JP2018154918A - 方法およびプリント物品 - Google Patents
方法およびプリント物品 Download PDFInfo
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- JP2018154918A JP2018154918A JP2017245719A JP2017245719A JP2018154918A JP 2018154918 A JP2018154918 A JP 2018154918A JP 2017245719 A JP2017245719 A JP 2017245719A JP 2017245719 A JP2017245719 A JP 2017245719A JP 2018154918 A JP2018154918 A JP 2018154918A
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- 238000000034 method Methods 0.000 title claims abstract description 48
- 230000008569 process Effects 0.000 title abstract description 5
- 238000000576 coating method Methods 0.000 claims abstract description 34
- 239000011248 coating agent Substances 0.000 claims abstract description 29
- 239000000654 additive Substances 0.000 claims abstract description 25
- 230000000996 additive effect Effects 0.000 claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 claims abstract description 14
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 113
- 239000011651 chromium Substances 0.000 claims description 81
- 239000012535 impurity Substances 0.000 claims description 73
- 229910052804 chromium Inorganic materials 0.000 claims description 72
- 229910052721 tungsten Inorganic materials 0.000 claims description 61
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 60
- 239000011572 manganese Substances 0.000 claims description 50
- 229910052759 nickel Inorganic materials 0.000 claims description 49
- 239000010936 titanium Substances 0.000 claims description 42
- 229910052782 aluminium Inorganic materials 0.000 claims description 41
- 229910052799 carbon Inorganic materials 0.000 claims description 39
- 229910052715 tantalum Inorganic materials 0.000 claims description 37
- 229910045601 alloy Inorganic materials 0.000 claims description 36
- 239000000956 alloy Substances 0.000 claims description 36
- 239000010955 niobium Substances 0.000 claims description 35
- 229910052719 titanium Inorganic materials 0.000 claims description 33
- 229910052750 molybdenum Inorganic materials 0.000 claims description 31
- 239000010949 copper Substances 0.000 claims description 25
- 239000000203 mixture Substances 0.000 claims description 25
- 229910052758 niobium Inorganic materials 0.000 claims description 25
- 229910052710 silicon Inorganic materials 0.000 claims description 25
- 229910052796 boron Inorganic materials 0.000 claims description 21
- 229910052742 iron Inorganic materials 0.000 claims description 21
- 229910052751 metal Inorganic materials 0.000 claims description 20
- 239000002184 metal Substances 0.000 claims description 20
- 229910052802 copper Inorganic materials 0.000 claims description 18
- 229910052748 manganese Inorganic materials 0.000 claims description 17
- 229910052726 zirconium Inorganic materials 0.000 claims description 17
- 229910052735 hafnium Inorganic materials 0.000 claims description 16
- 238000000280 densification Methods 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 15
- 229910000601 superalloy Inorganic materials 0.000 claims description 13
- 238000005240 physical vapour deposition Methods 0.000 claims description 11
- 229910052717 sulfur Inorganic materials 0.000 claims description 11
- 239000011230 binding agent Substances 0.000 claims description 10
- 229910052698 phosphorus Inorganic materials 0.000 claims description 10
- 229910052702 rhenium Inorganic materials 0.000 claims description 10
- 239000010941 cobalt Substances 0.000 claims description 9
- 229910017052 cobalt Inorganic materials 0.000 claims description 9
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 9
- 238000005229 chemical vapour deposition Methods 0.000 claims description 8
- 238000007747 plating Methods 0.000 claims description 8
- 239000007921 spray Substances 0.000 claims description 6
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 5
- 229910000531 Co alloy Inorganic materials 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 5
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 5
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 5
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 5
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 5
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 5
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims description 5
- 229910052746 lanthanum Inorganic materials 0.000 claims description 5
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 claims description 5
- 239000011733 molybdenum Substances 0.000 claims description 5
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims description 5
- 239000011574 phosphorus Substances 0.000 claims description 5
- 238000007750 plasma spraying Methods 0.000 claims description 5
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 claims description 5
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical compound [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 claims description 5
- 239000010703 silicon Substances 0.000 claims description 5
- 239000011593 sulfur Substances 0.000 claims description 5
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims description 5
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 5
- 239000010937 tungsten Substances 0.000 claims description 5
- 239000011148 porous material Substances 0.000 claims description 3
- 238000007751 thermal spraying Methods 0.000 claims description 3
- 238000000151 deposition Methods 0.000 claims description 2
- 238000002490 spark plasma sintering Methods 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 abstract description 4
- 230000008018 melting Effects 0.000 description 12
- 238000002844 melting Methods 0.000 description 12
- 238000005219 brazing Methods 0.000 description 9
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- 239000007789 gas Substances 0.000 description 7
- 230000007246 mechanism Effects 0.000 description 7
- 238000007789 sealing Methods 0.000 description 6
- 238000010146 3D printing Methods 0.000 description 4
- 238000005328 electron beam physical vapour deposition Methods 0.000 description 4
- 238000010894 electron beam technology Methods 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 238000007639 printing Methods 0.000 description 4
- 238000005245 sintering Methods 0.000 description 4
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 3
- 239000008199 coating composition Substances 0.000 description 3
- 238000007772 electroless plating Methods 0.000 description 3
- 239000010931 gold Substances 0.000 description 3
- 238000000149 argon plasma sintering Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 229910052737 gold Inorganic materials 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000000110 selective laser sintering Methods 0.000 description 2
- 230000000903 blocking effect Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
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- 238000007648 laser printing Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000004518 low pressure chemical vapour deposition Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
Classifications
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- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
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- B32B15/00—Layered products comprising a layer of metal
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- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
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- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- B33Y80/00—Products made by additive manufacturing
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- C—CHEMISTRY; METALLURGY
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- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
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- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
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- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
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Abstract
【解決手段】外面と、付加製造による内面を備えた少なくとも1つの微細機構とを有するプリント物品を形成し、前記プリント物品の前記外面および前記内面を金属マイクロレイヤでコーティングしてコーティング物品を形成し、前記コーティング物品を高密度化して部品を形成する。形成後、プリント物品は、該プリント物品が完全密度でないような多孔性を有する。高密度化部品は、外面と、内面を備えた少なくとも1つの微細機構とを有するプリント物品、ならびに該プリント物品の外面および内面をコーティングする金属マイクロレイヤを含む。プリント物品は、付加製造によって形成される。
【選択図】なし
Description
いくつかの実施形態において、付加製造された物品は部品である。いくつかの実施形態において、前記部品はガスタービン部品である。いくつかの実施形態において、前記ガスタービン部品は、微細機構および/または複雑な内部機構を有するノズル、シュラウド、またはブレードである。いくつかの実施形態において、前記部品は予備焼結プリフォーム(pre−sintered preform)(PSP)である。いくつかの実施形態において、前記微細機構はマイクロチャネルを含む。
付加製造された物品を形成した後、該物品の表面にコーティングを施し、該表面をシールすることが好ましい。コーティングは、好ましくはマイクロレイヤコーティングである。いくつかの実施形態において、この方法は、付加製造された物品の外面および内面をシールする。いくつかの実施形態において、コーティングは、付加製造された物品の微細機構の固有の表面結合多孔性をシールする。
物品の表面にコーティングを施し、表面をシールした後、該物品を高密度化に供し、内部多孔性を排除するかまたは実質的に排除する。いくつかの実施形態において、多孔性を有する表面またはその付近にろう材を施した後、高温において実施されるろう付けの間に少なくとも一部またはすべての高密度化が生じ、その際にろう材は流動し、多孔性を埋め、さらに表面をシールする。いくつかの実施形態において、このようなろう付けは、ろう付けのみが表面の付近の多孔性を軽減するように、多孔性断面を完全密度にすることができる。いくつかの実施形態において、高密度化は、表面の多孔性を排除するかまたは実質的に排除するための熱間静水圧プレス(HIP)を含む。
[実施態様1]
外面と、付加製造による内面を備えた少なくとも1つの微細機構とを有する、完全密度でないような多孔性を有するプリント物品を形成する工程、
前記プリント物品の前記外面および前記内面を金属マイクロレイヤでコーティングしてコーティング物品を形成する工程、ならびに
前記コーティング物品を高密度化して部品を形成する工程、
を含む方法。
[実施態様2]
前記コーティングが、めっき、物理蒸着、化学蒸着、熱溶射、コールドスプレー、プラズマ溶射、陰極アーク、放電プラズマ焼結、およびプラズマ溶射物理蒸着から成る群から選択されるコーティング方法により、前記プリント物品の外面および内面に金属マイクロレイヤを付着させる工程を含む、実施態様1に記載の方法。
[実施態様3]
前記高密度化工程が熱間静水圧プレスを含む、実施態様1に記載の方法。
[実施態様4]
前記部品が完全密度の90%超である、実施態様1に記載の方法。
[実施態様5]
前記プリント物品が、約9.3重量%〜約9.7重量%のタングステン(W)、約9.0重量%〜約9.5重量%のコバルト(Co)、約8.0重量%〜約8.5%のクロム(Cr)、約5.4重量%〜約5.7重量%のアルミニウム(Al)、約3.2重量%のタンタル(Ta)、約1.4重量%のハフニウム(Hf)、約0.25重量%以下のケイ素(Si)、約0.1重量%以下のマンガン(Mn)、約0.06重量%〜約0.09重量%の炭素(C)、不可避的不純物、および残部ニッケル(Ni);約9重量%〜約10重量%のCo、約9.3重量%〜約9.7重量%のW、約8.0重量%〜約8.7重量%のCr、約5.25重量%〜約5.75重量%のAl、約2.8重量%〜約3.3重量%のTa、約1.3重量%〜約1.7重量%のHf、約0.9重量%以下のチタン(Ti)、約0.6重量%以下のモリブデン(Mo)、約0.2重量%以下の鉄(Fe)、約0.12重量%以下のSi、約0.1重量%以下のMn、約0.1重量%以下の銅(Cu)、約0.1重量%以下のC、約0.1重量%以下のニオブ(Nb)、約0.02%以下のジルコニウム(Zr)、約0.02重量%以下のホウ素(B)、約0.01重量%以下のリン(P)、約0.004重量%以下の硫黄(S)、不可避的不純物、および残部Ni;約9.75重量%のCr、約7.5重量%のCo、約4.2重量%のAl、約3.5重量%のTi、約4.8重量%のTa、約6重量%のW、約1.5重量%のMo、約0.5重量%以下のNb、約0.2重量%以下のFe、約0.2重量%以下のSi、約0.15重量%以下のHf、約0.08重量%以下のC、約0.009重量%以下のZr、約0.009重量%以下のB、不可避的不純物、および残部Ni;約15.7重量%〜約16.3重量%のCr、約8.0重量%〜約9.0重量%のCo、約3.2〜約3.7重量%のTi、約3.2〜約3.7重量%のAl、約2.4〜約2.8重量%のW、約1.5〜約2.0重量%のTa、約1.5重量%〜約2.0重量%のMo、約0.6重量%〜約1.1重量%のNb、約0.5重量%以下のFe、約0.3重量%以下のSi、約0.2重量%以下のMn、約0.15重量%〜約0.20重量%のC、約0.05重量%〜約0.15重量%のZr、約0.015重量%以下のS、約0.005重量%〜約0.015重量%のB、不可避的不純物、および残部Ni;約13.70重量%〜約14.30重量%のCr、約9.0重量%〜約10.0重量%のCo、約4.7重量%〜約5.1重量%のTi、約3.5重量%〜約4.1重量%のW、約2.8重量%〜約3.2重量%のAl、約2.4重量%〜約3.1重量%のTa、約1.4重量%〜約1.7重量%のMo、約0.35重量%のFe、約0.3重量%のSi、約0.15重量%のNb、約0.08重量%〜約0.12重量%のC、約0.1重量%のMn、約0.1重量%のCu、約0.04重量%のZr、約0.005重量%〜約0.020重量%のB、約0.015重量%のP、約0.005重量%のS、不可避的不純物、および残部Ni;約12重量%のCo、約6.8重量%のCr、約6.4重量%のTa、約6.1重量%のAl、約4.9重量%のW、約2.8重量%のレニウム(Re)、約1.5重量%のMo、約1.5重量%のHf、約0.12重量%のC、約0.02重量%のZr、約0.015重量%のB、不可避的不純物、および残部Ni;約13重量%のCr、約7.5重量%のCo、約6.6重量%のAl、約5重量%のTa、約3.8重量%のW、約1.6重量%のRe、約0.15重量%のHf、不可避的不純物、および残部Ni;約22.5重量%のCr、約19重量%のCo、約2重量%のW、約1.35重量%のNb、約2.3重量%のTi、約1.7重量%のAl、約0.1重量%のC、不可避的不純物、および残部のNi;約29重量%のCr、約10重量%のNi、約7重量%のW、約1重量%のFe、約0.7重量%のMn、約0.75重量%のSi、約0.25重量%のC、約0.01重量%のB、不可避的不純物、および残部Co;約21重量%〜約23重量%のCr、約20重量%〜約24重量%のNi、約13重量%〜約15重量%のW、約3重量%以下のFe、約1.25重量%以下のMn、約0.2重量%〜約0.5重量%のSi、約0.05重量%〜約0.15重量%のC、約0.03重量%〜約0.12重量%のランタン(La)、約0.02重量%以下のP、約0.015重量%以下のB、約0.015重量%以下のS、不可避的不純物、および残部Co;約19重量%〜約21重量%のCr、約14重量%〜約16重量%のW、約9重量%〜約11重量%のNi、約3重量%以下のFe、約1重量%〜約2重量%のMn、約0.05重量%〜約0.15重量%のC、約0.4重量%以下のSi、約0.04重量%以下のP、約0.03重量%以下のS、不可避的不純物、および残部Co;約22.5重量%〜約24.25重量%のCr、約9重量%〜約11重量%のNi、約6.5重量%〜約7.5重量%のW、約3重量%〜約4重量%のTa、約0.3重量%の以下のTi、約0.65重量%以下のC、約0.55重量%以下のZr、不可避的不純物、および残部Co;約42.5重量%のNi、約12.5重量%のCr、約5.75重量%のMo、約2.9重量%のTi、約1重量%以下のCo、0.5重量%以下のCu、約0.5重量%以下のMn、約0.4重量%以下のSi、約0.35重量%以下のAl、約0.1重量%以下のC、約0.03重量%以下のS、不可避的不純物および残部Fe;ならびに約15重量%〜約17.5重量%のCr、約3重量%〜約5重量%のNi、約3重量%〜約5重量%のCu、約1重量%以下のMn、約1重量%以下のSi、約0.15重量%〜約0.45重量%のNb+Ta、約0.07重量%以下のC、約0.04重量%以下のP、約0.03重量%以下のS、不可避的不純物、および残部Fe;から成る群から選択される組成を含む超合金で形成される、実施態様1に記載の方法。
[実施態様6]
前記プリント物品が、金属、金属合金、および超合金から成る群から選択される材料で形成される、実施態様1に記載の方法。
[実施態様7]
前記部品がガスタービン部品である、実施態様1に記載の方法。
[実施態様8]
前記コーティングが、前記内面に沿って少なくとも1つの細孔をシールする、実施態様1に記載の方法。
[実施態様9]
前記金属マイクロレイヤが約5μm(0.2ミル)〜約100μm(4ミル)の範囲の厚さを有する、実施態様1に記載の方法。
[実施態様10]
前記付加製造がバインダージェット方式である、実施態様1に記載の方法。
[実施態様11]
前記コーティング工程が、前記微細機構を通してニッケル基めっき溶液を提供する工程を含む、実施態様1に記載の方法。
[実施態様12]
前記コーティング工程が、前記高密度化工程が行われる処理温度よりも高い融点温度を有するろう材を適用する工程を含む、実施態様1に記載の方法。
[実施態様13]
前記プリント物品および前記金属マイクロレイヤが、ニッケル基合金、コバルト基合金および鉄基合金から成る群から独立して選択される材料で形成される、実施態様1に記載の方法。
[実施態様14]
外面と、内面を備えた少なくとも1つの微細機構とを有し、付加製造により形成され、完全密度でないような多孔性を有するプリント物品、ならびに
前記プリント物品の前記外面および前記内面をコーティングして、前記プリント物品の多孔性をシールする金属マイクロレイヤを含む高密度化部品。
[実施態様15]
前記プリント物品が、約9.3重量%〜約9.7重量%のタングステン(W)、約9.0重量%〜約9.5重量%のコバルト(Co)、約8.0重量%〜約8.5%のクロム(Cr)、約5.4重量%〜約5.7重量%のアルミニウム(Al)、約3.2重量%のタンタル(Ta)、約1.4重量%のハフニウム(Hf)、約0.25重量%以下のケイ素(Si)、約0.1重量%以下のマンガン(Mn)、約0.06重量%〜約0.09重量%の炭素(C)、不可避的不純物、および残部ニッケル(Ni);約9重量%〜約10重量%のCo、約9.3重量%〜約9.7重量%のW、約8.0重量%〜約8.7重量%のCr、約5.25重量%〜約5.75重量%のAl、約2.8重量%〜約3.3重量%のTa、約1.3重量%〜約1.7重量%のHf、約0.9重量%以下のチタン(Ti)、約0.6重量%以下のモリブデン(Mo)、約0.2重量%以下の鉄(Fe)、約0.12重量%以下のSi、約0.1重量%以下のMn、約0.1重量%以下の銅(Cu)、約0.1重量%以下のC、約0.1重量%以下のニオブ(Nb)、約0.02%以下のジルコニウム(Zr)、約0.02重量%以下のホウ素(B)、約0.01重量%以下のリン(P)、約0.004重量%以下の硫黄(S)、不可避的不純物、および残部Ni;約9.75重量%のCr、約7.5重量%のCo、約4.2重量%のAl、約3.5重量%のTi、約4.8重量%のTa、約6重量%のW、約1.5重量%のMo、約0.5重量%以下のNb、約0.2重量%以下のFe、約0.2重量%以下のSi、約0.15重量%以下のHf、約0.08重量%以下のC、約0.009重量%以下のZr、約0.009重量%以下のB、不可避的不純物、および残部Ni;約15.7重量%〜約16.3重量%のCr、約8.0重量%〜約9.0重量%のCo、約3.2〜約3.7重量%のTi、約3.2〜約3.7重量%のAl、約2.4〜約2.8重量%のW、約1.5〜約2.0重量%のTa、約1.5重量%〜約2.0重量%のMo、約0.6重量%〜約1.1重量%のNb、約0.5重量%以下のFe、約0.3重量%以下のSi、約0.2重量%以下のMn、約0.15重量%〜約0.20重量%のC、約0.05重量%〜約0.15重量%のZr、約0.015重量%以下のS、約0.005重量%〜約0.015重量%のB、不可避的不純物、および残部Ni;約13.70重量%〜約14.30重量%のCr、約9.0重量%〜約10.0重量%のCo、約4.7重量%〜約5.1重量%のTi、約3.5重量%〜約4.1重量%のW、約2.8重量%〜約3.2重量%のAl、約2.4重量%〜約3.1重量%のTa、約1.4重量%〜約1.7重量%のMo、約0.35重量%のFe、約0.3重量%のSi、約0.15重量%のNb、約0.08重量%〜約0.12重量%のC、約0.1重量%のMn、約0.1重量%のCu、約0.04重量%のZr、約0.005重量%〜約0.020重量%のB、約0.015重量%のP、約0.005重量%のS、不可避的不純物、および残部Ni;約12重量%のCo、約6.8重量%のCr、約6.4重量%のTa、約6.1重量%のAl、約4.9重量%のW、約2.8重量%のレニウム(Re)、約1.5重量%のMo、約1.5重量%のHf、約0.12重量%のC、約0.02重量%のZr、約0.015重量%のB、不可避的不純物、および残部Ni;約13重量%のCr、約7.5重量%のCo、約6.6重量%のAl、約5重量%のTa、約3.8重量%のW、約1.6重量%のRe、約0.15重量%のHf、不可避的不純物、および残部Ni;約22.5重量%のCr、約19重量%のCo、約2重量%のW、約1.35重量%のNb、約2.3重量%のTi、約1.7重量%のAl、約0.1重量%のC、不可避的不純物、および残部のNi;約29重量%のCr、約10重量%のNi、約7重量%のW、約1重量%のFe、約0.7重量%のMn、約0.75重量%のSi、約0.25重量%のC、約0.01重量%のB、不可避的不純物、および残部Co;約21重量%〜約23重量%のCr、約20重量%〜約24重量%のNi、約13重量%〜約15重量%のW、約3重量%以下のFe、約1.25重量%以下のMn、約0.2重量%〜約0.5重量%のSi、約0.05重量%〜約0.15重量%のC、約0.03重量%〜約0.12重量%のランタン(La)、約0.02重量%以下のP、約0.015重量%以下のB、約0.015重量%以下のS、不可避的不純物、および残部Co;約19重量%〜約21重量%のCr、約14重量%〜約16重量%のW、約9重量%〜約11重量%のNi、約3重量%以下のFe、約1重量%〜約2重量%のMn、約0.05重量%〜約0.15重量%のC、約0.4重量%以下のSi、約0.04重量%以下のP、約0.03重量%以下のS、不可避的不純物、および残部Co;約22.5重量%〜約24.25重量%のCr、約9重量%〜約11重量%のNi、約6.5重量%〜約7.5重量%のW、約3重量%〜約4重量%のTa、約0.3重量%の以下のTi、約0.65重量%以下のC、約0.55重量%以下のZr、不可避的不純物、および残部Co;約42.5重量%のNi、約12.5重量%のCr、約5.75重量%のMo、約2.9重量%のTi、約1重量%以下のCo、0.5重量%以下のCu、約0.5重量%以下のMn、約0.4重量%以下のSi、約0.35重量%以下のAl、約0.1重量%以下のC、約0.03重量%以下のS、不可避的不純物および残部Fe;ならびに約15重量%〜約17.5重量%のCr、約3重量%〜約5重量%のNi、約3重量%〜約5重量%のCu、約1重量%以下のMn、約1重量%以下のSi、約0.15重量%〜約0.45重量%のNb+Ta、約0.07重量%以下のC、約0.04重量%以下のP、約0.03重量%以下のS、不可避的不純物、および残部Fe;から成る群から選択される組成を含む超合金で形成される、実施態様14に記載の部品。
[実施態様16]
ガスタービン部品である、実施態様14に記載の部品。
[実施態様17]
前記微細機構がマイクロチャネルである、実施態様14に記載の部品。
[実施態様18]
前記金属マイクロレイヤが約5μm(0.2ミル)〜約100μm(4ミル)の範囲の厚さを有する、実施態様14に記載の部品。
[実施態様19]
前記プリント物品および前記金属マイクロレイヤが、ニッケル基合金、およびコバルト基合金から成る群から独立して選択される材料で形成される、実施態様14に記載の部品。
[実施態様20]
前記プリント物品が鉄基であり、前記金属マイクロレイヤがニッケル基合金、コバルト基合金、および鉄基合金から成る群から選択される材料で形成される、実施態様14に記載の部品。
Claims (10)
- 外面と、付加製造による内面を備えた少なくとも1つの微細機構とを有する、完全密度でないような多孔性を有するプリント物品を形成する工程、
前記プリント物品の前記外面および前記内面を金属マイクロレイヤでコーティングしてコーティング物品を形成する工程、ならびに
前記コーティング物品を高密度化して部品を形成する工程、
を含む方法。 - 前記コーティングが、めっき、物理蒸着、化学蒸着、熱溶射、コールドスプレー、プラズマ溶射、陰極アーク、放電プラズマ焼結、およびプラズマ溶射物理蒸着から成る群から選択されるコーティング方法により、前記プリント物品の外面および内面に金属マイクロレイヤを付着させる工程を含む、請求項1に記載の方法。
- 前記高密度化工程が熱間静水圧プレスを含む、請求項1に記載の方法。
- 前記プリント物品が、約9.3重量%〜約9.7重量%のタングステン(W)、約9.0重量%〜約9.5重量%のコバルト(Co)、約8.0重量%〜約8.5%のクロム(Cr)、約5.4重量%〜約5.7重量%のアルミニウム(Al)、約3.2重量%のタンタル(Ta)、約1.4重量%のハフニウム(Hf)、約0.25重量%以下のケイ素(Si)、約0.1重量%以下のマンガン(Mn)、約0.06重量%〜約0.09重量%の炭素(C)、不可避的不純物、および残部ニッケル(Ni);約9重量%〜約10重量%のCo、約9.3重量%〜約9.7重量%のW、約8.0重量%〜約8.7重量%のCr、約5.25重量%〜約5.75重量%のAl、約2.8重量%〜約3.3重量%のTa、約1.3重量%〜約1.7重量%のHf、約0.9重量%以下のチタン(Ti)、約0.6重量%以下のモリブデン(Mo)、約0.2重量%以下の鉄(Fe)、約0.12重量%以下のSi、約0.1重量%以下のMn、約0.1重量%以下の銅(Cu)、約0.1重量%以下のC、約0.1重量%以下のニオブ(Nb)、約0.02%以下のジルコニウム(Zr)、約0.02重量%以下のホウ素(B)、約0.01重量%以下のリン(P)、約0.004重量%以下の硫黄(S)、不可避的不純物、および残部Ni;約9.75重量%のCr、約7.5重量%のCo、約4.2重量%のAl、約3.5重量%のTi、約4.8重量%のTa、約6重量%のW、約1.5重量%のMo、約0.5重量%以下のNb、約0.2重量%以下のFe、約0.2重量%以下のSi、約0.15重量%以下のHf、約0.08重量%以下のC、約0.009重量%以下のZr、約0.009重量%以下のB、不可避的不純物、および残部Ni;約15.7重量%〜約16.3重量%のCr、約8.0重量%〜約9.0重量%のCo、約3.2〜約3.7重量%のTi、約3.2〜約3.7重量%のAl、約2.4〜約2.8重量%のW、約1.5〜約2.0重量%のTa、約1.5重量%〜約2.0重量%のMo、約0.6重量%〜約1.1重量%のNb、約0.5重量%以下のFe、約0.3重量%以下のSi、約0.2重量%以下のMn、約0.15重量%〜約0.20重量%のC、約0.05重量%〜約0.15重量%のZr、約0.015重量%以下のS、約0.005重量%〜約0.015重量%のB、不可避的不純物、および残部Ni;約13.70重量%〜約14.30重量%のCr、約9.0重量%〜約10.0重量%のCo、約4.7重量%〜約5.1重量%のTi、約3.5重量%〜約4.1重量%のW、約2.8重量%〜約3.2重量%のAl、約2.4重量%〜約3.1重量%のTa、約1.4重量%〜約1.7重量%のMo、約0.35重量%のFe、約0.3重量%のSi、約0.15重量%のNb、約0.08重量%〜約0.12重量%のC、約0.1重量%のMn、約0.1重量%のCu、約0.04重量%のZr、約0.005重量%〜約0.020重量%のB、約0.015重量%のP、約0.005重量%のS、不可避的不純物、および残部Ni;約12重量%のCo、約6.8重量%のCr、約6.4重量%のTa、約6.1重量%のAl、約4.9重量%のW、約2.8重量%のレニウム(Re)、約1.5重量%のMo、約1.5重量%のHf、約0.12重量%のC、約0.02重量%のZr、約0.015重量%のB、不可避的不純物、および残部Ni;約13重量%のCr、約7.5重量%のCo、約6.6重量%のAl、約5重量%のTa、約3.8重量%のW、約1.6重量%のRe、約0.15重量%のHf、不可避的不純物、および残部Ni;約22.5重量%のCr、約19重量%のCo、約2重量%のW、約1.35重量%のNb、約2.3重量%のTi、約1.7重量%のAl、約0.1重量%のC、不可避的不純物、および残部のNi;約29重量%のCr、約10重量%のNi、約7重量%のW、約1重量%のFe、約0.7重量%のMn、約0.75重量%のSi、約0.25重量%のC、約0.01重量%のB、不可避的不純物、および残部Co;約21重量%〜約23重量%のCr、約20重量%〜約24重量%のNi、約13重量%〜約15重量%のW、約3重量%以下のFe、約1.25重量%以下のMn、約0.2重量%〜約0.5重量%のSi、約0.05重量%〜約0.15重量%のC、約0.03重量%〜約0.12重量%のランタン(La)、約0.02重量%以下のP、約0.015重量%以下のB、約0.015重量%以下のS、不可避的不純物、および残部Co;約19重量%〜約21重量%のCr、約14重量%〜約16重量%のW、約9重量%〜約11重量%のNi、約3重量%以下のFe、約1重量%〜約2重量%のMn、約0.05重量%〜約0.15重量%のC、約0.4重量%以下のSi、約0.04重量%以下のP、約0.03重量%以下のS、不可避的不純物、および残部Co;約22.5重量%〜約24.25重量%のCr、約9重量%〜約11重量%のNi、約6.5重量%〜約7.5重量%のW、約3重量%〜約4重量%のTa、約0.3重量%の以下のTi、約0.65重量%以下のC、約0.55重量%以下のZr、不可避的不純物、および残部Co;約42.5重量%のNi、約12.5重量%のCr、約5.75重量%のMo、約2.9重量%のTi、約1重量%以下のCo、0.5重量%以下のCu、約0.5重量%以下のMn、約0.4重量%以下のSi、約0.35重量%以下のAl、約0.1重量%以下のC、約0.03重量%以下のS、不可避的不純物および残部Fe;ならびに約15重量%〜約17.5重量%のCr、約3重量%〜約5重量%のNi、約3重量%〜約5重量%のCu、約1重量%以下のMn、約1重量%以下のSi、約0.15重量%〜約0.45重量%のNb+Ta、約0.07重量%以下のC、約0.04重量%以下のP、約0.03重量%以下のS、不可避的不純物、および残部Fe;から成る群から選択される組成を含む超合金で形成される、請求項1に記載の方法。
- 前記コーティングが、前記内面に沿って少なくとも1つの細孔をシールする、請求項1に記載の方法。
- 前記付加製造がバインダージェット方式である、請求項1に記載の方法。
- 外面と、内面を備えた少なくとも1つの微細機構とを有し、付加製造により形成され、完全密度でないような多孔性を有するプリント物品、ならびに
前記プリント物品の前記外面および前記内面をコーティングして、前記プリント物品の多孔性をシールする金属マイクロレイヤを含む高密度化部品。 - 前記プリント物品が、約9.3重量%〜約9.7重量%のタングステン(W)、約9.0重量%〜約9.5重量%のコバルト(Co)、約8.0重量%〜約8.5%のクロム(Cr)、約5.4重量%〜約5.7重量%のアルミニウム(Al)、約3.2重量%のタンタル(Ta)、約1.4重量%のハフニウム(Hf)、約0.25重量%以下のケイ素(Si)、約0.1重量%以下のマンガン(Mn)、約0.06重量%〜約0.09重量%の炭素(C)、不可避的不純物、および残部ニッケル(Ni);約9重量%〜約10重量%のCo、約9.3重量%〜約9.7重量%のW、約8.0重量%〜約8.7重量%のCr、約5.25重量%〜約5.75重量%のAl、約2.8重量%〜約3.3重量%のTa、約1.3重量%〜約1.7重量%のHf、約0.9重量%以下のチタン(Ti)、約0.6重量%以下のモリブデン(Mo)、約0.2重量%以下の鉄(Fe)、約0.12重量%以下のSi、約0.1重量%以下のMn、約0.1重量%以下の銅(Cu)、約0.1重量%以下のC、約0.1重量%以下のニオブ(Nb)、約0.02%以下のジルコニウム(Zr)、約0.02重量%以下のホウ素(B)、約0.01重量%以下のリン(P)、約0.004重量%以下の硫黄(S)、不可避的不純物、および残部Ni;約9.75重量%のCr、約7.5重量%のCo、約4.2重量%のAl、約3.5重量%のTi、約4.8重量%のTa、約6重量%のW、約1.5重量%のMo、約0.5重量%以下のNb、約0.2重量%以下のFe、約0.2重量%以下のSi、約0.15重量%以下のHf、約0.08重量%以下のC、約0.009重量%以下のZr、約0.009重量%以下のB、不可避的不純物、および残部Ni;約15.7重量%〜約16.3重量%のCr、約8.0重量%〜約9.0重量%のCo、約3.2〜約3.7重量%のTi、約3.2〜約3.7重量%のAl、約2.4〜約2.8重量%のW、約1.5〜約2.0重量%のTa、約1.5重量%〜約2.0重量%のMo、約0.6重量%〜約1.1重量%のNb、約0.5重量%以下のFe、約0.3重量%以下のSi、約0.2重量%以下のMn、約0.15重量%〜約0.20重量%のC、約0.05重量%〜約0.15重量%のZr、約0.015重量%以下のS、約0.005重量%〜約0.015重量%のB、不可避的不純物、および残部Ni;約13.70重量%〜約14.30重量%のCr、約9.0重量%〜約10.0重量%のCo、約4.7重量%〜約5.1重量%のTi、約3.5重量%〜約4.1重量%のW、約2.8重量%〜約3.2重量%のAl、約2.4重量%〜約3.1重量%のTa、約1.4重量%〜約1.7重量%のMo、約0.35重量%のFe、約0.3重量%のSi、約0.15重量%のNb、約0.08重量%〜約0.12重量%のC、約0.1重量%のMn、約0.1重量%のCu、約0.04重量%のZr、約0.005重量%〜約0.020重量%のB、約0.015重量%のP、約0.005重量%のS、不可避的不純物、および残部Ni;約12重量%のCo、約6.8重量%のCr、約6.4重量%のTa、約6.1重量%のAl、約4.9重量%のW、約2.8重量%のレニウム(Re)、約1.5重量%のMo、約1.5重量%のHf、約0.12重量%のC、約0.02重量%のZr、約0.015重量%のB、不可避的不純物、および残部Ni;約13重量%のCr、約7.5重量%のCo、約6.6重量%のAl、約5重量%のTa、約3.8重量%のW、約1.6重量%のRe、約0.15重量%のHf、不可避的不純物、および残部Ni;約22.5重量%のCr、約19重量%のCo、約2重量%のW、約1.35重量%のNb、約2.3重量%のTi、約1.7重量%のAl、約0.1重量%のC、不可避的不純物、および残部のNi;約29重量%のCr、約10重量%のNi、約7重量%のW、約1重量%のFe、約0.7重量%のMn、約0.75重量%のSi、約0.25重量%のC、約0.01重量%のB、不可避的不純物、および残部Co;約21重量%〜約23重量%のCr、約20重量%〜約24重量%のNi、約13重量%〜約15重量%のW、約3重量%以下のFe、約1.25重量%以下のMn、約0.2重量%〜約0.5重量%のSi、約0.05重量%〜約0.15重量%のC、約0.03重量%〜約0.12重量%のランタン(La)、約0.02重量%以下のP、約0.015重量%以下のB、約0.015重量%以下のS、不可避的不純物、および残部Co;約19重量%〜約21重量%のCr、約14重量%〜約16重量%のW、約9重量%〜約11重量%のNi、約3重量%以下のFe、約1重量%〜約2重量%のMn、約0.05重量%〜約0.15重量%のC、約0.4重量%以下のSi、約0.04重量%以下のP、約0.03重量%以下のS、不可避的不純物、および残部Co;約22.5重量%〜約24.25重量%のCr、約9重量%〜約11重量%のNi、約6.5重量%〜約7.5重量%のW、約3重量%〜約4重量%のTa、約0.3重量%の以下のTi、約0.65重量%以下のC、約0.55重量%以下のZr、不可避的不純物、および残部Co;約42.5重量%のNi、約12.5重量%のCr、約5.75重量%のMo、約2.9重量%のTi、約1重量%以下のCo、0.5重量%以下のCu、約0.5重量%以下のMn、約0.4重量%以下のSi、約0.35重量%以下のAl、約0.1重量%以下のC、約0.03重量%以下のS、不可避的不純物および残部Fe;ならびに約15重量%〜約17.5重量%のCr、約3重量%〜約5重量%のNi、約3重量%〜約5重量%のCu、約1重量%以下のMn、約1重量%以下のSi、約0.15重量%〜約0.45重量%のNb+Ta、約0.07重量%以下のC、約0.04重量%以下のP、約0.03重量%以下のS、不可避的不純物、および残部Fe;から成る群から選択される組成を含む超合金で形成される、請求項7に記載の部品。
- 前記プリント物品および前記金属マイクロレイヤが、ニッケル基合金、およびコバルト基合金から成る群から独立して選択される材料で形成される、請求項7に記載の部品。
- 前記プリント物品が鉄基であり、前記金属マイクロレイヤがニッケル基合金、コバルト基合金、および鉄基合金から成る群から選択される材料で形成される、請求項7に記載の部品。
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