US20190072683A2 - Electroformed nickel-chromium alloy - Google Patents
Electroformed nickel-chromium alloy Download PDFInfo
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- US20190072683A2 US20190072683A2 US15/103,777 US201415103777A US2019072683A2 US 20190072683 A2 US20190072683 A2 US 20190072683A2 US 201415103777 A US201415103777 A US 201415103777A US 2019072683 A2 US2019072683 A2 US 2019072683A2
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- nickel
- chromium
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- 229910000623 nickel–chromium alloy Inorganic materials 0.000 title description 2
- 229910018487 Ni—Cr Inorganic materials 0.000 claims abstract description 70
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 claims abstract description 70
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 64
- 239000000956 alloy Substances 0.000 claims abstract description 64
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 45
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 21
- 239000011651 chromium Substances 0.000 claims abstract description 16
- 239000001763 2-hydroxyethyl(trimethyl)azanium Substances 0.000 claims abstract description 15
- 235000019743 Choline chloride Nutrition 0.000 claims abstract description 15
- SGMZJAMFUVOLNK-UHFFFAOYSA-M choline chloride Chemical compound [Cl-].C[N+](C)(C)CCO SGMZJAMFUVOLNK-UHFFFAOYSA-M 0.000 claims abstract description 15
- 229960003178 choline chloride Drugs 0.000 claims abstract description 15
- 239000002904 solvent Substances 0.000 claims abstract description 15
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 14
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 13
- QSWDMMVNRMROPK-UHFFFAOYSA-K chromium(3+) trichloride Chemical compound [Cl-].[Cl-].[Cl-].[Cr+3] QSWDMMVNRMROPK-UHFFFAOYSA-K 0.000 claims abstract description 13
- 238000007747 plating Methods 0.000 claims abstract description 12
- 239000004094 surface-active agent Substances 0.000 claims abstract description 10
- 229910021555 Chromium Chloride Inorganic materials 0.000 claims abstract description 9
- 229910021586 Nickel(II) chloride Inorganic materials 0.000 claims abstract description 9
- QMMRZOWCJAIUJA-UHFFFAOYSA-L nickel dichloride Chemical compound Cl[Ni]Cl QMMRZOWCJAIUJA-UHFFFAOYSA-L 0.000 claims abstract description 9
- 239000002608 ionic liquid Substances 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 32
- 238000005323 electroforming Methods 0.000 claims description 27
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 claims description 8
- 239000011253 protective coating Substances 0.000 claims description 7
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 claims description 6
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims description 6
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 claims description 6
- LZZYPRNAOMGNLH-UHFFFAOYSA-M Cetrimonium bromide Chemical compound [Br-].CCCCCCCCCCCCCCCC[N+](C)(C)C LZZYPRNAOMGNLH-UHFFFAOYSA-M 0.000 claims description 4
- WOWHHFRSBJGXCM-UHFFFAOYSA-M cetyltrimethylammonium chloride Chemical compound [Cl-].CCCCCCCCCCCCCCCC[N+](C)(C)C WOWHHFRSBJGXCM-UHFFFAOYSA-M 0.000 claims description 4
- 229910001510 metal chloride Inorganic materials 0.000 claims description 4
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 claims description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 4
- 239000003586 protic polar solvent Substances 0.000 claims description 3
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 claims description 2
- DBMJMQXJHONAFJ-UHFFFAOYSA-M Sodium laurylsulphate Chemical compound [Na+].CCCCCCCCCCCCOS([O-])(=O)=O DBMJMQXJHONAFJ-UHFFFAOYSA-M 0.000 claims description 2
- 125000000129 anionic group Chemical group 0.000 claims description 2
- 125000002091 cationic group Chemical group 0.000 claims description 2
- -1 fluorosurfactants Chemical compound 0.000 claims description 2
- 235000019253 formic acid Nutrition 0.000 claims description 2
- 239000003880 polar aprotic solvent Substances 0.000 claims description 2
- 239000002280 amphoteric surfactant Substances 0.000 claims 1
- 229910052751 metal Inorganic materials 0.000 description 11
- 239000002184 metal Substances 0.000 description 11
- 230000003647 oxidation Effects 0.000 description 9
- 238000007254 oxidation reaction Methods 0.000 description 9
- 230000008569 process Effects 0.000 description 9
- 238000004070 electrodeposition Methods 0.000 description 8
- 239000008151 electrolyte solution Substances 0.000 description 6
- 238000000151 deposition Methods 0.000 description 5
- 230000008021 deposition Effects 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 150000001768 cations Chemical class 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000012720 thermal barrier coating Substances 0.000 description 2
- 230000004913 activation Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 150000001450 anions Chemical class 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- JOPOVCBBYLSVDA-UHFFFAOYSA-N chromium(6+) Chemical compound [Cr+6] JOPOVCBBYLSVDA-UHFFFAOYSA-N 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000008199 coating composition Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 238000005137 deposition process Methods 0.000 description 1
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000002203 pretreatment Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000011829 room temperature ionic liquid solvent Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D1/00—Electroforming
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01V—GEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
- G01V1/00—Seismology; Seismic or acoustic prospecting or detecting
- G01V1/003—Seismic data acquisition in general, e.g. survey design
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/56—Electroplating: Baths therefor from solutions of alloys
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/56—Electroplating: Baths therefor from solutions of alloys
- C25D3/562—Electroplating: Baths therefor from solutions of alloys containing more than 50% by weight of iron or nickel or cobalt
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/66—Electroplating: Baths therefor from melts
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/66—Electroplating: Baths therefor from melts
- C25D3/665—Electroplating: Baths therefor from melts from ionic liquids
-
- 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
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
- G01S19/00—Satellite radio beacon positioning systems; Determining position, velocity or attitude using signals transmitted by such systems
- G01S19/01—Satellite radio beacon positioning systems transmitting time-stamped messages, e.g. GPS [Global Positioning System], GLONASS [Global Orbiting Navigation Satellite System] or GALILEO
- G01S19/13—Receivers
- G01S19/14—Receivers specially adapted for specific applications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/58—Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.5% by weight of manganese
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/10—Metals, alloys or intermetallic compounds
- F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
- F05D2300/132—Chromium
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/10—Metals, alloys or intermetallic compounds
- F05D2300/17—Alloys
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01V—GEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
- G01V1/00—Seismology; Seismic or acoustic prospecting or detecting
- G01V1/24—Recording seismic data
- G01V1/26—Reference-signal-transmitting devices, e.g. indicating moment of firing of shot
Definitions
- the present disclosure relates to an electroformed nickel-chromium (Ni—Cr) alloy suitable for making a turbine component intended to operate in hostile environments.
- the present disclosure also relates to processes for the production of a thick electroformed Ni—Cr alloy component.
- High and low pressure turbine components including rotor blades, vanes, and stators are generally made of nickel based alloys to stand hostile environments including high temperature. Electroformed Ni has been used in non-high temperature applications. Nickel has excellent high temperature creep resistance, but poor oxidation resistance. Thus, the addition of chromia or alumina formers to increase the oxidation resistance of the nickel based alloys is desirable, particularly for high temperature environment such gas turbine engines.
- Electroforming is a metal forming process that builds up metal components through electrodeposition.
- the part or component is produced by depositing a metal skin onto a base form, known as a mandrel which is removed after the electrodeposition is done.
- Electroforming differs from electroplating in that the deposit (e.g., Ni—Cr alloy) is much thicker and can exist as a self-supporting structure when the mandrel is removed.
- Electroformed Ni—Cr alloys can provide a cost-effective technique to fabricate high temperature-resistant structures with complex geometries, tighter tolerance, and oxidation resistance.
- electrodeposition in the conventional plating chemistry has not been successful in forming Ni—Cr alloys with high chromium content (>8% wt., 20% wt. preferred) that is substantially thicker than 10 ⁇ m.
- Ni—Cr alloys thicker than at least 10 ⁇ m it is desirable is to electroform Ni—Cr alloys thicker than at least 10 ⁇ m to make high temperature and oxidation-resistant turbine engine parts having complex geometries and requiring tighter tolerance. Further desirable considerations include the cost effectiveness and environmental impact of the deposition process.
- an electroformed nickel-chromium (Ni—Cr) alloy suitable for making turbine engine components is disclosed.
- the electroformed Ni—Cr alloy comprises from 2 to 50 wt % chromium balanced by nickel, wherein the electroformed Ni—Cr alloy is thicker than 10 ⁇ m.
- the addition of chromium increases the oxidation resistance of the nickel based alloys.
- an article comprising a Ni—Cr alloy including from 2 to 50 wt % chromium balanced by nickel.
- the article includes a turbine component, and the Ni—Cr alloy is thicker than 125 ⁇ m to make a self-supporting turbine component.
- a method for electroforming a thick nickel-chromium (Ni—Cr) alloy that is suitable for making turbine components.
- the method includes providing a plating bath containing a solvent, a surfactant, and an ionic liquid including choline chloride, nickel chloride, and chromium chloride, wherein a molar ratio of the choline chloride and chromium chloride ranges from 0.5 to 3.5, and the solvent comprises from 5 to 80 vol. % relative to a mixture of the choline chloride and metal chlorides including the nickel and chromium chlorides.
- the method further includes electroforming the Ni—Cr alloy on a mandrel, i.e.
- the method further comprises applying a protective coating on the Ni—Cr alloy to impart oxidation resistance to the turbine component.
- the method further includes electroforming a Ni—Cr alloy on a metallic mandrel cathode while using an anode that is either insoluble or soluble such as nickel under electrolytic conditions.
- anode that is either insoluble or soluble such as nickel under electrolytic conditions.
- the insoluble anode is used to promote the oxidation of water to produce oxygen as the main by-product while other minor products can be produced concurrently as well.
- the soluble nickel anode is used to replenish the nickel deposited onto the cathode.
- FIG. 1 illustrates a plating bath filled with an electrolytic solution for electroforming a Ni—Cr alloy according to an embodiment of the present disclosure.
- FIG. 2 illustrates an article comprising an electroformed Ni—Cr alloy according an embodiment of the present disclosure.
- FIG. 3 is a flow chart of an electroforming Ni—Cr alloy process of the present disclosure.
- Electroforming is a metal forming process that forms self-supporting metal parts or components through electrodeposition. Electroforming a Ni—Cr alloy is a cost-effective and environmentally friendly method to make some high temperature-resistant turbine engine components with complex geometries and tighter tolerance.
- an electroformed nickel-chromium (Ni—Cr) alloy for use as a turbine component is disclosed.
- the Ni—Cr alloy comprises from 2 to 50 wt % chromium and the balance nickel, and can be made thicker than at least 10 ⁇ m to form self-supporting turbine components.
- the Figure illustrates a plating bath containing an electrolyte solution for electroforming a Ni—Cr alloy according to an aspect of the present invention.
- FIG. 1 illustrates a plating bath filled with an electrolytic solution for electroforming a Ni—Cr alloy according to an embodiment of the present disclosure
- a plating bath 102 containing an electrolytic solution that consists of a room temperature ionic liquid, namely deep eutectic solvent, including choline chloride, nickel chloride, chromium chloride, solvents, and surfactants like anionic, cationic, or Zwitterionic (amphoteric) surfactants.
- the surfactant can be one of sodium dodecyl sulfate, fluorosurfactants, cetyl trimethylammonium bromide (CTAB), or cetyl trimethylammonium chloride (CTAC).
- choline chloride based metal processing is low-cost and environmentally friendly.
- a molar ratio of the choline chloride and chromium chloride ranges from 0.5 to 3.5.
- a turbine component is produced by depositing a metal onto a base form, known as a mandrel 104 which is removed after electroforming is done.
- polar aprotic and polar protic solvents are used to adjust the viscosity and conductivity of the plating bath 102 to attain high quality Ni—Cr alloy deposits.
- protic solvents are preferred due to their ability to donate hydrogen bonds.
- the solvents include formic acid, citric acid, Isopropanol (IPA), water, acetic acid, and ethylene glycol.
- preferred solvent content is from 10 to 80 vol % relative to the mixture of choline chloride and metal chlorides including the nickel and chromium chlorides on a pre-mixing basis.
- electroforming the Ni—Cr alloy begins by providing an external supply of current to an anode and a cathode.
- the mandrel is the cathode.
- the current can be a direct current (DC) or an alternating current (AC) including a pulse or pulse reverse current (not shown).
- the regime and/or magnitude of the current can be controlled during the deposition to achieve desired coating composition, density, and morphology.
- the metal at the soluble anode is oxidized from the zero valence state to form cations with a positive charge.
- Metal cations generally in complex forms in the presence of anions in the solution, are reduced at the cathode to deposit in the metallic, zero valence state. The result is the effective reduction and transfer of Ni and Cr ionic species from the electrolytic solution to the mandrel 104 .
- the mandrel 104 is removed after the electroforming is done.
- the turbine component to be made is electroformed on the mandrel 104 which is a cathode during electrodeposition.
- the anode is made of the metal to be plated on the mandrel, and includes a Ni—Cr alloy anode, a Ni and/or Cr anode, or any combination of these materials can be chosen to satisfy different requirements.
- An insoluble catalytic anode (catalyzing oxygen evolution, hexavalent chromium formation) is preferable, but the anode used is not specifically limited.
- a combination of soluble Ni anode and an insoluble catalytic anode can be used to control bath composition during the course of electrodeposition as well.
- the mandrel is pre-treated prior to electrodeposition.
- the pre-treatment includes degreasing, cleaning the surface, and activation before being placed in the plating bath for electrodeposition.
- the mandrel 104 can be moved in either a rotating or reciprocating mode or the electrolytic solution can be agitated during the electroforming process.
- the electroforming process inevitably decomposes water in the bath 102 , and thus the solution in the bath is replenished to maintain consistent deposition quality.
- FIG. 2 illustrates an article comprising an electroformed Ni—Cr alloy according an embodiment of the present disclosure. Feasibility of thick electroformed Ni—Cr alloys has been demonstrated by electroforming a Ni—Cr alloy which is thicker than 125 ⁇ m to make turbine components.
- an article 200 comprises an electroformed Ni—Cr alloy 202 that includes from 2 to 50 wt % chromium balanced by nickel, and is thicker than at least 10 ⁇ m which was not attainable through the conventional methods.
- an electroformed Ni—Cr alloy 202 comprises from 8 to 20 wt % chromium balanced by nickel.
- the Ni—Cr alloy is thicker than 125 ⁇ m to make a self-supporting turbine component.
- a protective coating 206 can be applied on a surface 204 of the Ni—Cr alloy 202 to impart further oxidation resistance to the article 200 .
- the protective coating 206 may include aluminum and a bond coat and other thermal barrier coatings. Heat treatment may be performance on the structure.
- FIG. 3 is a flow chart of an electroformed Ni—Cr process of the present disclosure.
- forming a thick electroformed Ni—Cr alloy to make turbine parts begins at step 300 where a part to be made or a mandrel is pre-treated prior to electroforming a Ni—Cr alloy to remove foreign materials on the surface of the part of mandrel.
- a plating bath filled with a solution including a solvent, a surfactant, and an ionic liquid is provided.
- the Ni—Cr alloy is electroformed on the part or mandrel by providing an external supply of current to an anode and a cathode.
- the mandrel can be moved in a rotating or reciprocating mode during the electroforming process to increase the deposition rate.
- the electroforming step 304 is done when the Ni—Cr alloy reaches the desired thickness.
- a protective coating 206 may be applied at step 306 .
- the protective coating 206 may include a bond coat or a thermal barrier coating.
- the protective coating 206 may be applied to a surface 204 of the electroformed Ni—Cr alloy 202 at step 306 to impart oxidation resistance to the Ni—Cr alloy 202 .
- the disclosed choline chloride based electroforming is a metal forming process that is cost-effective to make high temperature-resistant turbine parts with complex geometries and tighter tolerance, and is environmentally friendly.
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Abstract
Description
- This application claims priority to U.S. Provisional Application No. 61/914,548 filed on Dec. 11, 2013 and titled Electroformed Nickel-Chromium Alloy, the disclosure of which is hereby incorporated by reference in its entirety.
- The present disclosure relates to an electroformed nickel-chromium (Ni—Cr) alloy suitable for making a turbine component intended to operate in hostile environments. The present disclosure also relates to processes for the production of a thick electroformed Ni—Cr alloy component.
- High and low pressure turbine components including rotor blades, vanes, and stators are generally made of nickel based alloys to stand hostile environments including high temperature. Electroformed Ni has been used in non-high temperature applications. Nickel has excellent high temperature creep resistance, but poor oxidation resistance. Thus, the addition of chromia or alumina formers to increase the oxidation resistance of the nickel based alloys is desirable, particularly for high temperature environment such gas turbine engines.
- Electroforming is a metal forming process that builds up metal components through electrodeposition. The part or component is produced by depositing a metal skin onto a base form, known as a mandrel which is removed after the electrodeposition is done. Electroforming differs from electroplating in that the deposit (e.g., Ni—Cr alloy) is much thicker and can exist as a self-supporting structure when the mandrel is removed.
- Electroformed Ni—Cr alloys can provide a cost-effective technique to fabricate high temperature-resistant structures with complex geometries, tighter tolerance, and oxidation resistance. Typically, electrodeposition in the conventional plating chemistry has not been successful in forming Ni—Cr alloys with high chromium content (>8% wt., 20% wt. preferred) that is substantially thicker than 10 μm.
- Accordingly, it is desirable is to electroform Ni—Cr alloys thicker than at least 10 μm to make high temperature and oxidation-resistant turbine engine parts having complex geometries and requiring tighter tolerance. Further desirable considerations include the cost effectiveness and environmental impact of the deposition process.
- According to an aspect of the present disclosure, an electroformed nickel-chromium (Ni—Cr) alloy suitable for making turbine engine components is disclosed. The electroformed Ni—Cr alloy comprises from 2 to 50 wt % chromium balanced by nickel, wherein the electroformed Ni—Cr alloy is thicker than 10 μm. The addition of chromium increases the oxidation resistance of the nickel based alloys.
- According to an aspect of the present disclosure, an article comprising a Ni—Cr alloy including from 2 to 50 wt % chromium balanced by nickel is disclosed. The article includes a turbine component, and the Ni—Cr alloy is thicker than 125 μm to make a self-supporting turbine component.
- According to another aspect of the present disclosure, a method for electroforming a thick nickel-chromium (Ni—Cr) alloy that is suitable for making turbine components is disclosed. The method includes providing a plating bath containing a solvent, a surfactant, and an ionic liquid including choline chloride, nickel chloride, and chromium chloride, wherein a molar ratio of the choline chloride and chromium chloride ranges from 0.5 to 3.5, and the solvent comprises from 5 to 80 vol. % relative to a mixture of the choline chloride and metal chlorides including the nickel and chromium chlorides. The method further includes electroforming the Ni—Cr alloy on a mandrel, i.e. cathode by providing an external supply of current to an anode and the cathode, wherein the mandrel is removed after the Ni—Cr alloy is electroformed. Optionally, the method further comprises applying a protective coating on the Ni—Cr alloy to impart oxidation resistance to the turbine component.
- The method further includes electroforming a Ni—Cr alloy on a metallic mandrel cathode while using an anode that is either insoluble or soluble such as nickel under electrolytic conditions. Specifically, the insoluble anode is used to promote the oxidation of water to produce oxygen as the main by-product while other minor products can be produced concurrently as well. The soluble nickel anode is used to replenish the nickel deposited onto the cathode.
- The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, that the following description and drawings are intended to be exemplary in nature and non-limiting.
- The details of one or more embodiments of the present disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the present disclosure will be apparent from the description and drawings, and from the claims.
-
FIG. 1 illustrates a plating bath filled with an electrolytic solution for electroforming a Ni—Cr alloy according to an embodiment of the present disclosure. -
FIG. 2 illustrates an article comprising an electroformed Ni—Cr alloy according an embodiment of the present disclosure. -
FIG. 3 is a flow chart of an electroforming Ni—Cr alloy process of the present disclosure. - The drawing(s) depict various preferred embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein.
- Electroforming is a metal forming process that forms self-supporting metal parts or components through electrodeposition. Electroforming a Ni—Cr alloy is a cost-effective and environmentally friendly method to make some high temperature-resistant turbine engine components with complex geometries and tighter tolerance.
- According to an aspect of the present disclosure, an electroformed nickel-chromium (Ni—Cr) alloy for use as a turbine component is disclosed. The Ni—Cr alloy comprises from 2 to 50 wt % chromium and the balance nickel, and can be made thicker than at least 10 μm to form self-supporting turbine components. The Figure illustrates a plating bath containing an electrolyte solution for electroforming a Ni—Cr alloy according to an aspect of the present invention.
-
FIG. 1 illustrates a plating bath filled with an electrolytic solution for electroforming a Ni—Cr alloy according to an embodiment of the present disclosure Referring now toFIG. 1 , there is provided aplating bath 102 containing an electrolytic solution that consists of a room temperature ionic liquid, namely deep eutectic solvent, including choline chloride, nickel chloride, chromium chloride, solvents, and surfactants like anionic, cationic, or Zwitterionic (amphoteric) surfactants. The surfactant can be one of sodium dodecyl sulfate, fluorosurfactants, cetyl trimethylammonium bromide (CTAB), or cetyl trimethylammonium chloride (CTAC). It is noted that the choline chloride based metal processing is low-cost and environmentally friendly. In one embodiment, a molar ratio of the choline chloride and chromium chloride ranges from 0.5 to 3.5. A turbine component is produced by depositing a metal onto a base form, known as amandrel 104 which is removed after electroforming is done. - In the embodiment, polar aprotic and polar protic solvents are used to adjust the viscosity and conductivity of the plating
bath 102 to attain high quality Ni—Cr alloy deposits. Specifically, protic solvents are preferred due to their ability to donate hydrogen bonds. The solvents include formic acid, citric acid, Isopropanol (IPA), water, acetic acid, and ethylene glycol. - According to one embodiment, preferred solvent content is from 10 to 80 vol % relative to the mixture of choline chloride and metal chlorides including the nickel and chromium chlorides on a pre-mixing basis. Referring to
FIG. 1 , electroforming the Ni—Cr alloy begins by providing an external supply of current to an anode and a cathode. The mandrel is the cathode. The current can be a direct current (DC) or an alternating current (AC) including a pulse or pulse reverse current (not shown). The regime and/or magnitude of the current can be controlled during the deposition to achieve desired coating composition, density, and morphology. - When the current is supplied, the metal at the soluble anode is oxidized from the zero valence state to form cations with a positive charge. Metal cations, generally in complex forms in the presence of anions in the solution, are reduced at the cathode to deposit in the metallic, zero valence state. The result is the effective reduction and transfer of Ni and Cr ionic species from the electrolytic solution to the
mandrel 104. Themandrel 104 is removed after the electroforming is done. - The turbine component to be made is electroformed on the
mandrel 104 which is a cathode during electrodeposition. The anode is made of the metal to be plated on the mandrel, and includes a Ni—Cr alloy anode, a Ni and/or Cr anode, or any combination of these materials can be chosen to satisfy different requirements. An insoluble catalytic anode (catalyzing oxygen evolution, hexavalent chromium formation) is preferable, but the anode used is not specifically limited. A combination of soluble Ni anode and an insoluble catalytic anode can be used to control bath composition during the course of electrodeposition as well. - The mandrel is pre-treated prior to electrodeposition. The pre-treatment includes degreasing, cleaning the surface, and activation before being placed in the plating bath for electrodeposition. To enhance mass transport, the
mandrel 104 can be moved in either a rotating or reciprocating mode or the electrolytic solution can be agitated during the electroforming process. The electroforming process inevitably decomposes water in thebath 102, and thus the solution in the bath is replenished to maintain consistent deposition quality. -
FIG. 2 illustrates an article comprising an electroformed Ni—Cr alloy according an embodiment of the present disclosure. Feasibility of thick electroformed Ni—Cr alloys has been demonstrated by electroforming a Ni—Cr alloy which is thicker than 125 μm to make turbine components. In one embodiment, anarticle 200 comprises an electroformed Ni—Cr alloy 202 that includes from 2 to 50 wt % chromium balanced by nickel, and is thicker than at least 10 μm which was not attainable through the conventional methods. - In another embodiment, although not specifically limited, an electroformed Ni—
Cr alloy 202 comprises from 8 to 20 wt % chromium balanced by nickel. In the embodiment, the Ni—Cr alloy is thicker than 125 μm to make a self-supporting turbine component. Optionally, aprotective coating 206 can be applied on asurface 204 of the Ni—Cr alloy 202 to impart further oxidation resistance to thearticle 200. Theprotective coating 206 may include aluminum and a bond coat and other thermal barrier coatings. Heat treatment may be performance on the structure. -
FIG. 3 is a flow chart of an electroformed Ni—Cr process of the present disclosure. Referring now toFIG. 3 , forming a thick electroformed Ni—Cr alloy to make turbine parts begins atstep 300 where a part to be made or a mandrel is pre-treated prior to electroforming a Ni—Cr alloy to remove foreign materials on the surface of the part of mandrel. Atstep 302, a plating bath filled with a solution including a solvent, a surfactant, and an ionic liquid is provided. Atstep 304, the Ni—Cr alloy is electroformed on the part or mandrel by providing an external supply of current to an anode and a cathode. The mandrel can be moved in a rotating or reciprocating mode during the electroforming process to increase the deposition rate. Theelectroforming step 304 is done when the Ni—Cr alloy reaches the desired thickness. - After the electroforming is done at
step 304, optionally, aprotective coating 206 may be applied atstep 306. In one embodiment, theprotective coating 206 may include a bond coat or a thermal barrier coating. Theprotective coating 206 may be applied to asurface 204 of the electroformed Ni—Cr alloy 202 atstep 306 to impart oxidation resistance to the Ni—Cr alloy 202. The disclosed choline chloride based electroforming is a metal forming process that is cost-effective to make high temperature-resistant turbine parts with complex geometries and tighter tolerance, and is environmentally friendly. - It is to be understood that the disclosure of the present invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the disclosure, and which are susceptible to modification of form, size, arrangement of parts, and details of operation. The disclosure is intended to encompass all such modifications which are within its spirit and scope of the invention as defined by the following claims.
Claims (20)
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US15/103,777 US10378118B2 (en) | 2013-12-11 | 2014-12-03 | Electroformed nickel-chromium alloy |
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US201361914548P | 2013-12-11 | 2013-12-11 | |
PCT/US2014/068447 WO2015088861A1 (en) | 2013-12-11 | 2014-12-03 | Electroformed nickel-chromium alloy |
US14/559,768 US20150153466A1 (en) | 2013-12-04 | 2014-12-03 | Source Start Time Determination |
US15/103,777 US10378118B2 (en) | 2013-12-11 | 2014-12-03 | Electroformed nickel-chromium alloy |
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US20190368061A1 (en) | 2019-12-05 |
US20160320502A1 (en) | 2016-11-03 |
WO2015088861A1 (en) | 2015-06-18 |
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US11732372B2 (en) | 2023-08-22 |
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US10378118B2 (en) | 2019-08-13 |
EP3080323B1 (en) | 2019-05-15 |
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