U.S. patent application number 14/633442 was filed with the patent office on 2015-06-18 for nickel alloy for repairs.
The applicant listed for this patent is UNITED TECHNOLOGIES CORPORATION. Invention is credited to Beth Kwiatkowski Abriles, John H. Hyde, Norman Pietruska.
Application Number | 20150167125 14/633442 |
Document ID | / |
Family ID | 38508881 |
Filed Date | 2015-06-18 |
United States Patent
Application |
20150167125 |
Kind Code |
A1 |
Abriles; Beth Kwiatkowski ;
et al. |
June 18, 2015 |
Nickel Alloy For Repairs
Abstract
A nickel base repair alloy comprises a blend of about 40 to 60
wt % of a first nickel based braze alloy containing boron, about 15
to 35 wt % of a first nickel based filler material, and the
remainder consisting of a blend of a second nickel based filler
material and a low melting eutectic braze nickel based alloy.
Inventors: |
Abriles; Beth Kwiatkowski;
(Madison, CT) ; Pietruska; Norman; (Durham,
CT) ; Hyde; John H.; (South Meriden, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNITED TECHNOLOGIES CORPORATION |
HARTFORD |
CT |
US |
|
|
Family ID: |
38508881 |
Appl. No.: |
14/633442 |
Filed: |
February 27, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11440683 |
May 24, 2006 |
8999231 |
|
|
14633442 |
|
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Current U.S.
Class: |
420/443 ;
420/588 |
Current CPC
Class: |
B23P 6/002 20130101;
C22C 19/058 20130101; B22F 1/0003 20130101; C22C 19/056 20130101;
F01D 5/005 20130101; C22C 1/0433 20130101; B23K 35/3033 20130101;
B23K 35/025 20130101; B22F 7/064 20130101; F05D 2230/237 20130101;
C22C 19/05 20130101; F05D 2230/80 20130101; C22C 19/057
20130101 |
International
Class: |
C22C 19/05 20060101
C22C019/05; B23P 6/00 20060101 B23P006/00 |
Claims
1-16. (canceled)
17. A material for repairing a crack in a nickel based alloy
component consisting essentially of about 7.0 to 10.0 wt %
chromium, about 4.0 to 7.0 wt % tungsten, about 3.0 to 6.0 wt %
aluminum, about 1.0 to 5.0 wt % tantalum, about 0.5 to 3.0 wt %
boron, about 9.0 to 11.0 wt % cobalt, about 0.5 to 2.0 wt %
molybdenum, up to about 2.5 wt % rhenium, about 0.5 to 2.5 wt %
hafnium, up to 1.0 wt % titanium, up to 0.03 wt % yttrium, and the
balance nickel.
18. The material according to claim 17, wherein said chromium
content is about 8.5 to 9.5 wt %.
19. The material according to claim 17, wherein said tungsten
content is about 5.0 to 6.2 wt %.
20. The material according to claim 17, wherein said aluminum
content is about 4.0 to 5.0 wt %.
21. The material according to claim 17, wherein said titanium
content is about 0.15 to 0.4 wt %.
22. The material according to claim 17, wherein said tantalum
content is about 3.0 to 4.0 wt %.
23. The material according to claim 17, wherein said boron content
is about 1.0 to 1.5 wt %.
24. The material according to claim 17, wherein said cobalt content
is about 10 wt % to 11 wt %.
25. The material according to claim 17, wherein said molybdenum
content is about 0.9 to 1.3 wt %.
26. The material according to claim 17, wherein said rhenium
content is about 1.0 to 2.0 wt %.
27. The material according to claim 17, wherein said hafnium
content is about 1.0 to 1.3 wt %.
28. The material according to claim 17, wherein said yttrium
content is about 0.01 to 0.02 wt %.
Description
BACKGROUND
[0001] (1) Field of the Invention
[0002] The present invention relates to a nickel base repair alloy
which may be used to repair workpieces, such as turbine engine
components, and to methods for repairing such workpieces.
[0003] (2) Prior Art
[0004] Current materials used for repairing workpieces or
components formed from a nickel based alloy used in turbine engines
typically permit a maximum 0.010 inch wide crack to be repaired.
Thus, there is a need for a repair material which can be used to
repair wide gap cracks greater than about 0.010 inch wide.
SUMMARY OF THE INVENTION
[0005] In accordance with the present invention, there is provided
a nickel base repair alloy comprising a blend of about 40 to 60 wt
% of a first nickel based braze alloy containing boron, about 15 to
35 wt % of a first nickel based filler material, and the remainder
consisting of a blend of a second nickel based filler material and
a low melting eutectic braze nickel based alloy.
[0006] Further in accordance with the present invention, there is
provided a method for repairing cracks in a workpiece comprising:
applying a nickel base repair alloy to a cracked area on said
workpiece, said nickel base repair alloy comprising a blend of
about 40 to 60 wt % of a first nickel based braze alloy containing
boron, about 15 to 35 wt % of a first nickel based filler material,
and the remainder consisting of a blend of a second nickel based
filler material and a low melting eutectic braze nickel based
alloy.
[0007] Still further in accordance with the present invention,
there is provided a material for repairing a crack in a nickel
based alloy component, said material consisting essentially of
about 7.0 to 10.0 wt % chromium, about 4.0 to 7.0 wt % tungsten,
about 3.0 to 6.0 wt % aluminum, about 1.0 to 5.0 wt % tantalum,
about 0.5 to 3.0 wt % boron, about 9.0 to 11.0 wt % cobalt, about
0.5 to 2.0 wt % molybdenum, up to about 2.5 wt % rhenium, about 0.5
to 2.5 wt % hafnium, up to 0.03 yttrium, and the balance
nickel.
[0008] Other details of the nickel alloy for repairs of the present
invention, as well as other objects and advantages attendant
thereto, are set forth in the following detailed description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0009] As noted above, the present invention relates to a blend of
powders which are used to form a nickel based alloy which can be
used to repair turbine engine components having cracks with wide
gaps in the range of about 0.010 to 0.040 inches wide. The present
invention also relates to processes for repairing components having
such cracks and to the repair material itself.
[0010] The repair material is a nickel based alloy preferably
formed from four metallic powders mixed in a binder. The powders
are mixed together and suspended in a typical industry flux free
organic based brazing binder that is capable of burning off without
leaving an undesirable residue when paste is heated to not higher
than 1000.degree. F. A suitable binder is NicroBraz S binder or
Vitta Braz Binder Gel. The amount of binder used will vary from
manufacturer to manufacturer. For a paste form, 8 to 15 wt % should
be the binder. The four metallic powders may comprise a first
nickel based braze alloy containing boron, a first nickel based
filler material, a second nickel based filler material, and a low
melting eutectic braze nickel based alloy. A suitable blend may
contain about 40 to 60 wt % of a first nickel based braze alloy
containing boron, about 15 to 35 wt % of a first nickel based
filler material, and the remainder consisting of a blend of a
second nickel based filler material and a low melting eutectic
braze nickel based alloy.
[0011] In a preferred embodiment of the present invention, the
first nickel based braze alloy may contain about 6.0 to 6.8 wt %
chromium, about 1.175 to 1.225 wt % boron, about 0.080 to 0.12 wt %
carbon, about 5.7 to 6.1 wt % aluminum, about 0.04 to 0.12 wt %
zirconium, about 12.1 to 13.0 wt % cobalt, about 1.5 to 1.9 wt %
molybdenum, about 6.0 to 6.8 wt % tungsten, about 2.75 to 3.25 wt %
rhenium, about 3.75 to 4.24 wt % tantalum, about 1.0 to 2.0 wt %
hafnium, and the balance nickel.
[0012] Further in a preferred embodiment, the first nickel based
filler material may contain about 0.13 to 0.17 wt % carbon, about
8.0 to 8.8 wt % chromium, about 9.0 to 11.0 wt % cobalt, about 0.5
to 0.8 wt % molybdenum, about 2.8 to 3.3 wt % tantalum, about 0.9
to 1.2 wt % titanium, about 9.5 to 10.5 wt % tungsten, about 5.3 to
5.7 wt % aluminum, about 0.010 to 0.020 wt % boron, about 1.2 to
1.6 wt % hafnium, about 0.03 to 0.08 wt % zirconium, and the
balance nickel.
[0013] Further in a preferred embodiment, the second nickel base
filler material may contain 14 wt % chromium, 10 wt % cobalt, 3.5
wt % aluminum, 2.75 wt % boron, 2.5 wt % tantalum, 0.1 wt %
yttrium, and the balance nickel. A suitable material is a product
commercially known as DF-4B.
[0014] Still further in a preferred embodiment, the low melting
eutectic braze nickel based alloy may contain about 13.5 to 16.0 wt
% chromium, about 3.25 to 4.0 wt % boron, and the balance nickel. A
suitable material is a product commercially known as NICROBRAZ
150.
[0015] The four powders may be blended with the binder using any
suitable technique known in the art. While it is preferred that the
blended nickel base repair alloy be in powder form, if desired, the
blend may take the form of a paste or a paint. Alternatively, any
suitable technique known in the art may be used to convert a powder
form of the blend into a plate form.
[0016] The repair material has a composition consisting essentially
of about 7.0 to 10.0 wt % chromium, about 4.0 to 7.0 wt % tungsten,
about 3.0 to 6.0 wt % aluminum, about 1.0 to 5.0 wt % tantalum,
about 0.5 to 3.0 wt % boron, about 9.0 to 11.0 wt % cobalt, about
0.5 to 2.0 wt % molybdenum, up to about 2.5 wt % rhenium, about 0.5
to 2.5 wt % hafnium, up to 1.0 wt % titanium, up to 0.03 wt %
yttrium, and the balance nickel. In a preferred embodiment, the
repair material has a chromium content in the range of about 8.5 to
9.5 wt %, a tungsten content in the range of about 5.0 to 6.2 wt %,
an aluminum content in the range of about 4.0 to 5.0 wt %, a
titanium content in the range of about 0.15 to 0.4 wt %, a tantalum
content in the range of about 3.0 to 4.0 wt %, a boron content in
the range of about 1.0 to 1.5 wt %, a cobalt content in the range
of about 10 wt % to 11 wt %, a molybdenum content in the range of
about 0.9 to 1.3 wt %, a rhenium content in the range of about 1.0
to 2.0 wt %, a hafnium content in the range of 1.0 to 1.3 wt %, and
a yttrium content in the range of 0.01 to 0.02 wt %. The rhenium
improves high temperature creep, while yttrium is a grain boundary
strengthener.
[0017] In order to effect a repair, the repair area on the
component to be repaired may first be cleaned to remove any loose
debris and/or contaminants in the repair area. Any suitable
technique known in the art may be used to clean the repair area.
Thereafter, the nickel base repair alloy may be applied to the
repair area so that the repair alloy fills any crack in the area.
Following the application step, the component and the repair alloy
are preferably subjected to a melt cycle for a time period of about
15 to 30 minutes at a temperature greater than the melt temperature
of the blended nickel base repair alloy. Following the melt cycle,
the component with the melted repair alloy may be subjected to a
diffusion cycle at a temperature of about 2200 to 2300.degree. F.,
preferably about 2200 to 2250.degree. F., for a time period of
about 5.0 to 25 hours, preferably about 10 to 20 hours. After the
diffusion cycle has been completed, the component with the repair
material may be allowed to cool to room temperature. If necessary,
the component with the repair material may be subjected to further
processing to remove any bumps or other distortions.
[0018] After the diffusion process, the microstructure of the
repair alloy is generally isothermal with small amounts of
athermal. Extending the diffusion time may reduce the amount of
athermal phases.
[0019] If desired, the repair alloy of the present invention may be
used in conjunction with other nickel based repair alloys.
[0020] The repair alloy of the present invention may be used to
repair cracks about 0.010 to 0.040 inches wide. The repair alloy of
the present invention enables these wide cracks or gaps to achieve
complete or almost complete isothermal solidification during the
repair process, which is not possible with some current repair
alloy mixtures. The repair material may be used to repair a wide
variety of turbine engine components, especially those formed from
equiaxed and directionally solidified nickel based alloys.
[0021] It is apparent that there has been provided in accordance
with the present invention a nickel alloy for repairs which fully
satisfies the objects, means, and advantages set forth
hereinbefore. While the present invention has been described in the
context of specific embodiments thereof, other unforeseeable
alternatives, modifications, and variations may become apparent to
those skilled in the art having read the foregoing description.
Accordingly, it is intended to embrace those alternatives,
modifications, and variations as fall within the broad scope of the
appended claims.
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