US20040042927A1 - Reduced-tantalum superalloy composition of matter and article made therefrom, and method for selecting a reduced-tantalum superalloy - Google Patents

Reduced-tantalum superalloy composition of matter and article made therefrom, and method for selecting a reduced-tantalum superalloy Download PDF

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US20040042927A1
US20040042927A1 US10/229,741 US22974102A US2004042927A1 US 20040042927 A1 US20040042927 A1 US 20040042927A1 US 22974102 A US22974102 A US 22974102A US 2004042927 A1 US2004042927 A1 US 2004042927A1
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percent
content
modified
tantalum
baseline
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Kevin O'Hara
William Walston
Earl Ross
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Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY CORRECTION BECAUSE OF INSUFFICIENT FEES Assignors: O'HARA, KEVIN SWAYNE, ROSS, EARL WARREN, WALSTON, WILLIAM SCOTT
Priority to SG200304874A priority patent/SG108932A1/en
Priority to JP2003301002A priority patent/JP2004162173A/ja
Priority to EP03255313A priority patent/EP1394278A1/en
Publication of US20040042927A1 publication Critical patent/US20040042927A1/en
Priority to US10/812,628 priority patent/US20050139295A1/en
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C19/00Alloys based on nickel or cobalt
    • C22C19/03Alloys based on nickel or cobalt based on nickel
    • C22C19/05Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/057Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%

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  • This invention relates to a composition of matter suitable for use in aggressive, high-temperature gas turbine environments, and articles made therefrom.
  • Nickel-base superalloys are alloys having more nickel than any other element, and containing a group of elements that produce gamma-prime and related precipitates during an appropriate heat treatment.
  • Nickel-base superalloys are the currently preferred alloy choice for making the components of aircraft-gas turbine engines that are exposed to the highest temperatures. Examples include turbine blades, turbine vanes, some shafts, some rotors, interstage seals, and many high-temperature stationary gas-path components.
  • the nickel-base superalloys must exhibit acceptable mechanical properties at both low and high temperatures, such as good strength, good fatigue resistance, low creep rates, sufficient ductility, and acceptable density. They must also have good corrosion and oxidation resistance in the harsh combustion-gas environment. Further, the superalloys must have good stability in both extended exposure at elevated temperature and cyclic heating and cooling patterns. These properties are achieved through the careful selection of the alloying elements and the processing of the material. A number of superalloy compositions have been developed to supply the appropriate combinations of these properties for various applications in the gas turbine environment.
  • the cost of the superalloy material is a consideration. While achieving the required properties is of paramount concern, the manufacture and sales of gas turbine engines is a competitive business. Some of the elements used in the nickel-base superalloys are rather exotic in nature and costly, and therefore their presence and amount is an important factor in the cost of the gas turbine engine. Further, some elements are subject to periodic shortages wherein the price becomes almost prohibitively high.
  • tantalum An important nickel-base superalloy used in gas turbine blades and other applications, ReneTM N 5 , contains a nominal 6.2 weight percent tantalum, and other nickel-base superalloys contain 5 percent or more of tantalum.
  • ReneTM N 5 An important nickel-base superalloy used in gas turbine blades and other applications, ReneTM N 5 , contains a nominal 6.2 weight percent tantalum, and other nickel-base superalloys contain 5 percent or more of tantalum.
  • the price of tantalum of the quality required for use in nickelbase superalloys increased from about $100 per pound to $475 per pound, with some projections of even higher price based on worldwide shortages.
  • Other economic forces have temporarily lowered the price, but there is a future potential for comparable price increases and shortages. The high prices and potential shortages thus threaten the continued economic viability and availability of articles made of such materials.
  • the present invention provides a nickel-base superalloy and articles made from the nickel-base superalloy, and an approach for selecting and designing nickel-base superalloys.
  • the nickel-base superalloy contains a reduced nominal tantalum content as compared with higher-tantalum alloys, and with corresponding modifications of other alloying elements to provide the comparable performance of the higher-tantalum alloys.
  • An article comprises a composition consists essentially of, in weight percent, from about 4 to about 12 percent cobalt, from about 3.5 to about 7 percent tungsten, from about 2 to about 9 percent chromium, from about 0.5 to about 4.5 percent tantalum, from about 5.5 to about 7.5 percent aluminum, from 0 to about 5.5 percent rhenium, from about 0.1 to about 1.2 percent titanium, from 0 to about 3 percent molybdenum, from 0 to about 3 percent ruthenium, from about 0.5 to about 2 percent columbium, about 0.01 percent maximum boron, about 0.07 percent maximum carbon, from about 0.3 to about 1 percent hafnium, about 0.01 percent maximum zirconium, about 0.03 percent maximum yttrium, from 0 to about 0.5 percent vanadium, about 0.01 percent maximum cerium, and about 0.01 percent maximum lanthanum, balance nickel and impurity elements. Most preferably, the article includes from about 3.0 to about 4.0 percent tantalum.
  • the article includes from about 3.0 to about 4.0 percent tantalum, from about 0.2 to about 0.4 percent titanium, from about 0.5 to about 0.7 percent hafnium, and from about 1 to about 2 percent columbium.
  • the article includes from about 6 to about 12 percent cobalt, from about 4.5 to about 6.5 percent tungsten, from about 5.5 to about 6.5 percent chromium, from about 3.0 to about 4 percent tantalum, from about 5.8 to about 6.3 percent aluminum, from about 2.8 to about 3.5 percent rhenium, from about 0.2 to about 0.4 percent titanium, from about 1.3 to about 1.7 percent molybdenum, from about 0.5 to about 0.7 percent hafnium, and from about 1 to about 2 percent columbium.
  • the article includes from about 7 to about 10 percent cobalt, from about 6 to about 6.3 percent tungsten, about 6 percent chromium, from about 3.1. to about 3.5 percent tantalum, from about 5.9 to about 6.3 percent aluminum, about 0.3 percent titanium, about 0.6 percent hafnium, about 3 percent rhenium, about 1.5 percent molybdenum, and about 1.5 percent columbium.
  • the article is substantially a single crystal or a directionally oriented polycrystal produced by directional solidification. It is preferably shaped as a component of a gas turbine engine, such as a gas turbine blade.
  • a method for selecting a reduced-cost nickel-base superalloy comprises the steps of identifying a baseline nickel-base superalloy having a nominal composition, in weight percent, comprising a baseline tantalum content of more than about 5 weight percent tantalum, and a baseline sum (baseline hafnium content plus baseline columbium content plus baseline titanium content plus baseline tungsten content), in weight percent.
  • the method further includes selecting a modified nickel-base superalloy having a nominal composition, in weight percent, comprising a modified tantalum content at least 1.5 weight percent less than the baseline tantalum content, and a modified baseline sum of (modified hafnium content plus modified columbium content plus modified titanium content plus modified tungsten content) at least 1.5 weight percent greater than the baseline sum.
  • the reduction in tantalum content for cost reasons must be compensated for by increasing the sum of hafnium, columbium, titanium, and tungsten.
  • the increase in the sum of hafnium, columbium, titanium, and tungsten is at least as great as the decrease in the tantalum content.
  • the absolute value of (the modified baseline sum minus the baseline sum) is preferably at least as great as the absolute value of (the modified tantalum content minus the baseline tantalum content).
  • the modified nickel-base superalloy have a nonzero modified hafnium content, a nonzero modified columbium content, a nonzero modified titanium content, and a nonzero modified tungsten content.
  • the sum of the modified tungsten content plus a modified molybdenum content is at least about 6.5 weight percent, for most modified nickel-base superalloys.
  • the present article exhibits performance comparable with that of higher-tantalum alloys, but with a reduced tantalum content, and consequently a reduced cost.
  • the cost savings becomes highly significant when tantalum prices exceed several hundred dollars per pound, as has been the case recently and which may occur again in the future.
  • FIG. 1 is a perspective view of a gas turbine blade
  • FIG. 2 is a block flow diagram of a method for fabricating the article of FIG. 1;
  • FIG. 3 is a bar chart of oxidation weight loss in cyclic oxidation tests, for the tested alloys.
  • the single-crystal structure is prepared by the directional solidification of an alloy composition as discussed herein, usually from a seed or other structure which induces the growth of the single crystal and single grain orientation.
  • the component article 20 is a directionally oriented polycrystal, in which there are at least several grains all with a commonly oriented preferred growth direction.
  • the directionally oriented polycrystal is produced by directional solidification, typically without a seed.
  • alloy composition discussed herein is not limited to the gas turbine blade 22 , and it may be employed in other articles such as gas turbine vanes, or articles that are not to be used in gas turbine engines.
  • the article includes from about 6 to about 12 percent cobalt, from about 4.5 to about 6.5 percent tungsten, from about 5.5 to about 6.5 percent chromium, from about 3.0 to about 4 percent tantalum, from about 5.8 to about 6.3 percent aluminum, from about 2.8 to about 3.5 percent rhenium, from about 0.2 to about 0.4 percent titanium, from about 1.3 to about 1.7 percent molybdenum, from about 0.5 to about 0.7 percent hafnium, and from about 1 to about 2 percent columbium.
  • the article includes from about 7 to about 10 percent cobalt, from about 6 to about 6.3 percent tungsten, about 6 percent chromium, from about 3.1. to about 3.5 percent tantalum, from about 5.9 to about 6.3 percent aluminum, about 0.3 percent titanium, about 0.6 percent hafnium, about 3 percent rhenium, about 1.5 percent molybdenum, and about 1.5 percent columbium.
  • Most high performance superalloys for the most-demanding applications contain at least about 5-6 weight percent tantalum, and in some cases considerably more tantalum.
  • the present invention desirably reduces the tantalum content of the alloy of the invention to no more than about half the initial amount in the baseline nickel-base superalloy, and typically less than about 4 weight percent.
  • the resulting superalloy, with adjustments of other alloying proportions, has acceptable performance and also a cost which is significantly less than that of comparable superalloys, an important consideration at times when the cost of tantalum is high.
  • the tantalum in the gamma-prime hardened superalloy is an important ingredient because tantalum is a heavy refractory which can replace aluminum in the Ni 3 Al-based gamma-prime strengthening phase.
  • the tantalum has a secondary effect of improved castability with respect to grain defects by balancing out the density differences between the first and last liquid to solidify (i.e., between the dendrite core and the interdendritic regions).
  • the presence of tantalum also does not have a negative effect on environmental resistance in respect to oxidation and hot corrosion, unlike other refractory metals such as molybdenum and tungsten.
  • reducing the tantalum content below about 5 weight percent, while retaining strength and environmental-resistance properties is challenging.
  • tantalum may be replaced by columbium and/or hafnium and/or titanium and/or tungsten on the gamma-prime aluminum sites.
  • the tungsten partitions to both the gamma phase and to the gamma prime phase, so that it aids in increasing the strength of the gamma prime phase as well as the gamma matrix.
  • an excessively large increase in the tungsten content tends to lead to phase instability in the alloy over long exposure to elevated temperature, and therefore the tungsten content is limited.
  • the alloy contains from about 0.1 to about 1.2 percent titanium. Titanium is a potent gamma prime hardener, and at least about 0.1 percent must be present in order to compensate for the reduced tantalum content.
  • the optional titanium addition substitutes for aluminum and tantalum in the gamma prime phase, improving the strength. However, higher levels of titanium adversely affect oxidation resistance.
  • the alloy contains from about 0.3 to about 1 percent hafnium.
  • Hafnium improves the oxidation and hot corrosion resistance of coated alloys, but can degrade the corrosion resistance of uncoated alloys.
  • Hafnium also improves the life of thermal barrier coatings, where used.
  • Experience with other alloys has shown that hafnium contents on the order of 0.75 percent are satisfactory. However, when the hafnium content exceeds about 1 percent, the stress rupture properties are reduced and the incipient melting temperature is reduced.
  • the alloy contains from about 0.5 to about 2 percent columbium (also sometimes termed “niobium”), which substitutes for tantalum in the gamma prime phase. Lesser amounts result in insufficient amounts and strength of the gamma prime phase. Greater amounts excessively reduce the gamma-prime solvus temperature and reduce oxidation resistance.
  • columbium also sometimes termed “niobium”
  • the alloy contains from about from about 3.5 to about 7 percent tungsten. Lesser amounts unacceptably decrease the strength of the superalloy, and greater amounts produce instability with respect to TCP (topologically close packed) phase formation.
  • the alloy contains from about 2 to about 9 percent chromium. Lesser amounts reduce hot corrosion resistance while greater amounts lead to phase instability and poor cyclic oxidation resistance.
  • the alloy contains from about 5.5 to about 7.5 percent aluminum. Lesser amounts reduce strength due to a reduction in the gamma prime phase. Greater amounts produce instability with respect to TCP phase formation and incipient melting problems during alloy heat treatment.
  • the alloy contains from 0 to about 3 percent ruthenium. Greater amounts reduce oxidation resistance and do not improve alloy stability.
  • the alloy contains about 0.01 percent maximum boron, preferably about 0.006 percent maximum boron. Greater amounts cause incipient melting problems during alloy heat treatment.
  • the alloy contains about 0.07 percent maximum carbon.
  • the carbon is a deoxidizer to reduce inclusions. Greater amounts sap the strength of the superalloy by chemically combining to form carbides of hardening elements. The carbides also serve as the sites for fatigue failure initiation.
  • the alloy contains about 0.01 percent maximum zirconium. Greater amounts cause incipient melting problems during alloy heat treatment.
  • the alloy contains about 0.03 percent maximum yttrium. Greater amounts promote undesirable mold-metal reaction at the casting surface and increase the inclusion content of the cast article.
  • the alloy contains from 0 to about 0.5 percent vanadium. Greater amounts reduce the hot corrosion resistance of the alloy.
  • the alloy contains about 0.01 percent maximum cerium and about 0.01 percent maximum lanthanum. Greater amounts of either of these elements promote an undesirable mold-metal reaction at the casting surface and increase the inclusion content of the component.
  • the alloy preferably contains about 0.1 percent maximum silicon. Silicon in such minor amounts may aid oxidation resistance.
  • the alloy preferably contains about 0.04 percent maximum magnesium and about 0.01 percent maximum calcium as de-oxidizers. These elements in small quantities may also improve the oxidation resistance.
  • the balance of the alloy is nickel and impurity elements.
  • the nickel content is preferably in the range of from about 61 to about 64 weight percent.
  • the Mo content was 1.5 weight percent
  • the Re content was 3 weight percent
  • the Ru content was 0, and the carbon content was 0.05 weight percent.
  • compositional and property computed values for the alloys are set forth in Table II.
  • the value of ⁇ Ta is the change in tantalum content for the indicated alloy as compared with RN 5 .
  • the value of ⁇ (Ti+Hf+Cb+W) is the change in the computed sum for the indicated alloy as compared with RN 5 .
  • the value of (W+Mo) is the numerical sum of these two elements.
  • Alloys E 1 -E 8 are a full factorial in tungsten, columbium, and hafnium, while alloys E 1 , E 4 , E 6 - 7 , and E 9 - 12 are a 2 4+1 IV experiment to economically understand the effects of titanium modifications. Alloys E 8 and E 12 have the same tungsten, columbium, and hafnium contents, but alloy E 12 has 0.3 percent titanium, with the result that the mechanical performance of alloy E 12 is substantially improved over that of alloy E 8 .
  • Alloy RN 5 has the nominal composition of ReneTM N 5 alloy.
  • composition E 12 was selected as the preferred alloy composition, and acceptable variations were defined for specific applications as set forth above.
  • Some specific alloys of interest include: TABLE IV Alloy No. Al Ta W Co Hf Y-1716 6.25 3.5 6.0 10 0.60 Y-1717 6.25 3.5 6.0 7.5 0.60 Y-1718 6.20 3.25 6.25 10 0.50
  • the melted alloy is solidified to form an article, step 42 .
  • the solidification may be of any operable type, such as a multidirectional heat flow to produce an unoriented polycrystalline article, a substantially uniaxial directional solidification to produce a directionally oriented polycrystalline article, or a uniaxial solidification with a seed, constriction, or other approach to producing a substantially single crystal article.
  • the solidified article may optionally be post processed, step 44 , by any operable approach.
  • Post processing may include, for example, cleaning, coating, grinding, machining, and the like.
  • a reduced-cost nickel-base superalloy is selected by first identifying a baseline nickel-base superalloy having a nominal composition, in weight percent, comprising a baseline tantalum content of more than about 5 weight percent tantalum, and a baseline sum (baseline hafnium content plus baseline columbium content plus baseline titanium content plus baseline tungsten content), in weight percent.
  • a number of baseline nickel-base superalloys are candidates for the application of the present approach, because of their high tantalum contents.
  • Examples of such commercial baseline nickel-base superalloys include PWA 1484 (nominally 8.7 percent tantalum), ReneTM 142 (nominally 6.35 percent tantalum), and the CMSX alloys such as CMSX-4 (nominally 6.5 percent tantalum) and CMSX-10 (nominally 7.5 percent tantalum) may be modified according to these principles to reduce their tantalum contents while maintaining acceptable properties.
  • a modified nickel-base superalloy having a nominal composition, in weight percent, comprising a modified tantalum content at least 1.5 weight percent less than the baseline tantalum content, and a modified baseline sum of (modified hafnium content plus modified columbium content plus modified titanium content plus modified tungsten content) at least 1.5 weight percent greater than the baseline sum. It is preferred that the increase in the sum of hafnium, columbium, titanium, and tungsten contents be at least as great as the decrease in the tantalum content.
  • the modified nickel-base superalloy has a nonzero modified hafnium content, a nonzero modified columbium content, a nonzero modified titanium content, and a nonzero modified tungsten content; that is, all of these elements should be present in nonzero amounts.
  • the data also shows that the sum of the modified tungsten content plus a modified molybdenum content in the modified nickel-base superalloy should be at least about 6.5 weight percent.

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US10/229,741 2002-08-27 2002-08-27 Reduced-tantalum superalloy composition of matter and article made therefrom, and method for selecting a reduced-tantalum superalloy Abandoned US20040042927A1 (en)

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US10/229,741 US20040042927A1 (en) 2002-08-27 2002-08-27 Reduced-tantalum superalloy composition of matter and article made therefrom, and method for selecting a reduced-tantalum superalloy
SG200304874A SG108932A1 (en) 2002-08-27 2003-08-25 Reduced-tantalum superalloy composition of matter and article made therefrom, and method for selecting a reduced-tantalum superalloy
JP2003301002A JP2004162173A (ja) 2002-08-27 2003-08-26 物質のタンタルを低減した超合金組成及びこの組成で作られる製品、及びタンタルを低減した超合金を選択するための方法
EP03255313A EP1394278A1 (en) 2002-08-27 2003-08-27 Reduced-tantalum superalloy composition and article made therefrom, and method for selecting a reduced-tantalum superalloy
US10/812,628 US20050139295A1 (en) 2002-08-27 2004-03-29 Method for selecting a reduced-tantalum superalloy composition of matter and article made therefrom

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US20060182649A1 (en) * 2005-02-16 2006-08-17 Siemens Westinghouse Power Corp. High strength oxidation resistant superalloy with enhanced coating compatibility
US20070044869A1 (en) * 2005-09-01 2007-03-01 General Electric Company Nickel-base superalloy
US20070163682A1 (en) * 2003-05-09 2007-07-19 Hitachi, Ltd. Ni-based superalloy having high oxidation resistance and gas turbine part
US20070199629A1 (en) * 2004-12-23 2007-08-30 Siemens Power Generation, Inc. Corrosion resistant superalloy with improved oxidation resistance
US20080261073A1 (en) * 2006-03-24 2008-10-23 United Technologies Corporation Coating suitable for use as a bondcoat in a thermal barrier coating system
US20100196191A1 (en) * 2009-02-05 2010-08-05 Honeywell International Inc. Nickel-base superalloys
EP3489376A1 (en) * 2017-11-24 2019-05-29 Siemens Aktiengesellschaft Alloy for gas turbine applications with high oxidation resistance
US20210023606A1 (en) * 2017-11-29 2021-01-28 Hitachi Metals, Ltd. Hot-die ni-based alloy, hot-forging die employing same, and forged-product manufacturing method

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JP5344453B2 (ja) * 2005-09-27 2013-11-20 独立行政法人物質・材料研究機構 耐酸化性に優れたNi基超合金
JP5299899B2 (ja) * 2006-03-31 2013-09-25 独立行政法人物質・材料研究機構 Ni基超合金及びその製造方法
US20090041615A1 (en) * 2007-08-10 2009-02-12 Siemens Power Generation, Inc. Corrosion Resistant Alloy Compositions with Enhanced Castability and Mechanical Properties
US8708659B2 (en) 2010-09-24 2014-04-29 United Technologies Corporation Turbine engine component having protective coating
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JP2004162173A (ja) 2004-06-10
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US20050139295A1 (en) 2005-06-30

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