US20130129522A1 - Rhenium-free single crystal superalloy for turbine blades and vane applications - Google Patents

Rhenium-free single crystal superalloy for turbine blades and vane applications Download PDF

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US20130129522A1
US20130129522A1 US13/298,879 US201113298879A US2013129522A1 US 20130129522 A1 US20130129522 A1 US 20130129522A1 US 201113298879 A US201113298879 A US 201113298879A US 2013129522 A1 US2013129522 A1 US 2013129522A1
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Prior art keywords
ppm
single crystal
weight
nickel
base superalloy
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US13/298,879
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English (en)
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Kenneth Harris
Jacqueline B. Wahl
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Cannon Muskegon Corp
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Cannon Muskegon Corp
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Priority to US13/298,879 priority Critical patent/US20130129522A1/en
Assigned to CANNON-MUSKEGON CORPORATION reassignment CANNON-MUSKEGON CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HARRIS, KENNETH, WAHL, JACQUELINE B.
Priority to IL220656A priority patent/IL220656A/en
Priority to CA2781478A priority patent/CA2781478C/en
Priority to JP2012145568A priority patent/JP5663530B2/ja
Priority to PL12174283.7T priority patent/PL2612936T3/pl
Priority to ES12174283.7T priority patent/ES2580955T3/es
Priority to EP12174283.7A priority patent/EP2612936B9/en
Priority to KR1020120083584A priority patent/KR20130054904A/ko
Publication of US20130129522A1 publication Critical patent/US20130129522A1/en
Abandoned legal-status Critical Current

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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
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
    • 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%
    • CCHEMISTRY; METALLURGY
    • C30CRYSTAL GROWTH
    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B21/00Unidirectional solidification of eutectic materials
    • C30B21/02Unidirectional solidification of eutectic materials by normal casting or gradient freezing
    • CCHEMISTRY; METALLURGY
    • C30CRYSTAL GROWTH
    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B29/00Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
    • C30B29/10Inorganic compounds or compositions
    • C30B29/52Alloys
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/28Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02CGAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C7/00Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2201/00Treatment for obtaining particular effects
    • C21D2201/04Single or very large crystals
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/10Metals, alloys or intermetallic compounds
    • F05D2300/17Alloys
    • F05D2300/175Superalloys
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/60Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/607Monocrystallinity

Definitions

  • Rhenium is an example of a truly rare metal that is important to various industries. It is recovered in very small quantities as a by-product of copper-molybdenum and copper production. In addition to its high cost, use of rhenium presents a supply chain risk of both economic and strategic consequence.
  • Rhenium has been widely employed in the production of nickel-base superalloys used to cast single crystal gas turbine components for jet aircraft and power generation equipment. More specifically, rhenium is used as an alloying additive in advanced single crystal superalloys for turbine blades, vanes and seal segments, because of its potent effect at slowing diffusion and thus slowing creep deformation, particularly at high temperatures (e.g., in excess of 1,000 degrees C.) for sustained periods of time. High temperature creep resistance is directly related to the useful service life of gas turbine components and engine performance such as power output, fuel burn and carbon dioxide emissions.
  • Typical nickel-base superalloys used for single crystal castings contain from about 3% rhenium to about 7% rhenium by weight. Although rhenium has been used as only a relatively minor additive, it has been regarded as critical to single crystal nickel-base superalloys to inhibit diffusion and improve high temperature creep resistance, it adds considerable to the total cost of these alloys.
  • the rhenium-free single crystal nickel-base superalloys disclosed herein rely on, among other things, balancing the refractory metal elements (tantalum, tungsten and molybdenum) at a total amount of about 17% to 20% in order to achieve good creep-rupture mechanical properties along with acceptable alloy phase stability, in particular, ensuring freedom from excessive deleterious topological close-packed (TCP) phases that are rich in tungsten, molybdenum and chromium, while substantially eliminating rhenium from the alloy.
  • refractory metal elements tantalum, tungsten and molybdenum
  • TCP topological close-packed
  • the incidental elements of the alloy is controlled to maximums of 100 ppm carbon, 0.04% silicon, 0.01% manganese, 3 ppm sulfur, 30 ppm phosphorous, 30 ppm boron, 0.1% niobium, 150 ppm zirconium, 0.15% rhenium, 0.01% copper, 0.15% iron, 0.1% vanadium, 0.1% ruthenium, 0.15% platinum, 0.15% palladium, 200 ppm magnesium, 5 ppm nitrogen, and 5 ppm oxygen, with each of any other incidental elements being present as a trace element as a maximum of about 25 ppm.
  • the trace elements in the incidental impurities of the disclosed nickel-base superalloys is controlled to maximums of 2 ppm silver, 0.2 ppm bismuth, 10 ppm gallium, 25 ppm calcium, 1 ppm lead, 0.5 ppm selenium, 0.2 ppm tellurium, 0.2 ppm thallium, 10 ppm tin, 2 ppm antimony, 2 ppm arsenic, 5 ppm zinc, 2 ppm mercury, 2 ppm cadmium, 2 ppm germanium, 2 ppm gold, 2 ppm indium, 20 ppm sodium, 10 ppm potassium, 10 ppm barium, 30 ppm phosphorous, 2 ppm uranium, and 2 ppm thorium.
  • sulfur is present at a maximum amount of 0.5 ppm, and lanthanum and yttrium are added to target an amount of total lanthanum and yttrium of from about 5 ppm to about 80 ppm in single crystal components cast from the alloy.
  • carbon is added in an amount from about 0.02% to about 0.05% by weight and boron is added in an amount from about 40 ppm to about 100 ppm.
  • certain embodiments of the disclosed single crystal nickel-base superalloys have a desirably not excessive density that is about 8.8 gms/cc or less, such as 8.79 gms/cc (kg/dm 3 ).
  • FIGS. 1A , 1 B and 1 C are optical micrographs showing the fully heat treated microstructure of castings of a disclosed embodiment (LA-11753, CMSX-7, test bar #C912, fully heat treated, primary age 2050° F./4 hours).
  • FIGS. 2A , 2 B and 2 C are scanning electron micrographs of the microstructure of fully heat treated castings from embodiments disclosed herein (LA-11753, CMSX-7, test bar #C912, fully heat treated, primary age 2050° F./4 hours).
  • FIGS. 3 , 4 and 5 are Larson-Miller stress-rupture graphs showing the surprisingly good creep strength and/or stress-rupture life properties of single crystal test bars and turbine blade castings made from the disclosed alloys.
  • FIGS. 6A , 6 B and 6 C are optical micrographs showing the post-test phase stability of the disclosed alloys, which exhibit excellent phase stability and no TCP phases (LA-11772, CMSX-7, test bar #D912, 2050° F./15 ksi/141.6 hours, gage area).
  • FIGS. 7A , 7 B and 7 C are scanning electron micrographs showing the post-test phase stability of the disclosed alloys, which exhibit excellent phase stability and no TCP phases (LA-11772, CMSX-7, test bar #D912, 2050° F./15 ksi/141.6 hours, gage area).
  • FIGS. 8A , 8 B and 8 C are optical micrographs showing the post-test phase stability of the disclosed alloys, which exhibit excellent phase stability and no TCP phases (LA-11807, CMSX-7, mini-flat #53701Y-F, 2000° F./12 ksi/880.0 hours, gage area).
  • FIGS. 9A , 9 B and 9 C are scanning electron micrographs showing the post-test phase stability of the disclosed alloys, which exhibit excellent phase stability and no TCP phases (LA-11807, CMSX-7, mini-flat #53701Y-F, 2000° F./12 ksi/880.0 hours, gage area).
  • FIGS. 10A , 10 B and 10 C are optical micrographs showing the post-test phase stability of the disclosed alloys, which exhibit excellent phase stability and no TCP phases (LA-11772, CMSX-7, test bar #B913, 1800° F./36 ksi/151.1 hours, gage area).
  • FIGS. 11A , 11 B and 11 C are scanning electron micrographs showing the post-test phase stability of the disclosed alloys, which exhibit excellent phase stability and no TCP phases (LA-11772, CMSX-7, test bar #B913, 1800° F./36 ksi/151.1 hours, gage area).
  • FIGS. 12A , 12 B and 12 C are optical micrographs showing the post-test phase stability of the disclosed alloys, which exhibit excellent phase stability and no TCP phases (LA-11772, CMSX-7, test bar #A912, 1562° F./94.4 ksi/100.9 hours, gage area).
  • FIGS. 13A , 13 B and 13 C are scanning electron micrographs showing the post-test phase stability of the disclosed alloys, which exhibit excellent phase stability and no TCP phases (LA-11772, CMSX-7, test bar #A912, 1562° F./94.4 ksi/100.9 hours, gage area).
  • FIGS. 14A , 14 B and 14 C are optical micrographs showing the fully heat treated microstructures of CMSX-7 MOD B single crystal test bars.
  • FIGS. 15A , 15 B and 15 C are scanning electron micrographs showing the fully heat treated microstructures of CMSX-7 MOD B single crystal test bars.
  • FIG. 16 is a drawing in cross section of a single crystal solid turbine blade cast from an alloy as disclosed herein which has the facility to machine both mini-bar and mini-flat specimens for machined-from-blade (MFB) stress-rupture testing.
  • MFB machined-from-blade
  • FIGS. 17 and 18 show the tensile properties of the alloys versus test temperature.
  • FIGS. 19A , 19 B and 19 C are optical micrographs showing post test microstructures from a long term, high temperature stress-rupture test of an alloy as disclosed herein (LA-11891, CMSX-7 MOD. B, test bar #M923, 2000° F./12 ksi/1176.5 hours).
  • FIGS. 20A , 20 B and 20 C are scanning electron micrographs showing post test microstructures from a long term, high temperature stress-rupture test of an alloy as disclosed herein (LA-11891, CMSX-7 MOD. B, test bar #M923, 2000° F./12 ksi/1176.5 hours).
  • CMSX®-7 The alloys disclosed herein will be referred to as “CMSX®-7” alloys. This is the designation that will be used commercially, the expression “CMSX” being a registered trademark of the Cannon-Muskegon Corporation used in connection with the sale of a family or series of nickel-base single crystal (SX) superalloys.
  • alloys disclosed herein are alternatively described as being rhenium-free, or substantially free of rhenium. As used herein, these terms means that the alloys do not contain any added rhenium and/or that the amount of rhenium present in the alloy is a maximum of 0.15% by weight.
  • Single crystal superalloys and castings have been developed to exhibit an array of outstanding properties including high temperature creep resistance, long fatigue life, oxidation and corrosion resistance, solid solution strengthening, with desired casting properties and low rejection rates, and phase stability, among others. While it is possible to optimize a single additive alloying elements for a particular property, the effects on other properties are often extremely unpredictable. Generally, the relationships among the various properties and various elemental components are extremely complex and unpredictable such that it is surprising when a substantial change can be made to the composition without deleteriously affecting at least certain essential properties.
  • refractory metal elements tantalum, tungsten and molybdenum
  • refractory metal elements were maintained at a total amount of from about 17% to about 20% by weight, while balancing the amounts of the refractory elements to achieve good creep-rupture mechanical properties along with acceptable alloy phase stability (freedom from excessive deleterious topological close-packed (TCP) phase—normally tungsten, molybdenum and chromium rich in this type of alloy).
  • TCP topological close-packed
  • Chromium and cobalt were also adjusted to ensure the required phase stability.
  • the high amount of tantalum was selected to provide excellent single crystal castability, such as freedom from “freckling” defects.
  • the amount of titanium (approximately 0.8%) and tantalum (approximately 0.8%) were adjusted to provide low negative ⁇ / ⁇ ′ mismatch for high temperature creep strength and acceptable room temperature density (e.g., about 8.8 gms/cc, such as 8.79 gms/cc).
  • Aluminum, titanium and tantalum were adjusted to attain a suitable ⁇ ′ volume fraction (Vf), while the combination of aluminum, molybdenum, tantalum and titanium were selected to provide good high temperature oxidation resistance properties.
  • the amount of hafnium addition was selected for coating life attainment at high temperatures.
  • Typical chemistry for the alloys disclosed and claimed herein are listed in Table 1. However, there are certain minor variations.
  • FIGS. 1 - 2 Complete ⁇ ′ solutioning, some remnant ⁇ / ⁇ ′ eutectic, no incipient melting and approximately 0.5 ⁇ m average cubic, aligned ⁇ ′, indicating appropriate ⁇ / ⁇ ′ mis-match and ⁇ / ⁇ ′inter-facial chemistry, following the 4 hr/2050° F. (1121° C.) high temperature age.
  • Burner rig dynamic, cyclic oxidation and hot corrosion (sulfidation) testing is currently scheduled at a major turbine engine company.
  • the MFB 0.020′′ thick gage mini-flat results at 12 ksi/2000° F. (Table 4, FIG. 5 ) indicate good bare high temperature oxidation resistance for this alloy.
  • the alloy shows very high tensile strength (up to 200 ksi (1379 MPa) UTS at 1400° F. (760° C.)) and 0.2% proof stress (up 191 ksi (1318 MPa) at the same temperature and good ductility (Table 5, FIGS. 17 & 18 ).
  • the exceptionally high UTS and 0.2% PS at 1400° F. (760° C.) indicates strain hardening at this temperature, possibly due to further secondary or tertiary ⁇ ′ precipitation in the ⁇ channels at this temperature impeding dislocation movement —the ductility at this maximum strength level is in the range of 13% elongation (4D) and 17% reduction in area (RA).
  • a further heat (5V0459) of 100% Virgin (470 lbs) designated CMSX®-7 Mod B was melted in May 2011 in the CM V-5 Consarc VIM furnace using aim chemistry to CM KH Apr. 13, 2011 (CM CRMP #81-1703 Issue 1).
  • the heat (5V0459) chemistry is shown in Table 6.
  • FIGS. 14 & 15 almost complete ⁇ ′ solutioning, remnant ⁇ / ⁇ ′ eutectic, no incipient melting and approximately 0.45 ⁇ m average cubic aligned ⁇ ′, indicating appropriate ⁇ / ⁇ mismatch and ⁇ / ⁇ ′ inter-facial chemistry, following the 4 hr/2050° F. (1121° C.) high temperature age.
  • FIGS. 19A-19C Post-test microstructures from a longer term, high temperature stress-rupture test [2000° F./12 ksi (1093° C./83 MPa)/1176.5 hours] are shown ( FIGS. 19A-19C ) to exhibit good phase stability, with negligible TCP phase (“needles”) apparent, combined with good stress-rupture life and rupture ductility (34% elongation (4D)) and 42% RA ( FIGS. 19A-20C ).

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US13/298,879 2011-11-17 2011-11-17 Rhenium-free single crystal superalloy for turbine blades and vane applications Abandoned US20130129522A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US13/298,879 US20130129522A1 (en) 2011-11-17 2011-11-17 Rhenium-free single crystal superalloy for turbine blades and vane applications
IL220656A IL220656A (en) 2011-11-17 2012-06-26 Pure single crystal crystalline alloy from meranium for turbine and vane usability
CA2781478A CA2781478C (en) 2011-11-17 2012-06-26 Rhenium-free single crystal superalloy for turbine blades and vane applications
JP2012145568A JP5663530B2 (ja) 2011-11-17 2012-06-28 タービンブレード及びベーン用途向けのレニウムを含まない単結晶超合金
PL12174283.7T PL2612936T3 (pl) 2011-11-17 2012-06-29 Wolny od renu monokrystaliczny nadstop do łopatek turbiny i zastosowania do łopatek
ES12174283.7T ES2580955T3 (es) 2011-11-17 2012-06-29 Superaleación monocristalina libre de renio para álabes de turbinas y aplicaciones de palas
EP12174283.7A EP2612936B9 (en) 2011-11-17 2012-06-29 Rhenium-free single crystal superalloy for turbine blades and vane applications
KR1020120083584A KR20130054904A (ko) 2011-11-17 2012-07-31 터빈 블레이드 및 베인 용도를 위한 레늄 없는 단일 결정체 초합금

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US13/298,879 US20130129522A1 (en) 2011-11-17 2011-11-17 Rhenium-free single crystal superalloy for turbine blades and vane applications

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US (1) US20130129522A1 (ko)
EP (1) EP2612936B9 (ko)
JP (1) JP5663530B2 (ko)
KR (1) KR20130054904A (ko)
CA (1) CA2781478C (ko)
ES (1) ES2580955T3 (ko)
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PL (1) PL2612936T3 (ko)

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CN103334033A (zh) * 2013-06-14 2013-10-02 丹阳市华龙特钢有限公司 一种单晶镍基高温合金的成份及其制备方法
CN105624472A (zh) * 2015-12-28 2016-06-01 广东华科新材料研究院有限公司 一种3d打印用镍基高温合金粉及其制备方法
EP3091095A1 (de) 2015-05-05 2016-11-09 MTU Aero Engines GmbH Rheniumfreie nickelbasis-superlegierung mit niedriger dichte
US11396686B2 (en) * 2018-06-04 2022-07-26 Safran Nickel-based superalloy, single-crystal blade and turbomachine
US11466344B2 (en) 2019-03-06 2022-10-11 Energy, United States Department Of High-performance corrosion-resistant high-entropy alloys
EP3710611B1 (fr) * 2017-11-14 2024-01-10 Safran Superalliage a base de nickel, aube monocristalline et turbomachine

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JP6634674B2 (ja) * 2014-02-28 2020-01-22 大同特殊鋼株式会社 自動車用ターボチャージャのタービンホイール及びその製造方法
US9518311B2 (en) * 2014-05-08 2016-12-13 Cannon-Muskegon Corporation High strength single crystal superalloy
CN105755347A (zh) * 2016-04-20 2016-07-13 苏州市相城区明达复合材料厂 一种铸造用表面强化镍基硬面合金
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CN108715952A (zh) * 2018-05-31 2018-10-30 大连理工大学 一类镍基单晶高温合金Nideal 3
CN109082562A (zh) * 2018-09-22 2018-12-25 广州宇智科技有限公司 一种制冷传热管用液相调幅分解型铸造镍合金
CN112501476B (zh) * 2021-01-29 2021-06-25 北京科技大学 超高强韧性高密度合金及其制备方法和应用
WO2024075560A1 (ja) * 2022-10-03 2024-04-11 国立研究開発法人物質・材料研究機構 Sbによる耐酸化性の劣化を予防したNi基超合金の製造方法、Sbによる耐酸化性の劣化を予防したNi基超合金部材

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ES2580955T3 (es) 2016-08-30
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