US3698962A - Method for producing superalloy articles by hot isostatic pressing - Google Patents

Method for producing superalloy articles by hot isostatic pressing Download PDF

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Publication number
US3698962A
US3698962A US139126A US3698962DA US3698962A US 3698962 A US3698962 A US 3698962A US 139126 A US139126 A US 139126A US 3698962D A US3698962D A US 3698962DA US 3698962 A US3698962 A US 3698962A
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temperature
compacting
powder
gamma prime
heated
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August Kasak
Vernon R Thompson
John H Moll
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Crucible Materials Corp
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Crucible Inc
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Assigned to COLT INDUSTRIES OPERATING CORP. reassignment COLT INDUSTRIES OPERATING CORP. MERGER AND CHANGE OF NAME Assignors: CRUCIBLE CENTER COMPANY (INTO) CRUCIBLE INC. (CHANGED TO)
Assigned to CRUCIBLE MATERIALS CORPORATION reassignment CRUCIBLE MATERIALS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: COLT INDUSTRIES OPERATING CORP.
Assigned to MELLON BANK, N.A. AS AGENT FOR MELLON BANK N.A. & MELLON FINANCIAL SERVICES CORPORATION, MELLON FINANCIAL SERVICES CORPORATION reassignment MELLON BANK, N.A. AS AGENT FOR MELLON BANK N.A. & MELLON FINANCIAL SERVICES CORPORATION SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). 2ND Assignors: CRUCIBLE MATERIALS CORPORATION, A CORP. OF DE.
Assigned to MELLON BANK, N.A. FOR THE CHASE MANHATTAN BANK (NATIONAL ASSOCIATION) AND MELLON BANK N.A., CHASE MANHATTAN BANK, THE (NATIONAL ASSOCIATION) AS AGENT reassignment MELLON BANK, N.A. FOR THE CHASE MANHATTAN BANK (NATIONAL ASSOCIATION) AND MELLON BANK N.A. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). 1ST Assignors: CRUCIBLE MATERIALS CORPORATION, A CORP. OF DE.
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/16—Both compacting and sintering in successive or repeated steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • B22F3/15—Hot isostatic pressing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10—Changing 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

Definitions

  • articles after compacting may be subjected to alternate heat-treating practices wherein either high yield strengths, or high creep and creep-rupture strengths may be achieved in the final articles.
  • superalloy powder'of a size not'exceeding about'ininus 30 mesh is used.
  • the powder has a characteristic dispersion of gamma prime particles, and in addition the powder has an average grain diameter not exceeding 20 microns maximum.
  • the grain size is dependent upon the solidification rate of the powder during the powder-making operation, which generally involves atomizing a quantity of molten metal and thereafter solidifying the resulting molten metal droplets to form the powder. The more rapid the cooling rate the finer will be the grain size of the powder. Consequently, since smaller-size powder solidifies at a more rapid rate than larger-size powder, grain size of the powder will be a function of powder size.
  • the practice of the invention is preferably limited to minus 30 mesh maximum powder. This powder-size limitation, in turn, limits the average grain diameter to 20 microns maximum by typical powder-making practice.
  • the dispersion of gamma prime particles, or the gamma prime phase constitutes a characteristic intermetallic dispersion in the base-metal matrix of the superalloy.
  • the microstructure of nickel-base superalloys, as well as some cobalt-base superalloys includes (1) a continuous, solid-solution base-metal matrix (gamma phase); (2) gamma prime particles; and (3) carbides.
  • the gamma prime particles constitute a face-centered cubic intermetallic compound with a typical, generic formula of Ni Al.
  • the gamma prime particles of this character comprise a uniquely effective strengthening agent particularly in nickel-base and nickel-rich alloys by a precipitation hardening mechanism and are distributed throughout the base-metal matrix.
  • Powder of this character is placed in a container and treated to remove air from the container interior and surface impurities, such as oxides, by conventional outgassing techniques, which includes heating to a relatively low temperature on the order of 500 F. and pumping out the container interior to remove the air and any gaseous reaction products therefrom. Thereafter the particles are heated in a protective atmosphere, which may be either an inert gas or a vacuum, to a temperature at or above a selected compacting temperature. It is critical, however, that the particles not be heated above a maximum temperature constituting the gamma prime solvus temperature of the superalloy.
  • the gamma prime solvus temperature is the minimum temperature at which the gamma prime phase is essentially completely dissolved in the matrix of the alloy by heating for not longer than one minute.
  • the gamma prime solvus temperature will vary from alloy to alloy composition, specific examples of which for selected alloy compositions are given hereafter.
  • the minimum compacting temperature will vary from alloy to alloy composition, but is not lower than about 400 F. below the gamma prime solvus temperature for any said alloy composition.
  • the compacting be effected isostatically as by the use of a fluid pressure vessel.
  • the powder will be placed in a container wherein it is outgassed, evacuated, sealed against the atmosphere, heated and then compacted in the autoclave.
  • hot working is facilitated if the temperature at which hot working is conducted does not exceed the gamma prime solvus temperature.
  • any subsequent heating should not be at a temperature exceeding the gamma prime solvus temperature.
  • these values may be improved by heating the article at a temperature above the gamma prime solvus temperature.
  • the above alloys were provided in powder form having a size of minus 30 mesh and were placed in hollow cylinder containers which were evacuated and sealed against the atmosphere.
  • the containers were subjected to heating at various compacting temperatures and compacting pressures. After compacting, the compact specimens were subjected to the following heat treatments.
  • the Waspaloy material was heated to a temperature of 1875 F. for four hours, and thereafter air cooled; heated to 1550 F. for 24 hours and thereafter air cooled; and finally heated to 1400" F. for 16 hours and then thereafter air cooled.
  • the Astroloy compact was heated to a temperature on the order of 2025 to 2075 F. for four hours and thereafter air 4 cooled; heated to 1600 F. for eight hours and thereafter air cooled; heated to 1800 F. for four hours and thereafter air cooled; heated to 1200 F. for 24 hours and thereafter air cooled; and heated to 1400 F. for eight hours and thereafter air cooled.
  • the IN100 compact was given no heat treatment.
  • the grain size of the powders used was initially very fine and on the order of about 3 microns diameter.
  • the Waspaloy material has an inherently lower strength or resistance to deformation at high temperature than does the IN100 material. Specifically, the 0.2% offset yield strength at 1800 F. for Waspaloy is 20,000 p.s.i. and for IN-lOO is 54,000 p.s.i. However, when these materials in the powdered form as described above were heated to a temperature of 2000 F. and compacted using an autoclave operated at a fluid pressure of 15,000 p.s.i., the IN-lOO compact achieved an essentially full density (99% of theoretical density); whereas, the Waspaloy compact exhibited appreciable porosity and a density of less than about 97%.
  • the gamma prime particles when undissolved, act as grain growth inhibitors and consequently so long as heating is not effected at a temperature level wherein the gamma prime particles are dissolved the initially fine grain diameter is preserved.
  • the grain diameter should not exceed about 20 microns maximum, and preferably 10 microns maximum.
  • Table II presents mechanical property data for IN-lOO compacts that had been isostatically compacted at the temperatures listed in the table.
  • the gamma prime solvus temperature for IN-100 is about 2225 F. It may be seen from high temperature tension test results given in Table II that as compacting temperature was increased to about the gamma prime solvus temperature the alloys resistance to deformation, which is represented by the yield and tensile strength values, was increased and the alloys ductility, as represented by the percent elongation and reduction in area values, was decreased. Particularly remarkable ductility was obtained when the material that had been compacted at 2000 F. was tension tested at 1950 F.; elongation of 518% and reduction of area of 98% were measured.
  • Table V shows for Astroloy that if compacts of Astro- 10y are heated at temperatures above the gamma prime solvus temperature of 2050 F. for the alloy, the creeprupture strength increases significantly, particularly when the compact is heated to a temperature of 2275 F.
  • a method for producing powder metal articles from superalloy powder having therein a dispersion of gamma prime particles and an average grain diameter of 20 micron maximum comprising heating a charge of said powder to a temperature of at least a selected compacting temperature but below the gamma prime solvus temperature of said superalloy powder and isostatically compacting said charge to a density of at least by the application of fluid pressure prior to said charge cooling to a temperature below said selected compacting temperature.
  • a method for producing powder metal articles from superalloy powder having therein a dispersion of gamma prime particles and an average grain diameter of 20 micron maximum and an average powder size of minus 30 mesh maximum comprising placing a charge of said powder in a container, evacuating said container, introducing an inert gas to said container, heating said charge to a temperature not lower than 400 F. below the gamma prime solvus temperature of said superalloy powder, but below said gamma prime solvus temperature, introducing said heated, powder-filled container to a fluid pressure vessel for compacting and compacting said powder charge to a density of at least 95% by increasing the fluid pressure within said vessel to a level within the range of 1,000 to 50,000 p.s.i.
  • Kelso T. D. The Advent of Superplastic Superalloys, Manufacturing Engineering and Management; vol. 64, No. 5, May 1970, pp. 55 and 56.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
US139126A 1971-04-30 1971-04-30 Method for producing superalloy articles by hot isostatic pressing Expired - Lifetime US3698962A (en)

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US (1) US3698962A (fi)
JP (1) JPS5113443B1 (fi)
AT (1) AT318932B (fi)
CA (1) CA962415A (fi)
DE (1) DE2200670A1 (fi)
FR (1) FR2134345B1 (fi)
GB (1) GB1332876A (fi)
IT (1) IT948246B (fi)
SE (1) SE388553C (fi)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3893852A (en) * 1972-06-12 1975-07-08 Asea Ab Method of manufacturing billets from powder
US3940268A (en) * 1973-04-12 1976-02-24 Crucible Inc. Method for producing rotor discs
US3966422A (en) * 1974-05-17 1976-06-29 Cabot Corporation Powder metallurgically produced alloy sheet
US3973952A (en) * 1973-06-11 1976-08-10 The International Nickel Company, Inc. Heat resistant alloy casting
US4081295A (en) * 1977-06-02 1978-03-28 United Technologies Corporation Fabricating process for high strength, low ductility nickel base alloys
US4104061A (en) * 1976-10-21 1978-08-01 Kaiser Aluminum & Chemical Corporation Powder metallurgy
EP0069421A1 (de) * 1981-06-26 1983-01-12 BBC Aktiengesellschaft Brown, Boveri & Cie. Verfahren zur Herstellung eines Halbzeugs oder eines Fertigteils aus einem metallischen Werkstoff durch Warm-Formgebung
US5009704A (en) * 1989-06-28 1991-04-23 Allied-Signal Inc. Processing nickel-base superalloy powders for improved thermomechanical working
EP0676483A1 (en) * 1994-04-06 1995-10-11 Special Metals Corporation High strain rate deformation of nickel-base superalloy compact

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4063939A (en) * 1975-06-27 1977-12-20 Special Metals Corporation Composite turbine wheel and process for making same
CH599348A5 (fi) * 1975-10-20 1978-05-31 Bbc Brown Boveri & Cie
DE3162167D1 (en) * 1980-08-07 1984-03-15 Bbc Brown Boveri & Cie Method of manufacturing a copper-based memory alloy
EP0074679B1 (de) * 1981-09-03 1985-03-20 BBC Aktiengesellschaft Brown, Boveri & Cie. Verfahren zur Herstellung eines Werkstückes aus einer warmfesten Legierung
EP0203197B1 (en) * 1984-10-26 1991-03-06 Japan as represented by Director-General, Agency of Industrial Science and Technology Process for producing super-heat-resistant alloy material

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3893852A (en) * 1972-06-12 1975-07-08 Asea Ab Method of manufacturing billets from powder
US3940268A (en) * 1973-04-12 1976-02-24 Crucible Inc. Method for producing rotor discs
US3973952A (en) * 1973-06-11 1976-08-10 The International Nickel Company, Inc. Heat resistant alloy casting
US3966422A (en) * 1974-05-17 1976-06-29 Cabot Corporation Powder metallurgically produced alloy sheet
US4104061A (en) * 1976-10-21 1978-08-01 Kaiser Aluminum & Chemical Corporation Powder metallurgy
US4081295A (en) * 1977-06-02 1978-03-28 United Technologies Corporation Fabricating process for high strength, low ductility nickel base alloys
EP0069421A1 (de) * 1981-06-26 1983-01-12 BBC Aktiengesellschaft Brown, Boveri & Cie. Verfahren zur Herstellung eines Halbzeugs oder eines Fertigteils aus einem metallischen Werkstoff durch Warm-Formgebung
US5009704A (en) * 1989-06-28 1991-04-23 Allied-Signal Inc. Processing nickel-base superalloy powders for improved thermomechanical working
EP0676483A1 (en) * 1994-04-06 1995-10-11 Special Metals Corporation High strain rate deformation of nickel-base superalloy compact

Also Published As

Publication number Publication date
CA962415A (en) 1975-02-11
FR2134345B1 (fi) 1974-06-28
IT948246B (it) 1973-05-30
DE2200670B2 (fi) 1975-02-13
SE388553B (sv) 1976-10-11
AT318932B (de) 1974-11-25
GB1332876A (en) 1973-10-10
FR2134345A1 (fi) 1972-12-08
SE388553C (sv) 1985-04-29
JPS5113443B1 (fi) 1976-04-28
DE2200670A1 (de) 1972-11-16

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