Ni base forged alloy and gas turbine utilizing the same

Abstract

An Ni base forged alloy is easy to make hot forging and miniaturization of crystal grains while excellent high-temperature strength and segregation property are compatible. The Ni base forged alloy has solid solution temperature of a precipitation strengthening phase lower than or equal to 970 C., difference in the solid solution temperature between a -phase and the precipitation strength phase larger than or equal to 50 C., Al of 0.5 to 1.0%, Cr of 17 to 21%, Fe of 17 to 19%, Nb of 4.5 to 5.5%, Ti of 0.8 to 1.3%, W of 3.0 to 6.0%, B of 0.001 to 0.03%, C of 0.001 to 0.1% and Mo of 1.0% or less in mass percentage [%] and remainder made of Ni and inevitable impurities.

Claims

1. An Ni base forged alloy having solid solution temperature of a precipitation strengthening phase lower than or equal to 970 C., difference in the solid solution temperature between a -phase and the precipitation strength phase larger than or equal to 50 C., Al of 0.5 to 1.0%, Cr of 17 to 21%, Fe of 17 to 19%, Nb of 4.5 to 5.5%, Ti of 0.8 to 1.3%, W of 3.0 to 6.0%, B of 0.001 to 0.03%, C of 0.001 to 0.1% and Mo of 1.0% or less in mass percentage [%] and remainder made of Ni and inevitable impurities.

2. An Ni base forged alloy according to claim 1, wherein a value of an expression 1 defined by 2.20amount of Al+1.32amount of Ti0.46amount of Nb is smaller than or equal to 1.

3. An Ni base forged alloy according to claim 1, wherein an average diameter of crystal grains is smaller than or equal to 100 m.

4. An Ni base forged alloy according to claim 1, wherein the Ni base forged alloy has weight heavier than or equal to 2 tons and yield stress at 500 C. larger than or equal to 1000 Mpa.

5. A turbine disk larger than or equal to 1 ton and processed from the Ni base forged alloy according to claim 1.

6. A gas turbine comprising the turbine disk and/or the turbine spacer according to claim 5 and having output larger than or equal to 80 MW.

7. A turbine spacer larger than or equal to 1 ton and processed from the Ni base forged alloy according to claim 1.

8. A gas turbine comprising the turbine disk and/or the turbine spacer according to claim 7 and having output larger than or equal to 80 MW.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a diagram showing the relation of the solid solution temperature of the precipitation strengthening phase and the difference in the solid solution temperature between the -phase and the precipitation strengthening phase;

(2) FIG. 2 is a diagram showing phase fraction of the -phase;

(3) FIG. 3 is a diagram showing the relation of expression 1 and the solid solution temperature of the precipitation strengthening phase;

(4) FIG. 4 is a diagram showing the relation of expression 1 and the difference in the solid solution temperature between the -phase and the precipitation strengthening phase;

(5) FIG. 5 is a side view showing the external appearance and the inner part of a gas turbine; and

(6) FIG. 6 is a sectional view showing a high-temperature rotation part of the gas turbine.

DESCRIPTION OF THE EMBODIMENTS

(7) The present invention is now described in detail.

(8) The present invention is effective in large-sized high-strength Ni base forged alloy having the weight larger than or equal to 2 tons and the yield stress at 500 C. larger than or equal to 1000 MPa. Particularly, when the weight thereof is 3 tons or more, more remarkable effect is attained. The addition amount of the solid solution strengthening elements and the precipitation strengthening elements which is a main cause of segregation upon casting can be adjusted so that density difference in molten metal approaches 0 to thereby be applied to large-sized members. Further, a fixed amount or more of Al, Ti and Nb is added to thereby ensure the high-temperature strength of material.

(9) In order to improve the forgeability, it is preferable that the solid solution temperature of the precipitation strengthening phase is lower than or equal to 970 C. The general forging temperature is within the range of 900 to 1150 C., although since it takes a lot of time to forge a large-sized member as compared with a small-sized member, it is necessary to forge the large-sized member at a relatively low temperature in consideration of a possibility that crack is apt to be produced at high temperature and crystal grains are coarsened. Further, as measures of suppressing the crystal grains from being coarsened, it is effective in precipitating the -phase that is a grain boundary precipitate at forging temperature. The -phase is a phase produced by metamorphosing the -phase of the metastable phase by aging at high temperature for a long time. Since precipitation to crystal grain boundary is easy, it is easy to act as pinning and it is effective in suppressing growth and coarsening of crystal grains. Accordingly, in order to improve forgeability and suppress coarsening of crystal grains compatibly, it is necessary to precipitate only the -phase at the forging temperature. Particularly, since the temperature of material is gradually reduced upon forging, it is preferable that difference in solid solution temperature between the -phase and the precipitation strengthening phase is larger than or equal to 50 C. and a fixed amount of Nb is added to thereby ensure the phase fraction of the -phase and adjust the solid solution temperature of the precipitation strengthening phase by Al and Ti.

(10) The Ni base forged alloy of the present invention includes alloy components of Al of 0.5 to 1.0%, Cr of 17 to 21%, Fe of 17 to 19%, Nb of 4.5 to 5.5%, Ti of 0.8 to 1.3%, W of 3.0 to 6.0%, B of 0.001 to 0.03%, C of 0.001 to 0.1% and Mo of 1.0% or less in mass percentage (%) and the remainder made of Ni and inevitable impurities and is difficult to generate segregation in high strength and casting, excellent in hot forgeability and easy in miniaturization of crystal grains.

(11) In the above range of components, a value of expression 1 defined by 2.20amount of Al+1.32amount of Ti0.46amount of Nb in the mass percentage (%) is smaller than or equal to 1, so that more remarkable effect is attained. The expression 1 is a parameter for deciding the solid solution temperature of the -phase and the precipitation strengthening phase, and the solid solution temperatures of the -phase and the precipitation strengthening phase depend on the amount of Nb and on the amount of Al, Ti and Nb greatly, respectively.

(12) Elements contained in the alloy of the present invention are described below. Composition ranges are all expressed by mass percentage (%).

(13) Al: 0.5 to 1.0%

(14) Al is an element forming the -phase (Ni.sub.3Al) and bearing strength of Ni base alloy of -phase precipitation strengthening type. Further, the element also has the effect of improving oxidation resistance. When the element is lacking, the precipitation amount of the -phase is reduced due to aging and accordingly sufficient high-temperature strength is not obtained. In the present invention, Ti and Nb which are other precipitation strengthening elements are contained relatively much and accordingly the precipitation strengthening effect can be obtained from about 0.5%. When the element is contained excessively, appearance of harmful phase in which the element becomes hard and fragile is promoted and the solid solution temperature of the -phase is increased to reduce the hot forgeability. Accordingly, an upper

(15) Cr: 17 to 21%

(16) Cr is an element having the surface in which minute oxide scale made of Cr.sub.2O.sub.3 is formed to improve the oxidation resistance and the high-temperature corrosion resistance. In order to utilize the element in the high-temperature member which is an object of the present invention, it is necessary to contain the element at least 17%. However, when the element is added 21% or more, the -phase which is harmful phase is formed to deteriorate ductility and destruction toughness of material and accordingly the element is added within the range where 21% is not exceeded.

(17) Fe: 17 to 19%

(18) Fe has the higher ductility as compared with Ni and improves hot workability by addition of Fe. Further, Fe is inexpensive as compared with other elements and accordingly effective even for low cost of material. However, when Fe is added excessively, the -phase which is the precipitation strengthening phase is unstable and the high-temperature strength is reduced. Accordingly, the component range is set to be 17 to 19%.

(19) Nb: 4.5 to 5.5%

(20) Nb contributes to improvement of the high-temperature strength as the element for precipitating the -phase similarly to Al and Ti, although in the present invention Nb mainly contributes to the -phase (Ni.sub.3Nb) having the crystal structure which is very similar to the -phase. The -phase acts as the precipitation strengthening phase similarly to the -phase to improve the high-temperature strength of material. In order to attain this effect, it is necessary to add Nb 4.5% or more. Further, the -phase is metamorphosed to the -phase having different crystal structure due to aging at high temperature although the composition is the same. The -phase has no effect of precipitation strengthening, although since the -phase is apt to be precipitated to crystal grain boundary, the -phase plays a role of pinning upon hot forging and thermal processing, so that the -phase is effective in suppressing the crystal gains from being coarsened.

(21) Ti: 0.8 to 1.3%

(22) Ti is solidly dissolved into the -phase in the form of Ni.sub.3 (Al, Ti) and contributes to high-temperature strength. The effect can be recognized even with small addition, although it is necessary to add Ti at least 0.8% from the point of view of improvement of segregation property. When Ti is added excessively, intermetallic compound except the -phase is formed to deteriorate ductility and high-temperature workability. Furthermore, similarly to Al, the solid solution temperature of the -phase is increased to deteriorate the hot forgeability and accordingly 1.3% is the upper limit.

(23) W: 3.0 to 6.0%

(24) W strengthens the matrix phase by solid solution strengthening. From the point of view of the segregation property, there is a tendency that the segregation property is improved as the addition amount is increased and accordingly it is necessary to add W at least 3.0%. However, when 6.0% is exceeded, production of hard and fragile intermetallic compound phase is promoted and the high-temperature forgeability is deteriorated.

(25) B: 0.001 to 0.03%

(26) B strengthens the grain boundary with small addition and is effective in improvement of creep strength. However, excessive addition causes precipitation of harmful phase and partial melting due to reduction in a melting point. Accordingly, its proper range is set to be 0.001 to 0.03%.

(27) C: 0.001 to 0.1%

(28) C is solidly dissolved into the matrix phase to improve the tension strength at high temperature and forms carbide such as MC and M.sub.23C.sub.6 to improve the grain boundary strength. These effects are remarkable from about 0.001%, although excessive addition of C causes coarse eutectic carbide to reduce the toughness and accordingly the upper limit is set to be 0.1%.

(29) Mo: 1.0% or less

(30) Mo has the influence on strength that is very similar to W and is effective in strengthening matrix phase by solid solution strengthening. Improvement of strength is recognized even with small amount and the effect thereof is increased with the addition amount. However, since the segregation property is greatly deteriorated with addition, the upper limit is set to be 1.0%.

(31) As component elements except the above, one kind or two or more kinds of elements such as Co, Mg, Ca, Zr, Mn, Si, V, Ta and Re can be contained.

(32) Co: 5.0% or less

(33) Co is effective in improvement of high-temperature ductility and can be added to 5.0%. When 5% is exceeded, precipitation of embrittlement phase is promoted.

(34) Mg: 0.1% or less and Ca: 0.1% or less

(35) Mg and Ca may be added in order to reduce S which is harmful element in solution. However, when they are added excessively, inclusion is formed to reduce the fatigue strength and accordingly the upper limit of both is supposed to be 0.1%.

(36) Zr: 0 to 0.05% or less

(37) Zr is segregated on the crystal grain boundary and is effective in enhancing the grain boundary strength, although Zr almost forms nickel and intermetallic compound Ni.sub.3Zr which are main components of the alloy. This compound reduces the ductility of the alloy and has remarkably low melting point. Accordingly, the solution processing of alloy is made difficult and harmful action is increased. Hence, the upper limit is set to be 0.05% and it is preferable to be smaller than or equal to 0.01%.

(38) Si: 0.5% or less and Mn: 0.5% or less

(39) Si and Mn have deoxidation effect and reduce oxygen solidly dissolved in the alloy. When they are added excessively, the strengthening phase is unstable to reduce the strength and accordingly the upper limit is set to be 0.5%.

(40) V: 0.5% or less and Ta: 0.5% or less

(41) V and Ta can stabilize the -phase and -phase and be added to improve the strength, although when they are added excessively, the hot forgeability is deteriorated and accordingly the upper limit is set to be 0.5%.

(42) Re: 0.5% or less

(43) Re is an element which is solidly dissolved in matrix phase to strengthen solid solution and is effective in improvement of the corrosion resistance similarly to W and Mo. However, Re is expensive and its specific gravity is large to increase the specific gravity of the alloy. Accordingly, the upper limit is required to be 0.5% and it is preferable to be smaller than or equal to 0.1%.

(44) The following component elements are inevitable impurities.

(45) O: 0.005% or less and N: 0.005% or less

(46) O and N are impurities and both of them are often mixed from alloy material. O is mixed even from a melting pot and exists in the alloy as oxide Al.sub.2O.sub.3 and nitrides TiN and AlN massively. When these exist in a casting, they are starting points of crack in creep deformation, so that creep rupture life is reduced and they are starting points of fatigue crack generation, so that fatigue life is reduced. It is preferable that the content of these elements is smaller, although when actual ingot is formed, these elements cannot be reduced to 0 and accordingly the upper limit of both elements is set to be 0.005% as the range in which characteristic is not deteriorated greatly.

(47) P: 0.01% or less and S: 0.01% or less

(48) P and S are impurities. It is preferable that these elements are as small as possible and the content of these elements is required to be suppressed to 0.01% or less.

(49) The following experimental data is based on the result of thermodynamic simulation using database of Ni base alloy.

EMBODIMENT

(50) Table 1 shows chemical composition of alloys (A1 to A8) of the present invention and existing alloys (B1 to B7) as comparison. The unit of numerical values is all mass percentage (%). Higher solid solution temperature is adopted as the solid solution temperature of the precipitation strengthening phase in order to precipitate two kinds of -phase and -phase. Difference in the solid solution temperature between the -phase and the precipitation strengthening phase is a value obtained by subtracting the solid solution temperature of the precipitation strengthening phase from the solid solution temperature of the phase.

(51) TABLE-US-00001 TABLE 1 composition of alloys [mass %] section No. Ni Al Cr Fe Mo Nb Ti W B C alloys of the Invention A1 remainder 0.6 18.7 18.5 0.0 5.20 1.1 4.0 0.004 0.03 A2 remainder 065 19.2 18.5 0.5 5.20 1.3 3.6 0.006 0.03 A3 remainder 0.75 19.5 18.3 0.0 5.40 1.2 3.9 0.0037 0.031 A4 remainder 0.59 19 18.5 0.0 5.50 1.1 4.1 0.0035 0.03 A5 remainder 0.6 19 18.8 1.0 4.50 1.1 3.8 0.004 0.03 A6 remainder 0.8 19 18.5 0.0 5.00 0.8 4.5 0.004 0.02 A7 remainder 0.6 20 18.5 0.0 5.20 0.8 3.5 0.0045 0.03 A8 remainder 0.6 19 18 0.0 5.50 1.05 4.0 0.0042 0.028 existing alloys B1 remainder 1.0 19 18.5 0.0 5.20 1.05 4.0 0.004 0.03 B2 remainder 0.6 20 19.5 0.0 3.50 1.15 4.0 0.004 0.035 B3 remainder 0.9 18.5 18.5 0.0 5.00 1.1 5.0 0.0043 0.03 B4 remainder 0.8 19 18.5 0.5 4.00 1.5 3.5 0.004 0.03 B5 remainder 1.2 17 20 0.0 4.00 1.5 5.5 0.005 0.025 B6 remainder 0.8 18 18.5 0.0 5.00 1.7 4.0 0.003 0.05 B7 remainder 1.0 19 18 0.0 4.50 2 3.8 0.007 0.04 solid solution difference in solid phase fraction of - temperature of solution temperature phase at solid precipitation between -phase solution temperature strengthening and precipitation of precipitation phase strengthening phase strengthening phase section No. [ C.] [ C.] [%] expression 1 alloys of the Invention A1 939 82.3 8.8 0.38 A2 960 63.6 7.3 0.754 A3 963 60.6 7.4 0.75 A4 952 83.0 10.0 0.22 A5 938 57.7 6.0 0.702 A6 933 77.9 7.6 0.516 A7 952 84.0 10.6 0.016 A8 951 84.3 10.3 0.176 existing alloys B1 965 42.5 4.7 1.194 B2 939 20.7 2.1 1.228 B3 959 37.6 4.1 1.132 B4 972 5.3 0.0 1.9 B5 987 78.8 0.0 2.78 B6 982 10.7 1.5 1.704 B7 1010 40.3 0.0 2.77

(52) FIGS. 1, 2, 3 and 4 are graphs showing phase equilibrium calculation results in the composition of Table 1. FIG. 1 shows the relation of the solid solution temperature of the precipitation strengthening phase and the difference in the solid solution temperature between the -phase and the precipitation strengthening phase, and the alloys of the present invention have lower solid solution temperature of the precipitation strengthening phase as compared with the existing alloys. Particularly, when a large-sized member is subjected to hot forgeability, it is preferable that the precipitation strengthening phase which increases a distortion resistance is smaller and accordingly it is apparent that the forgeability of the alloys of the present invention is excellent. Further, since the difference in the solid solution temperature between the -phase and the precipitation strengthening phase is larger than or equal to 50 C., it is difficult to be influenced by precipitation strengthening due to reduction in temperature upon hot forging and forging can be made in the state that only the -phase is precipitated. Accordingly, the alloys of the present invention can suppress forging crack and is easy to miniaturize the crystal grains.

(53) FIG. 2 shows the phase fraction of the -phase at the solid solution temperature of the precipitation strengthening phase and there is a tendency that the phase fraction of the -phase is increased as the difference in the solid solution temperature between the -phase and the precipitation strengthening phase is larger. The phase fraction of the -phase of the alloys of the present invention is larger than or equal to 5% in the stable state and the -phase necessary for suppression of crystal grain coarsening can be ensured even in the state where the -phase of the metastable phase remains. Furthermore, since the remaining -phase is metamorphosed to the -phase during hot forging, the effect of miniaturization of crystal grains is improved as forging is performed repeatedly. The -phase is apt to be precipitated to the crystal grain boundary, although the -phase is precipitated even into grains when the phase fraction exceeds a certain value and accordingly it is preferable that the phase fraction in the stable state is smaller than or equal to about 10%. As described above, there is the effect of suppressing the crystal grain coarsening within the range of alloys of the present invention and it is possible to manufacture the Ni base forged alloy having an average diameter of crystal grain smaller than or equal to 100 m.

(54) FIGS. 3 and 4 show the relations of the solid solution temperature of the precipitation strengthening phase and difference in the solid solution temperature between the -phase and the precipitation strengthening phase versus the value of the expression 1 defined by 2.20amount of Al+1.32amount of Ti0.46amount of Nb, respectively. When the value of the expression 1 is smaller than or equal to 1, the solid solution temperature of the precipitation strengthening phase is lower than or equal to 970 C. and the difference in the solid solution temperature between the -phase and the precipitation strengthening phase is larger than or equal to 50 C., so that the effects of the present invention are satisfied sufficiently. Even in the existing alloy range, alloys (B1, B2 and B4) having the solid solution temperature of the precipitation strengthening phase lower than or equal to 970 C. are recognized, although the value of the expression 1 is larger than or equal to 1 since Nb is little as compared with Al and Ti and accordingly the difference in the solid solution temperature between the -phase and the precipitation strengthening phase is lower than 50 C.

(55) FIG. 5 is a schematic diagram illustrating a side of a gas turbine manufactured by the Ni base forged alloy containing the above composition elements (Al, Cr, Fe, Ni, Ti, W, B, C and Mo) and FIG. 6 is a schematic diagram illustrating a section of a high-temperature rotation part. As components used as large-sized forged member and for which the high-temperature strength is required among the above components, a turbine disk and a turbine spacer are enumerated. Since conventional material such as Alloy 718 or the like is difficult to make large-sized member, it is difficult to apply it to a large-sized turbine disk and instead it is possible to manufacture a large-sized steel lump. However, it is necessary to use material having low temperature resistance and high efficiency of the gas turbine is impeded.

(56) The alloy of the present invention has high temperature resistance and can be used to manufacture large-sized forged member sufficient to manufacture the gas turbine disk. Accordingly, the large-sized gas turbine having output larger than or equal to 80 MW can be manufactured. Further, a high-efficient thermal power plant to which the large-sized gas turbine is applied can be realized.

(57) It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.