JP7378911B2 - 不均質組成物、不均質組成物を含む物品、および物品の形成方法 - Google Patents
不均質組成物、不均質組成物を含む物品、および物品の形成方法 Download PDFInfo
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- JP7378911B2 JP7378911B2 JP2017228509A JP2017228509A JP7378911B2 JP 7378911 B2 JP7378911 B2 JP 7378911B2 JP 2017228509 A JP2017228509 A JP 2017228509A JP 2017228509 A JP2017228509 A JP 2017228509A JP 7378911 B2 JP7378911 B2 JP 7378911B2
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- 239000000203 mixture Substances 0.000 title claims description 119
- 238000000034 method Methods 0.000 title claims description 25
- 229910045601 alloy Inorganic materials 0.000 claims description 144
- 239000000956 alloy Substances 0.000 claims description 144
- 239000000654 additive Substances 0.000 claims description 41
- 230000000996 additive effect Effects 0.000 claims description 40
- 239000000919 ceramic Substances 0.000 claims description 35
- 239000000463 material Substances 0.000 claims description 22
- 238000002844 melting Methods 0.000 claims description 20
- 230000008018 melting Effects 0.000 claims description 20
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 14
- 229910052719 titanium Inorganic materials 0.000 claims description 14
- 239000010936 titanium Substances 0.000 claims description 14
- 238000005245 sintering Methods 0.000 claims description 8
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 claims description 3
- 239000000835 fiber Substances 0.000 claims description 3
- 238000001513 hot isostatic pressing Methods 0.000 claims description 3
- 239000002071 nanotube Substances 0.000 claims description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 3
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 3
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 40
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 22
- 229910052759 nickel Inorganic materials 0.000 description 20
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 13
- 229910052804 chromium Inorganic materials 0.000 description 13
- 239000011651 chromium Substances 0.000 description 13
- 239000010941 cobalt Substances 0.000 description 12
- 229910017052 cobalt Inorganic materials 0.000 description 12
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 12
- 229910052742 iron Inorganic materials 0.000 description 11
- 229910052782 aluminium Inorganic materials 0.000 description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 10
- 229910000601 superalloy Inorganic materials 0.000 description 9
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 9
- 229910052721 tungsten Inorganic materials 0.000 description 9
- 239000010937 tungsten Substances 0.000 description 9
- 229910052715 tantalum Inorganic materials 0.000 description 8
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 8
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 7
- 229910052750 molybdenum Inorganic materials 0.000 description 7
- 239000011733 molybdenum Substances 0.000 description 7
- 238000005219 brazing Methods 0.000 description 6
- 229910052735 hafnium Inorganic materials 0.000 description 6
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 6
- 229910000851 Alloy steel Inorganic materials 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 229910000531 Co alloy Inorganic materials 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 229910052710 silicon Inorganic materials 0.000 description 4
- 239000010703 silicon Substances 0.000 description 4
- 229910001256 stainless steel alloy Inorganic materials 0.000 description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 3
- 229910052796 boron Inorganic materials 0.000 description 3
- 238000000151 deposition Methods 0.000 description 3
- 229910052702 rhenium Inorganic materials 0.000 description 3
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 3
- 230000032683 aging Effects 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000010894 electron beam technology Methods 0.000 description 2
- 238000010828 elution Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052758 niobium Inorganic materials 0.000 description 2
- 239000010955 niobium Substances 0.000 description 2
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 229910000753 refractory alloy Inorganic materials 0.000 description 2
- 229910021324 titanium aluminide Inorganic materials 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- UQZIWOQVLUASCR-UHFFFAOYSA-N alumane;titanium Chemical compound [AlH3].[Ti] UQZIWOQVLUASCR-UHFFFAOYSA-N 0.000 description 1
- 238000000149 argon plasma sintering Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 239000011859 microparticle Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000000110 selective laser sintering Methods 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 239000000126 substance Substances 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
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
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- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
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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
- B23K15/00—Electron-beam welding or cutting
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- B23K15/0093—Welding characterised by the properties of the materials to be welded
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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
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- B23K26/342—Build-up welding
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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
- 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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- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
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- 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
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12861—Group VIII or IB metal-base component
- Y10T428/12951—Fe-base component
- Y10T428/12972—Containing 0.01-1.7% carbon [i.e., steel]
- Y10T428/12979—Containing more than 10% nonferrous elements [e.g., high alloy, stainless]
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Description
[実施態様1]
少なくとも第1の閾値温度の第1の融点を有する第1の合金(204)と、
前記第1の閾値温度よりも低い第2の閾値温度未満の第2の融点を有する第2の合金(206)と
セラミック添加剤(202)と、
を含む合金混合物(200)を含み、
前記第1の合金(204)、前記第2の合金(206)、および前記セラミック添加剤(202)が、別個の相として互いに混ざり合っている不均質組成物(108)。
[実施態様2]
前記第1の閾値温度が約2400°Fであり、前記第2の閾値温度が約2350°Fである、実施態様1に記載の不均質組成物(108)。
[実施態様3]
前記第1の合金(204)が、超合金、難溶接性(HTW)合金、耐火合金、ニッケル基超合金、コバルト基超合金、鉄基超合金、鉄基合金、合金鋼、ステンレス鋼合金、コバルト基合金、ニッケル基合金、チタン基合金、チタンアルミナイド、GTD111、GTD444、HAYNES188、INCONEL738、MAR-M-247、Rene108、Rene142、Rene195、およびReneN2、およびこれらの組み合わせからなる群から選択される、実施態様1に記載の不均質組成物(108)。
[実施態様4]
前記第2の合金(206)が、ろう付け合金、鉄基合金、合金鋼、ステンレス鋼合金、コバルト基合金、ニッケル基合金、チタン基合金、DF-4B、BNi-2、BNi-5(AMS4782)、BNi-9、およびこれらの組み合わせからなる群から選択される、実施態様1に記載の不均質組成物(108)。
[実施態様5]
前記セラミック添加剤(202)が、酸化アルミニウム、炭化ケイ素、炭化タングステン、窒化チタン、炭窒化チタン、炭化チタン、およびこれらの組み合わせからなる群から選択される、実施態様1に記載の不均質組成物(108)。
[実施態様6]
前記セラミック添加剤(202)が、粉末、繊維、ナノチューブ、またはこれらの組み合わせからなる群から選択される構成を有する、実施態様1に記載の不均質組成物(108)。
[実施態様7]
微粒子である、実施態様1に記載の不均質組成物(108)。
[実施態様8]
予備焼結プリフォームである、実施態様1に記載の不均質組成物(108)。
[実施態様9]
前記合金混合物(200)が、約95重量%までの前記第1の合金(204)、および約5重量%~約50重量%の前記第2の合金(206)を含む、実施態様1に記載の不均質組成物(108)。
[実施態様10]
約1体積%~約50体積%の間のセラミック添加剤(202)を含む、実施態様1に記載の不均質組成物(108)。
[実施態様11]
前記セラミック添加剤(202)と前記合金混合物(200)とを約15:85から約25:75の間の体積比で含む、実施態様1に記載の不均質組成物(108)。
[実施態様12]
前記第1の合金(204)と前記第2の合金(206)とを約85:15~約75:25の間の重量比で含む、実施態様1に記載の不均質組成物(108)。
[実施態様13]
材料組成物(106)を含む第1の部分(102)と、
不均質組成物(108)を含む第2の部分(104)とを含み、
前記不均質組成物(108)が、
少なくとも第1の閾値温度の第1の融点を有する第1の合金(204)と、
前記第1の閾値温度よりも低い第2の閾値温度未満の第2の融点を有する第2の合金(206)と
セラミック添加剤(202)と、
を含む合金混合物(200)を含み、
前記第1の合金(204)、前記第2の合金(206)、および前記セラミック添加剤(202)が、別個の相として互いに混ざり合っている、物品(100)。
[実施態様14]
前記材料組成物(106)および前記第1の合金(204)の少なくとも1つが、難溶接性(HTW)合金を含む、実施態様13に記載の物品(100)。
[実施態様15]
タービン部品(110)である、実施態様13に記載の物品(100)。
[実施態様16]
前記タービン部品(110)がバケット(ブレード)であり、前記第2の部分(104)がスキーラ先端(114)であるか、または前記タービン部品(110)がシュラウドバケット(ブレード)であり、前記第2の部分(104)が前記シュラウド間の接触面(304)に配置されている接触パッド(302)である、実施態様15に記載の物品(100)。
[実施態様17]
物品(100)を形成するための方法であって、
第2の部分(104)を第1の部分(102)に適用して、前記物品(100)を形成する工程を含み、
前記第1の部分(102)が材料組成物(106)を含み、前記第2の部分(104)が不均質組成物(108)を含み、前記不均質組成物(108)が、
少なくとも第1の閾値温度の第1の融点を有する第1の合金(204)と、
前記第1の閾値温度よりも低い第2の閾値温度未満の第2の融点を有する第2の合金(206)と
セラミック添加剤(202)と、
を含む合金混合物(200)を含み、
前記第1の合金(204)、前記第2の合金(206)、および前記セラミック添加剤(202)が、別個の相として互いに混ざり合っている、方法。
[実施態様18]
前記第2の部分(104)を前記第1の部分(102)に適用する工程が、付加製造技術によって前記不均質組成物(108)を前記第1の部分(102)上に堆積させる工程を含む、実施態様17に記載の方法。
[実施態様19]
前記第2の部分(104)を前記第1の部分(102)に適用する工程が、前記不均質組成物(108)を含む予備焼結されたプリフォームを前記第1の部分(102)上に堆積させる工程、および前記予備焼結されたプリフォームを前記第1の部分(102)にろう付けする工程を含む、実施態様17に記載の方法。
[実施態様20]
前記物品(100)を焼結および熱間静水圧プレスの少なくとも1つに供する工程をさらに含む、実施態様17に記載の方法。
102 第1の部分
104 第2の部分
106 材料組成物
108 不均質組成物
110 タービン部品
112 翼形部
114 スキーラ先端
200 合金混合物
202 セラミック添加剤
204 第1の合金
206 第2の合金
300 シュラウド部
302 接触パッド
304 接触面
Claims (9)
- 微粒子又は予備焼結プリフォームである不均質組成物(108)であって、当該不均質組成物(108)が、
第1の閾値温度以上の第1の融点を有する第1の合金(204)と第1の閾値温度よりも低い第2の閾値温度未満の第2の融点を有する第2の合金(206)との合金混合物(200)と、
セラミック添加剤(202)と
からなり、第1の合金(204)、第2の合金(206)及び前記セラミック添加剤(202)が、別個の相として互いに混ざり合っており、第1の閾値温度が2400°F(1316℃)であり、第2の閾値温度が2350°F(1288℃)であり、第1の合金(204)が、GTD111、GTD444、HAYNES188、INCONEL738、MAR-M-247、Rene108、Rene142、Rene195、ReneN2及びこれらの組み合わせからなる群から選択され、第2の合金(206)が、DF-4B、BNi-2、BNi-5(AMS4782)、BNi-9及びこれらの組み合わせからなる群から選択される、不均質組成物(108)。 - 前記セラミック添加剤(202)が、酸化アルミニウム、炭化ケイ素、炭化タングステン、窒化チタン、炭窒化チタン、炭化チタン及びこれらの組み合わせからなる群から選択される、請求項1に記載の不均質組成物(108)。
- 前記セラミック添加剤(202)が、粉末、繊維、ナノチューブ又はこれらの組み合わせからなる群から選択される構成を有する、請求項1又は請求項2に記載の不均質組成物(108)。
- 前記合金混合物(200)が、95重量%までの第1の合金(204)及び5重量%~50重量%の第2の合金(206)を含む、請求項1乃至請求項3のいずれか1項に記載の不均質組成物(108)。
- 1体積%~50体積%の間のセラミック添加剤(202)を含む、請求項1乃至請求項4のいずれか1項に記載の不均質組成物(108)。
- 材料組成物(106)を含む第1の部分(102)と、
請求項1乃至請求項5のいずれか1項に記載の不均質組成物(108)からなる第2の部分(104)と
を含む物品(100)。 - 当該物品(100)がタービン部品(110)であり、前記タービン部品(110)がバケット(ブレード)であって第2の部分(104)がスキーラ先端(114)であるか或いは前記タービン部品(110)がシュラウド付バケット(ブレード)であって第2の部分(104)が前記シュラウド間の接触面(304)に配置されている接触パッド(302)である、請求項6に記載の物品(100)。
- 物品(100)を形成するための方法であって、当該方法が、
第2の部分(104)を第1の部分(102)に適用して、前記物品(100)を形成する工程
を含んでおり、第1の部分(102)が材料組成物(106)を含み、第2の部分(104)が請求項1乃至請求項5のいずれか1項に記載の不均質組成物(108)からなる、方法。 - 前記物品(100)を焼結及び熱間静水圧プレスの少なくとも1つに供する工程をさらに含む、請求項8に記載の方法。
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