Gamma prime strengthened nickel superalloy for additive manufacturing

1. An additive manufactured product, comprising:

a fused multilayer component comprising a nickel superalloy, wherein the nickel superalloy has a composition comprising, by weight:

7% to 11% of cobalt;

9% to 14% of chromium;

1.5% to 8% of molybdenum;

up to 8% of tungsten;

4% to 6% of aluminum;

1% to 3% of titanium;

up to 4.6% tantalum;

up to 2% hafnium;

up to 0.04% zirconium;

up to 0.05% carbon;

up to 0.04% boron;

up to 1% niobium;

and the balance nickel along with unavoidable residual elements in trace amounts, wherein the composition has a sum of the weight percentage of zirconium and boron that is up to 0.06%.

2. The additive manufacturing product as in claim 1 , wherein the sum of the weight percentage of zirconium and boron is up to 0.05%.

3. The additive manufacturing product as in claim 1 , wherein the sum of the weight percentage of zirconium and boron is 0.01% to 0.04%.

4. The additive manufacturing product as in claim 1 , wherein the composition includes 0.005% to 0.04% by weight zirconium.

5. The additive manufacturing product as in claim 1 , wherein the composition includes 0.005% to 0.04% by weight boron.

6. The additive manufacturing product as in claim 1 , wherein the composition comprises, by weight:

8% to 11% of cobalt;

9% to 12% of chromium;

2% to 6% of molybdenum;

2% to 6% of tungsten;

4% to 6% of aluminum;

1% to 3% of titanium;

up to 2% tantalum;

up to 2% hafnium;

up to 0.03% zirconium;

up to 0.04% carbon;

up to 0.03% boron;

up to 1% niobium;

and the balance nickel along with unavoidable residual elements in trace amounts.

7. The additive manufacturing product as in claim 1 , wherein the composition comprises, by weight, greater than 0 to about 0.03 carbon.

8. The additive manufacturing product as in claim 1 , wherein the composition is substantially free from tantalum, hafnium, niobium, and rhenium.

9. The additive manufacturing product as in claim 1 , wherein the composition has a weight ratio of molybdenum to tungsten (Mo/W) of 0.25 to 2.

10. The additive manufacturing product as in claim 1 , wherein the composition has a weight ratio of molybdenum to tungsten (Mo/W) of 0.25 to 1.

11. The additive manufacturing product as in claim 1 , wherein the fused multilayer component has an areal microcrack density of less than 0.1%.

12. The additive manufacturing product as in claim 1 , wherein the fused multilayer component has an areal microcrack density of less than 0.05%.

13. The additive manufacturing product as in claim 1 , wherein the composition consists essentially of, by weight:

7% to 11% of cobalt;

9% to 14% of chromium;

1.5% to 8% of molybdenum;

0.05% to 8% of tungsten;

4% to 6% of aluminum;

1% to 3% of titanium;

up to 0.04% zirconium;

up to 0.05% carbon;

up to 0.04% boron; and

the balance Ni along with unavoidable residual elements in trace amounts.

14. An additive manufactured product, comprising:

a fused multilayer component comprising a nickel superalloy, wherein the nickel superalloy has a composition comprising, by weight:

9% to 11% of cobalt;

10% to 12% of chromium;

2.5% to 3.5% of molybdenum;

5.5% to 6% of tungsten;

5% to 6% of aluminum;

1% to 2% of titanium;

0.005% to 0.015% zirconium;

0.01% to 0.03% carbon;

0.005% to 0.015% boron;

and the balance nickel,

wherein the fused multilayer component has an areal microcrack density of less than 0.1%.

15. The additive manufacturing product as in claim 14 , wherein the composition is substantially free from tantalum; hafnium; niobium, and rhenium.

16. A method of forming an additive manufacturing product, the method comprising:

forming a layer of powder;

bonding a portion of the powder to form a bonded layer portion; and

repeating the forming and bonding steps to form a fused multilayer component comprising a plurality of the bonded layer portions,

wherein the powder comprises a nickel superalloy having a composition comprising, by weight:

7% to 11% of cobalt;

9% to 14% of chromium;

1.5% to 8% of molybdenum;

up to 8% of tungsten;

4% to 6% of aluminum;

1% to 3% of titanium;

up to 4.6% tantalum;

up to 2% hafnium;

up to 0.04% zirconium;

up to 0.05% carbon;

up to 0.04% boron;

up to 1% niobium;

and the balance nickel,

wherein the composition has a sum of the weight percentage of zirconium and boron is up to 0.06%.

17. The method as in claim 16 , wherein the composition includes 0.005% to 0.04% by weight zirconium, and wherein the composition includes 0.005% to 0.04% by weight boron.

18. The method as in claim 16 , further comprising:

heat treating the fused multilayer component to recrystallize at least 50% by volume of the nickel superalloy, and wherein the fused multilayer component has an areal microcrack density of less than 0.1%.

19. The method as in claim 18 , wherein the fused multilayer component is heat treated at a temperature of 1150° C. or higher.

20. The method as in claim 16 , wherein bonding the portion of the powder comprises directing energy onto the powder to at least partially melt the portion of the powder to form the bonded layer portion.