CA2036810A1 - Method of forming article with variable alloy composition - Google Patents
Method of forming article with variable alloy compositionInfo
- Publication number
- CA2036810A1 CA2036810A1 CA002036810A CA2036810A CA2036810A1 CA 2036810 A1 CA2036810 A1 CA 2036810A1 CA 002036810 A CA002036810 A CA 002036810A CA 2036810 A CA2036810 A CA 2036810A CA 2036810 A1 CA2036810 A1 CA 2036810A1
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- Canada
- Prior art keywords
- metal
- alloy
- melt
- crucible
- preform
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/123—Spraying molten metal
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Powder Metallurgy (AREA)
Abstract
RD-19,522 METHOD OF FORMING ARTICLE WITH VARIABLE ALLOY
COMPOSITION
Abstract of the Disclosure The method of forming a structure having multiple alloy properties is taught. The method involves spray forming and employs a single alloy system which is subject to modification by addition of modifying elements. The initial preform is made of the alloy without the modifiers present.
The modifiers are added to mix with and dissolve in the alloy in a dispensing crucible supplying the spray forming operation. The latter portions of the preform have modified alloy content and properties which are modified based on the modification of alloy content.
COMPOSITION
Abstract of the Disclosure The method of forming a structure having multiple alloy properties is taught. The method involves spray forming and employs a single alloy system which is subject to modification by addition of modifying elements. The initial preform is made of the alloy without the modifiers present.
The modifiers are added to mix with and dissolve in the alloy in a dispensing crucible supplying the spray forming operation. The latter portions of the preform have modified alloy content and properties which are modified based on the modification of alloy content.
Description
Rn~ s22 T~OD OF FO~U~ING ~U~TIC~E WIT~ ~iRI ~ ~E ~ ~OY
CO3oeO-QI~ION
_ _ The subject application relates to copending applications Serial No. (Attorney Docket RD-17,399) filed ; Serial No. (Attorney Docket RD-18,041) filed ; and Serial No. (Attorney Docket RD-20,134) filed The text of the related applications are incorporated herein by reference.
~
The pressnt invention relates to the formation of structures with variable alloy composition. More particularly, it relates to a method by which structures can be formed having an inner portion of one composition and an outer portion of a different composition.
It is known that superalloys including nickel base and iron base superalloys have been employed extensively in applications which require high strength at high temperature.
The design of jet engines has in large part been determined by the properties which superalloys used as fabricating materials for components of the engine can display. As the properties of the alloys are improved the design of the jet engine improves and greater thrust to weight ratios are achieved. Generally, higher temperature operation results in greater fuel efficiency for such engines and the drive for higher operating temperatures and for superalloy materials which can operate at such higher temperatures is a continuous design criteria for fabrication of more and more efficient - 2 - ~ 3 RD-1 4, 52 jet engines. The need for higher temperature capability in high strength superalloys continues as efforts are made to continue to improve operatlng performance for jet engines.
Many metallurgical advances have assisted in improving high strength superalloys. These have included the increase in the precipitate volume fraction for the gamma prime precipitate strengthening agent of s~ch alloys. Also improvements have been made through powder metallurgy and through the use of isothermal forging. Improvements in the alloy temperature capability of superalloys have been achieved in this way. It has also been recognized that not all components of a jet engine are subject to the same operating conditions and that different metallurgical compositions may be employed in different components of the engine to best suit the needs of that component.
There are some parts where tradeoffs have been made in properties because the part i5 large enough so that the engine operating conditions over the full extent of the part are not uniform. In other words, certain large pieces which are installed in an engine encounter different temperatures and different property requirements and service from one portion of the component to another. Accordingly, for such large components it is necessary to sacrifice a property in one location of the component in order to obtain an acceptable property at another location. Such different properties are needed for example in engine disks which rotate at high speeds of 12,000 revolutions per minute and more and result in the application of high stress to portions of the disk and particularly to the outer portions of the ~0 disk.
In order to compensate for the different property requirements of the different portions of disks, schemes and methods have been devised to impart desirable combinations of properties to the inner and outer portions of such disks.
CO3oeO-QI~ION
_ _ The subject application relates to copending applications Serial No. (Attorney Docket RD-17,399) filed ; Serial No. (Attorney Docket RD-18,041) filed ; and Serial No. (Attorney Docket RD-20,134) filed The text of the related applications are incorporated herein by reference.
~
The pressnt invention relates to the formation of structures with variable alloy composition. More particularly, it relates to a method by which structures can be formed having an inner portion of one composition and an outer portion of a different composition.
It is known that superalloys including nickel base and iron base superalloys have been employed extensively in applications which require high strength at high temperature.
The design of jet engines has in large part been determined by the properties which superalloys used as fabricating materials for components of the engine can display. As the properties of the alloys are improved the design of the jet engine improves and greater thrust to weight ratios are achieved. Generally, higher temperature operation results in greater fuel efficiency for such engines and the drive for higher operating temperatures and for superalloy materials which can operate at such higher temperatures is a continuous design criteria for fabrication of more and more efficient - 2 - ~ 3 RD-1 4, 52 jet engines. The need for higher temperature capability in high strength superalloys continues as efforts are made to continue to improve operatlng performance for jet engines.
Many metallurgical advances have assisted in improving high strength superalloys. These have included the increase in the precipitate volume fraction for the gamma prime precipitate strengthening agent of s~ch alloys. Also improvements have been made through powder metallurgy and through the use of isothermal forging. Improvements in the alloy temperature capability of superalloys have been achieved in this way. It has also been recognized that not all components of a jet engine are subject to the same operating conditions and that different metallurgical compositions may be employed in different components of the engine to best suit the needs of that component.
There are some parts where tradeoffs have been made in properties because the part i5 large enough so that the engine operating conditions over the full extent of the part are not uniform. In other words, certain large pieces which are installed in an engine encounter different temperatures and different property requirements and service from one portion of the component to another. Accordingly, for such large components it is necessary to sacrifice a property in one location of the component in order to obtain an acceptable property at another location. Such different properties are needed for example in engine disks which rotate at high speeds of 12,000 revolutions per minute and more and result in the application of high stress to portions of the disk and particularly to the outer portions of the ~0 disk.
In order to compensate for the different property requirements of the different portions of disks, schemes and methods have been devised to impart desirable combinations of properties to the inner and outer portions of such disks.
-3- 2~3~
Rn-l2~5~2 For example, the patent 4,820,358 issued to the ~ssignee of the sub~ect application has taught a method by which a disk made of a single alloy can be given different properties at its inner or core portion as contrasted with its outer or rim portion. The attainment of different properties in the different portions of the disk is a valuable achievement.
Other efforts have been made to form an inner portion of a disk of one alloy and an outer portion of a different alloy. However, problemq have arisen where efforts are made to join the two alloys together. If oxide layers exist at the boundary it is difficult to be sure that any welding that has occurred overcomes the presence of the oxide and does not leave a region of weakness in the disk. The detection of flaws in such weldments between an inner and outer portion of a disk is difficult.
The present method is directed toward altering the composition of an alloy during spray processing so that one portion of spray deposit, with the attendant properties of that portion, is of a first composition and another portion of the spray deposit, with its different set of alloy properties is of a second composition.
It is, accordingly, one object of the present invention to provide a method for forming a composite structure having two or more different compositions at the different portions thereof.
Another ohject is to provide a structure in which two alloy portions are joined without a sharp demarcation therebetween.
Still another object is to provide a method for forming a preform of a disk having at least two differer.t metals compositions therein.
Rn-l2~5~2 For example, the patent 4,820,358 issued to the ~ssignee of the sub~ect application has taught a method by which a disk made of a single alloy can be given different properties at its inner or core portion as contrasted with its outer or rim portion. The attainment of different properties in the different portions of the disk is a valuable achievement.
Other efforts have been made to form an inner portion of a disk of one alloy and an outer portion of a different alloy. However, problemq have arisen where efforts are made to join the two alloys together. If oxide layers exist at the boundary it is difficult to be sure that any welding that has occurred overcomes the presence of the oxide and does not leave a region of weakness in the disk. The detection of flaws in such weldments between an inner and outer portion of a disk is difficult.
The present method is directed toward altering the composition of an alloy during spray processing so that one portion of spray deposit, with the attendant properties of that portion, is of a first composition and another portion of the spray deposit, with its different set of alloy properties is of a second composition.
It is, accordingly, one object of the present invention to provide a method for forming a composite structure having two or more different compositions at the different portions thereof.
Another ohject is to provide a structure in which two alloy portions are joined without a sharp demarcation therebetween.
Still another object is to provide a method for forming a preform of a disk having at least two differer.t metals compositions therein.
4 ~ 3 ~J ''.' .J
R~-19CS?2 Another object is to provide an alloy structure in which two different alloy~ are present in different portions thereof.
Other objects will be in part apparent and in part pointed out in the description which follows.
In one of its broader aspects objects of the invention can be achieved by providing a spray forming apparatus in which a first metal is flowed as a ~tream from a dispensing crucible to an atomization zone. The first metal is atomized in said zone and is spray deposited onto a recei~ing surface to form a first layer of a preform on the surface. The spray of said first metal to form a preform on said surface is continued. When a significant portion of the first metal is present in the atomization crucible a small portion of an additional metal is added to the atomization crucible to mix the first and second metals therein to form a modification of the first composition. The spray deposit of metal from the atom dispensing crucible onto the preform is continued to enlarge the preform but no more metal is added to the dispensing crucible. The result is the formation of a preform which has the first metal disposed on the receiving surface and wh~ch has the modified metal bonded to the first metal and forming the outer portions of the preform.
The description which follows will be understood with greater clarity if reference is made to the accompanying drawings in which:
FIG~R~ 1 is a schematic illustration of the arrangement of a mandrel, preform, and dispensing crucible;
FIG~R~ 2 is a schematic illustration similar to that of Figure 1 but illustrating the addition of alloying agents to the dispensing crucible; and ~ ~,~ !'j '; ', .
R~-l 9L52 FlGnRE 3 is a graph in which experimental data is displayed showing the change in concentration in an alloying element against depth in a preform.
~
There are certain alloy systems which are altered significantly depending on the additives which are present in the alloy. It is recognized for example, that certain additive elements au~nent the strength of an alloy system so that an alloy which has less of the strengthening additive has lower strength and the same alloy which has the strengthening additives in higher concentration display a higher level of strength.
Similarly, there are modifiers which alter the ductility of an alloy system so that an alloy with lower concentrations of the ductilizing additive have lower ductility and the same alloy with a higher concentration of the ductilizing additive has a higher level of ductility.
The subject invention takes advantage of the alloy systems which are subjec~ to such alteration in desired propertie~ depending on the level of alloy property modifying elements such a~ strengthening agents or ductilizing agents or other property modifying agents. One such agent is mentioned in the background statement of the invention. In particular, it has been found that the high strength of superalloys has been increased and improved by an increase in the precipitate volume fraction for the gamma prime precipitate strengthened superalloys. In other words, it was found that by specific addition of the precipitate forming elements to cause an increase in the volume content of gamma prime precipitate, that a strengthening of the alloy itself resulted.
~3~ ~
Rn~ 2 2 Pursuant to the present invention, a spray forming processing of an alloy is started employing an alloy composition which is free of a modifier or which has a lower level of a modifier element of elements present and the spray processing with the alloy is continued after a modifier is included in the alloy composition so that the latter part of the spray forming is accomplished with the modified alloy rather than with the unmodified alloy which was used at the start of the spray processin~. Unique advantages are derived from the use of a single alloy base in two different parts of a spray formed article where different properties are needed in the two different portions of the article.
For example, in the case of a disk, it is known that higher strength is needed in the rim portions of the disk than is needed in the core or central portions of the disk.
Accordingly, one appropriate use for the subject invention is the spray forming of a disk preform in which the core of the preform has a base alloy content which has a lower concentration of certain additive or modifier elements and in which the outer portion of the preform has the higher concentration of the additive or modifier where this modifier or additive imparts additional strength to the outer portion of the disk eventually produced from the preform.
The manner in which this may be accomplished is now described with reference to the Figures 1 and 2. The results of this trial o:E the invention are then described with respect to Figure 3 which is a plot of data obtained from a measurement of the results of carrying out the invention on a particular alloy system.
Referring now first to Figure 1, the figure is a schematic elevational view in part in section of a spray forming operation sucA as may be used in connection with the present invention. In this regard, a crucible 10 is provided as a dispensing crucible. The crucible is used to hold a -7- ~3 c ~ {j . ~ : ~
Rn-lq~s~2 body of liquid metal and to dispenYe it ac a stream to an atomization zone located beneath the crucible. The crucible is preferably a segmented crucible made up of a number of water cooled metal segments which fit around and form the walls of the crucible much as the staves of a barrel. Each segment is electrically isolated from its adjoining segments and each segment is individually water cooled. A benefit of the water cooling is to permit a skull of the metal of the melt to form on the inside of the crucible to avoid the entrapment of ceramic particles in the melt. However, the melt is kept at its operating tempera~ure by the action of a set of induction coils 14. The segmented character of such a crucible permits the electric flux to penetrate the crucible 12 to act on the liquid metal content- of the crucible 16. In this way, some of the disadvantages of ceramic particle inclusion as discussed in the background of the invention are avoided and overcome.
The stream 18 of liquid metal which pours from the bottom spout 20 of crucible 10 passes into an atomization zone 20 where it is acted on by a jet or jets of atomizing gas delivered from a source which is not shown to the nozzle 22.
The result of the atomization of the liquid stream 18 by the atomizing gas in zone 21 is a production of a cone 24 of droplets of liquid metal. The formation of such a cone is consistent with the normal practice of the art of spray forming. The droplets impact on a receiving surface 26 which is shown in the form of an annular band formed on the hollow mandrel 28. The mandrel 28 is given both a rotary and a reciprocating motion indicated by the arrows by drive means which are not shown. Such motion causes a uniform layer to form on the receiving surface. The first part, and in the illustration shown, the inner part of the preform 26 is formed of an alloy which is subject to being modified by Rn-l9~522 addition of a modifying agent such as a strengthening or ductilizing or other type of modifying agent.
The second part of the preform, and in the illustration shown the outer portion of the preform, i~
formed with an alloy which has been modified. There are numerous ways in which modification of the alloy can be accomplished. Essentially, the modification is accomplished by the addition of a modifying agent to the remaining liquid in the dispensing crucible.
With reference now specifically to Figure 2, the apparatus as illustrated in Figure 1 is again shown with the preform deposit 26 about half completed. Further, about half of the liquid metal 16 has been exhausted from the dispensing crucible 10. At this point, a charge of a modifying agent 32-is added by any convenien~ means such as a scoop or probe 30.
The modifying agent may be added in a liquid or a solid powdered form or in any form which will readily dissolve in ~; the liquid body 16 within the dispensing crucible 10. The ~ heating coil 14 acts on the liquid within the crucible to not only heat in but also to stir it so that there is a continuous stirring action goi~g on and the modifier material 32 which is added is quickly stirred into and mixed with and dissolved in the molten metal liquid 16 within the crucible 10 .
Reference is next made to Figure 3. Figure 3 is a graph in which data is recorded on an experimental run which was made employing an alloy which could be modified by the addition of aluminum in a relatively small weight percent.
The expcriment was carried out by first forming the first half or the inner half of the preform 26 employing an alloy which exhibited a low volume ~ of a gamma prime microstructure. At a predetermined time during atomization, a known amount of aluminum was immersed into the remaining bath of the molten metal. Within seconds the composition of R~-1~ 52?
the bath had changed from a low gamma prime alloy to that of an alloy with a high gamma prime content. Figure 3 is a plot of the change in aluminum concentration of the alloy in relation to the thickness of the preform set forth on the abscissa. As is evident from the figure, the initial weight concentration of aluminum was approximately 2.2 znd this concentration of aluminum was pre-qent in the preform to a thickness of about 1.5 inches. At this point, an addition of aluminum was made and, as is evident from the graph, a dramatic increase in the aluminum content of the alloy at about 1.70 inches is the result of the addition. For the alloy at a depth or at a thickness of about 2.0 inches the aluminum content had risen to about 4 weight percent.
Concentration of the aluminum in the alloy remained at about 4 weight percent for the remainder of the run.
Two runs are represented in Figure 3 and the two runs are respectivelv mar~ed as run 1 and run 2.
Although in the illustrative example given, aluminum was added to a melt to vary the gamma prime content of the preform during the atomization, it will be understood that other modifier elements may also be added to an alloy system to modify the properties of a spray deposit in one portion relative to another portion. For example, it is contemplated that other elements such as tantalum or master alloys with or without aluminum may be dissolved in a dispensing crucible as the atomization is in progress to provide a desired microstructure and a tailored set of properties at different portions of the preform being formed.
R~-19CS?2 Another object is to provide an alloy structure in which two different alloy~ are present in different portions thereof.
Other objects will be in part apparent and in part pointed out in the description which follows.
In one of its broader aspects objects of the invention can be achieved by providing a spray forming apparatus in which a first metal is flowed as a ~tream from a dispensing crucible to an atomization zone. The first metal is atomized in said zone and is spray deposited onto a recei~ing surface to form a first layer of a preform on the surface. The spray of said first metal to form a preform on said surface is continued. When a significant portion of the first metal is present in the atomization crucible a small portion of an additional metal is added to the atomization crucible to mix the first and second metals therein to form a modification of the first composition. The spray deposit of metal from the atom dispensing crucible onto the preform is continued to enlarge the preform but no more metal is added to the dispensing crucible. The result is the formation of a preform which has the first metal disposed on the receiving surface and wh~ch has the modified metal bonded to the first metal and forming the outer portions of the preform.
The description which follows will be understood with greater clarity if reference is made to the accompanying drawings in which:
FIG~R~ 1 is a schematic illustration of the arrangement of a mandrel, preform, and dispensing crucible;
FIG~R~ 2 is a schematic illustration similar to that of Figure 1 but illustrating the addition of alloying agents to the dispensing crucible; and ~ ~,~ !'j '; ', .
R~-l 9L52 FlGnRE 3 is a graph in which experimental data is displayed showing the change in concentration in an alloying element against depth in a preform.
~
There are certain alloy systems which are altered significantly depending on the additives which are present in the alloy. It is recognized for example, that certain additive elements au~nent the strength of an alloy system so that an alloy which has less of the strengthening additive has lower strength and the same alloy which has the strengthening additives in higher concentration display a higher level of strength.
Similarly, there are modifiers which alter the ductility of an alloy system so that an alloy with lower concentrations of the ductilizing additive have lower ductility and the same alloy with a higher concentration of the ductilizing additive has a higher level of ductility.
The subject invention takes advantage of the alloy systems which are subjec~ to such alteration in desired propertie~ depending on the level of alloy property modifying elements such a~ strengthening agents or ductilizing agents or other property modifying agents. One such agent is mentioned in the background statement of the invention. In particular, it has been found that the high strength of superalloys has been increased and improved by an increase in the precipitate volume fraction for the gamma prime precipitate strengthened superalloys. In other words, it was found that by specific addition of the precipitate forming elements to cause an increase in the volume content of gamma prime precipitate, that a strengthening of the alloy itself resulted.
~3~ ~
Rn~ 2 2 Pursuant to the present invention, a spray forming processing of an alloy is started employing an alloy composition which is free of a modifier or which has a lower level of a modifier element of elements present and the spray processing with the alloy is continued after a modifier is included in the alloy composition so that the latter part of the spray forming is accomplished with the modified alloy rather than with the unmodified alloy which was used at the start of the spray processin~. Unique advantages are derived from the use of a single alloy base in two different parts of a spray formed article where different properties are needed in the two different portions of the article.
For example, in the case of a disk, it is known that higher strength is needed in the rim portions of the disk than is needed in the core or central portions of the disk.
Accordingly, one appropriate use for the subject invention is the spray forming of a disk preform in which the core of the preform has a base alloy content which has a lower concentration of certain additive or modifier elements and in which the outer portion of the preform has the higher concentration of the additive or modifier where this modifier or additive imparts additional strength to the outer portion of the disk eventually produced from the preform.
The manner in which this may be accomplished is now described with reference to the Figures 1 and 2. The results of this trial o:E the invention are then described with respect to Figure 3 which is a plot of data obtained from a measurement of the results of carrying out the invention on a particular alloy system.
Referring now first to Figure 1, the figure is a schematic elevational view in part in section of a spray forming operation sucA as may be used in connection with the present invention. In this regard, a crucible 10 is provided as a dispensing crucible. The crucible is used to hold a -7- ~3 c ~ {j . ~ : ~
Rn-lq~s~2 body of liquid metal and to dispenYe it ac a stream to an atomization zone located beneath the crucible. The crucible is preferably a segmented crucible made up of a number of water cooled metal segments which fit around and form the walls of the crucible much as the staves of a barrel. Each segment is electrically isolated from its adjoining segments and each segment is individually water cooled. A benefit of the water cooling is to permit a skull of the metal of the melt to form on the inside of the crucible to avoid the entrapment of ceramic particles in the melt. However, the melt is kept at its operating tempera~ure by the action of a set of induction coils 14. The segmented character of such a crucible permits the electric flux to penetrate the crucible 12 to act on the liquid metal content- of the crucible 16. In this way, some of the disadvantages of ceramic particle inclusion as discussed in the background of the invention are avoided and overcome.
The stream 18 of liquid metal which pours from the bottom spout 20 of crucible 10 passes into an atomization zone 20 where it is acted on by a jet or jets of atomizing gas delivered from a source which is not shown to the nozzle 22.
The result of the atomization of the liquid stream 18 by the atomizing gas in zone 21 is a production of a cone 24 of droplets of liquid metal. The formation of such a cone is consistent with the normal practice of the art of spray forming. The droplets impact on a receiving surface 26 which is shown in the form of an annular band formed on the hollow mandrel 28. The mandrel 28 is given both a rotary and a reciprocating motion indicated by the arrows by drive means which are not shown. Such motion causes a uniform layer to form on the receiving surface. The first part, and in the illustration shown, the inner part of the preform 26 is formed of an alloy which is subject to being modified by Rn-l9~522 addition of a modifying agent such as a strengthening or ductilizing or other type of modifying agent.
The second part of the preform, and in the illustration shown the outer portion of the preform, i~
formed with an alloy which has been modified. There are numerous ways in which modification of the alloy can be accomplished. Essentially, the modification is accomplished by the addition of a modifying agent to the remaining liquid in the dispensing crucible.
With reference now specifically to Figure 2, the apparatus as illustrated in Figure 1 is again shown with the preform deposit 26 about half completed. Further, about half of the liquid metal 16 has been exhausted from the dispensing crucible 10. At this point, a charge of a modifying agent 32-is added by any convenien~ means such as a scoop or probe 30.
The modifying agent may be added in a liquid or a solid powdered form or in any form which will readily dissolve in ~; the liquid body 16 within the dispensing crucible 10. The ~ heating coil 14 acts on the liquid within the crucible to not only heat in but also to stir it so that there is a continuous stirring action goi~g on and the modifier material 32 which is added is quickly stirred into and mixed with and dissolved in the molten metal liquid 16 within the crucible 10 .
Reference is next made to Figure 3. Figure 3 is a graph in which data is recorded on an experimental run which was made employing an alloy which could be modified by the addition of aluminum in a relatively small weight percent.
The expcriment was carried out by first forming the first half or the inner half of the preform 26 employing an alloy which exhibited a low volume ~ of a gamma prime microstructure. At a predetermined time during atomization, a known amount of aluminum was immersed into the remaining bath of the molten metal. Within seconds the composition of R~-1~ 52?
the bath had changed from a low gamma prime alloy to that of an alloy with a high gamma prime content. Figure 3 is a plot of the change in aluminum concentration of the alloy in relation to the thickness of the preform set forth on the abscissa. As is evident from the figure, the initial weight concentration of aluminum was approximately 2.2 znd this concentration of aluminum was pre-qent in the preform to a thickness of about 1.5 inches. At this point, an addition of aluminum was made and, as is evident from the graph, a dramatic increase in the aluminum content of the alloy at about 1.70 inches is the result of the addition. For the alloy at a depth or at a thickness of about 2.0 inches the aluminum content had risen to about 4 weight percent.
Concentration of the aluminum in the alloy remained at about 4 weight percent for the remainder of the run.
Two runs are represented in Figure 3 and the two runs are respectivelv mar~ed as run 1 and run 2.
Although in the illustrative example given, aluminum was added to a melt to vary the gamma prime content of the preform during the atomization, it will be understood that other modifier elements may also be added to an alloy system to modify the properties of a spray deposit in one portion relative to another portion. For example, it is contemplated that other elements such as tantalum or master alloys with or without aluminum may be dissolved in a dispensing crucible as the atomization is in progress to provide a desired microstructure and a tailored set of properties at different portions of the preform being formed.
Claims (5)
1. The method of forming a preform having different properties in different parts thereof which comprises, providing a dispensing crucible to contain a melt of a metal to be spray formed;
providing a bottom spout from said dispensing crucible to deliver a stream of liquid metal to an atomization zone beneath said crucible, providing a supply of atomizing gas to said zone to atomize the stream of liquid metal being delivered thereto from said dispensing crucible into a cone of fine droplets, disposing a receiving surface to be coated with said fine droplets of said cone, adding a modifier metal to melt in said dispensing crucible to modify the properties of the metal which is melted therein, mixing the modifier metal into the melt, and continuing the spray forming to spray deposit the modified melt onto the preform.
providing a bottom spout from said dispensing crucible to deliver a stream of liquid metal to an atomization zone beneath said crucible, providing a supply of atomizing gas to said zone to atomize the stream of liquid metal being delivered thereto from said dispensing crucible into a cone of fine droplets, disposing a receiving surface to be coated with said fine droplets of said cone, adding a modifier metal to melt in said dispensing crucible to modify the properties of the metal which is melted therein, mixing the modifier metal into the melt, and continuing the spray forming to spray deposit the modified melt onto the preform.
2. The method of claim 1, in which the metal melt is a nickel base superalloy.
3. The method of claim 1, in which the metal melt is a superalloy and the modifier metal is a strengthening modifier.
4. The method of claim 1, in which the metal melt is a superalloy and the modifier metal is a gamma prime former.
- 11 - RD-19,522
- 11 - RD-19,522
5. The method of claim 1, in which the metal melt is a superalloy and the modifier meter is aluminum.
7. The invention as defined in any of the preceding claims including any further features of novelty disclosed.
7. The invention as defined in any of the preceding claims including any further features of novelty disclosed.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US48751190A | 1990-03-02 | 1990-03-02 | |
| US487,511 | 1990-03-02 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2036810A1 true CA2036810A1 (en) | 1991-09-03 |
Family
ID=23936028
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002036810A Abandoned CA2036810A1 (en) | 1990-03-02 | 1991-02-21 | Method of forming article with variable alloy composition |
Country Status (6)
| Country | Link |
|---|---|
| JP (1) | JPH04221083A (en) |
| CA (1) | CA2036810A1 (en) |
| DE (1) | DE4105420A1 (en) |
| FR (1) | FR2659581B1 (en) |
| GB (1) | GB2241510B (en) |
| IT (1) | IT1247119B (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5240061A (en) * | 1990-12-28 | 1993-08-31 | Osprey Metals Limited | Substrate for spray cast strip |
| DE4235303A1 (en) * | 1992-10-20 | 1994-04-21 | Wieland Werke Ag | Rotationally symmetrical semi-finished product with properties that vary across the cross-section |
| US6305459B1 (en) * | 1999-08-09 | 2001-10-23 | Ford Global Technologies, Inc. | Method of making spray-formed articles using a polymeric mandrel |
| DE102011002872B4 (en) * | 2011-01-19 | 2018-11-15 | Federal-Mogul Sealing Systems Gmbh | Method for producing a cylinder head gasket and cylinder head gasket produced thereby |
| WO2018020296A1 (en) * | 2016-07-27 | 2018-02-01 | Arcelormittal | Apparatus and method for vacuum deposition |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1359486A (en) * | 1970-06-20 | 1974-07-10 | Vandervell Products Ltd | Methods and apparatus for producing composite metal material |
| FR2392746A2 (en) * | 1977-06-01 | 1978-12-29 | Air Liquide | METAL CASTING PROCESS |
| DE3409366A1 (en) * | 1984-03-12 | 1985-09-12 | Mannesmann AG, 4000 Düsseldorf | METHOD AND DEVICE FOR PRODUCING A MOLDED BODY |
| WO1989005870A1 (en) * | 1987-12-14 | 1989-06-29 | Osprey Metals Limited | Spray deposition |
-
1991
- 1991-02-21 CA CA002036810A patent/CA2036810A1/en not_active Abandoned
- 1991-02-21 DE DE4105420A patent/DE4105420A1/en not_active Withdrawn
- 1991-02-27 GB GB9104113A patent/GB2241510B/en not_active Expired - Fee Related
- 1991-02-28 JP JP3055631A patent/JPH04221083A/en not_active Withdrawn
- 1991-03-01 IT ITMI910547A patent/IT1247119B/en active IP Right Grant
- 1991-03-01 FR FR9102451A patent/FR2659581B1/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| JPH04221083A (en) | 1992-08-11 |
| IT1247119B (en) | 1994-12-12 |
| GB2241510B (en) | 1993-12-08 |
| FR2659581B1 (en) | 1992-10-09 |
| GB9104113D0 (en) | 1991-04-17 |
| FR2659581A1 (en) | 1991-09-20 |
| ITMI910547A0 (en) | 1991-03-01 |
| DE4105420A1 (en) | 1991-09-05 |
| GB2241510A (en) | 1991-09-04 |
| ITMI910547A1 (en) | 1992-09-01 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |