CN112823076A - 用于液态金属沉积或增材制造的材料的组成、方法和产品 - Google Patents

用于液态金属沉积或增材制造的材料的组成、方法和产品 Download PDF

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CN112823076A
CN112823076A CN201980066878.6A CN201980066878A CN112823076A CN 112823076 A CN112823076 A CN 112823076A CN 201980066878 A CN201980066878 A CN 201980066878A CN 112823076 A CN112823076 A CN 112823076A
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贝恩德·布尔鲍姆
亨宁·哈内布特
安德烈亚斯·鲁基
艾哈迈德·卡迈勒
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Abstract

在基于镍的超合金、MCrALY组合物和钎焊合金的混合物中，发现用于焊接或用于增材制造的良好的组成。

Description

用于液态金属沉积或增材制造的材料的组成、方法和产品
本发明涉及可以用于焊接特别地经由液态金属沉积的焊接或者用作增材制造方法的粉末床的基于镍的合金混合物的组成。
对于用激光金属沉积(Laser Metal Deposition，LMD)进行的叶尖修复，使用标准合金Inconel 625和Merl 72。两种合金在高温(T＞1273K)下的抗氧化性均不优于基础材料合金247。
因此，本发明的目的是克服上述问题。
所述问题通过根据权利要求1所述的材料、根据权利要求14所述的方法和根据权利要求16所述的产品来解决。
本发明的公开内容涉及使用粉末增材材料的激光金属沉积。
与大多数目前所使用的合金相比，该材料混合物可以以提高的抗氧化性优选地用于叶尖修复。
所开发的材料混合物的抗氧化性优于基础材料合金247。
钎焊材料的熔点总是比基于镍的超合金或基于钴的超合金低至少10K，特别地至少20K。
粉末混合物可以优选地使用标准电熔覆工艺来被焊接或者用于任何替代的制造工艺，特别地如SLM或SLS。
基于基础镍的合金的标准热处理工艺用于随后的钎焊工艺。
粉末混合物的组成以重量％计描述如下：
钎焊：≥5％，＜10％，特别地Amdry DF-4B，
NiCoCrAlY：70％至30％，
基于镍的超合金：20％至60％，特别地合金247，
其中钎焊的熔点比基于镍的超合金或基于钴的超合金的熔点低至少10K，特别地20K。
混合物包含具有不同组成的3种粉末，特别地由具有不同组成的3种粉末组成。
金属粉末混合物包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure BDA0003013514750000021
优点是
·高抗氧化材料由标准粉末合金制成
·标准焊接工艺“粉末熔覆”可以用于叶尖堆焊(blade tip build up welding)。
金属粉末混合物包含基于镍(Ni)的超合金，所述基于镍(Ni)的超合金包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure BDA0003013514750000022
Figure BDA0003013514750000031
任选地
Figure BDA0003013514750000032
特别地不含钇(Y)和/或
不含铼(Re)，
剩余部分的镍(Ni)，
特别地
基于镍(Ni)的超合金包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure BDA0003013514750000033
Figure BDA0003013514750000041
特别地不含钇(Y)和/或
不含铼(Re)。
优选地，基于镍的超合金选自合金247、Inconel 625、Rene 80和/或Merl 72，特别地合金247。
Inconel 625包含(以重量％计)：
Figure BDA0003013514750000042
Figure BDA0003013514750000051
Rene 80包含(以重量％计)：
Ni＝60.0％，
Cr＝14.0％，
Co＝9.5％，
Ti＝5.0％，
Mo＝4.0％，
W＝4.0％，
Al＝3.0％，
C＝0.17％，
B＝0.015％，
Zr＝0.03％。
Merl 72包含(以重量％计)：
47％的Co，
20％的Cr，
15％的Ni，
9％的W，
4.4％的Al，
3％的Ta，
1.1％的Hf，
0.35％的C，
0.2％的Ti，
0.04％的Y。
钎焊合金优选地包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure BDA0003013514750000052
Figure BDA0003013514750000061
任选地
Figure BDA0003013514750000062
特别地
不含钇(Y)，
和/或不含铼(Re)，
和/或不含碳(C)。
特别地，钎焊合金包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure BDA0003013514750000063
特别地
不含钇(Y)和/或
不含钨(W)，
和/或不含钛(Ti)，
和/或不含钼(Mo)，
和/或不含铼(Re)，
和/或不含碳(C)。
钎焊合金中的熔化抑制剂硼(B)至少部分被以下成分替代或者钎焊合金中的熔化抑制剂硼(B)另外添加以下成分：
硅(Si)和/或镁(Mg)和/或锰(Mn)。
NiCoCrAlY合金意指NiCoCrAlY-X，其中X任选地为钽(Ta)、硅(Si)和/或铼(Re)，......。
特别地NiCoCrAlY和任选的X＝钽(Ta)、硅(Si)、铁(Fe)或铼(Re)的列表。
NiCoCrAlY组合物优选地包含(以重量％计)：
20％至22％的铬(Cr)，
10.5％至11.5％的铝(Al)，
0.3％至0.5％的钇(Y)，
1.5％至2.5％的铼(Re)或
0.5％至1.5％的铼，和
11％至13％的钴(Co)以及
剩余部分的镍(Ni)。
进一步优选地，NiCoCrAlY组合物的实例包含(以重量％计)：
15％至21％的铬(Cr)，
24％至26％的钴(Co)，
9.0％至11.5％的铝(Al)，
0.05％至0.7％的钇(Y)，
0.5％至2.0％的铼(Re)以及
剩余部分的镍(Ni)。
NiCoCrAlY组合物的另一实例包含(以重量％计)：
22％至24％的钴(Co)，
14％至16％的铬(Cr)，
10.5％至11.5％的铝(A1)，
0.2％至0.4％的钇(Y)，
任选地0.3％至0.9％的钽(Ta)，
剩余部分的镍(Ni)。
钎焊合金包含硼(B)和/或硅(Si)和/或镁(Mg)和/或锰(Mn)作为熔化抑制剂，并且市售的钎焊的实例为所谓的Amdry粉末，实例给出Amdry DF-4B。
钎焊材料优选地为具有以下成分的基于镍的合金：
至少0.5重量％的硼(B)，特别地至少0.7重量％的硼(B)
和/或
至少1.0重量％的硅(Si)，
特别地至少1.5重量％的硅(Si)和/或
至少2.0重量％的镁(Mg)，
非常特别地钎焊合金Amdry DF-4B。
图1示出了在焊接期间如何施加本发明的材料的方法，图2示出了使用本发明的粉末进行增材制造，特别地经由激光进行增材制造的示意性布置。
说明书和附图仅为本发明的实例。
该方法和材料可以用于在基板上开始构建全新的组件或修复现有的基底4，这二者都意指材料的构建。
对于已经被除去的裂纹或腐蚀，有必要进行材料构建。在这种情况下，仅例如，通过将材料构建到叶尖7上来修复叶尖。基底4的表面10露出其上施加材料的基材。材料16经由与粉末供给源19连接的喷嘴13施加，材料16为本发明的材料。喷嘴13还包括与粉末16一起用于通过经由激光束使粉末熔化来进行焊接的激光器(未示出)。
本发明的材料还可以生产为棒和或丝，并且可以经由丝焊来使用。
在图2中，示出了本发明的材料的另一种应用。
在此，使用选择性激光熔化工艺(也可以使用电子束代替激光)(其中粉末床22具有本发明的粉末混合物)来产生全新的组件或者甚至修复基底4。
基底4完全在粉末床22内部，并且使用具有激光束28的激光器25来使粉末熔化或将粉末部分烧结，其中将材料构建到基底4的需要或想要所述材料的地方。
本发明的材料是三种不同粉末的金属粉末混合物。
特别地，粉末混合物包含合金247或一般的基于镍的超合金以及
NiCoCrAlY，一种熔点至少比基于镍的超合金低至少20K的钎焊合金。
图3中列出了基于镍的超合金的另外的实例。
NiCoCrAlY还可以任选地包含添加物如铼(Re)、钽(Ta)和/或硅(Si)，非常特别地仅这些。
另一个实例是，其中首先直接在基底上施加由以下成分组成的混合物的层：NiCoCrAlY，特别是根据权利要求3、4或5所述的NiCoCrAlY，和基于镍的超合金或基于钴的超合金，特别是根据权利要求10、11、12所述的基于镍的超合金或基于钴的超合金；然后施加根据权利要求1至13所述的混合物的层。

Claims (18)

1.一种金属粉末混合物，
特别地可用于经由液态金属沉积或任何增材制造方法的构建，
所述金属粉末混合物包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
含量为20％至60％的基于钴(Co)的超合金或基于镍(Ni)的超合金，
含量为70％至30％的NiCoCrAlY组合物以及
含量为10％至5％的金属钎焊材料，
其中所述钎焊材料的熔点比所述基于镍的超合金或所述基于钴的超合金的熔点低至少10K，特别地至少20K，
特别地，所述粉末混合物由具有不同组成的3种粉末组成。
2.根据权利要求1所述的金属粉末混合物，
包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure FDA0003013514740000011
Figure FDA0003013514740000021
3.根据权利要求1或2所述的金属粉末混合物，
其中所述基于镍(Ni)的超合金包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure FDA0003013514740000022
任选地
Figure FDA0003013514740000023
Figure FDA0003013514740000031
特别地不含钇(Y)和/或
不含铼(Re)，
剩余部分的镍(Ni)。
4.根据权利要求1、2或3中任一项所述的金属粉末混合物，
其中所述基于镍(Ni)的超合金包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure FDA0003013514740000032
特别地不含钇(Y)和/或
不含铼(Re)。
5.根据权利要求1、2、3或4中任一项所述的混合物，
其中所述基于镍的超合金选自
合金247、Inconel 625、Rene 80和/或Merl 72，
特别地合金247。
6.根据权利要求1至5中任一项所述的金属粉末混合物，
其中钎焊合金包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure FDA0003013514740000041
任选地
Figure FDA0003013514740000042
特别地
不含钇(Y)，
和/或不含铼(Re)，
和/或不含碳(C)。
7.根据权利要求1至6中任一项所述的金属粉末混合物，
其中钎焊合金包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
Figure FDA0003013514740000043
特别地
不含钇(Y)和/或
不含钨(W)，
和/或不含钛(Ti)，
和/或不含钼(Mo)，
和/或不含铼(Re)，
和/或不含碳(C)。
8.根据权利要求1、6或7中任一项所述的金属粉末混合物，
其中熔化抑制剂硼(B)至少部分被以下成分替代或者所述熔化抑制剂硼(B)另外添加以下成分：
硅(Si)和/或镁(Mg)和/或锰(Mn)。
9.根据权利要求1、2、3、4、5、6、7或8中任一项所述的混合物，
其中所述钎焊材料为具有以下成分的基于镍的合金：至少0.5重量％的硼(B)，特别地至少0.7重量％的硼(B)和/或
至少1.0重量％的硅(Si)，
特别地至少1.5重量％的硅(Si)和/或
至少2.0重量％的镁(Mg)，
非常特别地钎焊合金Amdry DF-4B。
10.根据前述权利要求1至9中任一项所述的混合物，
其中NiCoCrAlY由NiCoCrAlY以及任选的钽(Ta)、铼(Re)、铁(Fe)和/或硅(Si)组成。
11.根据权利要求1、2、3、4、5、6、7、8、9或10中任一项所述的金属混合物，
其中所述NiCoCrAlY组合物包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
14％至22％的铬(Cr)
9.0％至11.5％的铝(Al)
0.3％至0.5％的钇(Y)
11％至26％的钴(Co)
0％至1.0％的硅(Si)，
特别地0.1％至1.0％的硅(Si)，
0％至2.5％的铼(Re)或
以及剩余部分的镍(Ni)。
12.根据权利要求1至10中任一项所述的混合物，
其中所述NiCoCrAlY组合物包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
20％至22％的铬(Cr)
10.5％至11.5％的铝(Al)
0.3％至0.5％的钇(Y)
1.5％至2.5％的铼(Re)或0.5％至1.5％的铼
11％至13％的钴(Co)以及
剩余部分的镍(Ni)。
13.根据权利要求1至10中任一项所述的混合物，
其中所述NiCoCrAlY组合物包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
15％至21％的铬(Cr)
24％至26％的钴(Co)
9.0％至11.5％的铝(Al)
0.05％至0.7％的钇(Y)
0.5％至2.0％的铼(Re)以及
剩余部分的镍(Ni)。
14.根据权利要求1至10中任一项所述的混合物，
其中所述NiCoCrAlY组合物包含(以重量％计)以下成分，
特别地由以下成分组成(以重量％计)：
22％至24％的钴(Co)
14％至16％的铬(Cr)
10.5％至11.5％的铝(Al)
0.2％至0.4％的钇(Y)
任选地0.3％至0.9％的钽(Ta)以及
剩余部分的镍(Ni)。
15.一种构建金属材料的方法，
其中使用根据权利要求1至14中任一项所述的金属粉末混合物。
16.根据权利要求15所述的方法，
用于使用粉末熔覆、丝焊的焊接，或者
用于使用粉末床的增材制造，
特别地SLM、SLS。
17.一种产品，
通过根据权利要求15或16所述的方法生产，或者
包含根据权利要求1至14中任一项所述的金属粉末混合物。
18.根据权利要求17所述的产品，
其中首先直接在基底上，将由以下成分组成的混合物的层施加在所述基底上：NiCoCrAlY，特别是根据权利要求10、11、12、13或14所述的NiCoCrAlY，和基于镍的超合金或基于钴的超合金，特别是根据权利要求3、4或5所述的基于镍的超合金或基于钴的超合金，
以及然后施加根据权利要求1至14所述的混合物的层。
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