Presintered preform for repair of superalloy component
A method of making pre-sintered preforms using a mixture of base superalloy particles and titanium-containing boron and silicon free braze alloy particles, such as for the repair of superalloy gas turbine engine components. Alloy particles as large as 2 mm provide reduced shrinkage when compared to prior art preforms. Braze material compositions disclosed herein are boron and silicon free and may have melting temperature ranges as low as 10° C., and they include no element not already present in the composition of the superalloy component.
1. A method comprising:
forming a preform from a powder mixture comprising superalloy material particles and boron and silicon free braze material particles comprising titanium, a size range of the superalloy material particles comprising particles larger than 140 US mesh; and
sintering the preform at a temperature below solidus temperatures of the superalloy and braze material particles,
wherein a first size of the superalloy particles is larger than a second size of the braze material particles, and
wherein the powder mixture comprises from 5% to 50% by weight braze material particles.
2. The method of claim 1 , further comprising joining the sintered preform to a superalloy component with a braze joint formed from braze material particles disposed on a periphery of the preform.
3. The method of claim 1 , further comprising joining the sintered preform to a superalloy component with a braze joint formed from braze material applied between the preform and a surface of the component.
4. The method of claim 1 , further comprising forming the preform from a powder mixture comprising superalloy material particles larger than 100 US mesh.
5. The method of claim 1 , further comprising forming the preform from a powder mixture comprising superalloy material particles as large as 2,000 microns.
6. The method of claim 1 , further comprising sintering the preform to a porosity of less than 5% by volume.
7. The method of claim 1 , further comprising forming the preform from a powder mixture comprising braze material particles having a composition of Cr 15-25%; Ti 15-25%; balance Ni.
8. The method of claim 1 , further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:
Cr 12-16%;
Ti 13-16%;
Al 0-2.5%
Co 2-4%
W 3-5%
Mo 0-2%;
Ta 0-2%;
Balance Ni.
9. The method of claim 1 , further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:
Cr 15-18%;
Ti 10-15%;
Al 0-2.5%
Co 2-4%
W 3-5%
Mo 0-2%;
Ta 0-2%;
balance Ni.
10. The method of claim 1 , further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:
Cr 15-19%;
Ti 8-10%;
Al 0-2.5%
Co 14-18%
Mo 12-16%;
balance Ni.
11. The method of claim 1 , further comprising:
joining the sintered preform to a superalloy component with a braze joint; and
homogenizing the braze joint with a solution heat treatment applied to the component in order to rejuvenate material properties of the superalloy component.
12. The method of claim 1 , further comprising selecting a composition of the braze material particles to include no element that is not part of a composition of the superalloy particles.
13. A method comprising:
forming a preform from a powder mixture comprising superalloy material particles and braze material particles, a size range of the superalloy material particles comprising particles larger than 140 US mesh, and a composition of the braze material particles having a melting temperature range of less than 50° C.; and
sintering the preform at a temperature less than solidus temperatures of the superalloy material and braze material particles, under a pressure of minimum of 15 ksi and an inert atmosphere until the porosity is less than 5% by volume, wherein a first size of the superalloy particles is larger than a second size of the braze material particles, and
wherein the powder mixture comprises from 5% to 50% by weight braze material particles.
14. The method of claim 13 , further comprising forming the preform from a powder mixture comprising braze material particles having a composition of Cr 15-25%; Ti 15-25%; balance Ni.
15. The method of claim 13 , further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:
Cr 12-16%;
Ti 13-16%;
Al 0-2.5%;
Co 2-4%;
W 3-5%;
Mo 0-2%;
Ta 0-2%;
balance Ni.
16. The method of claim 13 , further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:
Cr 15-18%;
Ti 10-15%;
Al 0-2.5%;
Co 2-4%;
W 3-5%;
Mo 0-2%;
Ta 0-2%;
balance Ni.
17. The method of claim 13 , further comprising forming the preform from a powder mixture comprising braze material particles having a composition of:
Cr 15-19%;
Ti 8-10%;
Al 0-2.5%
Co 14-18%
Mo 12-16%;
balance Ni.
18. The method of claim 13 , further comprising:
joining the sintered preform to a superalloy component with a braze joint; and
homogenizing the braze joint with a solution heat treatment applied to the component in order to rejuvenate material properties of the superalloy component.
19. The method of claim 1 , further comprising forming the preform with the braze material particles having a melting temperature range of less than 50° C.