JOINING PROCESS AND JOINED ARTICLE
A joining process and a joined article are disclosed. The joining process includes positioning an article having a base material, and friction welding a pre-sintered preform to the base material. The pre-sintered preform forms a feature on the article. The joined article includes a feature joined to a base material by friction welding of a pre-sintered preform.
1 . A joining process, comprising:
positioning an article having a base material; and
friction welding a pre-sintered preform to the base material;
wherein the pre-sintered preform forms a feature on the article.
2 . The joining process of claim 1 , wherein the friction welding is at a weld pressure between about 30 ksi and about 50 ksi.
3 . The joining process of claim 1 , wherein the friction welding is for a duration of between about 15 seconds and about 19 seconds.
4 . The joining process of claim 1 , wherein the friction welding has an amplitude of between about 4 mm and about 6 mm.
5 . The joining process of claim 1 , wherein the friction welding has an oscillatory frequency of between about 25 Hz and about 400 Hz.
6 . The joining process of claim 1 , wherein an interface region between the base material and the feature remains devoid of cracking when exposed to a temperature of between about 2000° F. and about 2100° F. for a duration of between about 90 minutes and about 150 minutes.
7 . The joining process of claim 1 , wherein the base material is incompatible for non-friction based joining with the pre-sintered preform.
8 . The joining process of claim 1 , wherein the base material includes a nickel-based alloy.
9 . The joining process of claim 1 , wherein the base material includes a cobalt-based alloy.
10 . The joining process of claim 1 , wherein the base material has a composition, by weight, of:
between about 8.0% and about 8.7% Cr, between about 9% and about 10% Co, between about 5.25% and about 5.75% Al, up to about 0.9% Ti, between about 9.3% and about 9.7% W, up to about 0.6% Mo, between about 2.8% and about 3.3% Ta, between about 1.3% and about 1.7% Hf, up to about 0.1% C, up to about 0.02% Zr, up to about 0.02% B, up to about 0.2% Fe, up to about 0.06% Si, up to about 0.1% Mn, up to about 0.1% Cu, up to about 0.01% P, up to about 0.004% S, up to about 0.1% Nb, and a balance of nickel;
between about 13.7% and about 14.3% Cr, between about 9% and about 10% Co, between about 2.8% and about 3.2% Al, between about 4.7% and about 5.1% Ti, between about 3.5% and about 4.1% W, between about 1.4% and about 1.7% Mo, between about 2.4% and about 3.1% Ta, up to about 0.12% C, up to about 0.04% Zr, up to about 0.02% B, up to about 0.35% Fe, up to about 0.3% Si, up to about 0.1% Mn, up to about 0.1% Cu, up to about 0.015% P, up to about 0.005% S, up to about 0.15% Nb, and a balance of nickel;
about 7.5% Co, 9.75% Cr, about 4.2% Al, 3.5% Ti, about 1.5% Mo, about 4.8% Ta, about 6% W, up to about 0.5% Nb, up to about 0.15% Hf, up to about 0.08% C, up to about 0.00925% B, and a balance nickel; or
about 7% Cr, about 8% Co, about 2% Mo, about 5% W, about 6% Ta, about 6.2% Al, up to about 0.2% Hf, about 3% Re, and a balance nickel.
11 . The joining process of claim 1 , wherein the pre-sintered preform includes a first material having a first melting point and a second material having a second melting point, the first melting point being lower than the second melting point.
12 . The joining process of claim 11 , wherein the second material is at a concentration, by weight, of between about 5% and about 60%.
13 . The joining process of claim 11 , wherein the first material is at a concentration, by weight, of between about 40% and about 95%.
14 . The joining process of claim 11 , wherein the first material has a composition selected from the group consisting of, by weight, of:
between about 13.7% and about 14.3% Cr, between about 9% and about 10% Co, between about 2.8% and about 3.2% Al, between about 4.7% and about 5.1% Ti, between about 3.5% and about 4.1% W, between about 1.4% and about 1.7% Mo, between about 2.4% and about 3.1% Ta, up to about 0.12% C, up to about 0.04% Zr, up to about 0.02% B, up to about 0.35% Fe, up to about 0.3% Si, up to about 0.1% Mn, up to about 0.1% Cu, up to about 0.015% P, up to about 0.005% S, up to about 0.15% Nb, and a balance of nickel;
between about 8.0% and about 8.7% Cr, between about 9% and about 10% Co, between about 5.25% and about 5.75% Al, up to about 0.9% Ti, between about 9.3% and about 9.7% W, up to about 0.6% Mo, between about 2.8% and about 3.3% Ta, between about 1.3% and about 1.7% Hf, up to about 0.1% C, up to about 0.02% Zr, up to about 0.02% B, up to about 0.2% Fe, up to about 0.06% Si, up to about 0.1% Mn, up to about 0.1% Cu, up to about 0.01% P, up to about 0.004% S, up to about 0.1% Nb, and a balance of nickel;
between about 13.7% and about 14.3% Cr, between about 9% and about 10% Co, between about 2.8% and about 3.2% Al, between about 4.8% and about 5.2% Ti, between about 3.7% and about 4.3% W, between about 3.7% and about 4.3% Mo, up to about 0.1% Re, up to about 0.1% Ta, up to about 0.1% Hf, up to about 0.19% C, up to about 0.15% Pd, up to about 0.3% Pt, up to about 0.01% Mg, up to about 0.1% Zr, up to about 0.02% B, up to about 0.35% Fe, up to about 0.1% Si, up to about 0.1% Mn, up to about 0.015% P, up to about 0.0075% S, up to about 0.1% Nb, and a balance of nickel;
between about 6.6% and about 7% Cr, between about 11.45% and about 12.05% Co, between about 5.94% and about 6.3% Al, up to about 0.02% Ti, between about 4.7% and about 5.1% W, between about 1.3% and about 1.7% Mo, between about 2.6% and about 3% Re, between about 6.2% and about 6.5% Ta, between about 1.3% and about 1.7% Hf, up to about 0.14% C, up to about 0.3% Pt, up to about 0.0035% Mg, up to about 0.03% Zr, up to about 0.02% B, up to about 0.2% Fe, up to about 0.06% Si, up to about 0.1% Mn, up to about 0.01% P, up to about 0.004% S, up to about 0.1% Nb, and a balance of nickel; or
between about 16.5% and about 18.5% Cr, between about 27% and about 30% Mo, about 1.5% Ni, up to about 0.08% C, about 1.5% Fe, between about 3% and about 3.8% Si, up to about 0.03% P, up to about 0.03% S, up to about 0.15% O, and a balance of cobalt.
15 . The joining process of claim 11 , wherein the second material has a composition selected from the group consisting of, by weight, of:
between about 22.5% and about 24.25% Cr, up to about 0.3% Ti, between about 6.5% and about 7.5% W, between about 9% and about 11% Ni, between about 3% and about 4% Ta, up to about 0.65% C, between about 2% and about 3% B, about 1.3% Fe, up to about 0.4% Si, up to about 0.1% Mn, up to about 0.02% S, and a balance of cobalt;
about 14% Cr, about 10% Co, about 3.5% Al, about 2.75% B, between about 2.5% and about 2.75% Ta, up to about 0.1% Y, and a balance of nickel;
about 14% Cr, about 9% Co, about 4% Al, about 2.5% B, and a balance of nickel;
about 15.3% Cr, about 10.3% Co, about 3.5% Ta, about 3.5% Al, about 2.3% B, and a balance of nickel; or
about 28% Mo, about 17% Cr, about 3% Si, and a balance cobalt.
16 . The joining process of claim 1 , wherein the friction welding is in an inert environment with heat of at least about 400° F.
17 . The joining process of claim 1 , wherein the article is a turbine component selected from the group consisting of a bucket, a blade, a nozzle, a turbine wheel, a platform, a dovetail, a seal, and combinations thereof.
18 . The joining process of claim 1 , wherein the article is a component of a system selected from the group consisting of a gas turbine, a turbine engine, a steam turbine, a wind turbine, a power generation system, a propulsion system, and combinations thereof.
19 . A joining process, comprising:
positioning a turbine component having a base material; and
friction welding a pre-sintered preform to the base material;
wherein the pre-sintered preform forms a feature on the turbine component;
wherein the base material has a composition, by weight, of between about 8.0% and about 8.7% Cr, between about 9% and about 10% Co, between about 5.25% and about 5.75% Al, up to about 0.9% Ti, between about 9.3% and about 9.7% W, up to about 0.6% Mo, between about 2.8% and about 3.3% Ta, between about 1.3% and about 1.7% Hf, up to about 0.1% C, up to about 0.02% Zr, up to about 0.02% B, up to about 0.2% Fe, up to about 0.06% Si, up to about 0.1% Mn, up to about 0.1% Cu, up to about 0.01% P, up to about 0.004% S, up to about 0.1% Nb, and a balance of nickel;
wherein the pre-sintered preform has a composition of, by weight, about 50% a first material and 50% a second material;
wherein the first material has a composition, by weight, of between about 8.0% and about 8.7% Cr, between about 9% and about 10% Co, between about 5.25% and about 5.75% Al, up to about 0.9% Ti, between about 9.3% and about 9.7% W, up to about 0.6% Mo, between about 2.8% and about 3.3% Ta, between about 1.3% and about 1.7% Hf, up to about 0.1% C, up to about 0.02% Zr, up to about 0.02% B, up to about 0.2% Fe, up to about 0.06% Si, up to about 0.1% Mn, up to about 0.1% Cu, up to about 0.01% P, up to about 0.004% S, up to about 0.1% Nb, and a balance of nickel;
wherein the second material has a composition, by weight, of about 14% Cr, about 10% Co, about 3.5% Al, about 2.75% B, between about 2.5% and about 2.75% Ta, up to about 0.1% Y, and a balance of nickel;
wherein an interface region between the base material and the feature remains devoid of cracking when exposed to a temperature of between about 2000° F. and about 2100° F. for a duration of between about 90 minutes and about 150 minutes.
20 . A joined article, comprising a feature joined to a base material by friction welding of a pre-sintered preform.