Combustion Turbine Component Having Rare-Earth Elements and Associated Methods
A method of making a combustion turbine component includes forming a nanosized powder including a plurality of metals and at least one rare-earth element and agglomerating the nanosized powder to form a microsized powder including a plurality of metals and at least one rare-earth element. The microsized powder is processed to form a cohesive metallic mass and a primary aging heat treating is performed on the cohesive metallic mass. A solution heat treating may be performed on the cohesive metallic mass prior to the primary aging heat treating. A secondary aging treating may be performed on the cohesive metallic mass after the primary aging treating.
1 . A method of making a combustion turbine component comprising:
forming a nanosized powder comprising a plurality of metals and at least one rare-earth element;
agglomerating the nanosized powder to form a microsized powder comprising a plurality of metals and at least one rare-earth element;
processing the microsized powder to form a cohesive metallic mass; and
performing a primary aging heat treating on the cohesive metallic mass.
2 . The method of claim 1 wherein forming the nanosized powder comprises:
forming an alloy powder comprising a plurality of metals; forming a metallic powder comprising at least one rare-earth element; and
milling the alloy powder comprising a plurality of metals and the metallic powder comprising at least one rare-earth element together to form the nanosized powder.
3 . The method of claim 2 wherein forming the metallic powder comprising the at least one rare-earth element comprises atomizing a metallic liquid comprising at least one rare-earth element to form a metallic powder comprising at least one rare-earth element and heat treating the metallic powder comprising at least one rare-earth element to form a metallic powder comprising at least one rare-earth element and at least one oxide thereof.
4 . The method of claim 1 wherein performing the primary aging heat treating comprises:
heating the cohesive metallic mass to a primary aging temperature being greater than a secondary carbide phase field temperature of the cohesive metallic mass and less than a solvus temperature of a gamma prime phase of the cohesive metallic mass;
holding the cohesive metallic mass at the primary aging temperature; and
cooling the cohesive metallic to a desired temperature related to the secondary carbide phase field temperature.
5 . The method of claim 4 wherein the cohesive metallic mass is held at the primary aging temperature for 1.5 to 2.5 hours; wherein the cohesive metallic mass is cooled at a rate of 20° C. to 30° C. per second; and wherein the desired temperature is within 300° C. of the secondary carbide phase field temperature.
6 . The method of claim 1 further comprising performing a solution heat treating on the cohesive metallic mass prior to the primary aging treating.
7 . The method of claim 6 wherein performing the solution heat treating comprises:
heating the cohesive metallic mass at a first heating rate to a temperature below the solvus temperature of a gamma prime phase of the cohesive metallic mass;
heating the cohesive metallic mass at a second heating rate less than the first heating rate to a solution temperature being at least the solvus temperature of the gamma prime phase of the cohesive metallic mass;
holding the cohesive metallic mass at the solution temperature; and
cooling the cohesive metallic mass to a temperature below the solution temperature.
8 . The method of claim 7 wherein the first heating rate is in a range of 10° C. to 25° C. per minute; wherein the second heating rate is in a range of 1° C. to 3° C. per minute; wherein the cohesive metallic mass is held at the solution temperature for 1.5 to 2.5 hours; and wherein the cohesive metallic mass is cooled at a rate of 20° C. to 30° C. per minute.
9 . The method of claim 6 further comprising performing a secondary aging heat treating on the cohesive metallic mass after performing the primary aging heat treating.
10 . The method of claim 9 wherein performing the secondary aging heat treating comprises:
heating the cohesive metallic mass to a secondary carbide phase field temperature of the cohesive metallic mass;
holding the cohesive metallic mass at the secondary carbide phase field temperature; and
cooling the cohesive metallic mass to below the secondary carbide phase field temperature.
11 . The method of claim 10 wherein the cohesive metallic mass is heated to the secondary carbide phase field temperature at a rate of less than 25° C. per minute; wherein the cohesive metallic mass is held at the secondary carbide phase field temperature for 15 to 25 hours; and wherein the cohesive metallic mass is cooled at a rate of 20° C. to 30° C. per minute.
12 . A method as in claim 1 wherein the metallic powder comprising at least one rare-earth element further comprises at least one oxide of the at least one rare-earth element,
13 . A method as in claim 1 wherein processing the microsized powder to form the cohesive metallic mass comprises compacting the microsized powder to form a cohesive metallic mass.
14 . A method as in claim 1 wherein processing the microsized powder to form the cohesive metallic mass comprises thermally spraying the microsized powder onto a metallic substrate.
15 . A method as in claim 1 further comprising forming the combustion turbine component from the cohesive metallic mass.
16 . A method of making a combustion turbine component comprising:
forming an alloy powder comprising a plurality of metals;
forming a metallic powder comprising at least one rare-earth element;
milling the alloy powder comprising a plurality of metals and the metallic powder comprising at least one rare-earth element together to form a nanosized powder comprising a plurality of metals and at least one rare-earth element;
agglomerating the nanosized powder to form a microsized powder comprising a plurality of metals and at least one rare-earth element;
processing the microsized powder to form a cohesive metallic mass;
performing a solution heat treating on the cohesive metallic mass; and
performing a primary aging heat treating on the cohesive metallic mass.
17 . A method as in claim 16 wherein the metallic powder comprising at least one rare-earth element further comprises at least one oxide of the at least one rare-earth element.
18 . A method as in claim 16 wherein forming the metallic powder comprises atomizing a metallic liquid comprising at least one rare-earth element to form a metallic powder comprising at least one rare-earth element and heat treating the metallic powder comprising at least one rare-earth element to form the metallic powder comprising the at least one rare-earth element and at least one oxide thereof.
19 . A method as in claim 16 wherein forming the alloy powder comprising the plurality of metals comprises atomizing an alloy liquid comprising a plurality of metals to form an alloy powder comprising a plurality of metals.
20 . A method as in claim 16 wherein processing the microsized powder to form the cohesive metallic mass comprises compacting the microsized powder to form a cohesive metallic mass.
21 . A method as in claim 16 wherein processing the microsized powder to form the cohesive metallic mass comprises thermally spraying the microsized powder onto a metallic substrate.
22 . A method of making a combustion turbine component comprising:
forming a nanosized powder comprising a plurality of metals and at least one rare-earth element;
agglomerating the nanosized powder to form a microsized powder comprising a plurality of metals and at least one rare-earth element;
processing the microsized powder to form a cohesive metallic mass; and
performing a solution heat treating on the cohesive metallic mass.
23 . A method as in claim 22 wherein the metallic powder comprising at least one rare-earth element further comprises at least one oxide of the at least one rare-earth element.
24 . A method as in claim 22 wherein processing the microsized powder to form the cohesive metallic mass comprises compacting the microsized powder to form a cohesive metallic mass.
25 . A method as in claim 22 wherein processing the microsized powder to form the cohesive metallic mass comprises thermally spraying the microsized powder onto a metallic substrate.