EP1013790B1 - Procédé de fabrication des objets en superalliage formés par projection et traités thermiquement - Google Patents
Procédé de fabrication des objets en superalliage formés par projection et traités thermiquement Download PDFInfo
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- EP1013790B1 EP1013790B1 EP99309128A EP99309128A EP1013790B1 EP 1013790 B1 EP1013790 B1 EP 1013790B1 EP 99309128 A EP99309128 A EP 99309128A EP 99309128 A EP99309128 A EP 99309128A EP 1013790 B1 EP1013790 B1 EP 1013790B1
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/30—Ferrous alloys, e.g. steel alloys containing chromium with cobalt
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- 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
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/055—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/22—Ferrous alloys, e.g. steel alloys containing chromium with molybdenum or tungsten
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
-
- 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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- 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
- C23C4/18—After-treatment
Definitions
- the present invention relates generally to spray formed components, and more particularly to spray formed components having properties comparable to those of corresponding forged components.
- Forging has long been used to produce components for demanding applications, e.g., for components which require a combination of high strength and other desired properties such as low crack growth rates and high stress rupture resistance.
- forging is used to produce rotating and static parts, each of which typically requires a combination of high strength, low crack growth rates and high stress rupture resistance.
- Such parts can have complex shapes such as blades and vanes, and also include annular-shaped components such as engine cases, flanges and seals
- a billet of material is obtained having a composition corresponding to the desired composition of the finished component.
- the billet typically must be specially prepared from ingots of the material.
- the billet is first pierced, and is then thermomechanically processed, such as by ring-rolling multiple times to transform the billet material into the general component shape.
- the component may also be heat treated to obtain the combination of desired properties, e.g., a particular level of fatigue crack growth resistance, and then finished, e.g., polished or machined to provide the component with the precise dimensions or features.
- Spray forming has not previously been used to produce components directly from bulk material, e.g., material in ingot form, which exhibit not only high strength, but also low crack growth rates and high stress rupture resistance.
- a nickel base superalloy material having a nominal composition in weight percent of about 19.5 w/o chromium (Cr), 4.3 w/o molybdenum (Mo), 13.5 cobalt (Co), 3.0 w/o titanium (Ti), 1.4 w/o aluminium (Al), 0.05 w/o zirconium (Zr), 0.006 w/o boron (B), balance substantially nickel and nominal amounts of other elements (sometimes referred to as "Waspaloy”), high strength, low crack growth rates and high stress rupture resistance corresponds to meeting the requirements set forth in Aerospace Material Specification AMS 5707 (Rev. H, publ. Aug. 1994), published by SAE Int'l of Warrendale, PA, and incorporated by reference herein. It is this combination of properties which is
- FIG. 1 A typical spray forming apparatus is illustrated in FIG. 1.
- Metal is provided in ingot form and melted in a crucible 12, preferably in a vacuum melt chamber 14 at low pressure and/or in a non-reactive environment.
- the molten metal 16 is transferred to a tundish 18, and then passes through an atomizer 20, which utilizes an inert carrier gas such as argon to entrain atomized metal droplets.
- the atomized material 22 impinges upon and is deposited onto a cooler mandrel or substrate 24 that is located in a spray chamber 26.
- the mandrel In order to form an annular component, the mandrel is cylindrical and may be rotated, and the stream of atomized metal and the mandrel may be scanned relative to one another The metal impinges upon the substrate and previously deposited metal, and solidifies rapidly. Layers of the solidified metal then build upon one another to form the desired article. See, e.g., U.S. Pat. 4,830,084.
- the article may then be further treated, e.g., by hot isostatic pressing (HIP'ing) and/or thermomechanically processing such as by ring rolling to densify and strengthen the material.
- HIP'ing hot isostatic pressing
- thermomechanically processing such as by ring rolling to densify and strengthen the material.
- Superalloys have been melted and spray formed in this manner to form parts, although such parts as formed lack properties such as high strength, low crack growth rates or stress rupture resistance and thus cannot be employed as formed in demanding applications such as gas turbine engines or other high temperature and pressure environments.
- AMS 5707 includes a conventional heat treatment for parts forged from this material and is incorporated by reference herein.
- a forged component is heat treated in three steps.
- the first step includes a solution heat treatment at a temperature of between 1825-1900°F (996-1037°C), for about 4 hours, and then cooling at a rate equivalent to air cooling or faster.
- the second step includes a stabilization heat treatment at a temperature of about 1550°F (843°C) for about 4 hours, and then air cooling.
- the third step includes a precipitation heat treatment at a temperature of about 1400°F (760°C) for about 16 hours.
- the resulting parts have yield strengths of at least about 110 ksi (0.76 GPa) at room temperature, and exhibit relatively low notch sensitivity and high stress rupture resistance.
- parts produced by forging Waspaloy and heat treated in accordance with AMS 5707 are suitable for use as gas turbine engine cases, flanges or seals, blades and vanes, as well as other demanding applications.
- forged components also often exhibit significant levels of coarse carbides and other inclusions, the levels of which vary significantly from component to component. Forged components tend to be difficult to machine and inspect.
- precise reproducibility is also a concern - forging does not always result in components having dimensions that are identical from part to part. After inspection, many parts must still be re-worked. As a general rule, it is believed that forged parts must be scrapped or re-worked about 20 % of the time.
- AMS 5707 a standard, conventional heat treatment for components composed of forged Waspaloy is set out in AMS 5707.
- parts composed of sprayformed Waspaloy HIP'ed and heat treated in accordance with AMS 5707 or other conventional heat treatments exhibit yield and tensile strengths similar to forged, but exhibit relatively inferior crack growth rates, stress rupture resistance and other properties that the components cannot be used in demanding applications when these considerations must be addressed.
- a metal article composed of Waspaloy is formed by metal droplets built up on one another, for example by sprayforming.
- the article is then heat treated to provide the article with high strength, and resistance to stress rupture and crack growth, the crack growth rates and stress rupture resistance being comparable to the values for forged components heat treated in accordance with AMS 5707.
- the article is also typically characterized by material having an isotropic microstructure, but may include flowlines to the extent that the sprayformed articles are used as preforms, i.e., the articles are sprayformed and thermomechanically processed.
- the method comprises the steps of: spray forming an article, the article as formed characterized by a porosity of up to about 3 percent by volume; and heat treating the article sufficiently to reduce porosity and provide an article having crack growth rates and stress rupture resistance comparable to the values for forged components heat treated in accordance with AMS 5707.
- a sprayformed HIP'd and heat treated article is first spray formed, in a manner known in the art. See, e.g., U. S. Pat. No. 4,515,864 to Singer entitled “Solid Metal Articles From Built Up Splat Particles", and 3,900,921 to Brooks entitled “Method and Apparatus for Making Shaped Metal Articles From Sprayed Metal or Metal Alloy”.
- the material has a broad composition (in weight percent) of about 18-21 Cr, 3.5-5 Mo, 12-15 Co, 2.75-3.25 Ti, 1.2-1.6 Al, 0.01-0.08 Zr, 0.003-0.010 B, balance generally Ni; more preferably about 19.5 Cr, 4.3 Mo, 13.5 Co, 3.0 Ti, 1.4 Al, 0.05 Zr, 0.006 B, balance essentially nickel and nominal amounts of other elements (the material is sometimes referred to as "Waspaloy" and is used so herein).
- the material may also include about 0.04-0.075 C, up to about 0.15 Mn, up to about 0.175 Si, up to about 0.01 S, up to about 0.02 P, up to about 2.25 iron, up to about 0.15 Cu, up to about 0.00075 Pb, up to about 0.000035 Bi, up to about 0.0005 Ag, up to about 0.01 O, up to about 0.01 N.
- the articles are spray formed and HIP'ed and heat treated in accordance with the present invention, as described further below.
- Resulting articles are comparable to forgings, with respect to yield and tensile strengths at room temperature and elevated temperatures (e.g., up to at least about 1300°F (704°C)), and also low crack growth rates and high stress rupture resistance - all at significantly less expense, waste, effort and substantially reduced lead times compared to forging.
- metal to be used in spray forming is provided, e.g., in ingot form, by melting an elemental mix, by re-melting scrap material or by other manner.
- the material is melted in a crucible 12, which preferably is positioned in a vacuum melt chamber 14 maintained at low pressure and/or in a non-reactive environment.
- the molten metal 16 is transferred to a tundish 18, and then passes through an atomizer 20, which utilizes an inert carrier gas such as argon to entrain the atomized metal.
- the atomized material 22 is directed towards a cooled mandrel or substrate 24 located in a spray chamber 26, which is preferably maintained at low pressure and/or in a non-reactive environment.
- the mandrel In order to form an annular component, the mandrel is cylindrical and may be rotated, and the stream of atomized metal and the mandrel may be scanned relative to one another The metal impinges upon the substrate first and then upon previously deposited metal, and solidifies rapidly, thus providing a finer grain size than forgings. Layers of the solidified metal build up to form the desired article.
- plasma spraying in a low pressure or vacuum environment which could be employed to form the article.
- the droplets are smaller rather than larger, and more preferably on the order of about 10-10,000 microns in diameter.
- the droplets be applied at a temperature that is lower rather than higher.
- the droplets preferably should be no hotter than necessary to remain in a semi-molten state until impingement upon the substrate and previously deposited material, but hot enough so as not to substantially solidify prior to impingement.
- the velocity of the droplets must be fast enough to deliver the droplets in a molten state but slow enough so that the droplets are able to adhere to the substrate and previously deposited droplets.
- the distance between the spray nozzle and the substrate may also be adjusted, as may the rate at which the material is deposited.
- Spray formed articles, as formed, are characterized by the presence of porosity, typically about 1-3 percent by volume (v/o). In contrast, forged articles exhibit no porosity. Porosity tends to reduce the strength of an article.
- the spray formed articles are treated to densify the material. With reference to FIG. 2, the articles which have been rough formed by spray forming are preferably first densified by HIP'ing.
- the part is preferably HIP'ed at between about 1,800-2,000°F (982-1093°C) and 15,000-25,000 psi (103 GPa-172 GPa) for about four hours, more preferably in an inert atmosphere such as argon.
- the pressure and temperature are monitored, e.g., at least once every five minutes, to ensure consistent HIP'ing.
- FIG. 2 illustrates any subsequent processing or machining as occurring after the heat treatment, the articles may be machined to final dimensions at any time after HIP'ing.
- the articles as spray formed exhibit stress rupture resistance and crack growth rates which are significantly inferior to corresponding forged articles. HIP'ing the articles does not significantly improve those properties. Heat treating these articles using industry standards for forged articles, such as AMS 5707 for Waspaloy, does not restore these properties to forged levels. Accordingly, the articles as spray formed and HIP'd only cannot be used in demanding applications such as gas turbine engines.
- the spray formed and HIP'd articles are heat treated in order to provide a balance of strength, low crack growth rates and high stress rupture resistance, and thereby render articles suitable for use in at least these demanding applications.
- the heat treatment includes a solution heat treatment 32, a stabilization heat treatment 34 and a precipitation heat treatment 36.
- the specific temperatures, times and cooling rates described below will vary according to the particular material being processed.
- the preferred heat treatment provides a spray formed article having a microstructure that is significantly finer and more uniform than that of conventionally forged material. Compare the microstructure of FIGS. 3 and 4.
- the articles are also finished 38 (FIG. 2) as needed, e.g., machined. The finishing is preferably but not necessarily performed after HIP'ing.
- the solution heat treatment 32 comprises the first portion of the heat treatment, and will vary depending upon the particular material being treated.
- FIG. 3 is a photomicrograph illustrating the microstructure of an article after the article is heat treated in accordance with the present invention.
- the part is heated to a solution heat treatment temperature between about 1925-2025°F (1052-1107°C), and preferably at about 1975°F (1080°C) for about 2 hours, and quenched in oil or water.
- the combination of solution heat treatment temperature and time is selected to be lower than the temperature and time at which the grain size of the material would grow significantly, as larger grain sizes do not provide the desired properties.
- sprayformed material appears to be less susceptible to grain growth at elevated heat treatment temperatures than corresponding forged material, and accordingly the solution heat treatment may be performed at higher temperatures than a corresponding solution heat treatment provided in AMS 5707 for forged articles.
- the part is subjected to a stabilization heat treatment 34, the specifics of which will vary depending upon the particular material being treated.
- a stabilization heat treatment 34 the specifics of which will vary depending upon the particular material being treated.
- the article is heated to a temperature of between about 1500-1600°F (816-871°C), and preferably about 1550°F (843°C) and held at the stabilization heat treatment temperature for about 4 hours, and then cooled at a rate equivalent to air cooling or faster.
- the part is subjected to a precipitation heat treatment 36, which will vary depending upon the particular material being treated.
- a precipitation heat treatment 36 which will vary depending upon the particular material being treated.
- the part is heated to a temperature of between 1350-1450°F (732-788°C), and preferably at about 1400°F (760°C) for at least about 16 hours, followed by cooling at a rate equivalent to air cooling or faster.
- the illustrated application of the preferred heat treatments enables the production of spray formed articles that have not only good strength, but also have other properties that are comparable to or better than forged components, e.g., low crack growth rates and high stress rupture resistance.
- Samples of the spray formed Waspaloy HIP'd and heat treated in accordance with a preferred embodiment of the present invention were tested to determine yield and ultimate tensile strengths, as well as ductility. With respect to tensile properties, samples were tested both at room temperature (about 68°F (20°C)) and elevated temperature (about 1200°F (649°C)) held for a period of time prior to testing.
- the samples were subjected to strain rate of between 0.005 in./in./minute (8.3 x 10 -5 m/m/s) through the yield strength (about 110 ksi (0.75 GPa) at room temperature and 93.5 ksi (0.64 GPa) at 1200°F (649°C)).
- the following properties were obtained: Property Room Temp. (20°C) 1200°F (649°C) Tensile Strength, min. 160 ksi(1.09 GPa) 140 ksi (0.95 GPa) Yield Strength, 0.2% offset, min. 110 ksi(0.75 GPa) 93.5 ksi(0.64 GPa) Elongation in 4D, min. 15% 15% Reduction in area, min. 18% 18%
- the minimum values for these properties may be higher or lower, depending upon the particular application of the part.
- the above values correspond, for example, to the above mentioned parts such as gas turbine engine cases, flanges and seals.
- the above properties are designed for specific parts such as engine cases and rings.
- the properties for forged material should be comparable whether the samples are tested longitudinally or transversely.
- test specimens comprising material produced in accordance with preferred embodiments of the present invention, e.g., conforming to ASTM E292, were tested.
- the specimens were maintained at 1350°F (732°C) and loaded continuously, after generating an initial axial stress of between about 75 ksi (0.51 GPa).
- the specimens ruptured only after at least 23 hours.
- the above values for Waspaloy processed in accordance with preferred embodiments of the present invention are comparable to forged material heat treated in accordance with AMS 5707.
- ring rolling is typically employed for annular articles such as engine cases and seals, and includes heating the article and repeatedly passing the article between a series of rollers to form and enlarge the article to the desired size.
- FIGS. 5 and 6 (each at about 100x magnification; the grains in FIG. 6 being roughly ASTM 8) illustrate the resulting microstructure of sprayformed articles which are ring rolled to produce moderate reduction and high reduction, respectively.
- sprayformed (and ring rolled) Waspaloy articles produced in accordance with preferred embodiments of the present invention are generally characterized by a microstructure similar to that of forged Waspaloy articles, but exhibit less edge cracking and result in significantly less grinding losses during finishing than forged Waspaloy. Moreover, sprayformed, ring rolled Waspaloy exhibits superior strength at room and elevated temperatures.
- spray formed and ring rolled Waspaloy articles produced in accordance with preferred embodiments of the present invention have a 0.2% yield strength of at least about 140 ksi (0.95 GPa) and more preferably above about 155 ksi (1.06 GPa), and an ultimate tensile strength of at least about 180 ksi (1.26 GPa) and more preferably at least about 200 ksi (1.36 GPa).
- such articles At elevated temperatures (about 1200°F (649°C)) such articles have a 0.2% yield strength of at least about 90 ksi (0.61 GPa) and more preferably above about 93 ksi (0.63 GPa), and an ultimate tensile strength of at least about 135 ksi (0.92 GPa) and more preferably at least about 140 ksi (0.95 GPa).
- forged Waspaloy material prepared in accordance with AMS 5707 has been tested to 0.5% creep for various temperatures and stresses (the dashed lines in FIG. 7), and for stress rupture at various temperatures and stresses (the dashed lines in FIG. 8).
- samples of sprayformed Waspaloy, HIP'd and heat treated in accordance with preferred embodiments of the present invention are characterized by relatively small grains.
- grain sizes are about ASTM 3 (three) and more preferably about ASTM 5 or finer, which is comparable to the grains in corresponding forged material heat treated in accordance with AMS 5707.
- the microstructure of the finished material is substantially more homogeneous and isotropic in properties than forged material.
- the microstructure is also characterized by the absence of elemental segregation (in contrast to forgings), unless the material is subsequently plastically deformed, and accordingly sections of the material are typically characterized by an absence of flow lines, i.e., which indicate the direction of plastic flow.
- the finished material exhibits low crack growth rates and good stress rupture resistance in addition to an absence of porosity.
- the present heat treatment is not generally interchangeable with standard heat treatments, such as AMS 5707.
- standard heat treatments for Waspaloy such as AMS 5707 do not produce satisfactory results when applied to sprayformed articles.
- the solution heat treatment in AMS 5707 is significantly cooler than that of the present invention, and the cooling occurs by air rather than quenching.
- Spray formed articles heat treated in accordance with AMS 5707 exhibit reduced creep resistance compared to corresponding forged articles treated in accordance with AMS 5707.
- the present invention provides other significant advantages over forgings.
- the present invention enables spray forming to be used in the direct production of components that have properties comparable to forging.
- Parts produced in accordance with the present invention are more consistent, with more homogeneous microstructures. Individual parts exhibit isotropic microstructures, unless the articles are subsequently thermomechanically processed such as by ring rolling.
- the parts are also characterized by a microstructure lacking segregation, especially relative to forgings.
- These properties also provide components fabricated in accordance with preferred embodiments of the present invention that are more easily machined and inspected.
- the present invention obviates the need to obtain specially-prepared billets of material, and long lead times associated with obtaining billets are therefore minimized or eliminated.
- the present invention enables bulk material to be converted directly to ready-to-machine or use components. Thus, a substantial portion of the effort, expense and waste associated with forging is substantially reduced or eliminated.
- Spray formed articles processed in accordance with preferred embodiments of the present invention exhibit not only strengths similar to the conventional, forged articles, but also resist crack growth and stress rupture resistance at least as well as forged articles. Moreover, articles prepared in accordance with preferred embodiments of the present invention are manufactured at significantly reduced time and expense. From the standpoint of microstructure, sprayformed articles exhibit more uniform, generally finer grains than forgings, and importantly also exhibit significantly less variability in properties as produced, i.e., the properties of the parts lie within a narrower range than do corresponding forged articles.
- the present invention may provide spray formed articles having properties comparable to properties of corresponding forged articles; which have a balance of strength, crack growth rates and stress rupture resistance comparable to corresponding forged articles; in which crack growth rates of the articles are low and stress rupture resistance of the articles are high; and furthermore provides such a heat treatment to provide articles composed of spray formed Waspaloy with properties comparable to those of corresponding articles forged from Waspaloy.
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Claims (12)
- Procédé de fabrication d'un objet en superalliage à base de nickel présentant :une limite élastique à 0,2% d'au moins 0,68 GPa (100 ksi) à température ambiante ;une limite élastique à 0,2% d'au moins 0,58 GPa (85 ksi) à une température de 649°C (1200°F) ;une résistance à la traction d'au moins 1,02 GPa (150 ksi) à température ambiante ; etune résistance à la traction d'au moins 0,89 GPa (130 ksi) à une température de 649°C (1200°F),dans lequel l'objet est formé par :la constitution de gouttelettes de métal les unes sur les autres, lesdites gouttelettes de métal présentant une composition en % en poids de 18-21 Cr, 3,5-5 Mo, 12-15 Co, 2,75-3,25 Ti, 1,2-1,6 Al, 0,04-0,075 C, 0,01-0,08 Zr, 0,003-0,010 B, facultativement jusqu'à 0,15 Mn, jusqu'à 0,175% Si, jusqu'à 0,01% S, jusqu'à 0,02 P, jusqu'à 2,25 de fer, jusqu'à 0,15 Cu, jusqu'à 0,00075 Pb, jusqu'à 0,000035 Bi, jusqu'à 0,0005 Ag, jusqu'à 0,01 O, et jusqu'à 0,01 N, le restant en Ni et en impuretés accidentelles ;la compaction de l'objet ; etle traitement thermique de l'objet, dans lequel le traitement thermique comprend un traitement thermique en solution avec une trempe à l'huile ou à l'eau, un traitement thermique de stabilisation à une température comprise entre 816°C et 871°C (1500-1600°F) pendant environ quatre heures et ensuite refroidissement à une vitesse égale ou supérieure au refroidissement à l'air et un traitement thermique de précipitation à une température comprise entre 732°C et 788°C (1350-1450°F) pendant au moins environ 16 heures, ledit procédé étant caractérisé en ce que l'objet est traité thermiquement en solution à une température comprise entre 1052°C et 1107°C (1925-2025°F) pendant environ 2 heures.
- Procédé selon la revendication 1, dans lequel les gouttelettes de métal ont un diamètre de 10 à 10 000 µm.
- Procédé selon la revendication 1 ou 2, dans lequel l'étape de traitement thermique fournit un objet d'une microstructure caractérisée essentiellement par des grains ayant une taille inférieure ou égale à ASTM3, mesurée selon la norme ASTM E129.
- Procédé selon la revendication 3, dans lequel l'étape de traitement thermique fournit un objet d'une microstructure caractérisée essentiellement par des grains d'une taille inférieure à ASTM 5, mesurée selon la norme ASTM E129.
- Procédé selon l'une quelconque des revendications précédentes, dans lequel l'objet est comprimé par compaction isostatique à chaud à une température comprise entre 982°C et 1093°C (1800-2000°F) et à une valeur de contrainte comprise entre 103 à 172 GPa (15000-25000 psi) pendant environ quatre heures.
- Procédé selon la revendication 5, dans lequel l'article subit une compaction isostatique à chaud dans une atmosphère d'argon.
- Procédé selon l'une quelconque des revendications précédentes, dans lequel les gouttelettes de métal sont assemblées afin de créer un objet de forme annulaire.
- Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de traitement thermique fournit également un objet présentant une microstructure isotrope.
- Procédé selon l'une quelconque des revendications précédentes, comprenant en outre l'étape consistant à :faire subir par la suite à l'objet un traitement thermomécanique pour produire une forme souhaitée.
- Procédé selon l'une quelconque des revendications précédentes, dans lequel l'objet est un composant de moteur de turbine à gaz.
- Procédé selon la revendication 10, dans lequel l'objet est choisi dans le groupe constitué d'un carter de moteur, d'un flasque de moteur et d'un joint de moteur.
- Procédé selon l'une quelconque des revendications précédentes, dans lequel l'objet subit un laminage circulaire.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US21690498A | 1998-12-21 | 1998-12-21 | |
US216904 | 1998-12-21 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP1013790A2 EP1013790A2 (fr) | 2000-06-28 |
EP1013790A3 EP1013790A3 (fr) | 2000-07-26 |
EP1013790B1 true EP1013790B1 (fr) | 2004-04-28 |
Family
ID=22808945
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP99309128A Expired - Lifetime EP1013790B1 (fr) | 1998-12-21 | 1999-11-17 | Procédé de fabrication des objets en superalliage formés par projection et traités thermiquement |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP1013790B1 (fr) |
JP (1) | JP3905674B2 (fr) |
KR (1) | KR100603882B1 (fr) |
DE (1) | DE69916763T2 (fr) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050214560A1 (en) * | 2004-03-25 | 2005-09-29 | Stephen Yue | Thermal spray reinforcement of a stabilizer bar |
CN104057085B (zh) * | 2014-06-18 | 2016-02-24 | 西安交通大学 | 一种熔滴微喷沉积成型喷嘴 |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4418124A (en) * | 1980-10-06 | 1983-11-29 | General Electric Company | Plasma spray-cast components |
US5584948A (en) * | 1994-09-19 | 1996-12-17 | General Electric Company | Method for reducing thermally induced porosity in a polycrystalline nickel-base superalloy article |
-
1999
- 1999-11-17 DE DE69916763T patent/DE69916763T2/de not_active Expired - Lifetime
- 1999-11-17 EP EP99309128A patent/EP1013790B1/fr not_active Expired - Lifetime
- 1999-11-30 KR KR1019990053743A patent/KR100603882B1/ko not_active IP Right Cessation
- 1999-12-21 JP JP36208399A patent/JP3905674B2/ja not_active Expired - Fee Related
Also Published As
Publication number | Publication date |
---|---|
EP1013790A2 (fr) | 2000-06-28 |
EP1013790A3 (fr) | 2000-07-26 |
KR20000047783A (ko) | 2000-07-25 |
JP3905674B2 (ja) | 2007-04-18 |
JP2000192218A (ja) | 2000-07-11 |
KR100603882B1 (ko) | 2006-07-25 |
DE69916763T2 (de) | 2005-03-31 |
DE69916763D1 (de) | 2004-06-03 |
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