JP6104408B2 - 超合金材料のクラッド層を形成する方法 - Google Patents
超合金材料のクラッド層を形成する方法 Download PDFInfo
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- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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- B23K25/00—Slag welding, i.e. using a heated layer or mass of powder, slag, or the like in contact with the material to be joined
- B23K25/005—Welding for purposes other than joining, e.g. built-up welding
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- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
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- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
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- B23K35/0266—Rods, electrodes, wires flux-cored
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- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
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- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3033—Ni as the principal constituent
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- 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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
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- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3033—Ni as the principal constituent
- B23K35/304—Ni as the principal constituent with Cr as the next major constituent
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- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/32—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
- B23K35/322—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C a Pt-group metal as principal constituent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/32—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
- B23K35/325—Ti as the principal constituent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/32—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
- B23K35/327—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C comprising refractory compounds, e.g. carbides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/362—Selection of compositions of fluxes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/38—Selection of media, e.g. special atmospheres for surrounding the working area
- B23K35/383—Selection of media, e.g. special atmospheres for surrounding the working area mainly containing noble gases or nitrogen
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
- C23C24/106—Coating with metal alloys or metal elements only
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Description
溶接法は、溶接対象の材料の種類に依存して著しく大きく変わってくる。種々の条件下でも比較的容易に溶接することができる材料もあれば、他方では、周辺の基材を劣化させることなく構造的に確実な接合を実現するためには特殊な処理を必要とする材料もある。
レーザビームの焦点はずし距離
焦点において方形のエネルギー源を生成するダイオードレーザの使用
焦点において方形のエネルギー源を生成するための、セグメントミラー等のインテグレート光学系の使用
1次元以上でのレーザビームの走査(ラスタ走査)
可変ビーム径(たとえば、微細加工作業を行う際には、焦点ビーム径は0.5mmであり、比較的微細でない作業を行う際には、焦点ビーム径は2.0mmにまで及ぶ)の集光光学系の使用
カスタム形状の溶着層を形成するため、光学系および/または基材の移動を、選択的レーザ溶融プロセスまたは選択的レーザ焼結プロセスと同様にプログラミングすることができる。上述のプロセスにより奏される、公知のレーザ溶融法やレーザ焼結法に対する利点には、以下のものが含まれる:
溶着速度が速く、各層処理中の溶着厚が厚いこと。
シールドが、不活性ガスを用いる必要なく高温の溶着金属全体に及ぶように改善されたこと。
フラックスにより、凝固割れの原因となる成分の溶着物の洗浄が強化されること。
フラックスによってレーザビーム吸収が増大し、処理装置へ戻る反射が最小限になること。
スラグ形成により溶着物が成形されて支持され、熱が保存されて冷却速度が緩慢になり、これにより、溶接後熱処理中にひずみ時効(再加熱)割れに寄与してしまう残留応力が低下すること。
フラックスにより成分損失が補償されるか、または合金成分が追加され、溶着が厚いことにより、部品形成全体にかかる総時間が大幅に短縮するので、粉末およびフラックスの事前配置または供給を効率的に、選択的に行うことが可能であること。
・シースソリッド体積は、総金属ソリッド体積の約60%であり、純粋なNiである。
・コア金属粉末体積は、総金属ソリッド体積の約40%であり、前記シースからの純粋ニッケルと共に溶解または混合したときに、公称で8.3重量%のCrと、10重量%のCoと、0.7重量%のMoと、10重量%のWと、5.5重量%のAlと、1重量%のTiと、3重量%のTaと、0.14重量%のCと、0.015重量%のBと、0.05重量%のZrと、1.5重量%のHfとの組成の合金247を生成するのに十分なCr,Co,Mo,W,Al,Ti,Ta,C,B,ZrおよびHfを含む。
・コアフラックス粉末体積は、大部分が非金属である追加的なワイヤ体積であり、アルミナ、フッ化物およびケイ酸塩を35:30:35の比で含む。当該ワイヤ体積のサイズは場合によっては、金属粉末体積のサイズと等しくすることができる。フラックスのメッシュサイズ範囲は、コア金属粉末内において均等に分布するようにされている。
・欠陥を除去するために、修理対象の超合金材料の表面を規定通りに研磨することにより前処理するステップと、
・前記表面を洗浄するステップと、
・その後、前記表面上に、フラックス材料を含む粉末材料の層を事前配置または供給するステップと、
・その後、スラグ層が浮かんでいる溶湯プールに、前記粉末と前記表面の上部層とを溶解するため、当該表面全体にわたってエネルギービームを移動させ、前記溶湯プールおよびスラグを凝固させるステップと
を有することができる。
前記溶解は、典型的には公知の機械的および/または化学的処理によってスラグを除去することにより、基材の前記表面におけるあらゆる素地欠陥を治癒して当該表面を修復状態にするという機能を有する。前記粉末状材料はフラックス材料のみとすることができ、または、超合金クラッド材料層を形成したい実施形態の場合には、前記溶解によって前記表面上に当該クラッド層を形成するように、当該粉末状材料は金属粉末を含むことができ、当該金属粉末は、粉末状フラックス材料層の下方に配置される別個の層とするか、または、当該粉末状フラックス材料と混合するか、または、フラックス材料と組み合わせて複合粒子とすることができる。このような溶解は、クラッド材料層を表面上に形成する。オプションとして、供給材料をストリップまたはワイヤの形態で溶湯プールに導入することができる。前記粉末状金属材料および供給材料(もし使用する場合)と、前記フラックス材料からの中性またはアディティブの任意の金属寄与分とが、溶湯プール中にて組み合わされて、所望の超合金材料の組成を有するクラッド層を生成する。幾つかの実施形態では、ニッケル、ニッケルクロム、ニッケルクロムコバルト、または、押出成形しやすい他の金属の供給材料を、適切な合金金属粉末と組み合わせることにより、前記クラッドにおいて所望の超合金組成を実現する。このことにより、所望の超合金材料をワイヤまたはストリップの形状に成形する問題を回避することができる。
Claims (4)
- 粉末状コア材料が入れられている中空の金属シースを含んでいる供給材料を基材上に溶解して、所望の超合金クラッド材料の層を、スラグの層の下に形成するステップを有し、
当該金属シースは、所望の超合金材料の押出成形可能な元素サブセットを含んでおり、前記粉末状コア材料は粉末状金属と粉末状フラックスとを含んでおり、当該粉末状金属と粉末状フラックスは、前記シースと溶融したときに、前記所望の超合金材料の元素を補完し、
前記超合金クラッド材料とスラグとを冷ました後に、前記スラグを除去して、所望の超合金クラッド材料の層を露出させるステップとを有する、
ことを特徴とする方法。 - 前記粉末状金属のメッシュサイズ範囲と前記粉末状フラックスのメッシュサイズ範囲とは重なっている、請求項1記載の方法。
- 前記供給材料にエネルギービームを印加することによって、前記供給材料を溶解するステップをさらに有している、請求項1記載の方法。
- アークを形成するために前記供給材料を通して前記基材に電流を印加することによって前記供給材料を溶解するステップと、
酸素と二酸化炭素のうちの少なくとも1つを含むシールドガスを供給して、前記溶解ステップの間、前記アークを安定させるステップと、
酸素と二酸化炭素のうちの少なくとも1つと反応するチタンを補填するために、前記所望の超合金クラッド材料内に含まれる量を超える量のチタンを前記粉末状金属に含ませるステップとを有している、請求項1記載の方法。
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US13/754,983 US9393644B2 (en) | 2013-01-31 | 2013-01-31 | Cladding of alloys using flux and metal powder cored feed material |
US13/754,983 | 2013-01-31 | ||
PCT/US2014/014096 WO2014121046A2 (en) | 2013-01-31 | 2014-01-31 | Cladding of alloys using flux and metal powder cored feed material |
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JP2016514052A JP2016514052A (ja) | 2016-05-19 |
JP6104408B2 true JP6104408B2 (ja) | 2017-03-29 |
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US (1) | US9393644B2 (ja) |
EP (1) | EP2950959B1 (ja) |
JP (1) | JP6104408B2 (ja) |
KR (1) | KR20150110815A (ja) |
CN (1) | CN105377494A (ja) |
RU (1) | RU2015136598A (ja) |
WO (1) | WO2014121046A2 (ja) |
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RU2015136598A (ru) | 2017-03-07 |
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KR20150110815A (ko) | 2015-10-02 |
WO2014121046A3 (en) | 2014-10-09 |
EP2950959B1 (en) | 2017-03-08 |
CN105377494A (zh) | 2016-03-02 |
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