Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C30/00—Alloys containing less than 50% by weight of each constituent
• • 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
• • 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%

Definitions

• the present invention is directed to alloys, articles including alloys, and processes of forming alloys. More specifically, the present invention is directed to a nickel-iron-base alloy and a process of forming a nickel-iron-base alloy.
• the operating temperature within a gas turbine engine is both thermally and chemically hostile.
• Significant advances in high temperature capabilities have been achieved through the development of iron, nickel and cobalt-based superalloys and the use of environmental coatings capable of protecting superalloys from oxidation, hot corrosion, etc., but coating systems continue to be developed to improve the performance of the materials.
• Stator components are hot gas path components for gas turbines. It is desirable for the stator components to have oxidation resistance, thermal-mechanical fatigue capability and high temperature creep strength. Traditionally, the stator components are made of Ni-based or Co-based cast superalloys. These superalloys suffer from the drawback that they can have very high costs.
• advanced stainless steels for example Alumina-Forming Austenitic (AFA) alloys, developed by Oak Ridge National Laboratory
• AFA Alumina-Forming Austenitic
• these advanced stainless steels have undesirably low creep strength for nozzles.
• the creep strength of these advanced stainless steels only reaches about one half of design requirement for gas turbine nozzles.
• Nita-iron-base superalloys including A286, INCOLOY R 901, INCOLOY ® 903 and IN706, have been regarded as suffering from several drawbacks.
• INCOLOY is a federally registered trademark of alloy produced by Inco Alloys International, Inc., Huntington, West Virginia.
• INCOLOY R 901 has been regarded as lacking gamma prime phases (resulting in low creep strength), containing significant amounts of eta, sigma, and laves phases (resulting in low ductility and/or poor long-term mechanical properties), and having a wide solidification range and poor castability.
• a nickel-iron-base alloy and a process of forming a nickel-iron-base alloy that do not suffer from the above drawbacks is desirable in the art.
• a nickel-iron-base alloy having by weight about 0.06 % to about 0.09 % C, about 35 % to about 37 % Fe, about 12.0 % to about 16.5 % Cr, about 1.0 % to about 2.0 % Al, about 1.0 % to about 3.0 % Ti, about 1.5 % to about 3.0 % W, up to about 5.0 % Mo, up to about 0.75 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and balance essentially Ni.
• a nickel-iron-base alloy has a solidification range of less than about 110°F, a gamma prime solvus of greater than about 1700°F, substantially no eta phase, a laves phase of less than about 5%, a sigma phase of less than about 5%, and is devoid of Co.
• a process of forming a modified alloy includes providing a base alloy composition, identifying a plurality of predetermined properties, and modifying the base alloy composition to form a modified alloy composition having the plurality of predetermined properties.
• the plurality of predetermined properties includes having a solidification range of less than about 110°F, having a gamma prime solvus of greater than about 1700°F, having substantially no eta phase, having a laves phase of less than about 5%, and having a sigma phase of less than about 5%.
• the base alloy composition includes one or more of a first composition comprising about 0.05% C, about 36 % Fe, about 12.50 % Cr, about 0.20 % Al, about 2.80 % Ti, up to about 0.12 % W, about 5.70 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, balance essentially Ni and a second composition including about 0.02 % C, about 37 % Fe, 16.00 % Cr, about 0.20 % Al, about 1.75 % Ti, up to about 0.12 % W, up to about 0.12 % Mo, about 2.90 % Nb, up to about 0.2 % Mn, up to about 0.1 % S i, up to about 0.006 % B, balance essentially Ni.
• a first composition comprising about 0.05% C, about 36 % Fe, about 12.50 % Cr, about 0.20 % Al, about 2.80 % Ti, up to about 0.12
• One advantage of an embodiment of the present disclosure includes the modified alloy having a desirable creep strength through the formation of sufficient amount of gamma prime phase and reduced or eliminated Eta phase.
• Another advantage of an embodiment of the present disclosure includes the modified alloy having desirable ductility and/or long-term mechanical properties.
• Another advantage of an embodiment of the present disclosure includes the modified alloy having desirable castability.
• a nickel-iron-base alloy having a plurality of predetermined properties and a process of forming a nickel-iron-base alloy having a plurality of predetermined properties.
• Embodiments of the present disclosure involve a nickel-iron-base alloy formed from one or more low cost alloys previously regarded as unsuitable for hot gas path components such as engine turbine stators.
• the nickel-iron-base alloy does not contain Eta phaseresulting in a desirable creep strength.
• the nickel-iron-base alloy has desirable ductility and/or long-term mechanical properties. Also, the nickel-iron-base alloy has desirable castability.
• the nickel-iron-base alloy can be formed by any suitable process.
• the nickel-iron-base alloy has a creep rupture life of about 1000 hours at about 1400 °F and at about 25 ksi to about 30 ksi of loading.
• the nickel-iron-base alloy is resistant to oxidation for 48,000 hours.
• low cycle fatigue of the modified alloy is substantially the same as FSX414 alloy.
• the process includes providing a base alloy.
• the base alloy is one or more alloys previously considered undesirable for hot gas path components.
• the base alloy is Base Alloy 1.
• Base Alloy 1 refers to an alloy having a composition of about 0.05% C, about 0.20 % Al, about 2.80 % Ti, about 12.50 % Cr, about 5.70 % Mo, about 36 % Fe, and other suitable elements (throughout the disclosure, all percents are by weight unless otherwise specified).
• Base Alloy 1 further includes up to about 0.12 % W, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si., up to about 0.006 B, and a balance essentially Ni. In a further embodiment, Base Alloy 1 does not include Co.
• the base alloy is Base Alloy 2.
• Base Alloy 2 refers to an alloy having a composition of about 16.00 % Cr, about 37 % Fe, about 2.90 % Nb, about 1.75 % Ti, about 0.20 % Al, about 0.02 % C, and other suitable elements.
• Base Alloy 2 further includes up to about 0.12 % W, up to about 0.2 % Mn, up to about 0.1 % Si., up to about 0.006 B, and a balance essentially Ni.
• Base Alloy 2 does not include Co.
• the process continues by identifying a plurality of predetermined properties desired for the modified alloy.
• Data corresponding to the plurality of predetermined properties can be analyzed by a computer executed program such as a computational thermodynamic modeling program.
• the computer executed program correlates data regarding the base alloys and generates outputs of properties corresponding to the modified alloy.
• the outputs generated are based upon the modifications to composition of the base alloy that form the modified alloy. Analysis of the generated outputs permits identification of one or more compositions to be further analyzed.
• the properties include any suitable quantifiable properties.
• the properties include a solidification range, a gamma prime solvus, a lack of eta phase, a laves phase percent, a sigma phase percent, a laves phase formation temperature, other suitable properties, or any combination thereof.
• the solidification range is less than about 110°F resulting in good castability.
• the gamma prime solvus is greater than about 1700°F.
• the lack of eta phase includes being devoid of eta phase.
• the laves sigma percent is less than about 5%.
• the formation temperature is less than about 1200°F.
• the correlation of data regarding the base alloys and outputs of properties corresponding to the nickel-iron-base alloy can involve any suitable relationship between compositional modifications to the base alloy and properties affected.
• Al reduces eta phase. Including a concentration of greater than about 1% Al eliminates eta phase.
• the correlation of data can generate an output indicating an absence of eta phase upon a concentration of Al exceeding about 1%.
• Other relationships that can be correlated are that increasing the concentration of Mo increases eta phase, increasing the concentration of W reduces eta phase, increasing the concentration of Al reduces the solidification range, and combinations thereof. Combined correlations can also be utilized. For instance, when Al is at about 0.8%, increasing the concentration of W increases solidification. However, when Al is at about 1.5%, increasing the concentration of W reduces solidification. Thus, the concentration of Al and the concentration of W can be related in the correlation.
• the correlation can further include additional experimental data based upon analysis of a component formed with the nickel-iron-base alloy and comparisons of the predetermined properties for different compositions of the nickel-iron-base alloy.
• the data can include any combination of specific chemistries, scale-up heats, long-term microstructure stability studies, long-term oxidation tests, creep tests (for example 5,000 hour creep tests), and other mechanical property tests.
• the component can be formed by any suitable technique (for example, casting, forging, heat treating, repair welding, or any suitable combination thereof).
• the nickel-iron-base alloy includes a compositional range of about 0.07 % to about 0.09 % C, about 35 % to about 37 % Fe, about 12.0 % to about 16.5 % Cr, about 1.0 % to about 2.0 % Al, about 2.0 % to about 3.0 % Ti, about 2.0 % to about 3.0 % W, about 3.0 % to about 5.0 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy includes a compositional range of about 0.07 % to about 0.09 % C, about 35 % to about 37 % Fe, about 12.0 % to about 13.0 % Cr, about 1.35 % to about 1.65 % Al, about 2.25 % to about 2.75 % Ti, about 2.3 % to about 2.7 % W, about 3.4 % to about 3.6 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy is devoid of Co.
• the nickel-iron-base alloy includes a compositional range of about 0.07 % to about 0.09 % C, about 35 % to about 37 % Fe, about 12.0 % to about 16.5 % Cr, about 1.0 % to about 2.0 % Al, about 2.0 % to about 3.0 % Ti, about 1.5 % to about 2.5 % W, about 3.0 % to about 5.0 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy includes a compositional range of about 0.07 % to about 0.09 % C, about 35 % to about 37 % Fe, about 13.5 % to about 14.5 % Cr, about 1.35 % to about 1.65 % Al, about 2.25 % to about 2.75 % Ti, about 1.8 % to about 2.2 % W, about 3.9 % to about 4.1 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy is devoid of Co.
• the nickel-iron-base alloy includes a compositional range of about 0.07 % to about 0.09 % C, about 35 % to about 37 % Fe, about 12.0 % to about 16.5 % Cr, about 1.0 % to about 2.0 % Al, about 2.0 % to about 3.0 % Ti, about 1.5 % to about 2.5 % W, about 0.5 % to about 1.5 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy includes a compositional range of about 0.07 % to about 0.09 % C, about 35 % to about 37 % Fe, about 15.5 % to about 16.5 % Cr, about 1.35 % to about 1.65 % Al, about 2.25 % to about 2.75 % Ti, about 1.8 % to about 2.2 % W, about 0.9 % to about 1.1 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy is devoid of Co.
• the nickel-iron-base alloy includes a compositional range of about 0.06 % to about 0.08 % C, about 35 % to about 37 % Fe, about 12.0 % to about 16.5 % Cr, about 1.0 % to about 2.0 % Al, about 1.0 % to about 2.5 % Ti, about 1.5 % to about 2.5 % W, up to about 0.25 % Mo, about 0.25 % to about 0.75 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy includes a compositional range of about 0.06 % to about 0.08 % C, about 35 % to about 37 % Fe, about 15.5 % to about 16.5 % Cr, about 1.35 % to about 1.65 % Al, about 1.5 % to about 1.8 % Ti, about 1.8 % to about 2.2 % W, up to about 0.12 % Mo, about 0.4 % to about 0.6 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy is devoid of Co.
• the nickel-iron-base alloy can have a composition originally based upon the composition of Base Alloy 1.
• the nickel-iron-base alloy includes a composition of about 0.08 % C, about 36 % Fe, about 12.5 % Cr, about 1.50 % Al, about 2.50 % Ti, about 2.50 % W, about 3.50 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy includes a composition of about 0.08 % C, about 36 % Fe, about 14.0 % Cr, about 1.50 % Al, about 2.50 % Ti, about 2.50 % W, about 4.00 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy includes a composition of about 0.08 % C, about 36 % Fe, about 16.0 % Cr, about 1.50 % Al, about 2.50 % Ti, about 2.50 % W, about 1.00 % Mo, up to about 0.1 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the nickel-iron-base alloy can have a composition originally based upon the composition of Base Alloy 2.
• the nickel-iron-base alloy includes a composition of about 0.07 % C, about 37 % Fe, about 16.0 % Cr, about 1.50 % Al, about 1.75 % Ti, about 2.00 % W, up to about 0.12 % Mo, about 0.50 % Nb, up to about 0.2 % Mn, up to about 0.1 % Si, up to about 0.006 % B, and a balance essentially Ni.
• the composition of the alloy is used in hot gas turbine components.
• the alloy can be used in stator components including, but not limited to, a nozzle, a shroud, other suitable portions, or combinations thereof.

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Mechanical Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Turbine Rotor Nozzle Sealing (AREA)

Applications Claiming Priority (1)

Publications (1)

Family

ID=44533958

Family Applications (1)

Country Status (6)

Cited By (1)

Families Citing this family (1)

Citations (1)

Family Cites Families (5)

• 2010
  • 2010-08-30 US US12/870,873 patent/US20120051963A1/en not_active Abandoned
• 2011
  • 2011-08-17 EP EP11177831A patent/EP2465959A1/de not_active Withdrawn
  • 2011-08-25 KR KR1020110085087A patent/KR20120021214A/ko not_active Application Discontinuation
  • 2011-08-26 JP JP2011184201A patent/JP5791998B2/ja not_active Expired - Fee Related
  • 2011-08-29 RU RU2011135629/02A patent/RU2011135629A/ru not_active Application Discontinuation
  • 2011-08-30 CN CN201110270202.4A patent/CN102383024B/zh not_active Expired - Fee Related

Patent Citations (1)

Also Published As

Similar Documents

Legal Events