EP2520678A2 - Nickel-base alloy - Google Patents
Nickel-base alloy Download PDFInfo
- Publication number
- EP2520678A2 EP2520678A2 EP12166469A EP12166469A EP2520678A2 EP 2520678 A2 EP2520678 A2 EP 2520678A2 EP 12166469 A EP12166469 A EP 12166469A EP 12166469 A EP12166469 A EP 12166469A EP 2520678 A2 EP2520678 A2 EP 2520678A2
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- EP
- European Patent Office
- Prior art keywords
- percent
- alloy
- titanium
- nickel
- tantalum
- 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.)
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- 239000000956 alloy Substances 0.000 title claims abstract description 115
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 115
- 239000010936 titanium Substances 0.000 claims abstract description 43
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 39
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 38
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 37
- 229910052715 tantalum Inorganic materials 0.000 claims abstract description 32
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims abstract description 32
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 28
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 28
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims abstract description 22
- 229910052721 tungsten Inorganic materials 0.000 claims abstract description 22
- 239000010937 tungsten Substances 0.000 claims abstract description 22
- 239000011651 chromium Substances 0.000 claims abstract description 19
- 239000010955 niobium Substances 0.000 claims abstract description 18
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims abstract description 16
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 16
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 16
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims abstract description 16
- 229910052796 boron Inorganic materials 0.000 claims abstract description 16
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 16
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 16
- 239000010941 cobalt Substances 0.000 claims abstract description 16
- 229910017052 cobalt Inorganic materials 0.000 claims abstract description 16
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims abstract description 16
- 229910052750 molybdenum Inorganic materials 0.000 claims abstract description 16
- 239000011733 molybdenum Substances 0.000 claims abstract description 16
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 16
- 238000004519 manufacturing process Methods 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 15
- 229910052758 niobium Inorganic materials 0.000 claims abstract description 15
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims abstract description 15
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 13
- 229910052735 hafnium Inorganic materials 0.000 claims abstract description 10
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims abstract description 10
- 238000005266 casting Methods 0.000 claims description 11
- 239000013078 crystal Substances 0.000 claims description 3
- 238000005260 corrosion Methods 0.000 abstract description 6
- 230000007797 corrosion Effects 0.000 abstract description 6
- 230000008569 process Effects 0.000 abstract description 4
- 230000008439 repair process Effects 0.000 abstract description 4
- 230000005496 eutectics Effects 0.000 description 11
- 239000000203 mixture Substances 0.000 description 8
- 238000011156 evaluation Methods 0.000 description 5
- 238000007711 solidification Methods 0.000 description 5
- 230000008023 solidification Effects 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 150000001247 metal acetylides Chemical class 0.000 description 4
- 238000003754 machining Methods 0.000 description 3
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical compound [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 description 3
- 238000005728 strengthening Methods 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000009795 derivation Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 238000001556 precipitation Methods 0.000 description 2
- 238000005204 segregation Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000006104 solid solution Substances 0.000 description 2
- 229910001005 Ni3Al Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
Images
Classifications
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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
- 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/607—Monocrystallinity
Definitions
- the present invention generally relates to nickel-base alloys for gas turbine applications, which possess a unique combination of mechanical properties, microstructural stability, and resistance to localized pitting and hot corrosion. More specifically, the invention relates to a class of nickel-base alloys having very low fractions of Eta phase and segregated titanium; resulting in improved yield, manufacturability, and repairability of articles formed therefrom.
- the present invention is an improvement to the class of alloys disclosed and claimed in U.S. Pat. No. 6,416,596 B1, issued Jul. 9, 2002 to John H. Wood et al. ; which was an improvement to the class of alloys disclosed and claimed in U.S. Pat. No. 3,615,376, issued Oct. 26, 1971 to Earl W. Ross . Both patents are assigned to the assignee hereof.
- the invention retains the advantageous attributes of those alloys; including high strength and ductility, high resistance to creep and fatigue, excellent microstructural stability, and high resistance to localized pitting and hot corrosion in high temperature corrosive environments. This unique combination of properties makes those alloys attractive for use in gas turbines.
- an attribute of the alloys disclosed and claimed in U.S. Pat. No. 6,416,596 is the presence of "Eta” phase, a hexagonal close-packed form of the intermetallic Ni 3 Ti, as well as segregated titanium metal in the solidified alloy.
- Te a hexagonal close-packed form of the intermetallic Ni 3 Ti
- the segregation of titanium also reduces the solidus temperature, increasing the fraction of ⁇ / ⁇ ' eutectic phases and resulting micro-shrinkages in the solidified alloy.
- the Eta phase in particular, may cause certain articles formed from those alloys to be rejected during the initial forming process, as well as post-forming manufacturing and repair processes.
- the presence of Eta phase may result in degradation of the alloy's mechanical properties during service exposure.
- the alloys exhibit a narrow solidification range (defined as the difference in temperature between the liquidus and solidus of the alloy) and the microstructures of the solidified alloys exhibit a finer ⁇ / ⁇ ' eutectic and carbide structure than the microstructures of the reference alloys.
- the present invention provides a class of nickel-base alloys for gas turbine applications, and useful articles of manufacture formed therefrom, which possess a unique combination of mechanical properties, microstructural stability, resistance to localized pitting and hot corrosion in high temperature corrosive environments, and high yields during the initial forming process as well as post-forming manufacturing and repair processes.
- the invention is further characterized by having very low fractions of Eta phase and segregated Titanium in the solidified nickel-base alloys.
- the nickel-base alloy comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel.
- the nickel-base alloy comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel.
- the present invention was the result of an investigation to develop a class of nickel-base alloys for gas turbine applications, and useful articles of manufacture formed therefrom, which possess a unique combination of mechanical properties, microstructural stability, resistance to localized pitting and hot corrosion in high temperature corrosive environments, and high yields during the initial forming process as well as post-forming manufacturing and repair processes.
- the invention is further characterized by having very low fractions of Eta phase and segregated Titanium in the solidified nickel-base alloys.
- the nickel-base alloy comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel.
- the nickel-base alloy is characterized by having very low fractions of Eta phase and segregated Titanium; and comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel.
- the nickel-base alloy comprises, by weight, about 13.9 percent chromium, about 9.5 percent cobalt, about 4.5 percent tungsten, about 4.2 percent titanium, about 3.7 percent aluminum, about 3.4 percent tantalum, about 1.6 percent molybdenum, about 0.1 percent carbon, about 0.01 percent boron, less than 0.01 percent zirconium, and the balance substantially nickel.
- the nickel-base alloy comprises, by weight, about 13.9 percent chromium, about 9.5 percent cobalt, about 4.2 percent tungsten, about 3.7 percent titanium, about 3.7 percent aluminum, about 3.2 percent tantalum, about 1.5 percent molybdenum, about 0.1 percent carbon, about 0.01 percent boron, about 0.002 percent zirconium, and the balance substantially nickel.
- the article may be formed by a casting method comprising the following steps: (1) preparing an ingot of the composition in the amounts stated above, (2) remelting the ingot and casting it to a form of the size and shape of the desired article, (3) heat treating the article in a suitable atmosphere and in accordance with a suitable time and temperature schedule, and (4) coating the article, if desired, with a suitable material for thermal or environmental protection.
- the grain structure of the cast articles may be either equiaxed (having no preferred orientation), directionally solidified (having a preferred orientation), or single crystal (having no grain boundaries).
- the article may be a gas turbine bucket or other form of rotating airfoil, or a gas turbine nozzle or other form of stationary airfoil, or another gas turbine component, that is located in the gas turbine hot section and designed in such a manner as to take advantage of the beneficial properties of the alloy.
- the nickel-base alloy comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel; and the article may be formed by a casting method that produces gas turbine airfoils or other components having either an equiaxed, directionally solidified, or single crystal grain structure.
- the nickel-base alloy comprises, by weight, about 13.9 percent chromium, about 9.5 percent cobalt, about 4.5 percent tungsten, about 4.2 percent titanium, about 3.7 percent aluminum, about 3.4 percent tantalum, about 1.6 percent molybdenum, about 0.1 percent carbon, about 0.01 percent boron, less than 0.01 percent zirconium, and the balance substantially nickel; and the article may be formed by a casting method that produces gas turbine airfoils or other components having an equiaxed grain structure.
- the nickel-base alloy comprises, by weight, about 13.9 percent chromium, about 9.5 percent cobalt, about 4.2 percent tungsten, about 3.7 percent titanium, about 3.7 percent aluminum, about 3.2 percent tantalum, about 1.5 percent molybdenum, about 0.1 percent carbon, about 0.01 percent boron, about 0.002 percent zirconium, and the balance substantially nickel; and the article may be formed by a casting method that produces gas turbine airfoils or other components having a directionally solidified grain structure.
- a feature of embodiments of the present invention is that the contents of aluminum and titanium and their relative ratios may be adjusted in such a manner that reduces the fractions of the ⁇ / ⁇ ' eutectic phase, Eta phase, and segregated titanium that form during alloy solidification.
- the solidified alloys are substantially free of Eta phase when the ratio of aluminum to titanium is between about 0.8 and about 1.0, by weight.
- a further benefit is a strengthening effect that may be due to an increase in ⁇ ' phase in the ⁇ matrix.
- the contents of aluminum and tantalum and their relative ratios may be adjusted in such a manner that further reduces the formation of Eta phase, while maintaining the fraction of ⁇ ' phase, in the solidified alloy.
- the solidified alloys are substantially free of Eta phase when the ratio of aluminum to tantalum is between about 0.9 and about 1.3, by weight.
- Another feature of embodiments of the present invention is that the content of tantalum may be reduced and the content of niobium may be increased, such that niobium may be entirely substituted for tantalum if desired.
- Another feature of embodiments of the present invention is that the contents of tantalum and tungsten may be adjusted in such a manner that results in a combination of precipitation and solid solution strengthening.
- Alloys 2 and 3 are variations of the reference alloys, having ratios of aluminum to titanium near the upper limit (Alloy 2) and lower limit (Alloy 3) of the ranges specified for the reference alloys.
- Alloys 1 and 4 are derivations of the reference alloys, having higher ratios of aluminum to titanium, as well as higher contents of tantalum and tungsten, than the ranges specified for the reference alloys.
- the microstructures of the four experimental alloys from Table 1 are shown in FIGS. 1 to 4 , respectively.
- the microstructural evaluations showed that Alloy 1 had no visible Eta phase, a low fraction of eutectic phase, and a low fraction of carbides ( FIG. 1 ); Alloy 2 had no visible Eta phase, an expected fraction of eutectic phase, and an expected fraction of carbides ( FIG. 2 ) ; Alloy 3 had visible Eta phase, an expected fraction of eutectic phase, and an expected fraction of carbides ( FIG. 3 ) ; and Alloy 4 had no visible Eta phase, a low fraction of eutectic phase, and a low fraction of carbides ( FIG. 4 ).
- Alloy 5 is a derivation of the reference alloys, having a higher ratio of aluminum to titanium, as well as higher contents of tantalum and tungsten, than the ranges specified for the reference alloys; while Alloys 6 and 7 are variations of the reference alloys.
- FIGS. 5 to 7 The microstructures of the three experimental alloys from Table 2 are shown in FIGS. 5 to 7 , respectively.
- the microstructural evaluations showed that Alloy 5 had no visible Eta phase and a low fraction of eutectic phase ( FIG. 5 ); Alloy 6 had no visible Eta phase and an expected fraction of eutectic phase ( FIG. 6 ); and Alloy 7 had visible Eta phase and an expected fraction of eutectic phase ( FIG. 7 ).
- FIGS. 8 to 10 The results of representative mechanical and manufacturing evaluations performed on the test articles prepared from the four experimental alloys from Table 1 are shown in FIGS. 8 to 10 , respectively. These results show that all four experimental alloys have tensile strength that is above 90% of the tensile strength of the reference alloys at both 20°C and 760°C ( FIG. 8 ). The results also showed that the creep life of Alloy 1 at 732°C is generally equal to or greater than the creep life of the reference alloys at 1.0% strain ( FIG. 9 ), and that Alloy 1 required less machining energy than Alloy 2 (avariation of the reference alloys) during milling ( FIG. 12 ).
- the present invention contemplates the use in a class of nickel-base alloys of the elements aluminum, titanium, tantalum, and tungsten in a novel manner that advantageously improves both manufacturing yield and mechanical properties of alloys having superior microstructural stability and resistance to localized pitting and hot corrosion in high temperature corrosive environments.
- the broad, preferred, and nominal compositions (by weight) of this class of nickel-base alloys are summarized in Table 3.
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Abstract
Description
- The present invention generally relates to nickel-base alloys for gas turbine applications, which possess a unique combination of mechanical properties, microstructural stability, and resistance to localized pitting and hot corrosion. More specifically, the invention relates to a class of nickel-base alloys having very low fractions of Eta phase and segregated titanium; resulting in improved yield, manufacturability, and repairability of articles formed therefrom.
- The present invention is an improvement to the class of alloys disclosed and claimed in
U.S. Pat. No. 6,416,596 B1, issued Jul. 9, 2002 to John H. Wood et al. ; which was an improvement to the class of alloys disclosed and claimed inU.S. Pat. No. 3,615,376, issued Oct. 26, 1971 to Earl W. Ross . Both patents are assigned to the assignee hereof. The invention retains the advantageous attributes of those alloys; including high strength and ductility, high resistance to creep and fatigue, excellent microstructural stability, and high resistance to localized pitting and hot corrosion in high temperature corrosive environments. This unique combination of properties makes those alloys attractive for use in gas turbines. - However, an attribute of the alloys disclosed and claimed in
U.S. Pat. No. 6,416,596 (hereinafter referred to as the "reference alloys") is the presence of "Eta" phase, a hexagonal close-packed form of the intermetallic Ni3Ti, as well as segregated titanium metal in the solidified alloy. During alloy solidification, titanium has a strong tendency to be rejected from the liquid side of the solid/liquid interface, resulting in the segregation (local enrichment) of titanium in the solidification front and promoting the formation of Eta in the last solidified liquid. The segregation of titanium also reduces the solidus temperature, increasing the fraction of γ / γ' eutectic phases and resulting micro-shrinkages in the solidified alloy. The Eta phase, in particular, may cause certain articles formed from those alloys to be rejected during the initial forming process, as well as post-forming manufacturing and repair processes. In addition, the presence of Eta phase may result in degradation of the alloy's mechanical properties during service exposure. - It was learned from experimental evaluations that the fractions of both Eta phase and segregated titanium in the solidified alloy are reduced by changing the alloy composition in such a manner that the content of titanium is reduced, and the ratio of aluminum to titanium is increased, relative to the composition of the reference alloys. This results from atom partitioning in the solid/liquid interface during alloy solidification, causing a reduction in the fraction of the γ / γ' eutectic phase in the solidified alloy. It was also learned in these evaluations that the Eta phase is further reduced by changing the alloy composition in such a manner that the content of tantalum is increased, and the ratio of aluminum to tantalum is reduced, relative to the composition of the reference alloys. Tantalum was known to stabilize the gamma prime (γ') phase (Ni3Al), further reducing the availability of titanium in the alloy.
- It was also known that advantageous amounts of gamma prime (γ') phase are retained when the content of tantalum is reduced and the content of niobium is increased, such that niobium may be entirely substituted for tantalum if desired, as taught in
U.S. Pat. No. 6,902,633 B2, issued Jun. 7, 2005 to Warren T. King et al. and assigned to the assignee hereof; andU.S. Pat. Appl. Publ. No. 2007/0095441 A1, published May 3, 2007 by Liang Jiang et al. and assigned to the assignee hereof. - It was also known that increasing the contents of tantalum and tungsten relative to the reference alloys result in improved mechanical properties through a combination of solid solution and precipitation strengthening. These changes produced alloys having tensile strength, yield strength, ductility, and Low Cycle Fatigue (LCF) strength generally comparable to the reference alloys; as well as improved creep strength and lower machining energy relative to the reference alloys for certain embodiments of the present invention.
- The totality of these changes produced additional benefits. For example, the alloys exhibit a narrow solidification range (defined as the difference in temperature between the liquidus and solidus of the alloy) and the microstructures of the solidified alloys exhibit a finer γ / γ' eutectic and carbide structure than the microstructures of the reference alloys.
- The present invention provides a class of nickel-base alloys for gas turbine applications, and useful articles of manufacture formed therefrom, which possess a unique combination of mechanical properties, microstructural stability, resistance to localized pitting and hot corrosion in high temperature corrosive environments, and high yields during the initial forming process as well as post-forming manufacturing and repair processes. The invention is further characterized by having very low fractions of Eta phase and segregated Titanium in the solidified nickel-base alloys.
- According to a particular embodiment of the present invention, the nickel-base alloy comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel.
- According to another embodiment of the present invention, wherein the form of the invention is an article of manufacture; the nickel-base alloy comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel.
- Other objects and advantages of the present invention will be better appreciated from the following detailed description.
- Non-limiting and non-exhaustive embodiments are described with reference to the following drawings.
-
FIG. 1 is a photomicrograph of Alloy 1, as embodied by the invention. -
FIG. 2 is a photomicrograph of Alloy 2, as embodied by the invention. -
FIG. 3 is a photomicrograph of Alloy 3, as embodied by the invention. -
FIG. 4 is a photomicrograph of Alloy 4, as embodied by the invention. -
FIG. 5 is a photomicrograph of Alloy 5, as embodied by the invention. -
FIG. 6 is a photomicrograph of Alloy 6, as embodied by the invention. -
FIG. 7 is a photomicrograph of Alloy 7, as embodied by the invention. -
FIG. 8 is a plot showing normalized tensile strength of Alloys 1 to 4, measured at 20°C (68°F) and 760°C (1400°F), shown as the fraction of the average tensile strength of the reference alloys at those temperatures. -
FIG. 9 is a plot showing normalized creep life of Alloys 1 to 4, in terms of the times to 1.0% strain at 732°C (1350°F), shown as the fraction of the average creep life of the reference alloys at the same strain and temperature. -
FIG. 10 is a plot showing the machining energy (in Joules) required for Alloys 1 and 2 during a milling operation. - The present invention was the result of an investigation to develop a class of nickel-base alloys for gas turbine applications, and useful articles of manufacture formed therefrom, which possess a unique combination of mechanical properties, microstructural stability, resistance to localized pitting and hot corrosion in high temperature corrosive environments, and high yields during the initial forming process as well as post-forming manufacturing and repair processes. The invention is further characterized by having very low fractions of Eta phase and segregated Titanium in the solidified nickel-base alloys.
- According to a particular embodiment of the present invention, the nickel-base alloy comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel.
- According to another embodiment of the present invention, the nickel-base alloy is characterized by having very low fractions of Eta phase and segregated Titanium; and comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel.
- According to another embodiment of the present invention, the nickel-base alloy comprises, by weight, about 13.9 percent chromium, about 9.5 percent cobalt, about 4.5 percent tungsten, about 4.2 percent titanium, about 3.7 percent aluminum, about 3.4 percent tantalum, about 1.6 percent molybdenum, about 0.1 percent carbon, about 0.01 percent boron, less than 0.01 percent zirconium, and the balance substantially nickel.
- According to yet another embodiment of the present invention, the nickel-base alloy comprises, by weight, about 13.9 percent chromium, about 9.5 percent cobalt, about 4.2 percent tungsten, about 3.7 percent titanium, about 3.7 percent aluminum, about 3.2 percent tantalum, about 1.5 percent molybdenum, about 0.1 percent carbon, about 0.01 percent boron, about 0.002 percent zirconium, and the balance substantially nickel.
- According to embodiments of the present invention, wherein the form of the invention is an article of manufacture, the article may be formed by a casting method comprising the following steps: (1) preparing an ingot of the composition in the amounts stated above, (2) remelting the ingot and casting it to a form of the size and shape of the desired article, (3) heat treating the article in a suitable atmosphere and in accordance with a suitable time and temperature schedule, and (4) coating the article, if desired, with a suitable material for thermal or environmental protection. The grain structure of the cast articles may be either equiaxed (having no preferred orientation), directionally solidified (having a preferred orientation), or single crystal (having no grain boundaries). The article may be a gas turbine bucket or other form of rotating airfoil, or a gas turbine nozzle or other form of stationary airfoil, or another gas turbine component, that is located in the gas turbine hot section and designed in such a manner as to take advantage of the beneficial properties of the alloy.
- According to a particular embodiment of the present invention, wherein the form of the invention is an article of manufacture, the nickel-base alloy comprises, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel; and the article may be formed by a casting method that produces gas turbine airfoils or other components having either an equiaxed, directionally solidified, or single crystal grain structure.
- According to another embodiment of the present invention, wherein the form of the invention is an article of manufacture, the nickel-base alloy comprises, by weight, about 13.9 percent chromium, about 9.5 percent cobalt, about 4.5 percent tungsten, about 4.2 percent titanium, about 3.7 percent aluminum, about 3.4 percent tantalum, about 1.6 percent molybdenum, about 0.1 percent carbon, about 0.01 percent boron, less than 0.01 percent zirconium, and the balance substantially nickel; and the article may be formed by a casting method that produces gas turbine airfoils or other components having an equiaxed grain structure.
- According to yet another embodiment of the present invention, wherein the form of the invention is an article of manufacture, the nickel-base alloy comprises, by weight, about 13.9 percent chromium, about 9.5 percent cobalt, about 4.2 percent tungsten, about 3.7 percent titanium, about 3.7 percent aluminum, about 3.2 percent tantalum, about 1.5 percent molybdenum, about 0.1 percent carbon, about 0.01 percent boron, about 0.002 percent zirconium, and the balance substantially nickel; and the article may be formed by a casting method that produces gas turbine airfoils or other components having a directionally solidified grain structure.
- A feature of embodiments of the present invention is that the contents of aluminum and titanium and their relative ratios may be adjusted in such a manner that reduces the fractions of the γ / γ' eutectic phase, Eta phase, and segregated titanium that form during alloy solidification. For example, the solidified alloys are substantially free of Eta phase when the ratio of aluminum to titanium is between about 0.8 and about 1.0, by weight. A further benefit is a strengthening effect that may be due to an increase in γ' phase in the γ matrix.
- Another feature of embodiments of the present invention is that the contents of aluminum and tantalum and their relative ratios may be adjusted in such a manner that further reduces the formation of Eta phase, while maintaining the fraction of γ' phase, in the solidified alloy. For example, the solidified alloys are substantially free of Eta phase when the ratio of aluminum to tantalum is between about 0.9 and about 1.3, by weight.
- Another feature of embodiments of the present invention is that the content of tantalum may be reduced and the content of niobium may be increased, such that niobium may be entirely substituted for tantalum if desired.
- Another feature of embodiments of the present invention is that the contents of tantalum and tungsten may be adjusted in such a manner that results in a combination of precipitation and solid solution strengthening.
- Four experimental alloys having equiaxed grain structures were formed into test articles using a casting method and comprising the compositions given in Table 1 (in percent weight).
Alloys Alloys TABLE 1 Alloy 1Alloy 2Alloy 3Alloy 4Chromium (Cr) 13.9 13.9 13.9 14.0 Cobalt (Co) 9.5 9.5 9.5 9.5 Tungsten (W) 4.5 3.7 3.8 3.9 Titanium (Ti) 4.2 5.0 5.2 3.8 Aluminum (Al) 3.7 3.3 3.0 3.8 Tantalum (Ta) 3.4 2.9 2.8 3.4 Molybdenum (Mo) 1.6 1.5 1.5 1.5 Carbon (C) 0.1 0.1 0.1 0.1 Boron (B) 0.01 0.01 0.01 0.01 Niobium (Nb) 0.02 0.03 0.03 0.03 Hafnium (Hf) 0.02 0.01 0.02 0.02 Zirconium (Zr) < 0.01 <0.01 <0.01 <0.01 Nickel (Ni) Balance Balance Balance Balance - The microstructures of the four experimental alloys from Table 1 are shown in
FIGS. 1 to 4 , respectively. The microstructural evaluations showed thatAlloy 1 had no visible Eta phase, a low fraction of eutectic phase, and a low fraction of carbides (FIG. 1 );Alloy 2 had no visible Eta phase, an expected fraction of eutectic phase, and an expected fraction of carbides (FIG. 2 );Alloy 3 had visible Eta phase, an expected fraction of eutectic phase, and an expected fraction of carbides (FIG. 3 ); andAlloy 4 had no visible Eta phase, a low fraction of eutectic phase, and a low fraction of carbides (FIG. 4 ). - Three other experimental alloys having directionally solidified grain structures were formed into test articles using a casting method and comprising the compositions given in Table 2 (in percent weight). Alloy 5 is a derivation of the reference alloys, having a higher ratio of aluminum to titanium, as well as higher contents of tantalum and tungsten, than the ranges specified for the reference alloys; while
Alloys 6 and 7 are variations of the reference alloys.TABLE 2 Alloy 5 Alloy 6Alloy 7 Chromium (Cr) 13.9 13.9 13.9 Cobalt (Co) 9.5 9.5 9.5 Tungsten (W) 4.2 3.7 3.7 Titanium (Ti) 3.7 4.8 5.0 Aluminum (Al) 3.7 3.3 2.9 Tantalum (Ta) 3.2 2.6 2.6 Molybdenum (Mo) 1.5 1.5 1.5 Carbon (C) 0.1 0.1 0.1 Boron (B) 0.01 0.01 0.01 Niobium (Nb) 0.02 0.02 0.02 Hafnium (Hf) 0.01 0.01 0.01 Zirconium (Zr) 0.002 0.002 0.002 Nickel (Ni) Balance Balance Balance - The microstructures of the three experimental alloys from Table 2 are shown in
FIGS. 5 to 7 , respectively. The microstructural evaluations showed that Alloy 5 had no visible Eta phase and a low fraction of eutectic phase (FIG. 5 );Alloy 6 had no visible Eta phase and an expected fraction of eutectic phase (FIG. 6 ); and Alloy 7 had visible Eta phase and an expected fraction of eutectic phase (FIG. 7 ). - The results of representative mechanical and manufacturing evaluations performed on the test articles prepared from the four experimental alloys from Table 1 are shown in
FIGS. 8 to 10 , respectively. These results show that all four experimental alloys have tensile strength that is above 90% of the tensile strength of the reference alloys at both 20°C and 760°C (FIG. 8 ). The results also showed that the creep life ofAlloy 1 at 732°C is generally equal to or greater than the creep life of the reference alloys at 1.0% strain (FIG. 9 ), and thatAlloy 1 required less machining energy than Alloy 2 (avariation of the reference alloys) during milling (FIG. 12). - Summarizing, the present invention contemplates the use in a class of nickel-base alloys of the elements aluminum, titanium, tantalum, and tungsten in a novel manner that advantageously improves both manufacturing yield and mechanical properties of alloys having superior microstructural stability and resistance to localized pitting and hot corrosion in high temperature corrosive environments. The broad, preferred, and nominal compositions (by weight) of this class of nickel-base alloys are summarized in Table 3.
TABLE 3 Broad Preferred Nominal 1 Nominal 2 Chromium (Cr) 13.7 to 14.3 13.7 to 14.3 13.9 13.9 Cobalt (Co) 5.0 to 10.0 5.0 to 10.0 9.5 9.5 Tungsten (W) 3.5 to 5.2 4.0 to 4.6 4.5 4.2 Titanium (Ti) 2.8 to 5.2 3.6 to 4.3 4.2 3.7 Aluminum (Al) 2.8 to 4.6 3.5 to 3.9 3.7 3.7 Tantalum (Ta) 0.0 to 3.5 3.1 to 3.5 3.4 3.2 Molybdenum (Mo) 1.0 to 1.7 1.0 to 1.7 1.6 1.5 Carbon (C) 0.08 to 0.13 0.08 to 0.13 0.1 0.1 Boron (B) 0.005 to 0.02 0.005 to 0.02 0.01 0.01 Niobium (Nb) 0.0 to 1.5 0.0 to 1.5 0.02 0.02 Hafnium (Hf) 0.0 to 2.5 0.0 to 2.5 0.02 0.01 Zirconium (Zr) 0.0 to 0.04 0.0 to 0.04 <0.01 0.002 Nickel (Ni) Balance Balance Balance Balance - As used herein, an element or step recited in the singular and proceeded with the word "a" or "an" should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
- This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Claims (15)
- An alloy comprising the following elements, by weight:a. about 13.7 to about 14.3 percent chromium,b. about 5.0 to about 10.0 percent cobalt,c. about 3.5 to about 5.2 percent tungsten,d. about 2.8 to about 5.2 percent titanium,e. about 2.8 to about 4.6 percent aluminum,f. about 0.0 to about 3.5 percent tantalum,g. about 1.0 to about 1.7 percent molybdenum,h. about 0.08 to about 0.13 percent carbon,i. about 0.005 to about 0.02 percent boron,j. about 0.0 to about 1.5 percent niobium,k. about 0.0 to about 2.5 percent hafnium,l. about 0.0 to about 0.04 percent zirconium,m. the balance substantially nickel.
- The alloy of claim 1, comprising about 4.0 to about 4.6 percent tungsten.
- The alloy of claim 1 or claim 2, comprising about 3.6 to about 4.3 percent titanium.
- The alloy of any preceding claim, comprising about 3.5 to about 3.9 percent aluminum.
- The alloy of any preceding claim, comprising about 3.1 to about 3.5 percent tantalum.
- The alloy of any preceding claim, comprising about 0.0 to about 1.5 percent niobium or about 0.0 to about 3.5 percent tantalum.
- The alloy of any preceding claim, wherein the ratio of percent aluminum to percent titanium is about 0.8 to about 1.0, by weight.
- The alloy of any preceding claim, having about zero Eta phase (Ni3Ti) and segregated titanium.
- The alloy of claim 1, comprising the following elements, by weight:a. about 13.9 percent chromium,b. about 9.5 percent cobalt,c. about 4.5 percent tungsten,d. about 4.2 percent titanium,e. about 3.7 percent aluminum,f. about 3.4 percent tantalum,g. about 1.6 percent molybdenum,h. about 0.1 percent carbon,i. about 0.01 percent boron,j. less than 0.01 percent zirconium,k. the balance substantially nickel.
- The alloy of claim 1, comprising the following elements, by weight:a. about 13.9 percent chromium,b. about 9.5 percent cobalt,c. about 4.2 percent tungsten,d. about 3.7 percent titanium,e. about 3.7 percent aluminum,f. about 3.2 percent tantalum,g. about 1.5 percent molybdenum,h. about 0.1 percent carbon,i. about 0.01 percent boron,j. about 0.002 percent zirconium,k. the balance substantially nickel.
- An article of manufacture that may be used in a gas turbine and is formed from the alloy of any preceding claim.
- The article of claim 11, wherein the method of forming is casting.
- The article of claim 12, wherein the method of forming is casting performed in such a manner as to produce an equiaxed grain structure.
- The article of claim 12, wherein the method of forming is casting performed in such a manner as to produce a directionally solidified grain structure.
- The article of claim 12, wherein the method of forming is casting performed in such a manner as to produce a single crystal grain structure.
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EP2805784A1 (en) * | 2013-05-24 | 2014-11-26 | Rolls-Royce plc | A nickel alloy |
EP2913416A1 (en) * | 2014-02-28 | 2015-09-02 | General Electric Company | Article and method for forming an article |
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CN104894434B (en) * | 2014-03-04 | 2018-04-27 | 中国科学院金属研究所 | A kind of corrosion and heat resistant nickel base superalloy of tissue stabilization |
GB2567492B (en) * | 2017-10-16 | 2020-09-23 | Oxmet Tech Limited | A nickel-based alloy |
CN113481413A (en) * | 2021-05-24 | 2021-10-08 | 深圳市万泽中南研究院有限公司 | Directional solidification nickel-based high-temperature alloy, turbine blade and gas turbine |
CN116083771A (en) * | 2022-12-28 | 2023-05-09 | 东方电气集团东方汽轮机有限公司 | Preparation and application methods of high-performance boron-free precast slab |
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US20030111138A1 (en) * | 2001-12-18 | 2003-06-19 | Cetel Alan D. | High strength hot corrosion and oxidation resistant, directionally solidified nickel base superalloy and articles |
US20040200549A1 (en) * | 2002-12-10 | 2004-10-14 | Cetel Alan D. | High strength, hot corrosion and oxidation resistant, equiaxed nickel base superalloy and articles and method of making |
JP4036091B2 (en) * | 2002-12-17 | 2008-01-23 | 株式会社日立製作所 | Nickel-base heat-resistant alloy and gas turbine blade |
CN101525706B (en) * | 2009-04-17 | 2011-01-12 | 东华大学 | Modification method for enhancing high-temperature creep resistance in nickel-base single crystal superalloy |
US8226886B2 (en) * | 2009-08-31 | 2012-07-24 | General Electric Company | Nickel-based superalloys and articles |
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- 2011-05-04 US US13/100,441 patent/US20120282086A1/en not_active Abandoned
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US3615376A (en) | 1968-11-01 | 1971-10-26 | Gen Electric | Cast nickel base alloy |
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EP2805784A1 (en) * | 2013-05-24 | 2014-11-26 | Rolls-Royce plc | A nickel alloy |
EP2913416A1 (en) * | 2014-02-28 | 2015-09-02 | General Electric Company | Article and method for forming an article |
US9404388B2 (en) | 2014-02-28 | 2016-08-02 | General Electric Company | Article and method for forming an article |
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CN102766787A (en) | 2012-11-07 |
US20120282086A1 (en) | 2012-11-08 |
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