WIRE FOR LIQUID ASSISTED ADDITIVE MANUFACTURING OF A SUPERALLOY COMPONENT
A wire is provided for additive manufacturing a superalloy component using a liquid assisted additive manufacturing process. The wire has an elongated body that includes therein a superalloy powder mixture including at least 51% by weight a high melt superalloy powder and at least 5% by weight a low melt superalloy powder. The low melt superalloy powder may have a solidus temperature lower than the solidus temperature of the high melt superalloy powder by between 50° C. and 220° C. Each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture may have an aluminum content by weight of greater than 1.5%. The low melt superalloy powder may include at least 5% by weight of tantalum, and the high melt superalloy powder may include less than half the content by weight percent of tantalum compared to the content by weight percent of tantalum in the low melt superalloy powder.
1 . A wire for additively manufacturing or welding metal components or portions thereof comprising:
an elongated body, wherein the elongated body includes therein a superalloy powder mixture including:
at least 51% by weight a high melt superalloy powder; and
at least 5% by weight a low melt superalloy powder,
wherein the low melt superalloy powder has a solidus temperature lower than the solidus temperature of the high melt superalloy powder by between 50° C. and 220° C., wherein each of the high melt superalloy powder and the low melt superalloy powder include nickel, wherein the nickel content of the wire is greater than 40% by weight, wherein each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture have an aluminum content by weight of greater than 1.5%, wherein the low melt superalloy powder includes at least 5% by weight of tantalum, and wherein the high melt superalloy powder includes less than half the content by weight percent of tantalum compared to the content by weight percent of tantalum in the low melt superalloy powder.
2 . The wire according to claim 1 , wherein the superalloy powder mixture has a total of aluminum and optional titanium content by weight of greater than 4 %.
3 . The wire according to claim 2 , wherein at least one of the elongated body, the superalloy powder mixture, or both are comprised by weight of about 4% to about 23% chromium, about 4% to about 20% cobalt, 0% to about 8% titanium, about 1.5% to about 8% aluminum, 0% to about 11% tungsten, 0% to about 4% molybdenum, 1% to about 13% tantalum, 0% to about 0.2% carbon, 0% to about 1% zirconium, 0% to about 4% hafnium, 0% to about 4% rhenium, 0% to about 0.1% yttrium and/or cerium, 0% to about 0.04% boron, 0% to about 2% niobium, 0% to about 1.5% optional incidental elements and unavoidable impurities, and balance nickel.
4 . The wire according to claim 3 , wherein each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture have an aluminum content by weight of greater than 4.0%.
5 . The wire according to claim 3 , wherein each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture have a nickel content by weight greater than 40%.
6 . The wire according to claim 5 , wherein each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture have a nickel content by weight greater than 45% and an aluminum content by weight of greater than 5.5%.
7 . The wire according to claim 3 , wherein the low melt superalloy powder includes at least 10% by weight of tantalum.
8 . The wire according to claim 3 , wherein the low melt superalloy powder includes at least 0.5% by weight of hafnium, and wherein the high melt superalloy powder includes less than half the content by weight percent of hafnium compared to the content by weight percent of hafnium in the low melt superalloy powder.
9 . The wire according to claim 3 , wherein the low melt superalloy powder includes at least 7% by weight of titanium, and wherein the high melt superalloy powder includes less than half the content by weight percent of titanium compared to the content by weight percent of titanium in the low melt superalloy powder.
10 . The wire according to claim 3 , wherein at least one of the amounts of chromium, aluminum, or molybdenum in weight percent in the low melt superalloy powder is at least 15% to 75% less than the corresponding weight percent in the high melt superalloy powder.
11 . The wire according to claim 3 , wherein at least one of the amounts of cobalt or tungsten in weight percent in the high low melt superalloy powder is at least 50% to 75% less than the corresponding weight percent in the low melt superalloy powder.
12 . The wire according to claim 3 , wherein the low melt superalloy powder comprises by weight at least 8% aluminum.
13 . The wire according to claim 3 , wherein the low melt superalloy powder comprises by weight at least 3% hafnium.
14 . The wire according to claim 3 , wherein the high melt superalloy powder includes by weight at maximum 1% tantalum.
15 . The wire according to claim 3 , wherein the low melt superalloy powder comprises by weight at least 3.8% tungsten.
16 . The wire according to claim 3 , wherein the superalloy powder mixture comprises by weight at least 9% tungsten.
17 . The wire according to claim 3 , wherein at least one of the elongated body, the superalloy powder mixture, or both are comprises by weight at maximum 6.2% tantalum.
18 . The wire according to claim 3 , wherein the low melt superalloy powder has a liquidus temperature above 1300° C.
19 . The wire according to claim 3 , wherein the ratio of the high melt superalloy powder to the low melt superalloy powder by weight is between 94:06 and 76:24 in the superalloy powder mixture.
20 . The wire according to claim 19 , wherein the ratio of the high melt superalloy powder to the low melt superalloy powder by weight is between 85:15 and 75:25 in the superalloy powder mixture.
21 . The wire according to claim 3 , wherein the elongated body is a welding wire, wherein the welding wire includes a metal tubular sheath that surrounds the superalloy powder mixture.
22 . The wire according to claim 21 , wherein the metal tubular sheath is comprised of a nickel or a nickel alloy foil.
23 . The wire according to claim 22 , wherein the elongated body is a filament, wherein the filament includes a binder that binds the superalloy powder mixture together, wherein the binder includes a polymer, wherein the filament comprises greater than 50% by volume superalloy powder mixture and less than 50% by volume binder.
24 . The wire according to claim 23 , wherein the binder includes a thermoplastic.
25 . The wire according to claim 24 , wherein the binder includes a wax.