FCC MATERIALS OF ALUMINUM, COBALT, CHROMIUM, AND NICKEL, AND PRODUCTS MADE THEREFROM
The present disclosure relates to new materials comprising Al, Co, Cr, and Ni. The new materials may realize a single phase field of a face-centered cubic (fcc) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1000° C. The new materials may include 2.2-8.6 wt. % Al, 4.9-65.0 wt. % Co, 4.3-42.0 wt. % Cr, and 4.8-88.6 wt. % Ni. In one embodiment, the precipitate is selected from the group consisting of the L1 2 phase, the B2 phase, the sigma phase, the bcc phase, and combinations thereof. The new alloys may realize improved high temperature properties.
1 . A composition of matter comprising:
2.2-8.6 wt. % Al;
4.9-65.0 wt. % Co;
4.3-42.0 wt. % Cr; and
4.8-88.6 wt. % Ni;
the balance being any optional incidental elements and impurities.
2 . The composition of matter of claim 1 , wherein the incidental elements comprise up to 0.15 wt. % C, up to 0.15 wt. % B, up to 0.5 wt. % Hf and up to 0.5 wt. % Zr.
3 . The composition of matter of claim 1 , wherein the composition of matter includes 2.4-7.8 wt. % Al, 5.5-59.1 wt. % Co, 4.8-38.2 wt. % Cr, and 5.3-82.2 wt. % Ni.
4 . The composition of matter of claim 1 , wherein the composition of matter includes 6.7-8.5 wt. % Al, 4.9-24.4 wt. % Co, 4.3-16.2 wt. % Cr, and 54.4-84.1 wt. % Ni.
5 . The composition of matter of claim 1 , wherein the composition of matter includes 6.8-8.5 wt. % Al, 4.9-24.4 wt. % Co, 8.7-16.2 wt. % Cr, and 54.4-79.6 wt. % Ni.
6 . The composition of matter of claim 5 , wherein the composition of matter includes 5.0-12.3 wt. % Co, 13.2-16.2 wt. % Cr, and 59.8-75.0 wt. % Ni.
7 . The composition of matter of claim 1 , wherein the composition of matter includes 7.5-7.7 wt. % Al, 5.5-22.2 wt. % Co, 4.8-14.8 wt. % Cr, and 60.5-82.2 wt. % Ni.
8 . The composition of matter of claim 7 , wherein the composition of matter includes 9.7-14.8 wt. % Cr, and 60.5-77.3 wt. % Ni.
9 . The composition of matter of claim 7 , wherein the composition of matter includes 5.5-11.2 wt. % Co, 14.6-14.8 wt. % Cr, and 66.5-72.4 wt. % Ni.
10 . An alloy body comprising:
2.2-8.6 wt. % Al;
4.9-65.0 wt. % Co;
4.3-42.0 wt. % Cr; and
4.8-88.6 wt. % Ni;
the balance being any optional incidental elements and impurities.
11 . The alloy body of claim 10 , wherein the alloy body is in the form of an aerospace or automotive component.
12 . The aerospace component of claim 11 , wherein the aerospace or automotive component is a turbine.
13 . A method comprising:
(a) using a feedstock in an additive manufacturing apparatus, wherein the feedstock comprises:
2.2-8.6 wt. % Al;
4.9-65.0 wt. % Co;
4.3-42.0 wt. % Cr; and
4.8-88.6 wt. % Ni;
(b) producing a metal product in the additive manufacturing apparatus using the feedstock.
14 . The method of claim 13 , wherein the feedstock comprises a powder feedstock, wherein the method comprises:
(a) dispersing a metal powder of the powder feedstock in a bed and/or spraying a metal powder of the powder feedstock towards or on a substrate;
(b) selectively heating a portion of the metal powder above its liquidus temperature, thereby forming a molten pool;
(c) cooling the molten pool, thereby forming a portion of the metal product, wherein the cooling comprises cooling at a cooling rate of at least 100° C. per second; and
(d) repeating steps (a)-(c) until the metal product is completed, wherein the metal product comprises a metal matrix, wherein the Al, Co, Cr, and Ni make-up the matrix.
15 . The method of claim 13 , comprising: cooling at a rate sufficient to form at least one precipitate phase.
16 . The method of claim 15 , wherein the at least one precipitate phase comprises at least one of L1 2 , B2, bcc and sigma.
17 . The method of claim 16 , wherein the metal product comprises at least 0.5 vol. % of the precipitate phase.
18 . The method of claim 13 , comprising:
working the metal product.
19 . The method of claim 18 , wherein the producing step comprises:
first producing a portion of the metal product using the feedstock;
second producing another portion of the metal product using the feedstock;
wherein the working occurs at least after the first or second producing steps.
20 . The method of claim 19 , wherein the working occurs between the first producing step and the second producing step.