US20070199629A1 - Corrosion resistant superalloy with improved oxidation resistance - Google Patents

Corrosion resistant superalloy with improved oxidation resistance Download PDF

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Publication number
US20070199629A1
US20070199629A1 US11/788,299 US78829907A US2007199629A1 US 20070199629 A1 US20070199629 A1 US 20070199629A1 US 78829907 A US78829907 A US 78829907A US 2007199629 A1 US2007199629 A1 US 2007199629A1
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Prior art keywords
superalloy
oxidation resistance
rare earth
earth elements
corrosion resistant
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Abandoned
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US11/788,299
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Allister James
Douglas Arrell
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Siemens Energy Inc
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Siemens Power Generations Inc
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Assigned to SIEMENS POWER GENERATION, INC. reassignment SIEMENS POWER GENERATION, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ARRELL, DOUGLAS J., JAMES, ALLISTER W.
Publication of US20070199629A1 publication Critical patent/US20070199629A1/en
Assigned to UNITED STATES DEPARTMENT OF ENERGY reassignment UNITED STATES DEPARTMENT OF ENERGY CONFIRMATORY LICENSE (SEE DOCUMENT FOR DETAILS). Assignors: SIEMENS POWER GENERATION, INC.
Assigned to SIEMENS ENERGY, INC. reassignment SIEMENS ENERGY, INC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: SIEMENS POWER GENERATION, INC.
Abandoned legal-status Critical Current

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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
    • 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
    • C22C19/055—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
    • 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
    • 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
    • C22C19/057—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%

Definitions

  • the invention relates to a nickel-based superalloy with very high corrosion resistance and enhanced oxidation resistance and more particularly, to a nickel-based superalloy for directionally solidified and conventionally cast components suited for use in gas turbine engines.
  • Nickel-base superalloys have a very good material strength at high temperatures. These properties permit their use in components for gas turbine engines where the retention of excellent mechanical properties at high temperatures is required.
  • the use of these alloys at increasingly higher temperatures requires that a coating be applied to the superalloy component for thermal protection.
  • the coating typically consists of applying a bondcoat to the superalloy and then a thermal barrier coating (TBC) to the bondcoat.
  • TBC thermal barrier coating
  • Typical bond coats are alloys of the type MCrAlX where M is Ni, Co, or Fe and X is commonly Y, Zr, or Hf. The bondcoat tends to degrade during prolonged high temperature exposure. The degraded bondcoat does not adequately adhere the thermal barrier coating to the superalloy component.
  • the nickel-based superalloy may be formed from materials in the following weight percentages: 21.0 to 24.0 Cr; 18.0 to 20.0 Co; 0 to 0.5 Mo; 1.5 to 2.5 W; 1.0 to 2.0 Ta; 1.5 to 2.3 Al; 3.4 to 4.0 Ti; 0.7 to 1.2 Nb; 0.05 to 0.3 Hf; 0.05 to 0.3 Si; 0.002 to 0.008 B; 0.010 to 0.040 Zr; 0.10 to 0.20 C; 0.001 to 0.1 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni.
  • the superalloy may include the following materials in the following weight percentages: 22.0 to 22.8 Cr; 18.5 to 19.5 Co; 0 to 0.2 Mo; 1.8 to 2.2 W; 1.3 to 1.5 Ta; 1.8 to 2.0 Al; 3.6 to 3.8 Ti; 0.9 to 1.1 Nb; 0.1 to 0.25 Hf; 0.15 to 0.25 Si; 0.004 to 0.006 B; 0.020 to 0.030 Zr; 0.13 to 0.17 C; 0.01 to 0.05 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni.
  • the superalloy may also be formed from the following materials in weight percentages including: 22.4 Cr; 19.0 Co; 2.0 W; 1.4 Ta; 1.9 Al; 3.7 Ti; 1.0 Nb; 0.2 Hf; 0.2 Si; 0.005 B; 0.025 Zr; 0.15 C; 0.02 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni.
  • the superalloy may be formed from materials in the following weight percentages: 21.0 to 24.0 Cr; 18.0 to 20.0 Co; 0 to 0.5 Mo; 1.5 to 2.5 W; 1.0 to 2.0 Ta; 1.5 to 2.3 Al; 3.4 to 4.0 Ti; 0.7 to 1.2 Nb; 0.05 to 0.3 Hf; 0.05 to 0.3 Si; 0.002 to 0.008 B; 0.010 to 0.040 Zr; 0.10 to 0.20 C; 0.001 to 0.1 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni.
  • the inclusion of rare earth elements selected from the group of La, Ce, Nb, and Dy provides enhanced coating performance.
  • the desired coating performance is a result of the use of two or more rare earth
  • a chromium content of at least 21 weight percent results in excellent levels of high temperature corrosion resistance.
  • the aluminum content is relatively low compared to levels that are generally present in superalloys with high oxidation resistance, oxidation resistance is enhanced by the presence of the rare earth elements, the silicon, and the hafnium present in the superalloy.
  • the silicon in the alloy permits the formation of SiO 2 at the surface oxide layer to provide oxidation resistance.
  • the level of silicon must be kept at levels below 0.2 weight percent, a level where the silicon content is detrimental to the performance of the alloy.
  • the addition of the hafnium at levels similar to that of the silicon compensates for the limitation in silicon level without the detrimental performance resulting from excessive silicon levels.
  • rare earth elements dramatically improves the oxidation resistance.
  • the presence of rare earth elements is believed to promote the diffusion of aluminum to the surface increasing the proportion of alumina in the scale relative to alloys where no rare earth elements are present.
  • the presence of the rare earth elements enhances the coating life. This enhancement is attributed to the ability of the rare earth elements to form sulfides and oxysulfides fixing sulfur impurities which prevents their diffusion to the surface permitting the degradation of the alumina scale on the superalloy adjacent to the bondcoat.
  • a preferred superalloy for high corrosion resistance and an improved oxidation resistance may be formed from materials in the following weight percentages: 22.0 to 22.8 Cr; 18.5 to 19.5 Co; 0 to 0.2 Mo; 1.8 to 2.2 W; 1.3 to 1.5 Ta; 1.8 to 2.0 Al; 3.6 to 3.8 Ti; 0.9 to 1.1 Nb; 0.1 to 0.25 Hf; 0.15 to 0.25 Si; 0.004 to 0.006 B; 0.020 to 0.030 Zr; 0.13 to 0.17 C; 0.01 to 0.05 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni.
  • a most preferred superalloy composition may be formed from materials in the following weight percentages: 22.4 Cr; 19.0 Co; 2.0 W; 1.4 Ta; 1.9 Al; 3.7 Ti; 1.0 Nb; 0.2 Hf; 0.2 Si; 0.005 B; 0.025 Zr; 0.15 C; 0.02 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Physical Vapour Deposition (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)

Abstract

An improved nickel-based superalloy having high corrosion and oxidation resistance and good compatibility with a thermal barrier coating. The enhanced oxidation resistance and compatibility with the thermal barrier coating results from the inclusion of two or more rare earth elements. The superalloy is useful for the fabrication of components for a gas turbine.

Description

    STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
  • The U.S. Government has a paid-up license in the invention and the right in limited circumstances to require that patent owner to license others on reasonable terms as provided for by the terms of DE-FC26-05NT42644 awarded by the Department of Energy.
    • CROSS-REFERENCE TO RELATED APPLICATIONS
  • This application is a continuation-in-part of international patent application PCT/EP2005/057043 filed on Dec. 21, 2005, and claiming priority of Sweden application 0403162-1 filed on Dec. 23, 2004, which international application was published in English as WO 2006/067189 on Jun. 29, 2006.
    • FIELD OF THE INVENTION
  • The invention relates to a nickel-based superalloy with very high corrosion resistance and enhanced oxidation resistance and more particularly, to a nickel-based superalloy for directionally solidified and conventionally cast components suited for use in gas turbine engines.
    • BACKGROUND OF THE INVENTION
  • Nickel-base superalloys have a very good material strength at high temperatures. These properties permit their use in components for gas turbine engines where the retention of excellent mechanical properties at high temperatures is required. The use of these alloys at increasingly higher temperatures requires that a coating be applied to the superalloy component for thermal protection. The coating typically consists of applying a bondcoat to the superalloy and then a thermal barrier coating (TBC) to the bondcoat. Typical bond coats are alloys of the type MCrAlX where M is Ni, Co, or Fe and X is commonly Y, Zr, or Hf. The bondcoat tends to degrade during prolonged high temperature exposure. The degraded bondcoat does not adequately adhere the thermal barrier coating to the superalloy component. As a result, spallation of the TBC occurs with complete loss of thermal protection to the component. The rate at which the bondcoat degrades depends upon the composition of the superalloy to which it is applied. Generally alumina forming superalloys exhibit longer bondcoat lifetimes than chromia forming superalloys. However, it is often preferable to use high chromium containing superalloys for very high corrosion resistance. A need exists for a superalloy with a lower propensity to promote bondcoat degradation and significantly enhance the resistance of the TBC to spallation.
    • SUMMARY OF THE INVENTION
  • This application is directed to a nickel-based superalloy that has high corrosion and oxidation resistance and good compatibility with a thermal barrier coating deposited thereon. The nickel-based superalloy may be formed from materials in the following weight percentages: 21.0 to 24.0 Cr; 18.0 to 20.0 Co; 0 to 0.5 Mo; 1.5 to 2.5 W; 1.0 to 2.0 Ta; 1.5 to 2.3 Al; 3.4 to 4.0 Ti; 0.7 to 1.2 Nb; 0.05 to 0.3 Hf; 0.05 to 0.3 Si; 0.002 to 0.008 B; 0.010 to 0.040 Zr; 0.10 to 0.20 C; 0.001 to 0.1 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni. Preferably, the superalloy may include the following materials in the following weight percentages: 22.0 to 22.8 Cr; 18.5 to 19.5 Co; 0 to 0.2 Mo; 1.8 to 2.2 W; 1.3 to 1.5 Ta; 1.8 to 2.0 Al; 3.6 to 3.8 Ti; 0.9 to 1.1 Nb; 0.1 to 0.25 Hf; 0.15 to 0.25 Si; 0.004 to 0.006 B; 0.020 to 0.030 Zr; 0.13 to 0.17 C; 0.01 to 0.05 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni. The superalloy may also be formed from the following materials in weight percentages including: 22.4 Cr; 19.0 Co; 2.0 W; 1.4 Ta; 1.9 Al; 3.7 Ti; 1.0 Nb; 0.2 Hf; 0.2 Si; 0.005 B; 0.025 Zr; 0.15 C; 0.02 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni.
    • DETAILED DESCRIPTION OF THE INVENTION
  • This invention is directed to a high chromium superalloy that promotes superior corrosion and oxidation resistance and an improved compatibility with a TBC applied to the superalloy via a bondcoat. In one embodiment, the superalloy may be formed from materials in the following weight percentages: 21.0 to 24.0 Cr; 18.0 to 20.0 Co; 0 to 0.5 Mo; 1.5 to 2.5 W; 1.0 to 2.0 Ta; 1.5 to 2.3 Al; 3.4 to 4.0 Ti; 0.7 to 1.2 Nb; 0.05 to 0.3 Hf; 0.05 to 0.3 Si; 0.002 to 0.008 B; 0.010 to 0.040 Zr; 0.10 to 0.20 C; 0.001 to 0.1 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni. The inclusion of rare earth elements selected from the group of La, Ce, Nb, and Dy provides enhanced coating performance. Furthermore, the desired coating performance is a result of the use of two or more rare earth elements rather than a single element.
  • A chromium content of at least 21 weight percent results in excellent levels of high temperature corrosion resistance. Although the aluminum content is relatively low compared to levels that are generally present in superalloys with high oxidation resistance, oxidation resistance is enhanced by the presence of the rare earth elements, the silicon, and the hafnium present in the superalloy.
  • The silicon in the alloy permits the formation of SiO2 at the surface oxide layer to provide oxidation resistance. However, the level of silicon must be kept at levels below 0.2 weight percent, a level where the silicon content is detrimental to the performance of the alloy. The addition of the hafnium at levels similar to that of the silicon compensates for the limitation in silicon level without the detrimental performance resulting from excessive silicon levels.
  • Particularly the addition of the rare earth elements dramatically improves the oxidation resistance. The presence of rare earth elements is believed to promote the diffusion of aluminum to the surface increasing the proportion of alumina in the scale relative to alloys where no rare earth elements are present.
  • The presence of the rare earth elements enhances the coating life. This enhancement is attributed to the ability of the rare earth elements to form sulfides and oxysulfides fixing sulfur impurities which prevents their diffusion to the surface permitting the degradation of the alumina scale on the superalloy adjacent to the bondcoat.
  • A preferred superalloy for high corrosion resistance and an improved oxidation resistance may be formed from materials in the following weight percentages: 22.0 to 22.8 Cr; 18.5 to 19.5 Co; 0 to 0.2 Mo; 1.8 to 2.2 W; 1.3 to 1.5 Ta; 1.8 to 2.0 Al; 3.6 to 3.8 Ti; 0.9 to 1.1 Nb; 0.1 to 0.25 Hf; 0.15 to 0.25 Si; 0.004 to 0.006 B; 0.020 to 0.030 Zr; 0.13 to 0.17 C; 0.01 to 0.05 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni. A most preferred superalloy composition may be formed from materials in the following weight percentages: 22.4 Cr; 19.0 Co; 2.0 W; 1.4 Ta; 1.9 Al; 3.7 Ti; 1.0 Nb; 0.2 Hf; 0.2 Si; 0.005 B; 0.025 Zr; 0.15 C; 0.02 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and the balance formed from Ni.
  • Alternatives for the alloy composition and other variations within the range provided will be apparent to those skilled in the art. Variations and modifications can be made without departing from the scope and spirit of the invention as defined by the following claims.

Claims (3)

1. A nickel-based superalloy consisting essentially of materials as expressed in weight percentages:
21.0 to 24.0 Cr;
18.0 to 20.0 Co;
0 to 0.5 Mo;
1.5 to 2.5 W;
1.0 to 2.0 Ta;
1.5 to 2.3 Al;
3.4 to 4.0 Ti;
0.7 to 1.2 Nb;
0.05 to 0.3 Hf;
0.05 to 0.3 Si;
0.002 to 0.008 B;
0.010 to 0.040 Zr;
0.10 to 0.20 C;
0.001 to 0.1 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm and Gd; and
and the balance formed from Ni.
2. The superalloy of claim 1, wherein the alloy consisting essentially of materials as expressed in weight percentages:
22.0 to 22.8 Cr;
18.5 to 19.5 Co;
0 to 0.2 Mo;
1.8 to 2.2 W;
1.3 to 1.5 Ta;
1.8 to 2.0 Al;
3.6 to 3.8 Ti;
0.9 to 1.1 Nb;
0.1 to 0.25 Hf;
0.15 to 0.25 Si;
0.004 to 0.006 B;
0.020 to 0.030 Zr;
0.13 to 0.17 C;
0.01 to 0.05 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and
and the balance formed from Ni.
3. The superalloy of claim 1, wherein the alloy wherein the alloy consisting essentially of materials as expressed in weight percentages:
22.4. Cr;
19.0 Co;
2.0 W;
1.4 Ta;
1.9 Al;
3.7 Ti;
1.0 Nb;
0.2 Hf;
0.2 Si;
0.005 B;
0.025 Zr;
0.15 C;
0.02 of a mixture of two or more rare earth elements selected from the group of La, Ce, Nb, Dy, Pr, Sm, and Gd; and
and the balance formed from Ni.
US11/788,299 2004-12-23 2007-04-19 Corrosion resistant superalloy with improved oxidation resistance Abandoned US20070199629A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
SE0403162-1 2004-12-23
SE0403162A SE528807C2 (en) 2004-12-23 2004-12-23 Component of a superalloy containing palladium for use in a high temperature environment and use of palladium for resistance to hydrogen embrittlement
PCT/EP2005/057043 WO2006067189A1 (en) 2004-12-23 2005-12-21 A ni based alloy, a component, a gas turbine arrangement and use of pd in connection with such an alloy

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2005/057043 Continuation-In-Part WO2006067189A1 (en) 2004-12-23 2005-12-21 A ni based alloy, a component, a gas turbine arrangement and use of pd in connection with such an alloy

Publications (1)

Publication Number Publication Date
US20070199629A1 true US20070199629A1 (en) 2007-08-30

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ID=34102111

Family Applications (4)

Application Number Title Priority Date Filing Date
US11/794,071 Abandoned US20080101981A1 (en) 2004-12-23 2005-12-21 Ni Based Alloy, a Component, a Gas Turbine Arrangement and Use of Pd in Connection With Such an Alloy
US11/788,238 Abandoned US20070202002A1 (en) 2004-12-23 2007-04-19 Rare earth modified corrosion resistant superalloy with enhanced oxidation resistance and coating compatibility
US11/788,295 Abandoned US20070202003A1 (en) 2004-12-23 2007-04-19 Rare earth modified high strength oxidation resistant superalloy with enhanced coating compatibility
US11/788,299 Abandoned US20070199629A1 (en) 2004-12-23 2007-04-19 Corrosion resistant superalloy with improved oxidation resistance

Family Applications Before (3)

Application Number Title Priority Date Filing Date
US11/794,071 Abandoned US20080101981A1 (en) 2004-12-23 2005-12-21 Ni Based Alloy, a Component, a Gas Turbine Arrangement and Use of Pd in Connection With Such an Alloy
US11/788,238 Abandoned US20070202002A1 (en) 2004-12-23 2007-04-19 Rare earth modified corrosion resistant superalloy with enhanced oxidation resistance and coating compatibility
US11/788,295 Abandoned US20070202003A1 (en) 2004-12-23 2007-04-19 Rare earth modified high strength oxidation resistant superalloy with enhanced coating compatibility

Country Status (10)

Country Link
US (4) US20080101981A1 (en)
EP (1) EP1825012A1 (en)
JP (1) JP2008525634A (en)
KR (1) KR20070091350A (en)
CN (1) CN100587093C (en)
BR (1) BRPI0519432A2 (en)
CA (1) CA2592027A1 (en)
RU (1) RU2007127852A (en)
SE (1) SE528807C2 (en)
WO (1) WO2006067189A1 (en)

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