Crack healing additive manufacturing of a superalloy component
A method of additively manufacturing is provided. The method may include successively depositing and fusing together layers of a superalloy powder mixture comprised of a base material powder and a eutectic powder, to build up an additive portion, which eutectic powder has a solidus temperature lower than the solidus temperature of the base material powder. The method may also include heat treating the additive portion at a temperature greater than 1200° C. to heal cracks and/or fill pores and to homogenize the alloy of which the additive portion is comprised. The additive portion alloy has a chemistry defined by the superalloy powder mixture. The base material powder may be formed of a nickel-base superalloy with an aluminum content by weight of at least 1.5%. The eutectic powder may be a nickel-base alloy including by weight about 6% to about 11% chromium, about 5% to about 9% titanium, and about 9% to about 13% zirconium, with balance nickel as its primary components.
1. A method of additively manufacturing comprising:
successively depositing and fusing together layers of a superalloy powder mixture comprised of a base material powder and a eutectic powder, to build up an additive portion, wherein the eutectic powder has a solidus temperature lower than the solidus temperature of the base material powder; and
heat treating the additive portion at a temperature greater than 1200° C. to heal cracks and/or fill pores and to homogenize the alloy of which the additive portion is comprised, which additive portion alloy has a chemistry defined by the superalloy powder mixture,
wherein the base material powder has a nickel content by weight greater than 40% and an aluminum content by weight greater than 1.5%, wherein the eutectic powder includes by weight about 6% to about 11% chromium, about 5% to about 9% titanium, about 9% to about 13% zirconium, and greater than 40% nickel.
2. The method according to claim 1 , including:
removing a damaged portion from a component to leave a first interface;
printing a replacement portion via the successively depositing and fusing together layers of the superalloy powder mixture, which replacement portion has a second interface surface; and
attaching the second interface surface to the first interface surface to replace the damaged portion of the component.
3. The method according to claim 1 , wherein the solidus temperature of the eutectic powder is more than 220° C. below the solidus temperature of the base material powder.
4. The method according to claim 1 , wherein the eutectic powder has a liquidus temperature below 1300° C.
5. The method according to claim 1 , wherein heat treating includes heat treating the additive portion at a temperature at or above 1230° C.
6. The method according to claim 1 , wherein the ratio of the base material powder to the eutectic powder by weight is between about 94:06 and about 76:24 in the superalloy powder mixture.
7. The method according to claim 6 , wherein the ratio of the base material powder to the eutectic powder by weight is between about 94:06 and about 85:15 in the superalloy powder mixture.
8. The method according to claim 1 , wherein the eutectic powder includes at maximum 1% aluminum by weight.
9. The method according to claim 8 , wherein the base material powder is 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, 0% 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.
10. The method according to claim 9 , wherein the base material powder includes at least 4.5% by weight of aluminum.
11. The method according to claim 10 , wherein the base material powder is a nickel-base superalloy including at least 5.5% aluminum by weight and greater than 45% nickel by weight.
12. The method according to claim 9 , wherein the eutectic powder comprises the following composition by weight %:
Cr
6-11
Co
0-1
Ti
5-9
Al
0-1
W
0-1
Mo
0-0.55
Ta
0-0.05
C
0-0.08
Zr
9-13
Hf
0.0-0.05
Re
0.0-0.05
Y and/or Ce
0-0.01
B
0.0-0.04
the balance nickel and optional incidental elements and unavoidable impurities.
13. The method according to claim 12 , wherein the eutectic powder comprises by weight at maximum 0.01% of one or more unavoidable impurities.
14. The method according to claim 12 , wherein the eutectic powder comprises by weight at maximum 1.5% of one or more incidental elements other than Co, Al, W, Mo, Ta, C, Hf, Re, Y, Ce, and B.
15. The method according to claim 12 , wherein the eutectic powder comprises one or more incidental elements selected from the following with a respective maximum weight percent or maximum ppm as indicated:
S
30 ppm
Nb
1.5%
Mn
0.6%
Fe
0.05%
Si
0.30%
P
50 ppm
Mg
50 ppm
Cu
0.01 %
N
60 ppm
0
250 ppm
Ag
I ppm
As
5 PPm
Bi
0.1 ppm
Cd
2 ppm
Ga
25 ppm
In
0.2 ppm
Pb
2 ppm
Sb
2 ppm
Se
I ppm
Sn
10 ppm
Te
0.1 ppm
Ti
0.2 ppm
Zn
5 Ppm.
V
1.5%.
16. The method according to claim 15 , wherein the unavoidable impurities are within the maximum amounts for the respective incidental elements and for any other elements that maximum is about 0.001% by weight.
17. The method according to claim 12 , wherein the base material powder comprises the following composition in weight %:
Cr
8-8.5
Co
9-9.5
Ti
0.6-0.9
Al
5.4-5.7
W
9.3-9.7
Mo
0.4-0.6
Ta
3.1-3.3
C
0.05-0.11
Zr
0-0.02
Hf
1.3-1.5
Re
0-0.05
Y and/or Ce
0-0.1
B
0-0.04
the balance nickel and optional incidental elements and unavoidable impurities.
18. The method according to claim 12 , wherein the base material powder comprises the following composition in weight %:
Cr
5-7.3
Co
7-13
Ti
0-0.05
Al
5.5-6.5
W
4.7-5.2
Mo
1.2-2.2
Ta
0-4.5
C
0-0.15
Zr
0-1
Hf
0-1.7
Re
2.0-4.2
Y and/or Ce
0-0.1
B
0-0.04
the balance nickel and optional incidental elements and unavoidable impurities.
19. The method according to claim 12 , wherein the additive portion forms at least a portion of a turbine blade or turbine guide vane.
20. The method according to claim 12 , wherein the superalloy powder mixture is deposited and fused together via a selective laser melting (SLM) 3D printer to form the additive portion.
21. The method according to claim 12 , wherein the superalloy powder mixture is deposited and fused together via a laser wire deposition (LWD) system, which employs a welding wire to provide the superalloy powder mixture.
22. The method according to claim 21 , wherein the welding wire comprises a nickel or a nickel alloy foil sheath including therein the superalloy powder mixture.