Ni-Based Superalloy Powder for Additive Manufacturing and an Article Made Therefrom
A nickel base superalloy powder for additive manufacturing applications is disclosed. The alloy powder has the following broad weight percent composition: C 0-0.1 Mn 0.5 max. Si 0-0.03 Cr 4-16 Fe 0-1.5 Mo 0-6 W 0-8 Co 0-15 Ti 0-2 Al 0.5-5.5 Nb 0-6 Ta 7.5-14.5 Hf 0-2.0 Zr 0-0.1 Re 0-6 Ru 0-3 B 0-0.03 The balance of the alloy is at least 50% nickel and the usual impurities. An article of manufacture made from the alloy is also disclosed.
1 . A high γ′ volume fraction Ni-base alloy optimized for laser and electron beam additive manufacturing processes with improved solidification and strain-age cracking resistance and high strength and creep resistance at elevated temperature, said alloy consisting essentially of, in weight percent, about
C
0-0.1
Mn
0.5 max.
Si
0-0.03
Cr
4-16
Fe
1.5 max.
Mo
0-6
W
0-8
Co
0-15
Ti
0-2
Al
0.5-5.5
Nb
0-6
Ta
7.5-14.5
Hf
0-2.0
Zr
0-0.1
Re
0-6
Ru
0-3
B
0-0.03
and the balance of the alloy is at least about 50% nickel and the usual impurities found in commercial grades of Ni-base superalloys intended for the same use and service.
2 . The alloy claimed in claim 1 which contains, about
Cr
9-11
Fe
1 max.
Mo
2-5
W
0.5-2
Co
4-6
Ti
0-0.5
Al
3-5
Nb
3-5
Ta
7.5-9.5
Hf
0-0.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and usual impurities.
3 . The alloy claimed in claim 1 which contains about
Cr
9-11
Fe
1 max.
Mo
2-5
W
0.5-2
Co
0.5-2
Ti
0-0.5
Al
3-5
Nb
2.5-4
Ta
8.5-10.5
Hf
0-0.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and usual impurities.
4 . The alloy claimed in claim 1 which contains about
Cr
4-8
Fe
1 max.
Mo
0.5-1.5
W
6-8
Co
0-1
Ti
0-1
Al
3-5
Nb
0-1
Ta
8.5-10.5
Hf
0.5-1.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and usual impurities.
5 . The alloy claimed in claim 1 which contains about
Cr
9-11
Fe
1 max.
Mo
2-5
W
3.5-4.5
Co
0.5-2
Ti
0-0.5
Al
3-5
Nb
2.5-4
Ta
8.5-10.5
Hf
0-0.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and usual impurities.
6 . The alloy claimed in claim 1 which contains about:
Cr
8-10
Fe
1 max.
Mo
2-5
W
4-6
Co
9-11
Ti
0-0.5
Al
4-5.5
Nb
0-1
Ta
9.5-11.5
Hf
0-0.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and the usual impurities.
7 . The alloy claimed in claim 1 wherein Al+Ti is about 3 to about 6 weight percent and W+Mo+Ru+Re is about 2 to about 12 weight percent.
8 . The alloy claimed in claim 7 wherein C+B+Si+Zr is less than about 0.15 weight percent for reducing solidification range and improving solidification cracking resistance.
9 . A high γ′ volume fraction Ni-base alloy optimized for laser and electron beam additive manufacturing processes with improved solidification and strain-age cracking resistance and high strength and creep resistance at elevated temperature, said alloy consisting essentially of, in weight percent, about
C
0-0.1
Mn
0.5 max.
Si
0-0.03
Cr
4-11
Fe
1 max.
Mo
0-5
W
0.5-8
Co
0-10
Ti
0-1
Al
3-5
Nb
0-5
Ta
7.5-11.5
Hf
0-1.5
Zr
0-0.1
Re
0-5
Ru
0-3
B
0-0.03
and the balance of the alloy is at least about 50% nickel and the usual impurities found in commercial grades of Ni-base superalloys intended for the same use and service.
10 . The alloy claimed in claim 9 which contains, about
Cr
9-11
Fe
1 max.
Mo
2-5
W
0.5-2
Co
4-6
Ti
0-0.5
Al
3-5
Nb
3-5
Ta
7.5-9.5
Hf
0-0.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and usual impurities.
11 . The alloy claimed in claim 9 which contains about
Cr
9-11
Fe
1 max.
Mo
2-5
W
0.5-2
Co
0.5-2
Ti
0-0.5
Al
3-5
Nb
2.5-4
Ta
8.5-10.5
Hf
0-0.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and usual impurities.
12 . The alloy claimed in claim 9 which contains about
Cr
4-8
Fe
1 max.
Mo
0.5-1.5
W
6-8
Co
0-1
Ti
0-1
Al
3-5
Nb
0-1
Ta
8.5-10.5
Hf
0.5-1.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and usual impurities.
13 . The alloy claimed in claim 9 which contains about:
Cr
9-11
Fe
1 max.
Mo
2-5
W
3.5-4.5
Co
0.5-2
Ti
0-0.5
Al
3-5
Nb
2.5-4
Ta
8.5-10.5
Hf
0-0.5
Re
0-1
Ru
0-1
and the balance of the alloy is at least about 50% nickel and usual impurities.
14 . The alloy claimed in claim 9 wherein Al+Ti is about 3.5 to about 5.5 weight percent and W+Mo+Ru+Re is about 3 to about 10 weight percent.
15 . The alloy claimed in claim 14 wherein C+B+Si+Zr is less than about 0.10 weight percent for reducing solidification range and improving solidification cracking resistance.
16 . The alloy claimed in claim 1 or claim 9 comprising a γ′ strengthening phase.
17 . The alloy claimed in claim 16 wherein the γ′ phase has a volume fraction that is greater than 35%.
18 . The alloy claimed in claim 17 wherein the γ′ phase has a volume fraction that is greater than 50%.
19 . The alloy claimed in claim 1 or claim 9 which has a γ′ solvus temperature 7 higher than 2050° F. (1121° C.).