WO2010111200A1 - Superalliage à base de nickel superrésistant à l'oxydation et à un endommagement cyclique et articles formés à partir de celui-ci - Google Patents

Superalliage à base de nickel superrésistant à l'oxydation et à un endommagement cyclique et articles formés à partir de celui-ci Download PDF

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Publication number
WO2010111200A1
WO2010111200A1 PCT/US2010/028202 US2010028202W WO2010111200A1 WO 2010111200 A1 WO2010111200 A1 WO 2010111200A1 US 2010028202 W US2010028202 W US 2010028202W WO 2010111200 A1 WO2010111200 A1 WO 2010111200A1
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WO
WIPO (PCT)
Prior art keywords
composition
rhenium
tungsten
optionally
chromium
Prior art date
Application number
PCT/US2010/028202
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English (en)
Inventor
Kevin Swayne Ohara
Laura Jill Carroll
Original Assignee
General Electric Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Company filed Critical General Electric Company
Priority to EP10710968A priority Critical patent/EP2411552A1/fr
Priority to JP2012502151A priority patent/JP2012521497A/ja
Priority to CA2755018A priority patent/CA2755018A1/fr
Publication of WO2010111200A1 publication Critical patent/WO2010111200A1/fr

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Classifications

    • 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%
    • 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
    • F01D5/288Protective coatings for blades
    • 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
    • F05D2260/00Function
    • F05D2260/95Preventing corrosion

Definitions

  • This invention relates generally to compositions of matter suitable for use in aggressive, high-temperature gas turbine environments, and articles made therefrom.
  • Nickel-base single crystal superalloys are used extensively throughout the aeroengine in turbine blade, nozzle, and shroud applications. Aeroengine designs for improved engine performance demand alloys with increasingly higher temperature capability, primarily in the form of improved creep strength (creep resistance). Alloys with increased amounts of solid solution strengthening elements (e.g., Ta, W, Re, and Mo) for improved creep resistance generally exhibit decreased phase stability, increased density, and lower environmental resistance. Recently, thermal-mechanical fatigue (TMF) resistance has been a limiting design criterion for turbine components. Temperature gradients create cyclic thermally induced strains that promote damage by a complex combination of creep, fatigue, and oxidation. Directionally solidified superalloys have not historically been developed for cyclic damage resistance. However, increased cyclic damage resistance is desired for improved engine efficiency.
  • solid solution strengthening elements e.g., Ta, W, Re, and Mo
  • Single crystal (SX) superalloys may be classified into four generations based on similarities in alloy compositions and high temperature mechanical properties. So-called first generation single crystal superalloys contain no rhenium. Second generation superalloys typically contain about three weight percent rhenium. Third generation superalloys are designed to increase the temperature capability and creep resistance by raising the refractory metal content and lowering the chromium level. Exemplary alloys have rhenium levels of about 5.5 weight percent and chromium levels in the 2-4 weight percent range. A commercially available fourth generation alloy includes increased levels of rhenium and other refractory metals. Second generation alloys are not exceptionally strong, although they have relatively stable microstructures.
  • Oxidation resistance is achieved in second generation alloys with yttrium additions or low sulfur content.
  • Third and fourth generation alloys have improved creep resistance due to high levels of refractory metals in the alloy.
  • high levels of tungsten, rhenium, and ruthenium are used for strengthening these alloys.
  • These refractory metals have densities much higher than that of the nickel base.
  • fourth generation alloys may be about 6% heavier than second generation alloys.
  • the increased weight of these alloys limits their use to only specialized applications.
  • Third and fourth generation alloys are also limited by microstructural instabilities which can impact long-term mechanical properties.
  • third generation superalloys provide a 5O 0 F (about 28 °C) improvement in creep capability relative to second generation superalloys.
  • Fourth and fifth generation superalloys offer a further improvement in creep strength achieved by high levels of solid solutioning elements (e.g., rhenium, tungsten, tantalum, molybdenum) and the addition of ruthenium.
  • solid solutioning elements e.g., rhenium, tungsten, tantalum, molybdenum
  • ruthenium As the creep capability of directionally solidified superalloys has improved with generation, the continuous-cycle fatigue resistance, as well as the hold-time cyclic damage resistance, have also improved. These improvements in rupture and fatigue strength have been accompanied by an increase in alloy density.
  • exemplary embodiments which provide a composition of matter consisting essentially of, in weight percent, from about 6.8 to about 7.5% aluminum, from about 4 to about 8% tantalum, from about 4 to about 10% chromium, from about 2 to about 7% tungsten, from 0 to about 6% rhenium, from 0 to about 5% cobalt, from 0 to about 0.2% silicon, optionally, from about 0.15 to about 0.7% hafnium, from 0 to about 0.5% titanium, from 0 to about 4% molybdenum, from 0 to about 0.005% boron, from 0 to about 0.06% carbon, from 0 to about 0.03% of a rare earth addition selected from the group consisting of yttrium, lanthanum, cesium, and combinations thereof, balance nickel and incidental impurities.
  • a rare earth addition selected from the group consisting of yttrium, lanthanum, cesium, and combinations thereof, balance nickel and incidental impurities.
  • composition of matter consisting essentially of, in weight percent, from about 6.8 to about 7.5% aluminum, from about 4 to about 8% tantalum, from about 4 to about 10% chromium, from about 2 to about 7% tungsten, up to about 6% rhenium, up to about 5% cobalt, up to about 0.2% silicon, from about 0.15 to about 0.7% hafnium, optionally, up to about 0.5% titanium, optionally, up to about 4% molybdenum, optionally, up to about 0.0005% boron, optionally, up to about 0.06% carbon, optionally, up to about 0.03% of a rare earth addition selected from the group consisting of yttrium, lanthanum, cesium, and combinations thereof, balance nickel and incidental impurities.
  • Exemplary embodiments disclosed herein include an article comprising a substantially single crystal having a composition consisting essentially of, in weight percent, from about 6.8 to about 7.5% aluminum, from about 4 to about 8% tantalum, from about 4 to about 10% chromium, from about 2 to about 7% tungsten, from 0 to about 6% rhenium, from 0 to about 5% cobalt, from 0 to about 0.2% silicon, optionally, from about 0.15 to about 0.7% hafnium, from 0 to about 0.5% titanium, from 0 to about 4% molybdenum, from 0 to about 0.005% boron, from 0 to about 0.06% carbon, from 0 to about 0.03% of a rare earth addition selected from the group consisting of yttrium, lanthanum, cesium, and combinations thereof, balance nickel and incidental impurities.
  • a rare earth addition selected from the group consisting of yttrium, lanthanum, cesium, and combinations thereof, balance nickel and incidental impurities
  • FIG. 1 is a perspective view of a component article such as a gas turbine blade.
  • FIG. 2 is a schematic representation of SPLCF verses Creep Rupture Life comparing alloys disclosed herein and commercially available alloys.
  • FIG. 3 is a schematic representation comparing the density of the alloys disclosed herein with commercially available alloys.
  • FIG. 1 depicts a component article 20 of a gas turbine engine, illustrated as a gas turbine blade 22.
  • the gas turbine blade 22 includes an airfoil 24, an attachment 26 in the form of a dovetail to attach the gas turbine blade 22 to a turbine disk (not shown), and a laterally extending platform 28 intermediate the airfoil 24 and the attachment 26.
  • the component article 20 is substantially a single crystal. That is, the component article 20 is at least about 80 percent by volume, and more preferably at least about 95 percent by volume, a single grain with a single crystallographic orientation. There may be minor volume fractions of other crystallographic orientations and also regions separated by low-angle boundaries.
  • the single-crystal structure is prepared by the directional solidification of an alloy composition, usually from a seed or other structure that induces the growth of the single crystal and single grain orientation.
  • exemplary alloy compositions discussed herein is not limited to the gas turbine blade 22, and it may be employed in other articles such as gas turbine nozzles, vanes, shrouds, or other components for gas turbine engines.
  • FIG. 2 schematically represents the relationship between SPLCF (cycles to failure) verses Creep Rupture Life (hrs) for exemplary superalloys known in the art.
  • an exemplary first generation superalloy is designated by the reference numeral 50
  • an exemplary second generation superalloy is designated by the reference numeral 52
  • an exemplary third generation superalloy is designated by the reference numeral 54
  • an exemplary fourth generation superalloy is designated by the reference numeral 56.
  • Certain of the disclosed alloys are designated by the reference numerals 60, 62, 64, 66, 68. As illustrated, the disclosed alloys have significantly improved resistance to cyclic damage accumulation than what may be predicted from their creep strength.
  • certain alloys disclosed herein have densities more akin to first generation alloys as shown in FIG. 3.
  • the densities of exemplary first generation superalloys, second generation superalloys, third generation superalloys, and fourth generation superalloys are compared to the densities of certain disclosed alloys.
  • Exemplary embodiments disclosed herein may exhibit densities of less than about 0.315 lb/in 3 (about 8.71 g/cm 3 ).
  • Exemplary embodiments disclosed herein may exhibit densities in the range of about 0.3 to about 0.315 lb/in 3 (about 8.3 to about 8.71 g/cm 3 ). It has been observed that density trends with creep strength (i.e., increased creep rupture strength is linked to increased density).
  • Exemplary embodiments disclosed herein have shown outstanding oxidation resistance, as determined by Mach 1 burner rig oxidation testing at 2150 °F (about 1178 °C). It is believed that the super-oxidation resistance of the disclosed alloys is a key factor in providing the uncharacteristically good SPLCF resistance. Thus, it is believed that the exemplary embodiments disclosed herein provide a unique alloying approach, that is, alloying for exceptional oxidation capability in order to provide improved SPLCF resistant alloys. An exemplary compositional series is presented in Table 1.
  • Table II provides exemplary weight percent ranges for the alloying elements. Exemplary embodiments disclosed herein include a minimum of about 6.8% aluminum. Greater amounts result in improved oxidation resistance and SLCF resistance. Certain exemplary embodiments disclosed herein include from about 6.8 to about 7.5% aluminum. Percentages disclosed herein refer to percent by weight, unless otherwise noted. All amounts provided as ranges, for each element, should be construed to include endpoints and sub-ranges. For example, an aluminum range of from about 6.8 to about 7.5% means that the exemplary embodiments may include about 6.8% aluminum, about 7.5% aluminum, any amount of aluminum between 6.8 and 7.5%, and any range of aluminum between 6.8 and 7.5%, inclusive. Other exemplary embodiments include from about 6.8 to about 7.2 wt % aluminum.
  • Exemplary embodiments disclosed herein include about 4 to 8% tantalum to promote gamma prime strength.
  • Exemplary embodiments disclosed herein include from about 4 to about 10% chromium to reduce hot corrosion resistance. It is believed that amounts greater than about 10 % lead to TCP phase instability and poor cyclic oxidation resistance. Other exemplary embodiments may include from about 4 to about 7.5 wt % chromium. Exemplary embodiments disclosed herein may include from about 6 to about 7 wt % chromium.
  • Exemplary embodiments disclosed may herein include tungsten in amounts from about 2 to about 7%. Amounts less than about 2% tungsten may decrease strength. Amounts greater than about 7% may produce alloy instability with respect to TCP phase formation and reduced oxidation capacity. Tungsten may also be used as a strengthener in place of rhenium.
  • Exemplary embodiments disclosed herein may include rhenium in the range of from 0 to about 6% for high temperature creep resistance.
  • Rhenium is a potent solid solution strengthener that partitions to the gamma phase and also is a slow diffusing element, which limits coarsening of the gamma prime.
  • Exemplary embodiments disclosed herein may include from about 0 to 5% cobalt. Greater amounts reduce the gamma prime solvus temperature and thus the high temperature strength while impairing oxidation resistance. Cobalt in this range is not expected to greatly impact the creep strength or SPLCF capability.
  • Exemplary embodiments disclosed herein may optionally include silicon additions of up to about 0.2% for improved oxidation resistance.
  • Exemplary embodiments disclosed herein may optionally include from about 0.15% to about 0.7% hafnium.
  • Hafnium improves the oxidation and hot corrosion resistance of coated alloys, but can degrade the corrosion resistance of uncoated alloys.
  • Hafnium also improves the life of thermal barrier coatings where used.
  • Experience has shown that hafnium contents on the order of 0.7% are satisfactory.
  • the hafnium content exceeds about 1%, stress rupture properties are reduced along with the incipient melting temperature.
  • Exemplary embodiments disclosed herein may optionally include up to about 0.5% titanium as a potent gamma prime hardener.
  • Exemplary embodiments disclosed herein optionally include molybdenum in amounts limited from about 0 to 4% maximum. Molybdenum may be minimally present to impart solid solution strengthening. Higher additions of molybdenum result in reduced hot corrosion resistance.
  • Exemplary embodiments disclosed herein may optionally include boron additions up to about .005%. Boron provides tolerance for low angle boundaries.
  • Exemplary embodiments disclosed herein may optionally include carbon additions up to about 0.06%.
  • a preferred range of carbon is about 0.02% to about 0.06%.
  • the lower level is set in order to improve the alloy cleanliness since carbon provides de-oxidation. Beyond the 0.06% carbon amount, the carbide volume fraction increases and fatigue life is reduced since carbides serve as the sites for fatigue nucleation.
  • Exemplary embodiments disclosed herein may include a total of approximately 6% of tungsten, rhenium, and molybdenum for solid solution strengthening. Other exemplary embodiments may increase the percentage total for these alloying elements to improve the creep strength of the alloy. For example, exemplary embodiments as disclosed herein may include a total of from about 6 to about 8 wt% of tungsten, rhenium, and molybdenum.
  • Exemplary embodiments disclosed herein may further optionally include rare earth additions of yttrium, lanthanum and cerium, singly or in combination, up to about to 0.03%. These additions may improve the oxidation resistance by making the
  • protective alumina scale more retentive. Greater amounts promote mold-metal reaction at the casting surface and increase the component inclusion content.
  • Exemplary embodiments disclosed herein may include in weight percent, from about 6.8 to about 7.2% aluminum, from about 4.5 to about 6.4% tantalum, about 7.5% chromium, about 3.85% tungsten, from about 1.6 to about 3.0% rhenium, about 3.1 % cobalt, and about 0.05% silicon, optionally up to about 4% molybdenum, where the total of tungsten, rhenium, and molybdenum is about 6 wt%.
  • thermal-mechanical fatigue resistance of nickel-base superalloys has traditionally been considered as functionally related to strength.
  • Exemplary embodiments disclosed herein demonstrate that thermal-mechanical fatigue resistance, specifically sustained- peak low cycle fatigue resistance (SPLCF), may be improved by alloying to increase oxidation resistance.
  • SPLCF sustained- peak low cycle fatigue resistance
  • the super-oxidation resistant alloys disclosed herein provide the desired thermal-mechanical fatigue resistance.
  • the disclosed embodiments demonstrate a method for improving the thermal-mechanical properties of a nickel-base superalloy by alloy additions for super-oxidation resistance.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

L'invention porte sur une composition de superalliage à base de nickel comprenant (mesurés en % en poids) d'environ 6,8 à environ 7,5 % d'aluminium, d'environ 4 à environ à environ 8 % de tantale, d'environ 4 à environ 10 % de chrome, d'environ 2 à environ 7 % de tungstène, de 0 à environ 6 % de rhénium, de 0 à environ 5 % de cobalt, de 0 à environ 0,2 % de silicium, éventuellement d'environ 0,15 à environ 0,7 % d'hafnium, de 0 à environ 0,5 % de titane, de 0 à environ 4 % de molybdène, de 0 à environ 0,005 % de bore, de 0 à environ 0,06 % de carbone, de 0 à environ 0,3 % d'un ajout de terre rare choisi dans le groupe constitué par l'yttrium, le lanthane, le césium et des associations de ceux-ci, le reste étant du nickel et des impuretés fortuites. La composition de superalliage à base de nickel peut être utilisée dans des articles en superalliage monocristallin ou solidifié de façon directionnelle tels que des lames de turbine à haute pression pour une turbine à gaz.
PCT/US2010/028202 2009-03-24 2010-03-23 Superalliage à base de nickel superrésistant à l'oxydation et à un endommagement cyclique et articles formés à partir de celui-ci WO2010111200A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP10710968A EP2411552A1 (fr) 2009-03-24 2010-03-23 Superalliage à base de nickel superrésistant à l'oxydation et à un endommagement cyclique et articles formés à partir de celui-ci
JP2012502151A JP2012521497A (ja) 2009-03-24 2010-03-23 超耐酸化性および耐繰り返し損傷性のニッケル基超合金およびそれから形成された物品
CA2755018A CA2755018A1 (fr) 2009-03-24 2010-03-23 Superalliage a base de nickel superresistant a l'oxydation et a un endommagement cyclique et articles formes a partir de celui-ci

Applications Claiming Priority (2)

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US12/409,929 US20110076179A1 (en) 2009-03-24 2009-03-24 Super oxidation and cyclic damage resistant nickel-base superalloy and articles formed therefrom
US12/409,929 2009-03-24

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US8858876B2 (en) 2012-10-31 2014-10-14 General Electric Company Nickel-based superalloy and articles
US10221468B2 (en) 2016-06-30 2019-03-05 General Electric Company Article and additive manufacturing method for making
US10577679B1 (en) 2018-12-04 2020-03-03 General Electric Company Gamma prime strengthened nickel superalloy for additive manufacturing

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EP1930455A1 (fr) * 2005-09-27 2008-06-11 National Institute for Materials Science Superalliage a base de nickel ne presentant pas de tendance a l' oxydation

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JP2012521497A (ja) 2012-09-13
EP2411552A1 (fr) 2012-02-01
CA2755018A1 (fr) 2010-09-30
US20110076179A1 (en) 2011-03-31

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