Nickel-base superalloy and use thereof
The novel nickel-base superalloy useful in an additive manufacturing process or a powder-based manufacturing process includes the following composition in wt %: Cr 8.0-8.5; Co 9.0-9.5; Mo 0.4-0.6; W 9.3-9.7; Ta 2.9-3.6; Al 4.9-5.6; Ti 0.2-1.0; Hf 0-0.05; C 0.005-0.03; B 0.005-0.02; Zr 0.005-0.1; Nb 0.2-1; Mn 0-0.6; and S 0-0.002 (≤20 ppm); the balance nickel and incidental elements and unavoidable impurities.
1. A nickel-base superalloy comprising the following composition in wt %:
Cr
8.0-8.5
Co
9.0-9.5
Mo
0.4-0.6
W
9.3-9.7
Ta
2.9-3.6
Al
4.9-5.6
Ti
0.2-1.0
Hf
0-0.05
C
0.005-0.03
B
0.005-0.02
Zr
0.005-0.1
Nb
0.2-1
Mn
0-0.6
S
0-0.002 (≤20 ppm)
the balance nickel and incidental elements and unavoidable impurities.
2. A nickel-base superalloy as claimed in claim 1 , comprising the following composition in wt %:
Cr
8.0-8.5
Co
9.0-9.5
Mo
0.4-0.6
W
9.3-9.7
Ta
3.1-3.5
Al
5.1-5.5
Ti
0.5-0.9
Hf
0-0.05
C
0.005-0.02
B
0.005-0.02
Zr
0.005-0.02
Nb
0.6-1
S
0-0.0005 (≤5 ppm)
the balance nickel and incidental elements and unavoidable impurities.
3. A nickel-base superalloy as claimed in claim 1 , comprising the following composition in wt %:
Cr
8.00-8.50
Co
9.00-9.50
Mo
0.40-0.60
W
9.30-9.70
Ta
3.10-3.50
Al
5.10-5.50
Ti
0.50-0.90
Hf
0-0.05
C
0.005-0.015
B
0.005-0.015
Zr
0.005-0.015
Nb
0.6-1.0
S
0-0.0005 (≤5 ppm)
the balance nickel and incidental elements and unavoidable impurities.
4. A nickel-base superalloy as claimed in claim 1 , wherein the incidental elements are one or more element selected from the following (wt % unless indicated to be ppm):
V
0.10
max
Fe
0.05
max
Si
0.05
max
P
0.005
max
Mg
0.005
max
Cu
0.01
max
N
60
ppm max
O
250
ppm max
Ag
1
ppm max
As
5
ppm max
Bi
0.1
ppm max.
Cd
2
ppm max
Ga
25
ppm
In
0.2
ppm max
Pb
2
ppm max
Sb
2
ppm max
Se
1
ppm max
Sn
10
ppm max
Te
0.1
ppm max
Tl
0.2
ppm max
Zn
5
ppm max.
5. A nickel-base superalloy as claimed in claim 2 , wherein the incidental elements are one or more element selected from the following (wt % unless indicated to be ppm):
V
0.10
max
Fe
0.05
max
Si
0.05
max
P
0.005
max
Mg
0.005
max
Cu
0.01
max
N
60
ppm max
O
250
ppm max
Ag
1
ppm max
As
5
ppm max
Bi
0.1
ppm max.
Cd
2
ppm max
Ga
25
ppm
In
0.2
ppm max
Pb
2
ppm max
Sb
2
ppm max
Se
1
ppm max
Sn
10
ppm max
Te
0.1
ppm max
Tl
0.2
ppm max
Zn
5
ppm max.
6. A nickel-base superalloy as claimed in claim 3 , wherein the incidental elements are one or more element selected from the following (wt % unless indicated to be ppm):
V
0.10
max
Fe
0.05
max
Si
0.05
max
P
0.005
max
Mg
0.005
max
Cu
0.01
max
N
60
ppm max
O
250
ppm max
Ag
1
ppm max
As
5
ppm max
Bi
0.1
ppm max.
Cd
2
ppm max
Ga
25
ppm
In
0.2
ppm max
Pb
2
ppm max
Sb
2
ppm max
Se
1
ppm max
Sn
10
ppm max
Te
0.1
ppm max
Tl
0.2
ppm max
Zn
5
ppm max.
7. A nickel-base superalloy as claimed in claim 1 , in a physical form which is adapted for use in an additive manufacturing process.
8. A nickel-base superalloy as claimed in claim 1 , in the form of a wire, rod or powder adapted for use in an additive manufacturing process.
9. A nickel-base superalloy as claimed in claim 1 , in the form of a wire, rod or powder adapted for use in a directed energy deposition (DED) additive manufacturing process.
10. A nickel-base superalloy as claimed in claim 7 , wherein the physical form is adapted for use in a manufacturing process selected from laser-based additive manufacturing (LBAM), direct laser deposition (DLD), electron beam additive manufacturing (EBAM), laser engineered net shaping (LENS), selective laser melting (SLM), SLM three-dimensional printing (SLM 3D printing), direct metal laser sintering (DMLS), direct metal laser sintering three-dimensional printing (DML 3D printing), electron beam melting (EBM), direct metal deposition (DMD), direct metal tooling (DMT), direct metal tooling three-dimensional printing (DMT 3D printing), construction laser additive direct (CLAD) and ion fusion formation (IFF).
11. A nickel-base superalloy as claimed in claim 1 , in a physical form which is adapted for use in a powder-based manufacturing process.
12. A nickel-base superalloy as claimed in claim 11 , in the form of a powder adapted for use in a powder-based manufacturing process.
13. A nickel-base superalloy as claimed in claim 11 , in the form of a powder adapted for use in hot isostatic pressing (HIP).
14. A metal article, component or structure comprising a nickel-base superalloy comprising the following composition in wt %:
Cr
8.0-8.5
Co
9.0-9.5
Mo
0.4-0.6
W
9.3-9.7
Ta
2.9-3.6
Al
4.9-5.6
Ti
0.2-1.0
Hf
0-0.05
C
0.005-0.03
B
0.005-0.02
Zr
0.005-0.1
Nb
0.2-1
Mn
0-0.6
S
0-0.002 (≤20 ppm)
the balance nickel and incidental elements and unavoidable impurities.
15. A metal article, component or structure as claimed in claim 14 , wherein the article, component or structure is an article, component or structure for use in the aerospace industry.
16. A metal article, component or structure as claimed in claim 14 , which is selected from statics, turbine blades, other turbine components, and combustor components for use in the aerospace industry.
17. A method of manufacturing a metal article, component or structure which is selected from statics, turbine blades, other turbine components, and combustor components for use in the aerospace industry, which comprises applying energy to melt a nickel-base superalloy comprising the following composition in wt %:
Cr
8.0-8.5
Co
9.0-9.5
Mo
0.4-0.6
W
9.3-9.7
Ta
2.9-3.6
Al
4.9-5.6
Ti
0.2-1.0
Hf
0-0.05
C
0.005-0.03
B
0.005-0.02
Zr
0.005-0.1
Nb
0.2-1
Mn
0-0.6
S
0-0.002 (≤20 ppm)
the balance nickel and incidental elements and unavoidable impurities.
18. A method as claimed in claim 17 , wherein the nickel-base superalloy is in the physical form of a powder and the energy is applied in a powder-based manufacturing process, or the nickel-base superalloy is in the form of a metal body or a powder as a metal feed and the energy is applied in an additive manufacturing process.
19. A method of manufacturing a nickel-base superalloy as defined in claim 1 , the method comprising mixing the components of the superalloy in the required proportions at an elevated temperature in a melt, and allowing the molten mixture to cool to provide the superalloy.