of Cr, 1.0 wt % or more and 4.0 wt % or less of Mo, 8.1 wt % or more and 11.0 wt % or less of W, 4.0 wt % or more and 9.0 wt % or less of Ta, 5.2 wt % or more and 7.0 wt % or less of Al, 0.1 wt % or more and 2.0 wt % or less of Ti, 0.05 wt % or more and 0.3 wt % or less of Hf, 1.0 wt % or less of Nb and less than 3.0 wt % of Re with the remainder including Ni and unavoidable impurities. This Ni-based single crystal superalloy has a low Re content and also has excellent high-temperature strength, mainly creep strength.
Claims
1. A method of manufacturing a Ni-based single crystal superalloy which has the following composition by weight: 8.0 wt % of Co, 7.0 wt % of Cr, 1.8 wt % of Mo, 8.2 wt % of W, 6.0 wt % of Ta, 5.2 wt % of Al, 1.6 wt % of Ti, 0.10 wt % of Hf, and 0.8 wt % of Re with the remainder including Ni and unavoidable impurities, and wherein said superalloy contains no Nb or contains it as an unavoidable impurity, wherein the Ni-based single crystal superalloy is obtained by performing a solution heat treatment and an aging treatment to an alloy ingot which has the above-described composition, and wherein the solution heat treatment is carried out by raising the ingot from a temperature within a range of 1,503 to 1,563 K (1,230 to 1,290 C.) to a temperature within a range of 1,573 to 1,613 K (1,300 to 1340 C.) by a multi-stage step, followed by maintaining of such a temperature for 1 hour or more; and the aging treatment is carried out by performing a primary aging treatment of maintaining the ingot at a temperature within a range of 1,273 to 1,423 K (1,000 C. to 1,150 C.) for 3 to 5 hours and by performing a secondary aging treatment of maintaining the ingot at a temperature within a range of 1,073 to 1,223 K (800 C. to 950 C.) for 15 to 25 hours.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
(8) One embodiment of a Ni-based single crystal superalloy and a turbine blade according to the present invention will be described with reference to the accompanying drawings shown below. In the drawings shown below, the scale of each member has been appropriately altered in order to make each member a recognizable size.
(9) The Ni-based single crystal superalloy of the present embodiment has the following composition by weight: 0.1 wt % or more and 9.9 wt % or less of Co, 5.1 wt % or more and 10.0 wt % or less of Cr, 1.0 wt % or more and 4.0 wt % or less of Mo, 8.1 wt % or more and 11.0 wt % or less of W, 4.0 wt % or more and 9.0 wt % or less of Ta, 5.2 wt % or more and 7.0 wt % or less of Al, 0.1 wt % or more and 2.0 wt % or less of Ti, 0.05 wt % or more and 0.3 wt % or less of Hf, 1.0 wt % or less of Nb and less than 3.0 wt % of Re with the remainder including Ni and unavoidable impurities.
(10) Also, the amount of Re in the Ni-based single crystal superalloy of the present embodiment is more preferably 2.0 wt % or less, 1.4 wt % or less, or 0.8 wt % or less by weight.
(11) Unavoidable impurities are impurities which are included without being intentionally introduced in the production process until a Ni-based single crystal superalloy of the present embodiment is obtained and are present in trace amounts (for example, 0.1 wt % or less), and also which do not necessarily exert an influence on characteristics of the Ni-based single crystal superalloy.
(12) Examples of the unavoidable impurities include B, C, Si, Y, La, Ce, V, Zr, Nb, Ru, Re and the like.
(13) The composition ranges of the components of the Ni-based single crystal superalloy are controlled based on their characteristics described below.
(14) Co is an element that increases the solid solubility limit to the matrix containing Al, Ta and other elements in high-temperature environments and causes the fine phase to disperse and precipitate in heat treatment so as to enhance the high-temperature strength. If more than 9.9 wt % of Co exists, the composition ratio with other elements, including Al, Ta, Mo, W, Hf and Cr, becomes unbalanced. As a result, a harmful phase precipitates to decrease the high-temperature strength. Due to the necessity of enhancing the high-temperature strength, 0.1 wt % or more of Co preferably exists. The amount of Co is therefore preferably 0.1 wt % or more and 9.9 wt % or less.
(15) Cr is an element that has excellent oxidation resistance and improves, altogether with Hf and Al, high-temperature corrosion resistance of the Ni-based single crystal superalloy. If the amount of Cr is less than 5.1 wt %, it is difficult to provide a desired high-temperature corrosion resistance. If the amount of Cr exceeds 10.0 wt %, precipitation of the phase is inhibited and harmful phases, such as phase and phase, may precipitate to decrease the high-temperature strength. The amount of Cr is therefore preferably 5.1 wt % or more and 10.0 wt % or less.
(16) Mo is an element that enhances the high-temperature strength by solid-dissolving in the phase which becomes the matrix, in the copresence of W or Ta, and also improves high-temperature strength due to precipitation hardening. If the amount of Mo is less than 1.0 wt %, it is difficult to provide desired high-temperature strength. If the amount of Mo exceeds 4.0 wt %, the high-temperature strength decreases and the high-temperature corrosion resistance deteriorates. The amount of Mo is therefore preferably 1.0 wt % or more and 4.0 wt % or less.
(17) W is an element that enhances the high-temperature strength due to the actions of solution hardening and precipitation hardening in the copresence of Mo or Ta. In order to enhance the high-temperature strength, 8.1 wt % or more of W preferably exists. If the amount of W exceeds 11.0 wt %, the high-temperature corrosion resistance deteriorates. The amount of W is therefore preferably 8.1 wt % or more and 11.0 wt % or less.
(18) Ta is an element that enhances the high-temperature strength due to the actions of solution hardening and precipitation hardening in the copresence of Mo or W. Ta also enhances the high-temperature strength by the precipitation hardening relative to the phase. If the amount of Ta is less than 4.0 wt %, it is difficult to provide desired high-temperature strength. If the amount of Ta exceeds 9.0 wt %, a harmful phase, such as a phase and phase, may precipitate to decrease the high-temperature strength. The amount of Ta is therefore preferably 4.0 wt % or more and 9.0 wt % or less.
(19) Al combines with Ni to form a 60 to 70% (volume percentage) of an intermetallic compound represented by Ni.sub.3Al, which is the fine phase to be uniformly dispersed and precipitated into the matrix. That is, Al is an element that enhances the high-temperature strength altogether with Ni. Furthermore, Al is excellent in oxidation resistance, and improves, altogether with Cr and Hf, the high-temperature corrosion resistance of the Ni-based single crystal superalloy. If the amount of Al is less than 5.2 wt %, the precipitation amount of the phase is insufficient and it is thus difficult to provide desired high-temperature strength and high-temperature corrosion resistance. If the amount of Al exceeds 7.0 wt %, a large amount of a coarse eutectic phase called a eutectic phase is formed, which makes it impossible to carry out a solution heat treatment and thus it becomes difficult to provide desired high-temperature strength. The amount of Al is therefore preferably 5.2 wt % or more and 7.0 wt % or less.
(20) Ti is an element that enhances the high-temperature strength due to the actions of solution hardening and precipitation hardening in the copresence of Mo or W. Ti also enhances the high-temperature strength by the precipitation hardening with relative to the -phase. If the amount of Ti exceeds 2.0 wt %, a harmful phase may precipitate to decrease the high-temperature strength. In order to enhance the high-temperature strength, 0.1 wt % or more of Ti preferably exists. The amount of Ti is therefore preferably 0.1 wt % or more and 2.0 wt % or less.
(21) Hf is an element that segregates at the grain boundary and distributed unevenly in grain boundary to strengthen the same so as to enhance the high-temperature strength. Furthermore, Hf is excellent in oxidation resistance, and improves, altogether with Cr and Al, high-temperature corrosion resistance of the Ni-based single crystal superalloy. In order to enhance the high-temperature strength, 0.05 wt % or more of Hf preferably exists. If the amount of Hf exceeds 0.3 wt %, local melting occurs to decrease the high-temperature strength. The amount of Hf is therefore preferably 0.05 wt % or more and 0.3 wt % or less.
(22) Nb is an element that enhances the high-temperature strength. However, if the amount of Nb exceeds 1.0 wt %, a harmful phase precipitates to decrease the high-temperature strength. The amount of Nb is therefore preferably 1.0 wt % or less.
(23) Re is an element that enhances the high-temperature strength due to solid-solution strengthening by solid-dissolving in the phase which is the matrix. Re also enhances the corrosion resistance. However, if the amount of Re is 3.0 wt % or more, it becomes necessary to use Re in the same amount as that of a conventional second generation Ni-based single crystal superalloy. However, since it may be difficult to stably ensure supply of Re and also Re is expensive, the price of a Ni-based single crystal superalloy drastically rises when the amount of Re is large. In the present embodiment, even if the amount of Re is inhibited or Re is not included, it is possible to maintain enhanced high-temperature strength, mainly high creep strength in high-temperature environments by setting a composition ratio of other elements at an optimum range.
(24) In the Ni-based single crystal superalloy of the present embodiment, the amount of Re is less than 3 wt %. Furthermore, in the Ni-based single crystal superalloy of the present embodiment, the amount of Re is preferably 2.0 wt % or less, more preferably 1.4 wt % or less, and still more preferably 0.8 wt % or less.
(25) Subsequently, the results of tests carried out so as to make a comparison in a creep life between a Ni-based single crystal superalloy of the present embodiment and the first and second generation Ni-based single crystal superalloys with reference to
(26)
(27) Black dots A to C shown in
(28) The method of producing a Ni-based single crystal superalloy of the present embodiment is as follows.
(29) First, a molten Ni-based single crystal superalloy is prepared using a vacuum melting furnace and an alloy ingot is casted using this molten alloy.
(30) Furthermore, the alloy ingot is subjected to a solution heat treatment and an aging treatment to obtain a Ni-based single crystal superalloy. The solution heat treatment is carried out by raising the ingot from a temperature within a range of 1,503 to 1,563 K (1,230 to 1,290 C.) to a temperature within a range of 1,573 to 1,613 K (1,300 to 1340 C.) by a multi-stage step, followed by maintaining of such a temperature for 1 to 10 hours or more. The aging treatment is carried out by a primary aging treatment of maintaining the ingot at a temperature within a range of 1,273 to 1,423 K (1,000 C. to 1,150 C.) for 3 to 5 hours. Then, a secondary aging treatment of maintaining the ingot at a temperature within a range of 1,073 to 1,223 K (800 C. to 950 C.) for 15 to 25 hours is carried out.
(31) CMSX-2, CMSX-4, ReneN4, ReneN5, PWA1480 and PWA1484 shown by white dots in
(32) As is apparent from
(33) As used herein, do not contain Re as a useful component includes, in addition to the case where no Re is included at all, the case where Re is included as an unavoidable impurity.
(34) From the creep life of CMSX-2, PWA1480, ReneN4, ReneN5, CMSX-4 and PWA1484, it is assumes that, when the amount of Re in these conventional Ni-based single crystal superalloys varies within a range of 3.0 wt % or less, the life of the Ni-based single crystal superalloy is included in the region R1 shown in
(35) It is possible to confirm that the Ni-based single crystal superalloy C of the present embodiment clearly has longer creep life as compared to the creep life to be assumed in the case where a conventional Ni-based single crystal superalloy contains 1.4 wt % of Re, and also has higher creep strength.
(36) As is apparent from
(37) As is apparent from
(38) As is apparent from
(39) As is apparent from
(40) Regarding an actual value of the creep life in the present test, the actual values of the creep life of the Ni-based single crystal superalloys A of the present embodiment (which do not contain Re as a useful component) are 72 hours and 87 hours, the actual value of the creep life of the Ni-based single crystal superalloy B of the present embodiment (Re: 0.8 wt %) is 149 hours, the actual value of the creep life of the Ni-based single crystal superalloy B2 of the present embodiment (Re: 0.8 wt %) is 101 hours, the actual value of the creep life of the Ni-based single crystal superalloy C of the present embodiment (Re: 1.4 wt %) is 170 hours, the actual value of the creep life of PWA 1480 is 18 hours, the actual value of the creep life of ReneN4 is 31 hours, the actual value of the creep life of CMSX-2 is 45 hours, the actual value of the creep life of PWA1484 is 141 hours, the actual value of the creep life of ReneN5 is 89 hours, and the actual value of the creep life of CMSX-4 is 74 hours, respectively.
(41) Subsequently, the results of a simulation carried out so as to make a comparison in a creep life between a Ni-based single crystal superalloy of the present embodiment and the first and second generation Ni-based single crystal superalloys with reference to
(42) The present simulation was carried out using JMatPro V.5.0 developed by Sente Software Co. of Great Britain. The present software enables calculation of values of physical, thermodynamic and mechanical properties of a metal alloy by a chemical component thereof and it has already been proved that the creep life of the Ni-based single crystal superalloy corresponding to the technical field of the present invention can also be predicted with satisfactory accuracy as shown in FIG. 16 of the following literature (Literature: N. Saunders, Z. Guo, X. Li, A. P. Miodownik and J-Ph. Schille: MODELLING THE MATERIAL PROPERTIES AND BEHAVIOUR OF Ni-BASED SUPERALLOYS, Superalloys 2004, (TMS, 2004), pp.849-858.)
(43) The inventors of the present invention produced some single crystal superalloys and carried out a creep rupture test under the conditions at 1,100 C. under 137 MPa in the same manner as in the above test, and then made a comparison with the calculated value of the rupture life using JMatPro V.5.0.
(44) As shown in
(45)
(46) Herein, black dots shown in
(47) CMSX-2, CMSX-4, ReneN4, ReneN5, PWA1480 and PWA1484 4 shown by white dots in
(48) As is apparent from
(49) From the creep life of CMSX-2, PWA1480, ReneN4, ReneN5, CMSX-4 and PWA1484, it is assumes that, when the amount of Re in these conventional Ni-based single crystal superalloys varies within a range of 3.0 wt % or less, the life of the Ni-based single crystal superalloy is included in the region R2 shown in
(50) It is possible to confirm that the Ni-based single crystal superalloy c and p of the present embodiment clearly has longer creep life as compared to the creep life (region R2) to be assumed in the case where a conventional Ni-based single crystal superalloy contains 1.4 wt % of Re, and also has higher creep strength. As is apparent from
(51) Furthermore, the Ni-based single crystal superalloy r of the present embodiments is that for comparison and contains 3.0 wt % of Re, which is equal to that in the conventional second generation Ni-based single crystal superalloy, and it is possible to confirm that the creep strength becomes higher as compared to the conventional Ni-based single crystal superalloy.
(52) As is apparent from
(53) Specifically, it is possible to confirm that the Ni-based single crystal superalloy of the present embodiment has characteristics improved by 30% or more as compared to the conventional Ni-based single crystal superalloy having the same content of Re.
(54) The amount of Re in the above-described Ni-based single crystal superalloy of the present embodiment (excluding comparative Ni-based single crystal superalloy r used in the simulation) is less than 3.0 wt %. Therefore, the Ni-based single crystal superalloy of the present embodiment has smaller amount of Re as compared to the second generation Ni-based single crystal superalloy.
(55) The Ni-based single crystal superalloy of the present embodiment has higher creep strength as compared to the first generation Ni-based single crystal superalloy.
(56) Therefore, the Ni-based single crystal superalloy of the present embodiment has smaller amount of Re as compared to the second generation Ni-based single crystal superalloy, and is also excellent in creep strength as compared to the first generation Ni-based single crystal superalloy.
(57) In the conventional Ni-based single crystal superalloy, it is necessary to add Ru, as rare metal, so as to inhibit the generation of a deteriorated layer due to the addition of Re. However, in the Ni-based single crystal superalloy of the present embodiment, it is not necessary to contain Ru and thus it becomes possible to perform cost reduction.
(58) Subsequently, the results of a test carried out so as to make a comparison in a fatigue strength and a creep life between Ni-based single crystal superalloys of the present embodiment (Ni-based single crystal superalloys A and B2 (described above)) and the first and second generation Ni-based single crystal superalloys with reference to
(59)
(60) As is apparent from
(61)
(62) As is apparent from
(63) The Ni-based single crystal superalloy of the present embodiment can be used as the material that forms a turbine blade 1 shown in
(64) The turbine blade 1 which incorporates the Ni-based single crystal superalloy of the present embodiment has small amount of Re and is also excellent in high-temperature strength, mainly creep strength. Therefore, a turbine blade 1, which is inexpensive and has high strength, can be obtained.
(65) While the invention has been described by way of forgoing Examples, but is not limited to the Examples. Also various combinations and selections of various disclosed essential elements are for illustrative purpose only and can be made without departing from the scope of the present invention.
INDUSTRIAL APPLICABILITY
(66) According to the present invention, it is possible to obtain a Ni-based single crystal superalloy which has a smaller amount of Re as compared to a conventional Ni-based single crystal superalloy, and is also excellent in high-temperature strength, mainly creep strength.
DESCRIPTION OF THE REFERENCE SYMBOLS
(67) 1: Turbine blade
(68) A-C, a-r: Ni-based single crystal superalloys