EP2872661A2 - Superalliage à base de nickel, traitement associé et composants formés à partir de celui-ci - Google Patents

Superalliage à base de nickel, traitement associé et composants formés à partir de celui-ci

Info

Publication number
EP2872661A2
EP2872661A2 EP13826796.8A EP13826796A EP2872661A2 EP 2872661 A2 EP2872661 A2 EP 2872661A2 EP 13826796 A EP13826796 A EP 13826796A EP 2872661 A2 EP2872661 A2 EP 2872661A2
Authority
EP
European Patent Office
Prior art keywords
iron
alloy
superalloy
raw materials
melting
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.)
Withdrawn
Application number
EP13826796.8A
Other languages
German (de)
English (en)
Inventor
Michael Leslie LASONDE
David Paul Mourer
Joseph Aloysius HEANEY III
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Publication of EP2872661A2 publication Critical patent/EP2872661A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/023—Alloys based on nickel
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/21—Circular sheet or circular blank
    • Y10T428/211—Gear

Definitions

  • the present invention generally relates to alloy compositions, and more particularly to superalloys suitable for components requiring a polycrystalline microstructure and both high temperature dwell and/or creep capabilities, for example, turbine disks of gas turbine engines. Such alloys may also be useful in a multi-grain directionaily solidified form or single crystal form.
  • the turbine section of a gas turbine engine is located downstream of a combustor section and contains a rotor shaft and one or more turbine stages, each having a turbine disk (rotor) mounted or otherwise carried by the shaft, and turbine blades mounted to and radially extending from the periphery of the disk.
  • Components within the combustor and turbine sections are often formed of superalloy materials in order to achieve acceptable mechanical properties while at elevated temperatures resulting from the hot combustion gases. Higher compressor exit temperatures in modem high pressure ratio gas turbine engines can also necessitate the use of high performance superalloys for compressor disks, biisks, and other components.
  • Suitable alloy compositions and microstructures for a given component are dependent on the particular temperatures, stresses, and other conditions to which the component is subjected.
  • airfoil components such as blades and vanes are often formed of equiaxed, directionaily solidified (DS), or single crystal (SX) superalloys
  • turbine disks are typically formed of superalloys that must undergo carefully controlled forging, heat treatments, and surface treatments to produce a polycrystaliine niicrostracture having a controlled grain structure and desirable mechanical properties.
  • Turbine disks are often formed of gamma prime ( ⁇ ) precipitation- strengthened nickel-base superalloys (hereinafter, gamma prime nickel-base superalloys) containing chromium, tungsten, molybdenum, rhenium and/or cobalt as principal elements that combine with nickel to form the gamma ( ⁇ ) matrix, and contain aluminum, titanium, tantalum, niobium, and/or vanadium as principal elements that combine with nickel to form the desirable gamma prime precipitate strengthening phase, principally Ni 3 (Al,Ti).
  • gamma prime nickel-base superalloys include Rene 88DT (R88DT; U.S. Patent No.
  • Rene 104 Rene 104
  • U.S. Patent No. 6,521,175 Rene 104
  • certain nickel-base superalloys commercially available under the trademarks Inconel ® , Nimonic*, and Udimet* ' .
  • R88DT has a composition of, by weight, about 15.0-17.0% chromium, about 12.0-14.0% cobalt, about 3.5-4.5% molybdenum, about 3.5-4.5% tungsten, about 1 .5-2.5% aluminum, about 3.2-4.2% titanium, about 0.5- 1.0% niobium, about 0.010-0.060% carbon, about 0.010-0.060% zirconium, about 0.010- 0.040% boron, about 0.0-0.3% hafnium, about 0.0-0.01 vanadium, and about 0.0-0.01 yttrium, the balance nickel and incidental impurities.
  • Disks and other critical gas turbine engine components are often forged from billets produced by powder metallurgy (P/M), conventional cast and wrought processing, and spraycast or nucleated casting forming techniques.
  • Powder metallurgy P/M
  • Gamma prime nickel-base superalloys formed by powder metallurgy are particularly capable of providing a good balance of creep, tensile, and fatigue crack growth properties to meet the performance requirements of turbine disks and certain other gas turbine engine components.
  • a powder of the desired superalloy undergoes consolidation, such as by hot isostatic pressing (HIP) and/or extrasion consolidation.
  • HIP hot isostatic pressing
  • these alloys may be heat treated belo their gamma prime solvus temperature (generally referred to as subsolvus heat treatment) to maintain fine uniform grains.
  • these alloys are heat treated above their gamma prime solvus temperature (generally referred to as supersolvus heat treatment) to cause significant, uniform coarsening of the grains.
  • Rotor-grade superalloys may be produced by a variety of processes including powder processing and melt processing.
  • R88DT is typically manufactured using powder metal processing.
  • Some other disk alloys, such as the nickel-base superalloy IN718 are typically produced using conventional melting processes.
  • Nominal elemental composition ranges reported for IN718 are, by weight: 50-55% nickel, 17-21% chromium, 2.8-3.33%) molybdenum, 4.75- 5.5% niobium, 0-1.0% cobalt, 0.65-1.15 titanium, 0,2-0.8% aluminum, 0-0.35% manganese, 0-0.3% copper, 0-0.08% ⁇ carbon, 0-0.006% boron, the balance iron (18.5% nominal) and incidental impurities.
  • superalloys IN718 stands out for its pervasive use, reported to be at approximately 45% of total industrial production of wrought nickel base superalloys.
  • Sigma phase is a well-known topologically close-packed (TCP) phase which can adversely affect the mechanical capabilities of a gamma prime nickel-base alloy.
  • TCP topologically close-packed
  • an observable amount is considered to be any amount that can be seen in suitable etched metal! ographie samples at an optical magnification of 500X.
  • scrap or revert utilization for use in the production of R88DT would cany with it a high probability of iron contamination and sigma phase formation that is not desirable in R88DT.
  • Prior attempts to prevent iron cross-contamination while utilizing high levels of IN718 scrap or revert include alloy segregation by physically keeping chips of different alloys separate, Unfortunately, such methods have significant limitations in terms of additional personnel training and maintaining separate chips or containers.
  • there can be contamination from melting equipment or melt-handling or machining equipment that may have been previously used for the production of an iron- containing alloy, in which case extensive cleaning is required of equipment between switching over to production of different alloys.
  • the present invention provides gamma prime nickel-based superalloys suitable for use in forming components such as a turbine disk, compressor disk, blisk, seal, shaft or retainer, and processes for producing such superalloys, wherein the processes allow scrap and revert usage.
  • the superalloys accommodate limited amounts of iron in their compositions and are particularly well suited for achieving physical and chemical properties similar to those of R88DT, yet allow for an iron content that was previously considered excessive and unallowable in R88DT, including powder- metallurgy processed versions of 88DT.
  • a gamma prime nickel-based superalloy has a composition that falls within a compositional space defined by the following ranges, by weight: 15.8-16.2% chromium, about 12.9-13.3% cobalt, about 3.95-4.1% molybdenum, about 3.9-4.1% tungsten, about 2.01-2.24% aluminum, about 3.6-3.9% titanium, about 0,5-1.0% niobium, about 0.010-0.060% carbon, about 0.02- 0.06% zirconium, about 0.010-0.040% boron, about 0.0-0.3% hafnium, about 0.0-0.01 vanadium, and about 0.0-0.01 yttrium, the balance nickel and incidental impurities, wherein the superalloy further contains iron in an amount exceeding an impurity level and up to 2.0%, and the superalloy being free of an observable amount of sigma phase.
  • structural components can be formed from the superalloy described above, particular examples of which include turbine disks, compressor disks and blisks, seals, shafts, and retainers of gas turbine engines.
  • a third aspect of the invention is a process for making the superalloy described above which includes scrap and revert usage of alloys that contain iron, either intentionally or inadvertently, and/or using melting and melt-handling equipment without extensive cleaning after producing an iron-containing alloy,
  • a technical effect of the invention is that the superalloy described above is capable of providing approximately the same properties and structural and chemical capabilities as R88DT or a similar superalloy designed and processed to a consistent microstructure for high temperature properties, and is obtainable by suitable processing to achieve a desirable microstructure, but allows for significant iron content.
  • the superalloy is capable of being produced more economically and efficiently, with less material waste, higher scrap and revert utilization, less cleaning of machining, scrap and chip handling equipment, melting and melt-handling equipment, and lower personnel and time requirements,
  • FIG, 1 is a perspective view of a turbine disk of a type used in gas turbine engines.
  • the present invention is directed to nickel-base alloys, and particularly to gamma prime nickel-base alloys suitable for components produced by a hot working (e.g., forging) operation.
  • a particular but non-limiting example represented in FIG. 1 is a high pressure turbine disk 10 for a gas turbine engine.
  • the invention will be discussed in reference to alloys suitable for a high-pressure turbine disk for a gas turbine engine, though those skilled in the art will appreciate that the teachings and benefits of this invention are also applicable to compressor disks, blades, and blisks of gas turbine engines, as well as numerous other components that are subjected to stresses at high temperatures and therefore benefit from a high temperature capability,
  • Disks of the type shown in FIG. 1 are typically produced by isothermally forging a fine-grained billet formed by powder metallurgy (P/M), a cast and wrought processing, or a spraycast or nucleated casting type technique.
  • the billet can be formed by consolidating a powder of the desired nickel-base alloy, such as by hot isostatic pressing ( HIP), extaision consolidation, or combinations thereof.
  • HIP hot isostatic pressing
  • the billet is formed by casting an ingot and working the materia] to a billet form suitable for subsequent forging operations.
  • the billet is typically forged at a temperature at or near the recrystailization temperature of the alloy but less than the gamma prime solvus temperature of the alloy, and, if the bi llet is formed by powder metallurgy processes, under superplastic forming conditions.
  • a subsolvus or supersolvus (solution) heat treatment is performed, during which grain growth occurs consistent with the proximity of the heat-treat temperatures to the gamma prime solvus temperature, as is well known in the art,
  • a supersolvus solution heat treatment is performed at a temperature above the gamma prime solvus temperature (but below the incipient melting temperature) of the superalloy to recrystallize the worked grain structure and dissolve (solution) the gamma prime precipitates in the superalloy enabling significant grain growth to occur.
  • a subsolvus solution heat treatment is performed at a temperature below the gamma prime solvus temperature (and below the incipient melting temperature) of the superalloy to partially dissolve (solution) the gamma prime precipitates in the superalloy so that a finer grain size ca be maintained for some applications.
  • the component is cooled at an appropriate rate to re-precipitate gamma prime within the gamma matrix or at grain boundaries, so as to achieve the particular mechanical properties desired.
  • the component may also undergo aging or stress relief using known techniques.
  • the present invention discloses a set of compositions that share certain similarities with other nickel-base superalloys, including Rene 88DT (R88DT; U.S. Patent No. 4,957,567).
  • the present invention is particularly intended to maintain the structural and mechanical attributes of R88DT most advantageously in the subsolvus fine-grained condition, especially as produced in a cast and wrought form.
  • R88DT is considered to be unable to accommodate significant iron contamination while maintaining desirable mechanical properties and avoiding an observable amount of sigma phase. More particularly, conventional wisdom has been that the introduction of iron into R88DT promotes the formation of sigma phase, which can be detrimental to mechanical properties of R88DT.
  • the superalloys of this invention are capable of allowing scrap and revert usage of alloys that contain iron, either intentionally or inadvertently, and can also advantageously allow the use of machining equipment, scrap and revert handling equipment, and melting and melt-handling equipment without extensive cleaning after producing an iron-containing alloy.
  • An iron-containing alloy is IN718.
  • the sigma solvus temperature would be approximately 1400 °F (760 °C), coincident with a preferred heat-treat aging temperature, indicating that sigma phase formation is thermodynamically possible.
  • kinetics of phase formation are not often favorable for the formation of all thermodynamically predicted phases. This phenomenon suggested that a potential maximum iron content exists below which kinetics control the sigma phase formation and are not favorable for an observable amount of sigma phase formation.
  • a suitable composition comprises, and more preferably consists of, by weight, 15.8 to 16.2% chromium 12.9 to 13.3% cobalt, 3.95 to 4.1% molybdenum, 3.9 to 4.1% tungsten, 2.01 to 2.24% aluminum, 3.6 to 3.9% titanium, 0.67 to 0.74% niobium, 0.012 to 0.02% boron, about 0.0-0.3% hafnium, about 0.0-0.01 vanadium, and about 0.0-0.01 yttrium 0.005 to 0.01 1% carbon, 0.02 to 0.06% zirconium, and iron in an amount of about 0.6 to about 1.3%, the balance nickel and incidental impurities.
  • gamma prime nickel-base superailoys of this invention can have a composition that falls within a compositional space of, by weight, about 15.0-17.0% chromium, about 12.0-14.0% cobalt, about 3.5-4.5%) molybdenum, about 3.5-4.5% tungsten, about 1.5-2.5% aluminum, about 3.2-4.2% titanium, about 0.5- 1.0%) niobium, about 0.010-0,060% ⁇ carbon, about 0,010-0,060% ⁇ zirconium, about 0.010- 0.040% boron, about 0.0-0.3% hafnium, about 0.0-0.01 vanadium, and about 0.0-0.01 yttrium, the balance nickel and incidental impurities, the superallov further containing iron in an amount exceeding an impurity level and up to 2.0°/», the superallov being free of an observable amount of sigma phase.
  • typical impurity levels for iron in R88DT can be up to about 0, 1%.
  • the alloy may contain up to 0,0035% nitrogen, Also, it is generally recognized that carbon and nitrogen levels together influence the degree of carbo-nitride inclusions.
  • a particular embodiment of the alloy contains, by weight, about 13% cobalt, 16% chromium, 4% molybdenum, 4% tungsten, 2.1 % aluminum, 3.7% titanium, 0.7% niobium, 0.008% boron, about 0.0-0.3% hafnium, about 0.0-0.01 vanadium, about 0.0-0.01 yttrium 0.005 to 0.011% carbon, 0.03 to 0,06% zirconium, up to 0.0035% nitrogen and more preferably up to 0.0018% nitrogen, the balance nickel, incidental impurities, and iron in an amount greater than impurity levels and up to about 1.3%.
  • alloys as well as other alloys of the invention indicated through the composition ranges above, can be produced using scrap and revert usage of alloys that contain iron, intentionally or in advertently. Further, these alloys can be advantageously produced in melt equipment previously used for the production of iron- containing alloys without the need for significant decontamination or expensive alloy segregation procedures.
  • a nonlimiting example of a method capable of producing a superalloy of this invention includes combining at least one iron-containing alloy with raw materials that do not contain intentional additions of iron, wherein the iron-containing alloy(s) and raw materials are combined in appropriate amounts and then melted to produce the desired composition for the superallov and its intentional but limited addition of iron.
  • At least one iron-containing scrap alloy can be used in place of or in addition to the iron- containing alloy(s).
  • intentional additions of iron can be made present in a s peralloy of this invention as a result of melting raw materials, and/or iron-containing alloys(s), and/or iron-containing scrap a!loy(s) using melt equipment that had been immediately previously used to melt an iron-containing alloy and without cleaning the melt equipment to remove remnants of the iron-containing alloy. It should be apparent that the presence of iron can occur through any combination of the above techniques in a manner that may promote efficiencies and/or reduce material and processing costs.
  • alloy phase stability modeling indicated the potential absence of an observable amount of sigma phase in the iron-containing superalloys having the compositions described above.
  • the superalloys of this invention are capable of exhibiting comparable properties to similar high temperature superalloys, including R88DT, while accommodating significant iron content with negligible or no loss in advantageous properties.
  • This ability to accommodate significant levels of iron contamination allows superalloys to be produced with scrap and revert usage of alloys that contain iron, either intentionally or inadvertently, and can also allow for the advantageous use of melting and melt-handling equipment without extensive cleaning after an iron-containing alloy, for example, ⁇ 718, is produced with the equipment. This flexibility can lead to significant reduction in production costs of the superalloy.
  • Additional potential benefits include the ability to reduce or eliminate the need for special training of personnel and the expense of extensive cleaning of melting process equipment when the equipment is switched between iron-containing alloy compositions and superalloys of this invention.
  • the invention can reduce or eliminate the need to segregate iron from a recycling stream with specialized equipment capable of isolating an iron-containing material as well as reduce or eliminate the need for operator training in order to strictly maintain such isolation.
  • the invention can promote recycling economics by allowing superalloys to be produced with the use of machining chips or recycled material from articles having multi-alloy constructions that include iron-containing alloys, a notable example of which are compressor spools that often have multi-alloy constructions.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Powder Metallurgy (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

La présente invention concerne un superalliage à base de nickel gamma-prime approprié pour produire des composants structurels (10), par exemple, des disques de turbine (10) et d'autres composants de turbomachine. Selon l'invention, le superalliage comprend une quantité voulue de fer allant jusqu'à 2,0 % et peut, de préférence, présenter des propriétés structurelles comparables à celles des superalliages à base de nickel exempts de fer. Le superalliage peut être réalisé au moyen de procédés qui se prêtent à une utilisation avantageuse de déchets et de recyclage d'alliages contenant du fer. Le superalliage est exempt de quantité observable de phase sigma.
EP13826796.8A 2012-07-12 2013-07-11 Superalliage à base de nickel, traitement associé et composants formés à partir de celui-ci Withdrawn EP2872661A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261670634P 2012-07-12 2012-07-12
PCT/US2013/049999 WO2014058491A2 (fr) 2012-07-12 2013-07-11 Superalliage à base de nickel, traitement associé et composants formés à partir de celui-ci

Publications (1)

Publication Number Publication Date
EP2872661A2 true EP2872661A2 (fr) 2015-05-20

Family

ID=50031491

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13826796.8A Withdrawn EP2872661A2 (fr) 2012-07-12 2013-07-11 Superalliage à base de nickel, traitement associé et composants formés à partir de celui-ci

Country Status (7)

Country Link
US (1) US20150167123A1 (fr)
EP (1) EP2872661A2 (fr)
JP (1) JP2015529743A (fr)
CN (1) CN104428431A (fr)
BR (1) BR112015000531A2 (fr)
CA (1) CA2878711A1 (fr)
WO (1) WO2014058491A2 (fr)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10378087B2 (en) 2015-12-09 2019-08-13 General Electric Company Nickel base super alloys and methods of making the same
US10577679B1 (en) 2018-12-04 2020-03-03 General Electric Company Gamma prime strengthened nickel superalloy for additive manufacturing
CN109576621B (zh) * 2019-01-18 2020-09-22 中国航发北京航空材料研究院 一种镍基变形高温合金制件的精确热处理方法
JP7330132B2 (ja) * 2020-04-09 2023-08-21 本田技研工業株式会社 シール部材及びその製造方法
CN114318064A (zh) * 2021-12-29 2022-04-12 河南机电职业学院 一种镍基金属粉末、涡轮叶片的修复方法和应用

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US4957567A (en) * 1988-12-13 1990-09-18 General Electric Company Fatigue crack growth resistant nickel-base article and alloy and method for making
US5693159A (en) * 1991-04-15 1997-12-02 United Technologies Corporation Superalloy forging process
CN1204843A (zh) * 1997-07-04 1999-01-13 安费公司 用于高灵敏度继电器磁路的铁－镍－铬－钛型软磁合金
US6521175B1 (en) 1998-02-09 2003-02-18 General Electric Co. Superalloy optimized for high-temperature performance in high-pressure turbine disks
US6551372B1 (en) * 1999-09-17 2003-04-22 Rolls-Royce Corporation High performance wrought powder metal articles and method of manufacture
US6908519B2 (en) * 2002-07-19 2005-06-21 General Electric Company Isothermal forging of nickel-base superalloys in air
US7033448B2 (en) * 2003-09-15 2006-04-25 General Electric Company Method for preparing a nickel-base superalloy article using a two-step salt quench
US7763129B2 (en) * 2006-04-18 2010-07-27 General Electric Company Method of controlling final grain size in supersolvus heat treated nickel-base superalloys and articles formed thereby
US8038894B2 (en) * 2006-11-29 2011-10-18 General Electric Company Method of selectively stripping an engine-run ceramic coating
US7364801B1 (en) * 2006-12-06 2008-04-29 General Electric Company Turbine component protected with environmental coating
FR2949234B1 (fr) * 2009-08-20 2011-09-09 Aubert & Duval Sa Superalliage base nickel et pieces realisees en ce suparalliage

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See also references of WO2014058491A2 *

Also Published As

Publication number Publication date
CA2878711A1 (fr) 2014-04-17
JP2015529743A (ja) 2015-10-08
US20150167123A1 (en) 2015-06-18
BR112015000531A2 (pt) 2017-06-27
CN104428431A (zh) 2015-03-18
WO2014058491A2 (fr) 2014-04-17
WO2014058491A3 (fr) 2014-06-19

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