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GB2497128A - Nickel-based alloys comprising 0.2-0.6 % by weight silicon - Google Patents

Nickel-based alloys comprising 0.2-0.6 % by weight silicon Download PDF

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Publication number
GB2497128A
GB2497128A GB1120731.3A GB201120731A GB2497128A GB 2497128 A GB2497128 A GB 2497128A GB 201120731 A GB201120731 A GB 201120731A GB 2497128 A GB2497128 A GB 2497128A
Authority
GB
United Kingdom
Prior art keywords
text
nickel
alloy
silicon
hafnium
Prior art date
Legal status (The legal status 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 status listed.)
Withdrawn
Application number
GB1120731.3A
Other versions
GB201120731D0 (en
Inventor
Mark Christopher Hardy
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
Original Assignee
Rolls Royce PLC
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 Rolls Royce PLC filed Critical Rolls Royce PLC
Priority to GB1120731.3A priority Critical patent/GB2497128A/en
Publication of GB201120731D0 publication Critical patent/GB201120731D0/en
Priority to US13/686,220 priority patent/US20130142661A1/en
Publication of GB2497128A publication Critical patent/GB2497128A/en
Withdrawn legal-status Critical Current

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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
    • C22C19/056Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/04Making non-ferrous alloys by powder metallurgy
    • C22C1/0433Nickel- or cobalt-based alloys
    • 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
    • F01D5/02Blade-carrying members, e.g. rotors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12Both compacting and sintering
    • B22F3/14Both compacting and sintering simultaneously
    • B22F3/15Hot isostatic pressing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Powder Metallurgy (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

Silicon the range 0.2-0.6 % by weight is included in nickel-based alloys to improve oxidation, hot corrosion and dwell crack growth resistance without a detrimental effect on thermal stability of the microstructure and properties. The alloy can have the following composition (by weight): 14.6-15.4 % chromium; 18-19 % cobalt; 4.75-5.25 % molybdenum; 2.8-3.2 % aluminium; 3.4-3.8 % titanium; 1.8-2.2 % tantalum; 0.4-0.6 % hafnium; 0.020-0.034 % carbon; 0.005-0.025 % boron; 0.2-0.6 % silicon, the balance being nickel and impurities. Another alloy has the following composition (by weight): 15 % chromium; 18.5 % cobalt; 5 % molybdenum; 3 % aluminium; 3.6 % titanium; 2 % tantalum; 0.5 % hafnium; 0.027 % carbon; 0.015 % boron; 0.2-0.6 % silicon, the balance being nickel and impurities. The alloy can be used to make gas turbine engine discs.

Description

A NICKEL-BASED ALLOY
This invention relates to nickel-based alloys, and particularly (although not exclusively) to nickel-based alloys suitable for use in discs of gas turbine engines.
Known nickel-based alloys were developed for applications such as blades, nozzle guide vanes and combustor components in gas turbine engines. For such applications, the alloys were designed to have improved oxidation resistance in the temperature range 760-1100 °C. Such alloys were typically wrought processed, to produce a polycrystall me microstructure, or investment cast, to produce conventionally cast, directionally solidified or single crystal microstructure.
The so-called third-generation powder metallurgy alloys, such as ME3, Alloy 10 and is LSHR, are nickel alloys developed for disc rotor applications at temperatures up to about 700 °C. They are all processed using powder metallurgy techniques.
To enable high-temperature strength and creep resistance to be optimised and to maintain a stable microstructure during exposure to high temperatures, the chromium content in these alloys is 11-15 wt%, compared with about 20 wt% in previous alloys such as Inconel® 718 and Waspaloy®. However, these alloy compositions are not optimised for certain other mechanical properties, such as oxidation resistance, resistance to hot corrosion damage and resistance to dwell crack growth. All of these properties are particularly important for rotor disc applications, because they can limit component life.
The inventors have discovered a modification to the composition of the known nickel-based alloy RR1 000 that improves oxidation, hot corrosion and dwell crack growth resistance, without the detrimental effects on the thermal stability of the microstructure and on other material properties that have been found with known alloys.
Accordingly, the invention provides a nickel-based alloy and a component made from such an alloy, as set out in the claims.
Embodiments of the invention will now be described, by way of example only, so that it can be better understood how it is to be put into effect.
The inventors have discovered the unexpected result that adding silicon, in a defined range of weight percentage, to the composition of the known nickel-based alloy RR1 000 improves oxidation, hot corrosion and dwell crack growth resistance without the detrimental effects on the thermal stability of the microstructure and on other material properties that have been found with known alloys.
Powder particles of the compositions shown in Table 1 were produced by argon gas atomisation. The particles were screened to a final screen size of 53 pm and filled into a mild steel container. Hot isostatic pressing was then used to consolidate the particles.
The resulting compacts were isothermally forged to produce pancake forgings, and solution heat treated to produce fine-grained (average grain size <10 pm) and coarse-grained (average grain size 20-65 pm) microstructures.
Table 1
Alloy Cr Co Mo Al Ti Ta Hf C B Zr Si Ni RR1000 15 18.5 5 3 3.6 2 0.5 0.027 0.015 0.06 0 rem.
#1 15 18.5 5 3 3.6 2 0.5 0.027 0.015 0.06 0.2 rem.
#2 15 18.5 5 3 3.6 2 0.5 0.027 0.015 0.06 0.5 rem.
Oxidation damage at temperatures between 700 and 800 °C was evaluated by weight change by thermogravimetric analysis on RR1000 and on the alloys #1 and #2 according to the invention. The test pieces were prepared from forgings having fine-and coarse-grained microstructures.
Hot corrosion resistance was evaluated by deposit recoat experiments at 700 °C on the three alloys. The test pieces were prepared from forgings having a fine-grained microstructure. In these tests, samples were coated with deposits of 98% Na2SO4I 2% NaCI in a gas stream of air containing 300 vpm SO2. Corrosion damage is quantified by dimensional metrology of the samples before and after exposure, to determine the amount of sound metal loss.
Dwell crack growth resistance was evaluated in laboratory air at 700 °C on 5mm x 5mm square section, corner notch test pieces. The test pieces were prepared from forgings having a coarse-grained microstructure. Fatigue cycles consisting of a 3600s dwell period at peak load and a stress ratio of 0.1 were used.
By adding a quantity of silicon between 0.2 and 0.6 wt% to the known RR1 000 alloy composition, an unexpected improvement in key material properties has been achieved in temperature ranges that are important for gas turbine rotor disc applications, without the detrimental effects in other properties previously associated with such improvements.
Further improvements may be achievable with higher levels of silicon, but these are considered to reduce the stability of the microstructure, and promote the precipitation of topological close-packed phases (e.g. sigma) during prolonged exposure to temperatures above about 675 °C. Such phases form at grain boundaries and are detrimental to tensile strength and ductility, stress rupture and dwell crack growth resistance.
It is believed that additions of silicon, as described above, could provide similarly beneficial results in other rotor disc alloys. The results are not dependent on a particular processing method, but can be realised for cast, wrought and powder processed alloys.
It is believed that the most significant benefits are achieved when silicon is used in combination with reactive elements such as hafnium, zirconium and magnesium that "get" oxygen and sulphur and low levels of sulphur and phosphorous.

Claims (5)

  1. <claim-text>CLAIMS1. A nickel-based alloy including between 0.2 wt% and 0.6 wt% silicon to improve oxidation resistance, dwell crack growth resistance and hot corrosion resistance without detrimental effect on other mechanical properties of the alloy.</claim-text> <claim-text>2. An alloy as claimed in claim 1, further including at least one of the following: hafnium <= 0.75 wt%; zirconium <= 0.1 wt%; magnesium <= 0O3wt%; sulphur c= 5 ppm; phosphorous C 10 ppm.</claim-text> <claim-text>3. An alloy as claimed in claim 1 having the following composition in weight percent: chromium 14.6-15.4%; cobalt 18-19%; molybdenum 4.75-5.25%; aluminium 2.8-3.2%; titanium 3.4-3.8%; tantalum 1.8-2.2%; hafnium 0.4-0.6%; carbon 0.020-0.034%; boron 0.005-0.025%; silicon 0.2-0.6%; the remainder being nickel and incidental impurities.</claim-text> <claim-text>4. An alloy as claimed in claim 1, having the following composition in weight percent: chromium 15%; cobalt 18.5%; molybdenum 5%; aluminium 3%; titanium 3.6%; tantalum 2%; hafnium 0.5%; carbon 0.027%; boron 0.01 5%; silicon 0.2-0.6%; the remainder being nickel and incidental impurities.</claim-text> <claim-text>5. An alloy as claimed in claim 1, having the following composition in weight percent: chromium 15%; cobalt 18.5%; molybdenum 5%; aluminium 3%; titanium 3.6%; tantalum 2%; hafnium 0.5%; carbon 0.027%; boron 0.01 5%; silicon 0.2%; the remainder being nickel and incidental impurities.</claim-text> <claim-text>6. An alloy as claimed in claim 1, having the following composition in weight percent: chromium 15%; cobalt 18.5%; molybdenum 5%; aluminium 3%; titanium 3.6%; tantalum 2%; hafnium 0.5%; carbon 0.027%; boron 0.015%; silicon 0.5%; the remainder being nickel and incidental impurities.</claim-text> <claim-text>7. A component formed of an alloy as claimed in any preceding claim.</claim-text> <claim-text>8. A component as claimed in claim 7, the component being a disc for a gas turbine engine.</claim-text> <claim-text>9. An alloy substantially as described in this specification.</claim-text> <claim-text>10. A component formed of an alloy substantially as described in this specification.Amendments to the claims have been made as follows:CLAIMS1. A nickel-based alloy having the following composition in weight percent: chromium 14.6-15.4%; cobalt 18-19%; molybdenum 4.75-5.25%; aluminium 2.8-3.2%; titanium 3.4-3.8%; tantalum 1.8-2.2%; hafnium 0.4-0.6%; carbon 0.020-0.034%; boron O.005-0.025%; silicon 0.2-0.6%; the remainder being nickel and incidental impurities.
  2. 2. An alloy as claimed in claim 1, having the following composition in weight (0 percent: 04 chromium 15%; cobalt 18.5%; molybdenum 5%; aluminium 3%; titanium 3.6%; tantalum 2%; hafnium 0.5%; carbon 0.027%; boron 0.01 5%; silicon 0.2-0.6%; the remainder being nickel and incidental impurities.
  3. 3. An alloy as claimed in claim 1, having the following composition in weight percent: chromium 15%;Scobalt 18.5%; molybdenum 5%; aluminium 3%; titanium 3.6%; tantalum 2%; hafnium 0.5%; carbon 0.027%; boron 0.01 5%; silicon 0.2%; the remainder being nickel and incidental impurities.
  4. 4. An alloy as claimed in claim 1, having the following composition in weight percent: chromium 15%; cobalt 18.5%; molybdenum 5%; aluminium 3%; 04 titanium 3.6%; tantalum 2%; hafnium 0.5%; carbon 0.027%; boron 0.015%; silicon 0.5%; the remainder being nickel and incidental impurities.
  5. 5. A nickel-based alloy substantially as described in this specification.</claim-text>
GB1120731.3A 2011-12-02 2011-12-02 Nickel-based alloys comprising 0.2-0.6 % by weight silicon Withdrawn GB2497128A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB1120731.3A GB2497128A (en) 2011-12-02 2011-12-02 Nickel-based alloys comprising 0.2-0.6 % by weight silicon
US13/686,220 US20130142661A1 (en) 2011-12-02 2012-11-27 Nickel-based alloy

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1120731.3A GB2497128A (en) 2011-12-02 2011-12-02 Nickel-based alloys comprising 0.2-0.6 % by weight silicon

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GB201120731D0 GB201120731D0 (en) 2012-01-11
GB2497128A true GB2497128A (en) 2013-06-05

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Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10935241B2 (en) * 2014-05-09 2021-03-02 Raytheon Technologies Corporation Additively manufactured hotspot portion of a turbine engine component having heat resistant properties and method of manufacture
CN106563929B (en) * 2015-10-08 2019-09-17 利宝地工程有限公司 Repair and manufacture the method and turbine engine components of turbine engine components
US10415121B2 (en) 2016-08-05 2019-09-17 Onesubsea Ip Uk Limited Nickel alloy compositions for aggressive environments
CN113186431A (en) * 2021-05-06 2021-07-30 哈尔滨工业大学(深圳) Nickel-based high-temperature alloy powder suitable for powder metallurgy and preparation method thereof

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB607616A (en) * 1945-11-28 1948-09-02 Harold Ernest Gresham Nickel base alloy
GB708820A (en) * 1951-03-29 1954-05-12 Carpenter Steel Co Improvements in alloys
GB943141A (en) * 1961-01-24 1963-11-27 Rolls Royce Method of heat treating nickel alloys
US3420660A (en) * 1963-09-20 1969-01-07 Nippon Yakin Kogyo Co Ltd High strength precipitation hardening heat resisting alloys
GB1512984A (en) * 1974-06-17 1978-06-01 Cabot Corp Oxidation resistant nickel alloys and method of making the same
US20020195175A1 (en) * 2001-06-04 2002-12-26 Kiyohito Ishida Free-cutting Ni-base heat-resistant alloy

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1212020A (en) * 1981-09-14 1986-09-30 David N. Duhl Minor element additions to single crystals for improved oxidation resistance
US6468368B1 (en) * 2000-03-20 2002-10-22 Honeywell International, Inc. High strength powder metallurgy nickel base alloy
GB0719195D0 (en) * 2007-10-02 2007-11-14 Rolls Royce Plc A nickel base superalloy

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB607616A (en) * 1945-11-28 1948-09-02 Harold Ernest Gresham Nickel base alloy
GB708820A (en) * 1951-03-29 1954-05-12 Carpenter Steel Co Improvements in alloys
GB943141A (en) * 1961-01-24 1963-11-27 Rolls Royce Method of heat treating nickel alloys
US3420660A (en) * 1963-09-20 1969-01-07 Nippon Yakin Kogyo Co Ltd High strength precipitation hardening heat resisting alloys
GB1512984A (en) * 1974-06-17 1978-06-01 Cabot Corp Oxidation resistant nickel alloys and method of making the same
US20020195175A1 (en) * 2001-06-04 2002-12-26 Kiyohito Ishida Free-cutting Ni-base heat-resistant alloy

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GB201120731D0 (en) 2012-01-11
US20130142661A1 (en) 2013-06-06

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