CN105189029B - 超合金部件的结构钎焊修复 - Google Patents

超合金部件的结构钎焊修复 Download PDF

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CN105189029B
CN105189029B CN201480015310.9A CN201480015310A CN105189029B CN 105189029 B CN105189029 B CN 105189029B CN 201480015310 A CN201480015310 A CN 201480015310A CN 105189029 B CN105189029 B CN 105189029B
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brazing material
superalloy
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K.奥兹贝萨尔
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Siemens Energy Inc
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    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
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    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
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    • B23K35/3033—Ni as the principal constituent
    • B23K35/304—Ni as the principal constituent with Cr as the next major constituent
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    • C22C—ALLOYS
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    • C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
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    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
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Abstract

用于超合金燃气涡轮发动机部件的结构修复的无硼和硅的钎焊合金。该钎焊合金组合物可以仅含有在待修复的超合金材料中所含的元素，并可以具有低至10℃的熔融温度范围，以促进在该超合金基底材料的固溶热处理过程中产生高强度的均化的钎焊接头。

Description

超合金部件的结构钎焊修复
本申请要求美国临时专利申请号61/782,260（代理人案号2013P04581US）的2013年3月14日的提交日权益。本申请是2012年6月13日提交的美国专利申请号13/495,223（代理人案号2011P25126US01）的部分继续申请案，其又要求美国临时专利申请号61/555,113（代理人案号2011P25126US）的2011年11月03日的提交日权益。
发明领域
本发明大体上涉及材料技术的领域，并且更特别涉及用钎焊法修复超合金材料。
发明背景
公认的是，由于它们易于焊接凝固开裂和应变时效开裂，超合金材料的修复是困难的。术语“超合金”在本文中如其在本领域中常用的那样使用；即在高温下表现出优异的机械强度和抗蠕变性的非常抗腐蚀和抗氧化的合金（http://en.wikipedia.org/wiki/Superalloy）。超合金通常包含高的镍或钴含量。超合金的实例包括以商标和品牌名Hastelloy、Inconel合金（例如IN 738、IN 792、IN 939）、Rene合金（例如Rene N5、Rene 80、Rene 142）、Haynes合金、Mar M、CM 247、CM 247 LC、C263、718、X-750、ECY 768、282、X45、PWA 1483和CMSX（例如CMSX-4）单晶合金出售的合金。
在某些应用中使用钎焊法以修复超合金材料。尽管钎焊接头通常被理解为在机械上比焊接接头更弱并由于钎焊材料的相对低的熔融温度而具有较低的可接受操作温度，但钎焊修复在某些较低应力和/或较低温度应用中是可以接受的。
使用硼或硅作为熔点抑制材料的常见钎焊材料对超合金基底材料的价值有限，因为它们产生降低接头和修复区的延展性的有害相。已经研发出包含铪和/或锆的无硼和硅的钎焊合金，对其提出高达基础超合金性能的80%的机械性能的要求。但是，这样的材料倾向于在钎焊接头处形成碳化物。因此，需要进一步改进超合金材料的钎焊。
附图简述
在下列描述中基于附图解释本发明，其显示：
图1是燃气涡轮叶片的侧剖视图，其中通过钎焊修复大间隙断口。
图2是燃气涡轮叶片的侧剖视图，其中通过钎焊修复窄间隙断口。
发明详述
本发明人已研发出使用钛作为熔点抑制材料的几种无硼和硅的钎焊合金，包括共同审理的2012年5月09日提交的美国专利申请号13/467,402（代理人案号2011P24893US）和2012年6月13日提交的13/495,223（代理人案号2011P25126US01）中公开的那些。本文公开了特别用于修复超合金基底材料的额外的无硼和硅的钎焊合金，包括与现有技术的铪基钎焊合金相比时有利地具有减小的熔融温度范围的合金。选择所公开的钎焊组合物的实施方案，以仅包含存在于待修复的超合金中的元素，以使钎焊接头的均化不向该超合金材料基体中引入任何不同的元素。本合金提供具有足够接近于（例如大于80%）经修复的基底材料性能的机械性能的钎焊接头，以使该修复可以被视为结构修复并可用于该部件的受到相对高应力的区域中。
本发明人已研发出表现出低至不大于10℃或在其它实施方案中不大于15℃或不大于20℃或不大于50℃的各自熔融温度范围（在本领域中也称作凝固温度范围）的三元和多组分钎焊合金。本文所用的术语“熔融温度范围”表示液相线温度（材料100%为液体）和固相线温度（材料100%为固体）之间的差异。常见的已知铪基钎焊合金表现出明显更宽的熔融温度范围 - 参见例如美国专利申请公开号US 2009/0159645 A1的表2，其公开了具有不低于70℃（126℉）至高达176℃（317℉）的熔融温度范围的合金。本发明人已经发现，在超合金基底的固溶热处理过程中使用该合金钎焊时，其合金的窄熔融温度范围有利于部件修复。窄熔融温度范围提供对钎焊材料的流度性的改进的控制，这导致在钎焊材料流动（liquidity）之前更完全地排出溶剂、水和有机物，降低将排出的气体截留在钎焊材料内的倾向，改进基底裂纹和填充合金粉末颗粒之间的间隙的渗透，和由于降低的流动时间而对基底材料的较少侵蚀。
在本文中公开了例如在修复已被发现在其平台或翼面部分上具有运行诱发的裂纹的燃气涡轮发动机桨叶或叶片时特别用于修复超合金，包括Rene 80超合金材料的钎焊合金。Rene 80部件提出特别的挑战，因为它们可在1215℃下固溶热处理，这低于另一些合金，例如可在1235℃下固溶热处理的Alloy 247部件。下文公开的合金可配制成具有可调节的液相线和固相线温度和熔融温度范围，以与该部件的特定超合金材料的固溶热处理温度方案（regiment）协作，以在固溶热处理过程中实现钎焊并熔化和均化钎焊接头。可以选择这样的钎焊材料以具有包括或低于令人感兴趣的特定超合金基底材料的固溶热处理温度（即在该方案过程中使用的峰值保持温度）的熔融温度范围。该钎焊接头的均化和凝固有利地不向超合金基底材料中引入不已存在于该材料中的任何新的元素成分。
用于此类应用的三元合金可具有下列范围内的组成（本文中公开的所有组成以重量%为单位）：
Cr 15-25%；
Ti 15-25%；
余量Ni。
这组内的特定钎焊合金可具有下列组成：Cr 16.3%、Ti 21.2%、余量Ni；或Cr17.2%、Ti 20.9%、余量Ni。这些特定钎焊合金组合物表现出大约1205℃的固相线温度和大约1215℃的液相线温度和因此仅10℃的熔融温度范围。照此，在钎焊到Alloy 247或Rene80上时，它们可以是特别有用的。这组内的另一钎焊合金具有下列组成：Cr 20%、Ti 20%、Ni60%。
另外的钎焊合金可具有下列范围内的组成：
Cr 12-16%；
Ti 13-16%；
Al 0-2.5%；
Co 2-4%；
W 3-5%；
Mo 0-2%；
Ta 0-2%；
余量Ni。
这组内的特定钎焊合金可具有下列组成：Cr 14.1%、Ti 14%、Al 2.1%、Co 3.1%、W4.1%、Mo 1%、Ta 1%、余量Ni。当钎焊到Alloy 247上时，该特定的钎焊合金组合物可以是特别有用的。
另外的钎焊合金可具有下列范围内的组成：
Cr 15-18%；
Ti 10-15%；
Al 0-2.5%；
Co 2-4%；
W 3-5%；
Mo 0-2%；
Ta 0-2%；
余量Ni。
这组内的特定钎焊合金可具有下列组成：Cr 17.57%、Ti 13.54%、Al 2.39%、Co3.24%、W 3.47%、Mo 1.15%、Ta 0.83%、余量Ni。该特定钎焊合金组合物表现出大约1205℃的固相线温度和大约1220℃的液相线温度和因此仅15℃的熔融温度范围。照此，在钎焊到Alloy 247或Rene 80上时，其可以是特别有用的。
另外的钎焊合金可具有下列范围内的组成：
Cr 15-19%；
Ti 8-10%；
Al 0-2.5%；
Co 14-18%；
Mo 12-16%；
余量Ni。
这组内的特定钎焊合金可具有下列组成：Cr 15.12%、Ti 10%、Al 2.12%、Co15.8%、Mo 12.97%、余量Ni。该特定钎焊合金组合物表现出大约1205℃的固相线温度和大约1223℃的液相线温度和因此仅18℃的熔融温度范围。照此，在钎焊到Alloy 247或IN 939上时，其可以是特别有用的。
对于均化此类合金的钎焊接头有效的常见固溶热处理可以是：
- 以每分钟15-30℉（8.3-16.6℃）将该组合体加热到1472℉（800℃）；
- 在1472℉下保持20分钟；
- 以每分钟15-30℉加热到2125℉（1163℃）；
- 在2125℉下保持20分钟；
- 以每分钟1-30℉（0.6-16.6℃）加热到2192-2282℉（1200-1250℃）；
- 在2192-2282℉下保持2-12小时；
- 炉内冷却到2120-2192℉（1160-1200℃）；
- 在2120-2192℉下保持最多20分钟；
- 氩气冷却到室温。
使用上述合金的修复方法在图1中说明，其中由超合金基底材料12形成的燃气涡轮发动机叶片10具有运行诱发的断口14，其从基底材料12的表面16延伸到其中。在这一实施方案中，断口14被图解为在表面16处具有大于0.001英寸的开口的大间隙裂纹。在使用任何已知方法清洁后，用含合金的粉末18，例如含有超合金颗粒20和钎焊材料颗粒22的混合物的粉末填充裂纹14。含合金的粉末18中的钎焊颗粒22可构成粉末18的5-50重量%。在另一些实施方案中，含合金的粉末18可以仅是超合金颗粒20。钎焊材料颗粒22的筛目尺寸范围（例如-325目/+2微米）优选为小于超合金颗粒20（例如-120目/+2微米），以提供断口14的增强的填充。在含合金的粉末18上布置一层钎焊材料颗粒22，以确保在钎焊工艺过程中完全填充该断口。在基底材料12的固溶热处理过程中，在超合金颗粒20烧结在一起的同时钎焊材料颗粒22熔融并填充该断口。在该钎焊材料中比在基底超合金中更高浓度含有的钛或其它元素然后分布到周围的超合金材料中，以实现固态均匀接头。有利地，钎焊材料22不含有在待钎焊的基底12中不含的元素，从而不向超合金材料中引入新元素，且均化的接头材料的组成非常类似于基底材料12，这因此提供结构接头。该钎焊材料的非常窄的熔融温度范围和随后减小的流动时间也限制钎焊操作过程中的基底材料12的侵蚀。
图2说明基底基材12的不同区域，其中仅用钎焊材料颗粒22修复窄间隙断口24（小于0.001英寸）。由于断口24的宽度有限，不需要如图1中那样用超合金颗粒20填充断口，因为钎焊材料22在固溶热处理过程中将流入并填充该断口。
在另外的实施方案中，本文中公开的钎焊合金可形成为箔或线，并可以用任何已知方法施加。可如下实现含有多个断口的超合金材料表面的修复：任选地用超合金颗粒填充断口（如对于较宽开口所需），然后对具有置于表面上的公开的钛基钎焊合金之一的箔的该超合金实施热处理，使该钎焊材料熔融、流入断口中并填充在超合金颗粒周围，然后随着熔融温度元素扩散到基底12中而均化和凝固。
尽管在本文中已经展示和描述了本发明的各种实施方案，但明显是仅以实例的方式提供这样的实施方案。在本文中可以在不背离本发明的情况下作出多种变型、更改和替换。

Claims (19)

1.超合金材料的钎焊方法，其包括：
将无硼和硅的钎焊材料施加到超合金基底上，所述钎焊材料仅包含存在于所述超合金基底中的元素成分，并进一步包含具有不大于50℃和包括或低于所述超合金基底的固溶热处理温度的熔融温度范围的组合物；和
进行对于熔融所述钎焊材料和熔化和均化钎焊接头而言有效的所述超合金基底的固溶热处理。
2.如权利要求1所述的方法，其进一步包括将粉末形式的钎焊材料施加到所述超合金基底表面上的断口中，以使所述钎焊接头填充所述断口。
3.如权利要求2所述的方法，其进一步包括将超合金粉末材料与所述钎焊材料一起施加到所述断口中。
4.如权利要求3所述的方法，其进一步包括选择所述钎焊材料粉末的筛目尺寸范围以小于所述超合金粉末材料的筛目尺寸范围。
5.如权利要求1所述的方法，其进一步包括施加具有Cr 15-25%；Ti 15-25%；余量Ni的组成的钎焊材料。
6.如权利要求5所述的方法，其进一步包括选择所述钎焊材料组合物以具有1215℃的液相线温度和10℃的熔融温度范围，和选择所述超合金基底为Alloy 247或Rene 80。
7.如权利要求1所述的方法，其进一步包括施加具有下列组成的钎焊材料：
Cr 12-16%；
Ti 13-16%；
Al 0-2.5%；
Co 2-4%；
W 3-5%；
Mo 0-2%；
Ta 0-2%；
余量Ni。
8.如权利要求1所述的方法，其进一步包括施加具有下列组成的钎焊材料：
Cr 15-18%；
Ti 10-15%；
Al 0-2.5%；
Co 2-4%；
W 3-5%；
Mo 0-2%；
Ta 0-2%；
余量Ni。
9.如权利要求8所述的方法，其进一步包括选择所述钎焊材料组合物以具有15℃的熔融温度范围，和选择所述超合金基底为Alloy 247或Rene 80。
10.如权利要求1所述的方法，其进一步包括施加具有下列组成的钎焊材料：
Cr 15-19%；
Ti 8-10%；
Al 0-2.5%；
Co 14-18%；
Mo 12-16%；
余量Ni。
11.修复超合金燃气涡轮部件的方法，其包括：
使超合金燃气涡轮部件停止运行；
将无硼和硅的钎焊材料施加到所述部件表面上的断口处，所述钎焊材料具有不大于50℃的熔融温度范围；和
用对于熔融所述钎焊材料和熔化和均化钎焊接头而言有效的温度方案来热处理所述部件，以修复所述断口。
12.如权利要求11所述的方法，其进一步包括选择所述钎焊材料为具有不大于20℃的熔融温度范围的铬、钛和镍的三元组合物。
13.如权利要求11所述的方法，其进一步包括选择所述钎焊材料以具有不大于20℃的熔融温度范围。
14.如权利要求11所述的方法，其进一步包括选择所述钎焊材料以具有不大于15℃的熔融温度范围。
15.如权利要求11所述的方法，其进一步包括选择所述钎焊材料以具有不大于10℃的熔融温度范围。
16.如权利要求11所述的方法，其中所述部件包含Rene 80或Alloy 247超合金材料，并进一步包括选择所述钎焊材料以具有不大于1215℃的液相线温度并具有不大于20℃的熔融温度范围。
17.如权利要求11所述的方法，其进一步包括在施加钎焊材料的步骤之前清洁接近所述断口的部件表面。
18.如权利要求11所述的方法，其进一步包括施加具有Cr 15-25%；Ti 15-25%；余量Ni的组成的钎焊材料。
19.如权利要求11所述的方法，其进一步包括施加具有Cr 20%；Ti 20%；Ni 60%的组成的钎焊材料。
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