U.S. patent application number 10/490041 was filed with the patent office on 2005-03-31 for component repair materials.
Invention is credited to Humm, Stephan, Lungschider, E.
Application Number | 20050067069 10/490041 |
Document ID | / |
Family ID | 11042838 |
Filed Date | 2005-03-31 |
United States Patent
Application |
20050067069 |
Kind Code |
A1 |
Humm, Stephan ; et
al. |
March 31, 2005 |
Component repair materials
Abstract
A composition comprising Ni and the following additional
components: (i) Co in an amount in the range from about 4.5 to
about 11%; (ii) Cr in an amount in the range from about 7 to about
12%; (iii) Mo in an amount in the range from about 0.5 to about
1.4%; (iv) W in an amount in the range from about 1.8 to about
4.5%; (v) Re in an amount in the range from about 1.0 to about
2.6%; (vi) Al in an amount in the range from about 2.4 to about
5.6%; (vii) Ta in an amount in the range from about 2.4 to about
5.9%; (viii) Hf in an amount in the range from about 0.4% to about
6.0%; (ix) C in an amount up to about 0.1%; (x) B in an amount in
the range from 0.2 to about 2.2%; (xi) Zr in the range from to
about 0.02%; (xii) Fe in an amount in the range from about 0.07 to
about 0.2%; and (xiii) Mn in an amount in the range from about 0.03
to about 0.1% wherein all percentages are by weight based on the
total weight of the composition. The composition is particularly
suited for braze repair of alloy materials e.g. superalloys in
particular single crystal or directionally solidified alloys such
as those used in the manufacture of turbine engines of aircraft
etc.
Inventors: |
Humm, Stephan; (Oberusel,
DE) ; Lungschider, E; (Aachen, DE) |
Correspondence
Address: |
John F Letchford
Klehr Harrison Harvey Branzburg & Ellers
260 South Broad Street
Philadelphia
PA
19102
US
|
Family ID: |
11042838 |
Appl. No.: |
10/490041 |
Filed: |
November 9, 2004 |
PCT Filed: |
September 17, 2002 |
PCT NO: |
PCT/IE02/00134 |
Current U.S.
Class: |
148/675 ;
420/444 |
Current CPC
Class: |
B23K 35/304 20130101;
C22C 19/056 20130101; C22C 19/057 20130101 |
Class at
Publication: |
148/675 ;
420/444 |
International
Class: |
C22C 019/05 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 17, 2001 |
IE |
S010834 |
Claims
1-18. (Canceled).
19. A composition comprising Ni and the following additional
components: (i) Co in an amount in the range from about 4.5 to
about 11%; (ii) Cr in an amount in the range from about 7 to about
12%; (iii) Mo in an amount in the range from about 0.5 to about
1.4%; (iv) W in an amount in the range from about 1.8 to about
4.5%; (v) Re in an amount in the range from about 1.0 to about
2.6%; (vi) Al in an amount in the range from about 2.4 to about
5.6%; (vii) Ta in an amount in the range from about 2.4 to about
5.9%; (viii) Hf in an amount in the range from about 2.5% to about
6.0%; (ix) C in an amount up to about 0.1%; (x) B in an amount in
the range from 0.2 to about 2.2%; (xi) Zr in the range from 0 to
about 0.02%; (xii) Fe in an amount in the range from about 0.07 to
about 0.2%; and (xiii) Mn in an amount in the range from about 0.03
to about 0.1%,. wherein all percentages are by weight based on the
total weight of the composition.
20. A composition according to claim 19 wherein Ni makes up the
balance of the composition which is not taken up by components (i)
to (xiii).
21. A composition according to claim 19 wherein B is present in an
amount from about 0.4 to about 1.2% by weight based on the total
weight of the composition.
22. A composition according to claim 19 wherein Hf is present in an
amount from about 2.5 to about 4.6% by weight based on the total
weight of the composition.
23. A composition according to claim 19 wherein the composition is
in powder form.
24. A composition according to claim 19 comprising: (i) Co 6%; (ii)
Cr 10.6%; (iii) Mo 0.75%; (iv) W 2.45%; (v) Re 1.4%; (vi) Al 3.1%;
(vii) Ta 3.1%; (viii) Hf 2.75%; (ix) C in an amount up to about
0.1%; (x) B 1.26%; (xi) Zr from 0 to about 0.02%; (xii) Fe 0.1% and
(xiii) Mn 0.05%.
25. A composition according to claim 19 comprising: (i) Co 6%; (ii)
Cr 10.6%; (iii) Mo 0.75%; (iv) W 2.45%; (v) Re 1.4%; (vi) Al 3.1%;
(vii) Ta 3.1%; (viii) Hf 2.75%; (ix) C in an amount up to about
0.1%; (x) B 1.51%; (xi) Zr from 0 to about 0.02%; (xii) Fe 0.1% and
(xiii) Mn 0.05%.
26. A composition according to claim 19 comprising: (i) Co 8.3%;
(ii) Cr 8.6%; (iii) Mo 1.0%; (iv) W 3.4%; (v) Re 1.9%; (vi) Al
4.3%; (vii) Ta 4.4%; (viii) Hf 3.0%; (ix) C in an amount up to
about 0.1%; (x) B 1.0%; (xi) Zr from 0 to about 0.02%; (xii) Fe
0.13% and (xiii) Mn 0.07%.
27. A composition according to claim 19 comprising: (i) Co 8.1%;
(ii) Cr 8.5%; (iii) Mo 1%; (iv) W 3.3%; (v) Re 1.9%; (vi) Al 4.2%;
(vii) Ta 4.3%; (viii) Hf 4.5%; (ix) C in an amount up to about
0.1%; (x) B 1.0%; (xi) Zr from 0 to about 0.02%; (xii) Fe 0.13% and
(xiii) Mn 0.07%.
28. A composition according to claim 24 wherein the balance of the
composition is Ni.
29. A composition according to claim 25 wherein the balance of the
composition is Ni.
30. A composition according to claim 26 wherein the balance of the
composition is Ni.
31. A composition according to claim 27 wherein the balance of the
composition is Ni.
32. A process of repairing an article comprising the steps of
heating a composition according to claim 19 and/or heating an area
of an article to which the compositions is to be applied, to a
suitable temperature for a sufficient period of time to accomplish
the repair.
33. A process according to claim 32 wherein the temperature is in
the range from about 1200.degree. C. to about 1250.degree. C.
34. A process according to claim 33 wherein at least the repair
area is subsequently tempered.
35. A process according to claim 34 wherein the tempering is
carried out by heating to a temperature in the range from about
1125.degree. C. to about 1175.degree. C.
36. An article repaired by a process according to claim 32.
37. An article repaired by a process according to claim 33.
38. An article repaired by a process according to claim 34.
39. An article repaired by a process according to claim 35.
40. A composition comprising Ni and the following additional
components with the proviso that the composition does not contain
Si: (i) Co in an amount in the range from about 4.5 to about 11%;
(ii) Cr in an amount in the range from about 7 to about 12%; (iii)
Mo in an amount in the range from about 0.5 to about 1.4%; (iv) W
in an amount in the range from about 1.8 to about 4.5%; (v) Re in
an amount in the range from about 1.0 to about 2.6%; (vi) Al in an
amount in the range from about 2.4 to about 5.6%; (vii) Ta in an
amount in the range from about 2.4 to about 5.9%; (viii) Hf in an
amount in the range from about 0.4% to about 6.0%; (ix) C in an
amount up to about 0.1%; (x) B in an amount in the range from 0.2
to about 2.2%; (xi) Zr in the range from 0 to about 0.02%; (xii) Fe
in an amount in the range from about 0.07 to about 0.2%; and (xiii)
Mn in an amount in the range from about 0.03 to about 0.1%,.
wherein all percentages are by weight based on the total weight of
the composition.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to component repair materials
generally, and in particular to the repair of metallic components.
Of particular interest are components constructed of alloys (more
particularly superalloys) and their repair using suitable repair
materials.
BACKGROUND OF THE INVENTION
[0002] Alloys and in particular those alloys which are capable of
withstanding great pressures and temperatures are of interest as
components formed with these materials are often costly to produce
and it is more economical to repair rather than replace them.
[0003] A well known technique for repairing cracks and other
fractures in an article such as a component is brazing. Accordingly
there is a need for brazing materials which are suitable for use
for repairing components. It is desirable that the material used as
a braze results in a repair that restores the component to a
useable state. Braze materials and techniques which function well
to repair alloys such as for example superalloys are thus
important. Superalloys are well known to those skilled in the art.
Such materials are used to construct many types of component and in
particular in the context of the present invention the alloys
(superalloys) that are most of interest are those used in the
construction of turbine components (gas turbine components) of the
type found in (turbine) engines of aircraft and the like.
[0004] Use of braze materials can help prolong the in-service
lifetime of components which if not repaired to a sufficiently high
strength would otherwise have to be discarded and replaced. Brazing
techniques are well known to those skilled in the art and include
vacuum techniques. Such techniques are not discussed in detail
herein.
[0005] It will be appreciated that one of the main determining
factors of the strength of a repair is the ability of the repair to
withstand very high temperatures. It will be appreciated that the
temperatures reached in, for example a turbine engine, can be very
high so that not all braze materials (articles) are suited for
repair. In particular it is desirable to find materials which are
suited to the joining of superalloy materials for the purpose of
repair (e.g. joining opposing sides of a fracture). Of particular
interest in the context of the present invention are Single Crystal
("SC") and Directionally Solidified ("DS") superalloys.
[0006] The present invention relates to compositions which are
suited to use as repair materials for the repair of superalloy
materials. In particular the present invention relates to a solid
composition in particular a powder material which may be so used.
Of particular interest are compositions in powder form. More
particularly, this invention relates to a braze material comprising
a braze alloy (the braze alloy may be considered an alloy formed
from a powder mixture). The materials employed in the present
invention have a high melting temperature. The invention also
relates to a process for braze repairing components for example
turbine components. Also within the scope of the invention is an
article repaired by a process of the invention.
[0007] It has been found that many materials which are suitable for
repairing conventional articles/components do not sufficiently well
repair SC or DS superalloys. It is desirable to provide repair
materials and/or repair methods which are particularly suited to
repair of SC or DS materials.
[0008] Nickel and cobalt-based superalloys are the superalloys most
often used in the manufacture of turbine components such as turbine
blades. SC or DS superalloys incorporating these materials are of
particular interest in the present invention. Such materials have
not been repaired sufficiently well with prior art compositions. It
is desirable that the materials and methods of the invention allow
for reduced use of the melting point depressant boron, which is
believed to reduce repair strengths in repair materials. In
particular it is desirable that the compositions of the invention
are considered low-boron compositions. Repair materials used with
SC or DS materials usually contain relatively high amounts of
boron.
OBJECT OF THE INVENTION
[0009] It is an object of this invention to provide an alternative
braze material for use in the repair of substrates/components and
in particular to those substrates comprised of superalloys such as
nickel and cobalt-based superalloys.
[0010] The present invention seeks to address the requirement for
compositions and methods which prolong the in-service life of
components in particular components of gas turbines.
[0011] The invention provides a composition suitable for the repair
of superalloys for example to repair damage which occurs during
service operations.
[0012] It is desirable that the repair results in a repair of a
desired uniform microstructure that produces mechanical and
environmental properties which are similar to that of the
superalloy material (in particular SC or DS) itself. In particular
it is desirable that the repair results in a material which is
resistant to oxidation, deformation etc. at high temperatures (the
temperatures reached in a turbine engine).
[0013] In particular conventional alloys used for repair such as
brazing--often referred to as "repair alloys" comprise a "filler"
composition and a "braze" composition. The filler composition is a
composition which is itself usually an alloy and which has a
composition that is similar to that of the material to be repaired.
The material to be repaired is often referred to as the "parent"
alloy. The braze composition is also often similar to the
composition of the parent alloy and additionally comprises at least
one and usually a number of additional components. In particular it
is desirable that additional components usually have at least the
overall effect of depressing the melting point of the braze
composition. As stated above it is desirable to use low amounts of
boron.
[0014] The repair material which forms a repair alloy (or braze
alloy) may be thus considered a mixture of at least two alloy
forming powders--the parent alloy and the braze alloy. The repair
alloy will often have a defined mixture composition range.
SUMMARY OF THE INVENTION
[0015] In the present invention there is provided a composition
(the composition is suitable for the repair of articles at least
partially comprised of alloy, in particular superalloys and more
particularly SC or DS superalloys) comprising Ni and the following
additional components:
[0016] (i) Co in an amount in the range from about 4.5 to about
11%;
[0017] (ii) Cr in an amount in the range from about 7 to about
12%;
[0018] (iii) Mo in an amount in the range from about 0.5 to about
1.4%;
[0019] (iv) W in an amount in the range from about 1.8 to about
4.5%;
[0020] (v) Re in an amount in the range from about 1.0 to about
2.6%;
[0021] (vi) Al in an amount in the range from about 2.4 to about
5.6%;
[0022] (vii) Ta in an amount in the range from about 2.4 to about
5.9%;
[0023] (viii) Hf in an amount in the range from about 0.4% to about
6.0%;
[0024] (ix) C in an amount up to about 0.1%;
[0025] (x) B in an amount in the range from about 0.2 to about
2.2%;
[0026] (xi) Zr in the range from 0 to about 0.02%;
[0027] (xii) Fe in an amount in the range from about 0.07 to about
0.2%; and
[0028] (xiii) Mn in an amount in the range from about 0.03 to about
0.1%,
[0029] wherein all percentages are by weight based on the total
weight of the composition. Ni will usually substantially make up
the balance of the composition (which is not taken up by components
(i) to (xiii)).
[0030] For the components C and Zr it is desired that these are
each independently present in an amount of at least about 0.1%.
[0031] It is preferred that the boron component is present in an
amount of 0.4% to 1.2% by weight based on the total weight of the
composition. It is preferred that the hafnium component is present
in an amount of between 2.5 and 4.6% by weight based on the total
weight of the composition.
[0032] It is desirable that both boron and hafnium are present in
the composition in these preferred ranges.
[0033] A composition such as that just described is useful for the
repair of turbine components. The area repaired with the material
has minimum voiding and a desirable microstructure.
[0034] The compositions of the invention can be considered braze
material for repairing an article. An important component in the
composition is Hf and it is desirable that this component is
present. The presence of this component is thought to act as a
melting point depressant causing the repair composition to have a
lower melting point than at least some superalloy materials. The
presence of Hf and B together may provide a combined melting point
depression effect so that the presence of both of these components
is desirable. In other words it is an advantage of the invention
that the repair material comprises Hf and B. The invention thus
relates to the use of Hf and desirably Hf/B in the preparation of a
repair composition for the repair of superalloys. Desirably the
composition is provided in powder form. The braze or weld formed
(e.g. by application of a composition of the invention under
suitable conditions to effect repair of a component) will have
similar physical properties to that of the component. The braze or
weld formed material will have an alloy form.
[0035] Suitably the alloy of the component being repaired is a SC
or DS superalloy.
[0036] A method of repair may involve the step of heating the
repair material and/or an area of an article to which it is to be
applied to a suitable temperature (for example in the range from
about 1200.degree. C. to about 1250.degree. C.) for a period of
time suitable to accomplish the repair, and in particular to heat
the area to be repaired. The heating step may be carried out
subsequent to application of the composition to the repair area,
simultaneous with the application of the composition or prior to
application of composition as appropriate. The invention also
relates to an article repaired by a method of the present
invention.
[0037] Further heating can be carried out to temper the repair and
indeed the repaired article (at least the repair area). A secondary
heating (tempering) step may additionally be carried out by heating
at least the repaired area (and desirably the whole article being
repaired) to a temperature in the range from about 1125.degree. C.
to about 1175.degree. C. Such secondary heating step may be carried
out for a period suitable to temper the repair. Such periods are
often greater than about 6 hours and desirably the secondary
heating is carried out for a period of at least about 6 to about 25
hours.
BRIEF DESCRIPTION OF THE FIGURES
[0038] FIG. 1 is an image produced by a scanning electron
microscope [SEM] of a turbine component which has been brazed as
described in the example below;
[0039] FIG. 2 is an image produced by a scanning electron
microscope [SEM] of the same component as shown in FIG. 1 following
tempering of the component.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Experimental Procedure and Results
[0041] Powders of a repair alloy composition (composition 3 below)
according to the present invention in paste form were applied in
standard slotted lab samples, slots 0.3 mm wide, brazed under
controlled parameters in a temperature range of 1200-1250 for 15-45
minutes (optimum 30 minutes) followed by a second temperature
treatment in the range of 1125-1175.degree. C. for at least 6-25
hours (10 hours as tested). A component prepared according to the
experimental procedure above demonstrated a minimal microstructure
(see FIGS. 1 and 2). When tested against SC CMSX-4 material it
produced satisfactory tensile properties equivalent to about 60-70%
of CMSX-4 material. It produced equivalent static oxidation
properties. [CMSX-4 is a brand name of a single crystal material
produced by Canon Muskegan in Michigan in the US].
[0042] Further Compositions of the Present Invention:
[0043] The term "nominal" is used to expressly acknowledge the fact
that the compositions may not be in the exact percentage amounts
listed below but will be within tolerances acceptable to the person
skilled in the art. Such tolerance parameters are within the skill
and understanding of the person skilled in the art.
[0044] Composition No. 1.
[0045] (i) Co Nominal 6%;
[0046] (ii) Cr Nominal 10.6%;
[0047] (iii) Mo Nominal 0.75%;
[0048] (iv) W Nominal 2.45%;
[0049] (v) Re Nominal 1.4%;
[0050] (vi) Al Nominal 3.1%;
[0051] (vii) Ta Nominal 3.1%;
[0052] (viii) Hf Nominal 2.75%;
[0053] (ix) C in an amount up to about 0.1%;
[0054] (x) B Nominal 1.26%;
[0055] (xi) Zr Nominal up to 0.2%;
[0056] (xii) Fe Nominal 0.1% and
[0057] (xiii) Mn Nominal 0.05%.
[0058] Balance is Nickel.
[0059] Composition No. 2.
[0060] (i) Co Nominal 6%;
[0061] (ii) Cr Nominal 10.6%;
[0062] (iii) Mo Nominal 0.75%;
[0063] (iv) W Nominal 2.45%;
[0064] (v) Re Nominal 1.4%;
[0065] (vi) Al Nominal 3.1%;
[0066] (vii) Ta Nominal 3.1%;
[0067] (viii) Hf Nominal 2.75%;
[0068] (ix) C in an amount up to about 0.1%;
[0069] (x) B Nominal 1.51%;
[0070] (xi) Zr Nominal up to 0.2%;
[0071] (xii) Fe Nominal 0.1% and
[0072] (xiii) Mn Nominal 0.05%.
[0073] Balance is Nickel.
[0074] Composition No. 3.
[0075] (i) Co Nominal 8.3%;
[0076] (ii) Cr Nominal 8.6%;
[0077] (iii) Mo Nominal 1.0%;
[0078] (iv) W Nominal 3.4%;
[0079] (v) Re Nominal 1.9%;
[0080] (vi) Al Nominal 4.3%;
[0081] (vii) Ta Nominal 4.4%;
[0082] (viii) Hf Nominal 3.0%;
[0083] (ix) C in an amount up to about 0.1%;
[0084] (x) B Nominal 1.0%;
[0085] (xi) Zr Nominal up to 0.2%;
[0086] (xii) Fe Nominal 0.13% and
[0087] (xiii) Mn Nominal 0.07%.
[0088] Balance is Nickel.
[0089] Composition No. 4.
[0090] (i) Co Nominal 8.1%;
[0091] (ii) Cr Nominal 8.5%;
[0092] (iii) Mo Nominal 1%;
[0093] (iv) W Nominal 3.3%;
[0094] (v) Re Nominal 1.9%;
[0095] (vi) Al Nominal 4.2%;
[0096] (vii) Ta Nominal 4.3%;
[0097] (viii) Hf Nominal 4.5%;
[0098] (ix) C in an amount up to about 0.1%;
[0099] (x) B Nominal 1.0%;
[0100] (xi) Zr Nominal from up to 0.2%;
[0101] (xii) Fe Nominal 0.13% and
[0102] (xiii) Mn Nominal 0.07%.
[0103] Balance is Nickel.
[0104] Results with Compositions 1-4.
[0105] Test results for Compositions 1-4 used as braze materials
(as per the above description) are given in the Table below. The
results are tensile test results at 850.degree. C. on braze joints
made from each of these braze compositions. The data is expressed
as tensile strength of a test piece containing a 0.8 mm wide gap,
filled with braze material. The tensile strength was measured at
850.degree. C. and is expressed as UTS (Ultimate Tensile Strength).
The units are MPa (Mega Pascals).
1 Composition No. UTS, MPa 1. 247 2. 283 3. 208 4. 403
[0106] Compositions of the present invention have thus been shown
to be suitable materials for repair of alloy components, in
particular by braze repair.
[0107] The words "comprises/comprising" and the words
"having/including" when used herein with reference to the present
invention are used to specify the presence of stated features,
integers, steps or components but does not preclude the presence or
addition of one or more other features, integers, steps, components
or groups thereof.
[0108] It is appreciated that certain features of the invention,
which are, for clarity, described in the context of separate
embodiments, may also be provided in combination in a single
embodiment. Conversely, various features of the invention which
are, for brevity, described in the context of a single embodiment,
may also be provided separately or in any suitable
subcombination.
* * * * *