Nickel based alloys

Description

1 / 47 “NICKEL-BASED ALLOYS” CROSS-REFERENCE TO RELATED ORDERS

[001] This application claims priority to U.S. Provisional Patent Application No. 63 / 494,572, filed April 6, 2023, the contents of which are incorporated herein by reference. FIELD

[002] This disclosure relates to nickel-based alloys. BACKGROUND

[003] Superalloys are typically based on nickel, iron, or cobalt. Superalloys are used in aerospace, aeronautical, defense, marine, energy, and automotive applications, including, for example, gas turbines, hypersonic devices, and space launch vehicles. These applications can be very demanding, requiring superalloys to exhibit particularly advantageous combinations of strength, weldability, formability, microstructural stability, and a low coefficient of thermal expansion (CTE) at temperatures up to and above 760 °C (1,400 °F).

[004] In certain superalloy applications, it can be particularly critical to provide low CTE from cryogenic and / or ambient temperatures (e.g., 21 °C (70 °F)) up to temperatures equal to or greater than 760 °C (1,400 °F). In the past, two methods have been used to reduce the CTE of superalloys at high temperatures. A first method exploits magnetic effects at low temperatures to reduce the CTE in the operating temperature range. This first method was applied, for example, to the UNS R30783 alloy, the UNS N19903 alloy, and the UNS N19909 alloy. A second method to reduce the CTE at high temperatures involves engineering the alloy to include the conventional Ni2X phase (e.g., the Ni2(Cr, Mo, W) phase). This second method was applied to certain Ni-Mo-Cr and Ni-Mo-CrW alloys, such as, for example, the UNS N10242 alloy and the HAYNES® 244® alloy. The phase Petition 870250090293, dated 03 / 10 / 2025, p. 7 / 94 Conventional 2 / 47 Ni2X in UNS 10242 and Haynes® 244® can be expressed as the simplified versions Ni2(Cr, Mo) and Ni2(Cr, Mo, W), respectively, based on the alloying elements. Developing a superalloy that exhibits a desirable combination of strength, weldability, formability, and microstructural stability, while also displaying an acceptably low CTE at temperatures up to and including 760 °C (1400 °F), presents challenges. SUMMARY

[005] This disclosure is directed to nickel-based alloys that exhibit adequate strength and other mechanical properties, as well as an acceptably low CTE at temperatures up to and including 760 °C (1,400 °F). A non-limiting aspect of this disclosure is directed to a nickel-based alloy comprising, by weight percent based on the total weight of the nickel-based alloy: 8% to 24% molybdenum; 0% to 12% tungsten; 3.5% to 10% chromium; 2% to 10% vanadium; 0% to 10% iron; and nickel.

[006] Another non-limiting aspect of this disclosure relates to a nickel-based alloy comprising, by weight percentage based on the total weight of the nickel-based alloy: 14.5% to 17.5% molybdenum; 8% to 10% tungsten; 6% to 8% chromium; 3.5% to 5.5% vanadium; 0% to 0.3% niobium; 0% to 3% iron; and nickel. Certain embodiments of the nickel-based alloy exhibit an average linear thermal expansion coefficient from 21 °C (70 °F) to 760 °C (1,400 °F) that is not greater than 8.5 μin / in-°F.

[007] Yet another non-limiting aspect of this disclosure is directed to a manufactured article comprising a nickel-based alloy according to this disclosure. For example, a non-limiting aspect of this disclosure is directed to a manufactured article that includes a nickel-based alloy comprising: 8% to 24% molybdenum; 0% to 12% tungsten; 3.5% to 10% chromium; 2% to 10% vanadium; 0% to 10% iron; and Petition 870250090293, dated 03 / 10 / 2025, p. 8 / 94 3 / 47 nickel. In certain embodiments, the nickel-based alloy has an average linear thermal expansion coefficient from 21 °C (70 °F) to 760 °C (1,400 °F) not exceeding 8.5 μin / in-°F.

[008] Another non-limiting aspect of this disclosure relates to a nickel-based alloy comprising, by weight percentage based on the total weight of the nickel-based alloy: 13.5% to 16.5% molybdenum; 5% to 8% tungsten; 7% to 9% chromium; 3% to 5.5% vanadium; 0% to 2% niobium; 0% to 1.5% iron; and nickel. Certain embodiments of the nickel-based alloy exhibit an average linear thermal expansion coefficient from 21 °C (70 °F) to 760 °C (1400 °F) that does not exceed 8.5 pin / in-°F.

[009] It is understood that the inventions disclosed and described in this descriptive report are not limited to the aspects summarized in this Summary. The reader will appreciate the foregoing details, as well as others, by considering the following detailed description of various non-limiting and non-exhaustive aspects according to this descriptive report. BRIEF DESCRIPTION OF THE FIGURES

[010] The features and advantages of the examples presented in this document, and how to obtain them, will become more evident, and the examples will be better understood, with reference to the following description, taken together with the accompanying figures, in which:

[011] Figure 1 is a backscattered electron (BSE) image of the conventional example XB after being heat-treated for 64 hours at 760 °C (1,400 °F);

[012] Figure 2 is a BSE image of the conventional example XB after being heat-treated for 1,024 hours at 760 °C (1,400 °F);

[013] Figure 3 shows a BSE image of sample AA after being heat treated for 1,024 hours at 760 °C (1,400 °F); Petition 870250090293, dated 03 / 10 / 2025, page 9 / 94 4 / 47

[014] Figure 4 is a BSE image of example AB after being heat-treated for 1,024 hours at 760 °C (1,400 °F);

[015] Figure 5 is a BSE image of example AC after being heat-treated for 1,024 hours at 760 °C (1,400 °F);

[016] Figure 6 is a BSE image of sample AD after being heat-treated for 64 hours at 760 °C (1,400 °F);

[017] Figure 7 is a BSE image of example AE after being heat-treated for 64 hours at 760 °C (1,400 °F);

[018] Figure 8 shows a BSE image of sample AF after being heat-treated for 1,024 hours at 760 °C (1,400 °F);

[019] Figure 9 shows a BSE image of the AG sample after being heat treated for 1,024 hours at 760 °C (1,400 °F);

[020] Figure 10 shows a BSE image of example AI after a two-stage heat treatment, including 48 hours at 760 °C (1,400 °F) followed by 72 hours at 649 °C (1,200 °F);

[021] Figure 11 shows a BSE image of example IA after being heat-treated for 64 hours at 760 °C (1,400 °F);

[022] Figure 12 shows a BSE image of example IA after being heat-treated for 1,024 hours at 760 °C (1,400 °F);

[023] Figure 13 shows a BSE image of example AJ after being heat treated for 64 hours at 760 °C (1,400 °F);

[024] Figure 14 is a BSE image of sample AK after being heat treated for 64 hours at 760 °C (1,400 °F);

[025] Figure 15 shows a BSE image of sample AK after being heat treated for 1,024 hours at 760 °C (1,400 °F);

[026] Figure 16 shows a BSE image of the chemistry of example AL after being heat treated for 64 hours at 760 °C (1,400 °F); Petition 870250090293, dated 03 / 10 / 2025, page 10 / 94 5 / 47

[027] Figure 17 shows a BSE image of the AL sample after being heat treated for 1,024 hours at 760 °C (1,400 °F);

[028] Figure 18 shows a BSE image of the AM sample after being heat-treated for 64 hours at 760 °C (1,400 °F);

[029] Figure 19 shows a BSE image of example AN after being heat treated for 64 hours at 760 °C (1,400 °F);

[030] Figure 20 shows a BSE image of sample AO after being heat treated for 64 hours at 760 °C (1,400 °F);

[031] Figure 21 is a BSE image of the AP sample after being heat-treated for 64 hours at 760 °C (1,400 °F);

[032] Figure 22 is a BSE image of the AP sample after being heat-treated for 1,024 hours at 760 °C (1,400 °F);

[033] Figure 23 is a BSE image of sample AQ after being heat-treated for 64 hours at 760 °C (1,400 °F);

[034] Figure 24 shows a BSE image of sample AQ after being heat-treated for 1,024 hours at 760 °C (1,400 °F);

[035] Figure 25 is a BSE image of the AR sample after being heat-treated for 64 hours at 760 °C (1,400 °F);

[036] Figure 26 is a BSE image of the AR sample after being heat-treated for 1,024 hours at 760 °C (1,400 °F);

[037] Figure 27 shows a BSE image of the AS sample after being heat-treated for 64 hours at 760 °C (1,400 °F); and

[038] Figure 28 shows a BSE image of the AT sample after being heat-treated for 64 hours at 760 °C (1,400 °F).

[039] Figure 29 is a BSE image of example BB after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours. Petition 870250090293, dated 03 / 10 / 2025, page 11 / 94 6 / 47

[040] Figure 30 shows a BSE image of example BC after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[041] Figure 31 shows a BSE image of example CA after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[042] Figure 32 shows a BSE image of example CB after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[043] Figure 33 shows a BSE image of example DA after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[044] Figure 34 shows a BSE image of example DB after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[045] Figure 35 shows a BSE image of the DC sample after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[046] Figure 36 shows a BSE image of example DD after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[047] Figure 37 shows a BSE image of example DE after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[048] Figure 38 shows a BSE image of example DF after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours. Petition 870250090293, dated 03 / 10 / 2025, page 12 / 94 7 / 47

[049] Figure 39 shows a BSE image of example DG after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[050] Figure 40 is a BSE image of example DH after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[051] Figure 41 shows a BSE image of example DI after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[052] Figure 42 shows a BSE image of example DJ after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[053] Figure 43 shows a BSE image of example DK after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[054] Figure 44 shows a BSE image of example DL after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[055] Figure 45 shows a BSE image of the DM sample after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[056] Figure 46 shows a BSE image of example DN after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[057] Figure 47 shows a BSE image of example DO after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours. Petition 870250090293, dated 03 / 10 / 2025, page 13 / 94 8 / 47

[058] Figure 48 shows a BSE image of example DP after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[059] Figure 49 shows a BSE image of example DQ after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[060] Figure 50 shows a BSE image of example DR after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[061] Figure 51 shows a BSE image of the DS sample after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[062] Figure 52 shows a BSE image of example DT after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[063] Figure 53 shows a BSE image of example DU after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[064] Figure 54 shows a BSE image of example DV after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[065] Figure 55 shows a BSE image of example DW after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[066] Figure 56 shows a BSE image of example DX after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours. Petition 870250090293, dated 03 / 10 / 2025, page 14 / 94 9 / 47

[067] Figure 57 shows a BSE image of example DY after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[068] Figure 58 shows a BSE image of example DZ after being heat treated for 48 hours at 760 °C (1,400 °F), followed by an additional heat treatment step at 650 °C (1,200 °F) for 48 hours.

[069] Figure 59 shows an image of BSE from example E after being annealed in solution at 1,150 °C (2,100 °F) for 10 minutes.

[070] The examples presented in this document illustrate certain embodiments, in a form, and such examples should not be interpreted as limiting the scope of the appended claims in any way. DETAILED DESCRIPTION

[071] Various embodiments are described and illustrated in this document to provide a general understanding of nickel-based alloys and articles of manufacture disclosed. The various embodiments described and illustrated in this document are neither limiting nor exhaustive. Therefore, an invention is not limited to the description of the various non-limiting and non-exhaustive embodiments disclosed in this document. Instead, the invention is defined solely by the claims.

[072] The features and characteristics illustrated and / or described in relation to various modalities may be combined with the features and characteristics of other modalities. Such modifications and variations shall be included within the scope of this descriptive report. Therefore, claims may be amended to mention any features or characteristics expressly or inherently described or otherwise expressly or inherently supported by this descriptive report. Furthermore, the Applicant reserves the right to amend claims to affirmatively deny features or characteristics that may Petition 870250090293, dated 03 / 10 / 2025, p. 15 / 94 10 / 47 are present in the state of the art.

[073] The various embodiments disclosed and described in this descriptive report may include, consist of, or consist essentially of the features and characteristics described in this document. For example, the reference in this document to a nickel-based alloy “comprising” a specific elemental composition is intended to also encompass alloys “consisting essentially of” or “consisting of” the stated composition. It should be understood that the nickel-based alloy compositions described in this document that “comprise”, “consist of”, or “consist essentially of” a particular composition may also include impurities.

[074] All elemental concentrations given in this document for an alloy composition are weight percentages based on the total weight of the specific alloy composition, unless otherwise indicated in this document.

[075] It can be challenging to formulate a nickel-based alloy that exhibits an advantageous combination of strength (e.g., creep, yield strength, and / or tensile strength), weldability, formability (e.g., hardness and / or elongation), microstructural stability, and acceptably low CTE at extreme temperatures (e.g., up to 760 °C (1,400 °F) or below -90 °C (130 °F)). For example, there may be trade-offs between CTE, strength, weldability, formability, and / or microstructural stability in a nickel-based alloy formulation, such that an improvement in one property (e.g., a reduction in CTE) is accompanied by a deterioration in another property (e.g., a reduction in yield strength).

[076] As understood in the art, “creep” refers to time-dependent deformation that occurs under continuous stress below the yield strength of the material, such as, for example, at elevated temperature under a load. As used Petition 870250090293, dated 03 / 10 / 2025, page 16 / 94 11 / 47 in this document regarding creep properties, “high temperature” refers to temperatures above 93.3 °C (200 °F). “Stress rupture” is understood to be the point at which a metallic article breaks when subjected to a given sustained load at a given temperature. “Creep strength,” also known as “creep limit,” is a measure of a material’s resistance to creep. It can also be described as the stress under specific conditions that results in a particular creep rate. In other words, creep strength can be considered the combination of stress, temperature, and time required to achieve a particular percentage of creep or rupture. The stress rupture of an alloy article is generally indicative of its creep strength. A higher stress rupture value indicates greater creep strength for an alloy article.

[077] The alloy embodiments in accordance with this disclosure are expected to exhibit tensile rupture life comparable to or exceeding 760 °C (1,400 °F) and 816 °C (1,500 °F) compared to existing low CTE alloys such as HAYNES® 244® alloy and UNS N19909 alloy, due to the greater resistance of the nickel-based alloy embodiments of this disclosure at extreme temperatures.

[078] Certain demanding applications may require an alloy to exhibit high strength and low CTE at temperatures above 760 °C (1,400 °F), 816 °C (1,500 °F), or even 871 °C (1,600 °F). Although exploitation of magnetic effects has been used to reduce the CTE of certain alloys, these alloys may not have an efficient strengthening mechanism at temperatures equal to or above 816 °C (1,500 °F). Certain alloys designed to develop the Ni2X phase to reduce CTE at lower temperatures may show a rapid increase in CTE as operating temperatures increase, partly due to the dissolution of the Ni2X strengthening precipitate. This disclosure offers Petition 870250090293, dated 03 / 10 / 2025, p. 17 / 94 12 / 47 is a nickel-based alloy that can exhibit a combination of low CTE, high strength, and microstructural stability, even when subjected to extreme temperatures up to and including 760 °C (1,400 °F).

[079] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure comprise, as a weight percent based on the total weight of the nickel-based alloy: 8% to 24% molybdenum; 0% to 12% tungsten; 3.5% to 10% chromium; 2% to 10% vanadium; 0% to 10% iron; and nickel. In several non-limiting embodiments, the nickel-based alloys provided in this document may exhibit a low CTE, for example, not exceeding 9 pin / in-°F at 816 °C (1,500 °F), while maintaining substantial strength at extreme temperatures.

[080] In certain non-limiting embodiments, a nickel-based alloy according to this disclosure comprises, in weight percent, based on the total weight of the nickel-based alloy: 14.5% to 17.5% molybdenum; 8% to 10% tungsten; 6% to 8% chromium; 3.5% to 5.5% vanadium; 0% to 0.3% niobium; 0% to 3% iron; and nickel.In various non-limiting embodiments, a nickel-based alloy according to this disclosure comprises, by weight percent, based on the total weight of the nickel-based alloy: 15.5% to 16.5% molybdenum; 8.5% to 9.5% tungsten; 6.5% to 7.5% chromium; 5% to 6% vanadium; 0% to 0.3% niobium; 0.5% to 3% iron; 0% to 4% titanium; 0% to 15% cobalt; 0% to 5% tantalum; 0% to 2% silicon; 0% to 5% copper; 0% to 2% rhenium; 0% to 1% hafnium; 0% to 1% zirconium; 0% to 0.2% magnesium; 0 to 0.1% boron; 0 to 0.5% carbon; 0 to 1% rare earth elements; 0.05% to 2% aluminum; 0.1% to 2% manganese; impurities; and nickel.

[081] The high-temperature resistance properties of articles comprising nickel-based superalloys can depend on many factors, including, for example, matrix composition and microstructural characteristics. Petition 870250090293, dated 03 / 10 / 2025, p. 18 / 94 13 / 47 The microstructure of nickel-based alloys can include several phases, such as the gamma (γ) phase, which has a face-centered cubic structure, and the Ni2X phase, which has an orthorhombic structure. The γ phase forms a matrix in which the Ni2X phase precipitates.

[082] The γ phase may include the Ni2X phase (e.g., the Ni2(Cr, Mo, W, V, Nb etc.) phase), which may contribute to high-temperature strength properties and a low CTE. The CTE of some conventional nickel-based superalloys increases rapidly after heating the alloy to near, at, or above the Ni2X solvency temperature. The nickel-based alloy embodiments according to this disclosure may (i) increase the alloy strength compared to other alloys containing the Ni2X phase, nominally due to the increased Ni2X solvency temperature of the alloy and / or (ii) reduce the CTE of the nickel-based alloy relative to conventional alloys such as UNS N07718.

[083] Chromium can stabilize the Ni2X phase in nickel-based alloys according to the present disclosure. As the chromium content of the nickel-based alloy decreases, the microstructural stability of the nickel-based alloy may decrease. In several non-limiting embodiments, as the chromium content decreases below 4 wt%, the microstructural stability of the nickel-based alloy may decrease significantly. As used in this document, microstructural stability refers to the stability of the γ + Ni2X phase field. In microstructurally unstable alloys, the Ni2X phase and / or the γ phase will rapidly transform into other intermetallics, such as those of the NiaMo prototype. Chromium can also increase the hot corrosion and oxidation resistance of the nickel-based alloy. Chromium tends to reduce the hardness and slow aging kinetics of the nickel-based alloy.

[084] In several non-limiting embodiments, the CTE of the nickel-based alloy may decrease if the tungsten content is increased. Tungsten may increase the strength and temperature capacity of the nickel-based alloy relative to Petition 870250090293, dated 03 / 10 / 2025, p. 19 / 94 14 / 47 molybdenum and chromium, at the cost of higher density and lower workability. When tungsten is unbalanced relative to molybdenum, vanadium, and chromium, the microstructural stability of the nickel-based alloy can be reduced, and the Ni2X phase within the grains can transform into less desirable intermetallics, which can negatively affect the strength and / or ductility of the nickel-based alloy.

[085] Molybdenum can increase the strength and temperature capacity of nickel-based alloys compared to chromium, at the cost of higher density and lower workability. Furthermore, the addition of molybdenum in place of chromium can increase the aging kinetics of the Ni2X phase. When molybdenum is in disequilibrium with tungsten, vanadium, and chromium, the microstructural stability of the nickel-based alloy can be reduced, and the Ni2X phase within the grains can transform into less desirable intermetallics, which can negatively affect the strength and / or ductility of the nickel-based alloy.

[086] Vanadium can increase the temperature capacity of nickel-based alloys compared to additions of chromium, molybdenum, and tungsten. Vanadium additions can increase the fraction of the Ni2X phase, contributing to extreme temperature resistance and low CTE. When vanadium is in disequilibrium with tungsten, molybdenum, and chromium, the microstructural stability of the nickel-based alloy can be reduced, and the Ni2X phase within the grains can transform into less desirable intermetallics, which can negatively affect the strength and / or ductility of the nickel-based alloy.

[087] The proper balance between tungsten, molybdenum and chromium can be determined by the chromium content, as mentioned earlier, by the Creq number and by the ratio between the Moeq number and the Creq number. The Creq and Moeq numbers are defined below. Creq = {[Cr] + 0.54[Mo] + 0.28[W] + 1.02[V] + 0.55[Nb] + 1.09[Ti] + 0.29[Ta]} Petition 870250090293, dated 03 / 10 / 2025, p. 20 / 94 15 / 47 Moeq = {[Mo] + 1.06[W] + 6.61 [V] + 4.14[Nb] + 14.07[Ti] + 4.26[Ta]}

[088] In the equation above, [Cr], [Mo], [W], [V], [Nb], [Ti] and [Ta] refer to the weight percentage of the respective element in the nickel-based alloy.

[089] In several embodiments, the composition of the nickel-based alloy according to the present disclosure may satisfy the following equation: < Creq < 33

[090] In certain non-limiting embodiments, the composition of the nickel-based alloy according to this disclosure may satisfy the following equation: < Creq < 26

[091] In several embodiments, the composition of the nickel-based alloy according to the present disclosure may satisfy the following equation: Moeq / Creq > 1.8

[092] In certain non-limiting embodiments, the composition of the nickel-based alloy according to this disclosure may satisfy the following equation: Moeq / Creq > 2

[093] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 8% to 24% molybdenum, such as, for example, 8% to 22%, 8% to 20%, 10% to 20%, 10% to 19%, 10% to 18%, 11% to 19%, 13% to 19%, 14% to 18%, 12% to 17%, 13% to 17%, 14% to 17%, 15% to 17%, 14.5% to 17.5%, 14.5% to 17%, 14.5% to 16.5%, 15.25% to 16.75% 14.5% to 17.5% or 13.5% to 15% molybdenum.

[094] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 3.5% to 10% chromium, such as, for example, 4% to 10%, 4% to 9%, 5% to 9%, 6% to 8.5%, 6% to 8%, 6% to 9%, 6% to 7%, 5% to 8%, 5% to 8.5%, 5% to 7%, 5.5% to 7.5%, 5.5% to 7%, 7% to 9% or Petition 870250090293, dated 03 / 10 / 2025, p. 21 / 94 16 / 47 7.5% to 8.5% chromium.

[095] Certain non-limiting embodiments of a nickel-based alloy according to the present disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 12% tungsten, such as, for example, 1% to 12%, 2% to 12%, 3% to 12%, 4% to 12%, 8% to 12%, 4% to 11%, 4% to 8%, 5% to 8%, 5.5% to 7.5%, 5% to 7%, 5.5% to 6.5%, 5% to 11%, 6% to 8%, 6% to 11%, 7% to 11%, 8% to 11%, 8.5 % to 12%, 8.5% to 11%, 9% to 11%, 9% to 10%, 0% to 6%, 0% to 4%, 2% to 6%, 0% to 2%, 2% to 4% or 9.5% to 10.5% of tungsten.

[096] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 2% to 10% vanadium, such as, for example, 2% to 8%, 2% to 6%, 3% to 7%, 3% to 6%, 3% to 9%, 4% to 9%, 4% to 8%, 7% to 9%, 3.5% to 6%, 3.5% to 5.5%, 3.5% to 5%, 3.5% to 4.5%, 4% to 5%, 3% to 5.5%, 3.75% to 5.5% or 3% to 5% of vanadium.

[097] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may include a weight ratio between the chromium content and the vanadium content ([Cr] / [V]) in the alloy that is in a range of 0.8 to 5, such as, for example, 0.8 to 4.5, 0.9 to 5, 1 to 4.5, 1 to 3, 1.2 to 2.8, 1.5 to 4 or 1.5 to 2.5. All ranges described in this description include the endpoints of the stated range, unless otherwise indicated.

[098] Additions of niobium can increase the strength and aging kinetics of nickel-based alloys according to the present disclosure. Furthermore, niobium additions can increase the strength and temperature capabilities of the alloy more effectively on an atomic basis than additions of chromium, molybdenum, tungsten, and vanadium. If present, niobium can also inhibit secondary carbide precipitation. Niobium can form primary carbides (or Petition 870250090293, dated 03 / 10 / 2025, p. 22 / 94 17 / 47 i.e., MC carbides) and inhibit the precipitation of secondary carbides at grain boundaries and within grains. A significantly unbalanced amount of niobium can decrease the microstructural stability of the nickel-based alloy, resulting in the formation of detrimental intermetallic phases.

[099] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 3% niobium, such as, for example, 0 to 2%, 0.3% to 2%, 0.5% to 2%, 1% to 2%, 1.1% to 1.9%, 0.5% to 1.5%, 0 to 1%, 0 to 0.5% or 0 to 0.3% niobium.

[0100] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 10% iron, such as, for example, 0 to 7%, 0 to 5%, 0 to 4%, 0 to 3%, 0 to 2%, 0 to 1.5%, 0.1% to 5%, 0.1% to 3%, 0.5% to 4%, 0.5% to 3%, 0.5% to 2%, 0.5% to 1.5% or 0.75% to 1.25% iron.

[0101] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may optionally additionally comprise, in weight percent based on the total weight of the nickel-based alloy, one or more of the following elements: up to 4% titanium; up to 15% cobalt; up to 5% tantalum; up to 2% silicon; up to 5% copper; up to 2% rhenium; up to 1% hafnium; up to 1% zirconium; up to 0.2% magnesium; up to 0.1% boron; up to 0.5% carbon; up to a total of 1% rare earth elements; up to 2% aluminum; and up to 5% manganese.

[0102] Tantalum, if present, can affect the CTE, strength, hardness, and / or aging kinetics of nickel-based alloys, similarly to niobium. Tantalum can inhibit the precipitation of secondary carbides forming primary carbides (i.e., MC carbides) and inhibiting the precipitation of secondary carbides at grain boundaries and within grains. A quantity Petition 870250090293, dated 03 / 10 / 2025, p. 23 / 94 A significantly unbalanced 18 / 47 tantalum content can decrease the microstructural stability of nickel-based alloys, resulting in the formation of detrimental intermetallic phases.

[0103] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, in weight percent concentrations based on the total weight of the nickel-based alloy, 0 to 5% tantalum, such as, for example, 0 to 4%, 0 to 3%, 0 to 0.5%, 0 to 2%, 0 to 1%, 0.1% to 5%, 0.5% to 5%, 0.1% to 4%, 0.1% to 3%, 0.5% to 4%, 0.5% to 3%, 0.5% to 2% or 1% to 2% tantalum.

[0104] Titanium, if present, can affect the CTE, strength, hardness, and / or aging kinetics of nickel-based alloys, similarly to niobium. Titanium can inhibit the precipitation of secondary carbides forming primary carbides (i.e., MC carbides) and inhibit the precipitation of secondary carbides at grain boundaries and within grains. A significantly unbalanced amount of titanium can decrease the microstructural stability of nickel-based alloys, resulting in the formation of detrimental intermetallic phases.

[0105] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 4% titanium, such as, for example, 1% to 4%, 1.3% to 3.5%, 0.1% to 1.5%, 0.2% to 1.5%, 0.3% to 1.4%, 0.5% to 1.5%, 0.3% to 1.3% or 0.5% to 1.3% titanium.

[0106] Aluminum, if present, can increase the CTE and oxidation resistance of the nickel-based alloy. Excessive addition of aluminum can result in undesirably high CTE values ​​at high temperature or in the formation of the γ' phase with a simple cubic structure within the alloy, instead of or alongside the Ni2X phase.

[0107] Certain non-limiting embodiments of a nickel-based alloy of Petition 870250090293, dated 03 / 10 / 2025, p. 24 / 94 19 / 47 In accordance with this disclosure, the percentage of aluminum may comprise, by weight, based on the total weight of the nickel-based alloy, 0 to 2%, such as 0 to 0.5%, 0.05% to 2%, 0.05% to 0.5%, 0.1% to 1%, 0.1% to 0.75%, or 0.1% to 0.5% of aluminum.

[0108] Cobalt, if present, can be used to control the solvency temperature of Ni2X. Cobalt additions can also promote the formation of topologically closed phases (TCPs) (e.g., μ phase, σ phase) in the nickel-based alloy after long holding periods at elevated temperatures. Inhibition of TCP phase formation can increase the ductility of the nickel-based alloy. The cobalt concentration of the nickel-based alloy can affect the ductility and stress fracture life of the nickel-based alloy. For example, increasing the cobalt concentration can increase the creep resistance of the nickel-based alloy.

[0109] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 15% cobalt, such as, for example, 0 to 15%, 0 to 10%, 0 to 5%, 0 to 0.5%, 0 to 1%, 0.1 to 1%, 1% to 12%, 2% to 12%, 5% to 12%, 6% to 15%, 6% to 13%, 7% to 12%, 8% to 11% or 9% to 11% cobalt.

[0110] Silicon and manganese, if present, can improve the oxidation resistance of the nickel-based alloy according to this disclosure in specific oxidizing environments. Silicon and manganese can adversely affect the solvency temperature of Ni2X and the strength of the nickel-based alloy according to this disclosure if they are present at excessively high levels.

[0111] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 2 percent silicon, such as, for example, Petition 870250090293, dated 03 / 10 / 2025, p. 25 / 94 20 / 47 at 1%, 0 to 0.5%, 0.01% to 1.5%, 0.01% to 1.0%, 0.01% to 0.5%, 0.02% to 0.5% or 0.02% to 0.2% silicon.

[0112] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 5% manganese, such as, for example, 0 to 4%, 0 to 2%, greater than 0 to 0.5%, greater than 0 to 1%, greater than 0 to 1.5%, 0 to 1.5%, 0 to 1%, 0 to 0.5%, 0 to 0.1%, 0.1 to 2%, 0.1% to 1%, 0.1% to 0.5%, 0.25% to 1.5% or 1% to 2% manganese.

[0113] Copper may be included in several non-limiting embodiments of the nickel-based alloy according to the present disclosure, for example, to reduce solute solubility in the γ-phase matrix and increase corrosion resistance in certain environments. Certain non-limiting embodiments of a nickel-based alloy according to the present disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 5% copper, such as, for example, 0 to 4%, 0 to 3%, 0 to 2%, 0 to 1%, 0 to 0.5%, 0.01% to 4%, 0.01% to 2%, 0.01% to 1%, 0.01% to 0.5% or 0.01% to 0.2% copper.

[0114] Zirconium, hafnium, and rhenium can improve the tensile fracture life of nickel-based alloys according to this disclosure. Excessive levels of zirconium and hafnium additions may negatively affect workability and weldability.

[0115] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 1% zirconium, such as, for example, greater than 0 to 1%, greater than 0 to 0.5%, 0 to 0.5%, 0 to 0.25%, 0 to 0.2%, 0.1% to 1%, 0.1% to 0.5%, 0.25% to 1.0% or 0.25% to 0.75% zirconium.

[0116] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, by weight percent, Petition 870250090293, dated 03 / 10 / 2025, p. 26 / 94 21 / 47 based on the total weight of the nickel-based alloy, 0 to 1% hafnium, such as greater than 0 to 1%, greater than 0 to 0.5%, 0 to 0.5%, 0 to 0.25%, 0.1% to 1%, 0.1% to 0.5%, 0.25% to 1.0% or 0.25% to 0.75% hafnium.

[0117] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 2% rhenium, such as, for example, greater than 0 to 2%, greater than 0 to 1%, greater than 0 to 0.5%, 0 to 1%, 0 to 0.5%, 0 to 0.25%, 0.1% to 1%, 0.1% to 0.5%, 0.25% to 1.0% or 0.25% to 0.75% rhenium.

[0118] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, in weight percent concentrations based on the total weight of the nickel-based alloy, 0 to 0.2% magnesium, such as, for example, greater than 0 to 0.2%, greater than 0 to 0.1%, 0 to 0.1% or greater than 0 to 0.08% magnesium.

[0119] Additions of carbon and / or boron can improve the tensile fracture properties and workability of nickel-based alloys. Excessive levels of carbon and / or boron can adversely affect workability and weldability.

[0120] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a percentage by weight, based on the total weight of the nickel-based alloy, 0 to 0.5% carbon, such as, for example, greater than 0 to 0.5%, greater than 0 to 0.4%, 0 to 0.2%, 0 to 0.1%, 0.01% to 0.5%, 0.01% to 0.2%, 0.01% to 0.1%, 0 to 0.2%, 0.02% to 0.5%, 0.02% to 0.3%, 0.02% to 0.1%, 0.03% to 0.5%, 0.03% to 0.3%, 0.03% to 0.1% or 0.04% to 0.5% carbon.

[0121] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, 0 to 0.1% boron, such as, for example, greater than 0 to 0.1%, greater than 0 to 0.05%, 0 to 0.05%, 0 to 0.01%, 0.001% to 0.1%, Petition 870250090293, dated 03 / 10 / 2025, p. 27 / 94 22 / 47 0.001% to 0.05% or 0.001% to 0.01% boron.

[0122] Rare earth elements can increase the oxidation resistance of a nickel-based alloy. In several non-limiting embodiments, a nickel-based alloy according to this disclosure may include one or more rare earth elements selected from, for example, scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, and ytterbium. In certain non-limiting embodiments, a nickel-based alloy according to this disclosure may comprise, as a weight percent based on the total weight of the nickel-based alloy, a total of 0 to 1 percent of rare earth elements.Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, as a weight percentage based on the total weight of the nickel-based alloy, a total greater than 0 to 1%, greater than 0 to 0.5%, 0 to 0.5%, 0 to 0.25%, 0.1% to 1%, 0.1% to 0.5%, 0.25% to 1.0% or 0.25% to 0.75% of rare earth elements.

[0123] The percentage by weight of nickel in the nickel-based alloy embodiments according to this disclosure may be at least 40% based on the total weight of the alloy, such as, for example, at least 45%, at least 50%, at least 55%, at least 60% or at least 61%, based on the total weight of the alloy. Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may comprise, by weight percentage based on the total weight of the nickel-based alloy, 40% to 82% nickel, such as, for example, 45% to 80%, 50% to 75%, 55% to 75%, 55% to 70%, 60% to 75%, 60% to 70% or 61% to 68% nickel.

[0124] Nickel-based alloys according to this disclosure may include impurities. Impurities may be present in the alloys as a result of, for example, impurities in the starting materials (e.g., recycled scrap materials) and / or alloy processing during production. In several Petition 870250090293, dated 03 / 10 / 2025, p. 28 / 94 23 / 47 In non-limiting forms of alloys according to this disclosure, one or more of the following elements may be present as impurities: sulfur, phosphorus, calcium, oxygen, nitrogen, bismuth, lead, tin, antimony, selenium, arsenic, silver, tellurium, thallium, zinc, ruthenium, platinum, rhodium, palladium, osmium, iridium, gold, fluorine, and chlorine. The impurity elements, if present, are normally present in individual concentrations not exceeding about 0.1% by weight, and the total content of such impurities is normally not exceeding 5% by weight. It should be understood that the above list of impurity elements does not necessarily include all elements that may be present as impurities in an alloy according to this disclosure.

[0125] In several non-limiting embodiments, a nickel-based alloy according to the present disclosure can be aged at a temperature in the range of 538 °C (1,000 °F) to 1093 °C (2,000 °F), such as, for example, 704 °C (1,300 °F) to 982 °C (1,800 °F), for a period of time in the range of 0.1 hour to 168 hours, such as, for example, 1 hour to 12 hours. The aging can be a single-stage heat treatment or a multi-stage heat treatment. The aging parameters can be selected based on the desired properties of the nickel-based alloy after heat treatment.

[0126] Non-limiting examples of possible heat treatments that can be applied to a nickel-based alloy according to this disclosure include one-stage, two-stage and three-stage heat treatments. In certain non-limiting embodiments, a one-stage heat treatment that can be applied to a nickel-based alloy according to this disclosure may involve a single subsolvent aging heat treatment step, for example, at a temperature of 649 °C to 871 °C (1,200 °F to 1,600 °F), for example, approximately 760 °C (1,400 °F) for 1 to 72 hours, for example, 24 to 48 hours or about 36 hours. In certain non-limiting embodiments, a heat treatment of Petition 870250090293, dated 03 / 10 / 2025, page 29 / 94 24 / 47 Two steps that can be applied to a nickel-based alloy according to the present disclosure may involve a supersolvent heat treatment step (e.g., at about 927 °C to 1,038 °C (1,700 °F to 1,900 °F), e.g., at approximately 982 °C (1,800 °F)), followed by a subsolvent heat treatment step (e.g., at about 704 °C to 816 °C (1,300 °F to 1,500 °F), e.g., at approximately 732 °C (1,350 °F) or approximately 760 °C (1,400 °F)), for 1 to 72 hours. Several embodiments of a two-stage heat treatment that can be applied to a nickel-based alloy according to the present disclosure may involve two subsolvent heat treatment steps, such as, for example, a step at a higher subsolvent temperature (e.g., at about 704 °C to 816 °C (1,300 °F to 1,500 °F)) and a step at a lower subsolvent temperature (e.g., at about 593 °C to 704 °C (1,100 °F to 1,300 °F)).In certain non-limiting embodiments, a three-stage heat treatment that can be applied to a nickel-based alloy according to the present disclosure may involve a supersolvent heat treatment stage (e.g., at about 1,010 °C to 1,038 °C (1,850 °F to 1,900 °F)) followed by two subsolvent heat treatment stages, such as, for example, a stage at a higher subsolvent temperature (e.g., 704 °C to 816 °C (1,300 °F to 1,500 °F)) and a stage at a lower subsolvent temperature (e.g., 593 °C to 704 °C (1,100 °F to 1,300 °F)).

[0127] Balancing the chemistry of the nickel-based alloy to achieve a high solvency temperature of Ni2X and a high phase fraction of the Ni2X phase can reduce the CTE of the nickel-based alloy and increase the temperature range of the alloy. In certain non-limiting embodiments of nickel-based alloys according to this disclosure, the alloy composition is such that it satisfies one or more of the mechanical properties described in this document. For example, various embodiments of a nickel-based alloy according to this disclosure may exhibit a Petition 870250090293, dated 03 / 10 / 2025, p. 30 / 94 25 / 47 Average linear thermal expansion coefficient from 21 °C (70 °F) to 760 °C (1400 °F) not exceeding 8.5 μin / in-°F, such as not exceeding 8, not exceeding 7.9, not exceeding 7.8, not exceeding 7.6, or not exceeding 7.5 μin / in-°F. The average linear thermal expansion coefficient can be determined according to ASTM E228-17.

[0128] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may exhibit a yield strength in an aged condition at room temperature of at least 130 ksi (896 MPa), such as at least 135 ksi (931 MPa), at least 140 ksi (965 MPa) or at least 145 ksi (1,000 MPa) at room temperature. Tensile properties at room temperature may be determined in accordance with ASTM E8 / E8M16.

[0129] Certain non-limiting embodiments of the nickel-based alloy according to this disclosure may exhibit a yield strength at 760 °C (1,400 °F) of at least 414 MPa (60 ksi), such as, for example, 448 MPa (65 ksi) or 483 MPa (70 ksi). In certain non-limiting embodiments, the nickel-based alloy may exhibit a yield strength at 816 °C (1,500 °F) of at least 35 ksi (241 MPa), such as, for example, at least 45 ksi (310 MPa), at least 50 ksi (345 MPa) or at least 55 ksi (379 MPa). The yield strength at 760 °C (1,400 °F) and 816 °C (1,500 °F) may be measured in accordance with ASTM E21-20.

[0130] Certain non-limiting embodiments of a nickel-based alloy according to this disclosure may exhibit an average Rockwell hardness using the Rockwell C scale (HRC) in a range of 25 HRC to 60 HRC, after aging at 760 °C (1,400 °F) for approximately 1,024 hours, such as, for example, 35 to 55, 40 to 55, or 40 to 50 HRC. HRC values ​​may be measured in accordance with ASTM E18-02 (2017). EXAMPLES

[0131] The following examples are intended to better describe Petition 870250090293, dated 03 / 10 / 2025, p. 31 / 94 26 / 47 certain non-limiting modalities, without restricting the scope of this disclosure. People with common experience in the field will realize that variations of the following examples are possible within the scope of the disclosure.

[0132] Scanning electron microscopy (SEM) characterization was performed using backscattered electron imaging (BSE) and energy dispersive spectroscopy (EDS). Chemical analysis was performed using X-ray fluorescence spectroscopy (XRF) or EDS. Hardness testing was performed with a Rockwell hardness tester using the Rockwell C scale, unless otherwise indicated.

[0133] Twenty-one 1 lb arc-melted buttons were prepared. The measured chemistries of the twenty-one examples are shown in Table 1 below. Example XB has the nominal chemistry of a conventional alloy. Table 1 - Measured Chemistry Example Chemistry Measurement (wt %) Method of Measurement MOeq / Cfeq CTeq Ni Mo W Cr V Fe Nb XB 63.12 21.79 5.93 Fe Nb XB 63.12 0.04 0.01 1.03 0.01 XRF 1.3 21.490 AA 615 4.09 0.79 0.01 XRF 2.21 22.36 AB 63.70 13.68 10.05 7.88 4.02 0.79 0.01 XRF 2.29 22.18 CA 62.53 10.90 10.93 1 0.01 XRF 2.38 21.45 AD 61.1 16.5 11.2 6.5 3.9 0.8 EDS 2.40 22.52 AE 61.63 13.42 14.09 6.07 3.88 0.74 XRF 65.15 14.60 6.08 7.85 5.14 0.95 0.01 XRF 2.43 22.68 AG 64.10 12.04 10.05 7.75 4.92 0.93 0.00 9.81 1 XRF 2.5 14.20 7.51 4.75 0.92 0.01 XRF 2.61 21.34 IA 63.07 14.86 10.04 6.08 4.83 0.92 0.01 XRF 1.0 EDS 2.71 21.58 AK 65.01 14.36 6.08 7.95 4.17 0.82 1.44 XRF 2.42 22.45 AL 63.03 11.74 10.50 7.89 23.3.3. 21.75 AM 61.86 9.55 13.98 7.60 4.47 0.88 1.44 XRF 2.72 22.02 AN 62.86 14.73 9.97 6.16 3.82 0.78 A 2 1.6 11.8 14.8 6.4 3.8 0.8 1.1 EDS 2.67 21.40 AP 64.6 13.3 6.6 8.3 4.8 0.9 1.4 EDS 2.51 23,00 AQ 63.90 10.75 10.06 7.76 4.94 0.95 1.42 6.6 4.5 1.1 1.3 EDS 2.70 22.16, Petition 870250090293, dated 03 / 10 / 2025, p. 32 / 94 27 / 47 AT 61.9 10.7 14.2 6.6 4.5 0.9 1.2 EDS 2.80 21.60

[0134] The samples were plate-shaped, approximately 2.75 inches wide and long, and approximately 0.4 inches thick. No evidence of unmelted material or chemical inhomogeneities was observed in the samples.

[0135] The samples were homogenized and then hot-rolled. It was observed that decreasing the tungsten concentration increased the hot-workability of the samples. After hot rolling, the samples were annealed and then air-cooled. The samples exhibited a recrystallized grain structure after annealing.

[0136] Test coupons were cut from hot-rolled and annealed samples. Hardness test coupons were aged at 760 °C (1400 °F) for 4 hours, 16 hours, 64 hours, 256 hours, and 1024 hours. Microstructural stability was examined on a SEM using BSE after aging at 64 and / or 1024 hours. Microstructural stability in this document refers to the extent to which the γ matrix and fine Ni2X precipitates have transformed into coarse intermetallics. High stability means good retention of the γ matrix and fine Ni2X precipitates. Low stability means that the γ matrix and fine Ni2X precipitates have transformed substantially. Hardness was measured under all heat treatment conditions.

[0137] The measured hardness and the SEM microstructural analysis results of the aged button examples are shown in Tables 2 to 4. Table 2 - Rockwell C hardness and microstructural stability results Example Hours at 760 °C (1400 °F) XB AA AB AC AD AE AF 0 (As Annealed) 12* 11* 11* 12* 14* 37.2 8* Petition 870250090293, dated 03 / 10 / 2025, page 33 / 94 28 / 47 4 26.8 10* 10* 11.5* 31.4 42.6 11* *16 27.4 11* 11.5* 14* 32 44.9 11* 64 13.51 10.5* 11.5* 14* 362 46.84 11.5* 256 27.0 21.9 23.7 30.1 42.7 48.1 22.1 1024 22.41 26.61 29.81 34.92 46.7 47.6 29.21 *Measured using the Rockwell B scale and converted to the Rockwell C scale. 1Did not appear unstable in microstructural terms. 2Potential microstructural instability. 3Notable microstructural instability. 4Extensive microstructural instability. Table 3 - Rockwell C hardness and microstructural stability results Example Hours at 760 °C (1400 °F) AG AH Al AJ AK AL AM 0 (As Annealed) 11.5* 15.5* 12.5* 23.8 12* 12* 23.5 4 10.5* 15.5* 28.3 28.1 9* 11* 31.1 16 12.5* 16.5* 32.1 32.7 11* 12.5* 34 64 11* 17.5* 351 374 29.51 33.31 39.83 256 25.6 32.2 40.5 44.0 36.5 40.9 44.1 1024 32.7 37.7 45.11 45.6 41.21 43.53 43.9 *Measured using the Rockwell B scale and converted to the Rockwell C scale 1. Did not appear unstable in microstructural terms. 2. Potential for microstructural instability. 3. Notable microstructural instability. 4. Extensive microstructural instability. Table 4 - Rockwell C hardness and microstructural stability results Example Hours at 760 °C AN TO AP AQ AR AS AT Petition 870250090293, dated 03 / 10 / 2025, page 34 / 94 29 / 47 (1400 °F) 0 (As Annealed) 13* 26.2 13* 13* 15* 15.5* 23.7 4 28.7 26.7 11.5* 12* 27.3 29.6 33.7 16 31.9 38.2 15* 20* 30.8 34.9 39.6 64 44.72 44.84 35.51 32.71 33.91 40.62 45.34 256 45.2 48.1 38.7 38.1 39.2 43.7 46.4 1024 47.5 48.0 41.03 40.83 42.72 46.5 47.5 *Measured using the Rockwell B scale and converted to the Rockwell C scale. 1Did not appear unstable in microstructural terms. 2Potential microstructural instability. 3Notable microstructural instability. 4Extensive microstructural instability.

[0138] BSE images of the microstructure of the examples in Table 1 are shown in Figures 1 to 28. The dark particles shown in the BSE images are oxides, surface contamination, or holes. The coarser, brighter particles in the images may be primary phases or transformed primary phases from solidification. It was observed that almost all examples exhibited reasonable microstructural stability for short periods at 760 °C (1400 °F).

[0139] The 50 lb. ingots were prepared by vacuum induction melting (VIM) followed by vacuum arc remelting (VAR). The measured chemistries of the 50 lb. ingots are shown in Table 5. Table 5 - Measured Chemistry Alloy Element (wt%) MOeq / CTeq Cleq Ni Mo W Cr V Fe Al Mn Si CB XV Bal. 22.35 6.01 8.14 0.014 1.33 0.173 0.31 0.097 0.001 0.0062 1.31 21.90 BA Bal. 16.06 7.43 8.12 4.08 0.96 0.191 0.34 0.121 0.019 0.006 2.21 23.03 BB Bal. 15.15 7.24 8.22 4.79 0.96 0.20 0.35 0.117 0.019 0.0061 2.34 23.30 BC Bal. 15.08 11.86 6.50 4.51 0.97 0.17 0.34 0.111 0.017 0.0057 2.54 22.56 BD Bal. 14.67 7.38 8.09 4.04 0.96 0.185 0.34 0.103 0.020 0.0061 2.21 22.19 CA Bal. 15.86 10.28 6.87 4.86 1.04 0.25 0.46 0.12 0.018 0.006 2.53 22.3 Petition 870250090293, dated 03 / 10 / 2025, page 35 / 94 30 / 47 CB Bal. 14.96 6.74 8.38 3.98 1.01 0.24 0.33 0.117 0.012 0.0053 2.16 22.41

[0140] The processing steps for the alloys in Table 5 are as follows. First, the vacuum arc remelted ingots were homogenized. Then, a portion of the base of each ingot was cut, reheated, turned, water quenched, hot rolled, annealed, and aged. The alloys in this disclosure exhibited less cracking than conventional alloys. All alloys in Table 5 were aged using a two-stage subsolvent aging heat treatment. The first heating stage was 48 hours at 760 °C (1,400 °F) and the second heating stage was 48 hours at 649 °C (1,200 °F).

[0141] BSE images of the microstructure of selected alloys in Table 5 are shown in Figures 29 to 32. The dark particles shown in the BSE images are oxides, surface contamination, or holes. The coarser, brighter particles in the images may be primary phases or transformed primary phases from solidification. It was observed that almost all examples exhibited reasonable microstructural stability for short periods at 760 °C (1400 °F).

[0142] An aging study was conducted using the AA, AF, AI, and AK buttons. The results of the aging study are shown in Table 6 below. Table 6 - Results of the aging study Heat Treatment Hardness (HRC) Aging Stage 1 Aging Stage 2 AA AF Al AK 760 °C (1,400 °F) for 48 hours none 13.6 17.6 36.3 34.7 649 °C (1,200 °F) for 24 hours 32.3 34.8 44.8 45 33.4 33.7 44.8 44 649 °C (1,200 °F) for 48 hours 33.6 34 44.1 43 none 36.8 36.7 46 46.9 Petition 870250090293, dated 03 / 10 / 2025, page 36 / 94 31 / 47 649 °C (1,200 °F) for 72 hours 36.1 38.7 45.7 46.2 788 °C (1,450 °F) for 8 hours None 12.3 11.8 28.9 11.2 788 °C (1,450 °F) for 24 hours None 11.8 13.3 30.7 20.3 788 °C (1,450 °F) for 48 hours None 12.2 12.3 33 32.3 649 °C (1,200 °F) for 24 hours 33.4 35.3 43.8 41.7 649 °C (1,200 °F) for 48 hours 33.9 34.5 44 43 649 °C (1,200 °F) for 72 hours 37.7 35.1 44.9 42.5 816 °C (1,500 °F) for 1 hour none 10.8 12 12.3 12.2 816 °C (1,500 °F) for 2 hours None 11.7 13.2 13.8 15 816 °C (1,500 °F) for 4 hours none 10 11.7 15 14 816 °C (1,500 °F) for 8 hours none 11 11.5 16.5 13 816 °C (1,500 °F) for 24 hours none 11.2 16.7 16 18 816 °C (1,500 °F) for 48 hours none 11.8 21.7 13.7 28.4 649 °C (1200 °F) for 24 hours 33.1 34.5 38.8 37.8 649 °C (1200 °F) for 48 hours 34.4 34.7 37 37.3 649 °C (1200 °F) for 72 hours 34.1 37.8 38.1 39 704 °C (1300 °F) for 24 hours 27.3 30.4 39.2 33.2 Petition 870250090293, dated 03 / 10 / 2025, page 37 / 94 32 / 47 704 °C (1,300 °F) for 48 hours 31.2 33.3 41.4 39.1 704 °C (1,300 °F) for 72 hours 31.5 34.5 41.9 39.9 871 °C (1,600 °F) for 1 hour none 10.2 11.2 13.3 12.7 871 °C (1,600 °F) for 2 h none 10.5 10.5 14.8 10.5 871 °C (1,600 °F) for 4 hours none 9.8 9.3 14.2 11.4

[0143] It was observed that the alloys responded well to a variety of aging heat treatments and that there was a substantial hardening response even at 816 °C (1,500 °F) for AF and AK.

[0144] The chemical measurements of two heats produced by VIM melting to provide 50 lb. ingots are shown in Table 7. The ingots were homogenized, hot rolled, annealed, cold rolled, annealed, and aged. Table 7 - Measured Chemistry Alloy Element (% by weight) MOeq / Creq Creq Ni Mo W Cr VC Xl Bal. 22.49 5.94 8.07 0.014 0.012 1.31 21.89 B Bal. 22.64 5.98 3.76 4.17 0.002 2.55 22.28

[0145] The aging response of alloy B from Table 7 is shown in Table 8. The hot-rolled and annealed material has low hardness, indicating good formability. After aging, the hardness almost doubles, indicating a strong aging response. The tensile yield strength and elongation for both conditions are also shown in Table 8 for the cold-rolled and annealed sheet. The low tensile yield strength and high elongation in the annealed condition further suggest the formability of the alloy. Hardness measurements are... Petition 870250090293, dated 03 / 10 / 2025, page 38 / 94 33 / 47 average of three points, and the traction results are the average of two tests. Table 8 - Response to aging of alloy B Alloy Condition Hardness (HRC) Yield Strength (ksi) Elongation (%) B Annealed 23.8 64.5 53.1 1200F / 48h 42 139.7 30.7

[0146] Based on the test results of the 1 lb. buttons and 50 lb. ingots of examples AA-AT and XB, additional DA-DZ alloys were prepared and evaluated with the chemistries listed in Table 9. Although nickel contents are listed as “Bal.” in Table 9 and the tables above, it should be understood that alloys may include impurity elements and may also include relatively small concentrations of intentionally added elements that improve, or at least do not negatively affect, one or more important properties of the alloys. All alloy chemistries in Table 9 are measured chemistries.

[0147] The alloys listed in Table 9 were homogenized, hot rolled, and directly aged under various conditions to evaluate microstructural stability and mechanical properties, such as hardness. Table 9 - Chemical measurements Alloy Element (% by weight) MOeq / Creq Creq Ni Mo W Cr V Nb Fe Others DA Bal. 17.79 6.01 6.65 4.80 0.89 2.45 22.84 BD Bal. 13.19 6.07 7.95 3.96 2.96 0.76 2.45 22.42 DC Bal. 15.25 5.14 8.12 4.31 0.83 1.44 Ta 2.81 22.86 DD Bal. 14.87 5.73 7.53 4.13 0.76 3.03 Ta 2.69 23.07 DE Bal. 14.70 6.14 7.87 4.16 0.77 0.78 Ti 2.66 22.23 DF Bal. 13.55 6.09 7.76 3.92 0.74 1.52 Ti 2.99 23.43 DG Bal. 15.98 6.29 7.11 4.19 0.81 4.94 Co 2.21 20.78 DH Bal. 15.99 6.17 7.28 4.23 0.78 9.87 Co 2.31 21.77 Dl Bal. 15.99 6.18 7.99 4.04 0.76 0.11 Si 2.30 21.96 DJ Bal. 15.48 6.24 7.29 5.11 -0.92 -2.19 22.48 Petition 870250090293, dated 03 / 10 / 2025, p. 39 / 94 34 / 47 DK Bal. 15.91 6.08 7.48 6.18 1.06 2.47 22.61 DL Bal. 15.91 6.23 7.09 6.89 1.19 2.63 24.08 DM Bal. 15.89 6.10 7.83 4.16 4.73 2.78 24.45 DN Bal. 16.6 3.05 8.04 4.27 1.49 0.78 2.23 22.36 DO Bal. 16.87 3.06 7.98 4.36 0.77 0.76 Ti 2.72 23.86 DP Bal. 18.92 7.99 4.20 1.50 0.79 2.19 22.39 DQ Bal. 18.83 7.90 4.29 0.79 0.77 Ti 2.64 24.16 DR Bal. 15.80 6.18 7.77 3.96 0.76 3.85 Co, 0.71 Re 2.10 22.44 DS Bal. 15.98 6.35 7.99 3.83 0.72 3.61 Cu 2.20 22.07 DT Bal. 15.18 7.25 6.36 5.04 1.31 0.93 2.74 22.45 DU Bal. 15.78 6.03 6.46 5.41 0.97 0.84 Ti 3.02 23.10 DV Bal. 14.88 10.00 6.11 4.59 0.87 4.96 Co 2.58 21.63 DW Bal. 14.64 10.27 6.14 4.74 0.91 9.79 Co 2.61 21.76 DX Bal. 17.31 3.09 6.33 5.13 1.47 1.00 2.68 22.58 DY Bal. 19.47 6.46 5.30 1.48 0.96 2.61 23.19 DZ Bal. 13.58 10.19 6.08 5.63 - 1.00 - 2.80 22.01

[0148] The aging response of alloys DA to DZ is shown in Table 10. Each chemistry was aged using the following parameters: Loading in the furnace at 760 °C (1,400 °F) for 48 hours, then cooling from the furnace to 649 °C (1,200 °F) and holding for another 48 hours. All hardness measurements in Table 10 are a three-point average and are in Rockwell C. Table 10 - Rockwell C hardness results Alloy Hardness (HRC) DA 43.7 DB 49.5 DC 44.1 DD 50.0 DE 49.1 DF 47.6 DG 45.0 DH 47.0 Dl 46.5 DJ 49.7 Petition 870250090293, dated 03 / 10 / 2025, page 40 / 94 35 / 47 DK 48.7 DL 51.5 DM 44.8 DN 53.0 DO 47.0 DP 51.1 DQ 47.9 DR 45.9 DS 38.9 DT 52.0 DU 51.6 DV 51.1 DW 55.0 DX 55.1 DY 52.4 DZ 51.3

[0149] BSE images of the microstructure of DA to DZ alloys are shown in Figures 33 to 58. The dark particles shown in the BSE images are oxides, surface contamination, or holes. The coarser, brighter particles in the images may be primary phases or transformed primary phases from solidification. It was observed that almost all examples exhibited reasonable microstructural stability for short periods at 760 °C (1400 °F).

[0150] An alloy E with the chemistry of Table 11 was prepared by vacuum induction melting followed by vacuum arc remelting (VIM + VAR double melt) as an ingot. Alloy E was evaluated for mechanical properties and CTE. Table 11 - Measured Chemistry Alloy Element (% by weight) E Ni Mo W Cr V Fe Al Bal. 15.77 8.92 7.21 4.72 1.43 0.21 Element (% by weight) Petition 870250090293, dated 03 / 10 / 2025, p. 41 / 94 36 / 47 Mn Si CB Mg MOeq / CTeq CTeq 0.44 0.094 0.026 0.0078 0.05 2.45 23.04

[0151] A BSE image of the microstructure of alloy E is shown in Figure 59. The dark particles shown in the BSE image are oxides, surface contamination, or holes. The coarser, brighter particles in the image may be primary phases or transformed primary phases from solidification.

[0152] Tables 12 to 14 illustrate a comparison of the yield strength of several examples described above with commercially reported data for UNS N19909 alloy and HAYNES® 244® alloy. Table 15 illustrates an example of the stress fracture behavior of alloy CA. Table 16 illustrates a comparison of the CTE of several examples. Compared to commercial alloys, the alloy CA example shows a significant increase in strength at 760 °C (1,400 °F) and 816 °C (1,500 °F). Furthermore, the CTE of alloy CA example was observed to be lower than the CTE of alloy XI example at temperatures up to 760 °C (1,400 °F). Alloy XI examples and alloy B example were aged using a 48-hour / 649 °C (1,200 °F) heat treatment. The XV, BA, BB, BC, BD, CA, CB, DA, and E alloy samples were heat treated using a first aging step of 48 hours / 760 °C (1,400 °F) followed by a second aging step of 48 hours / 649 °C (1,200 °F). Table 12 - Tensile yield strength at ambient temperature (RT) Flow Limit Alloy (ksi) Petition 870250090293, dated 03 / 10 / 2025, p. 42 / 94 37 / 47 DA 154 E 161 HAYNES®244® 130 UNS N19909 150 Table 13 - Tensile yield strength at elevated temperature of 760 °C 1,400°F)____________________________________._____________________________________________________. Flow Limit Alloy (ksi) xv 76 B 91 BA 71 BB 72 CA 101 CB 84 HAYNES®244® 78 UNS N19909 77 Table 14 - Tensile yield strength at elevated temperature of 816 °C 1,500 °F Flow Limit Alloy (ksi) B 86 B 40 CA 70 CB 57 HAYNES®244® 43 Table 15 - Tensile strength properties at 760 °C (1400 °F) and 816 °C 1,500 °F Turns on Temperature (°F) Voltage (ksi) Time (h) AC 1400 50 37.8 AC 1500 40 3.2 Table 16 - Average CTE of selected alloys from 21 °C (70 °F) to 760 °C (1,400 °F) Petition 870250090293, dated 03 / 10 / 2025, p. 43 / 94 38 / 47 Alloy RT Medium CTE at 760°C (1,400°F) (pin / in / °F) xv 7.7 B 7.1 BA 7.9 CA 7.6 E 7.5 Haynes® 244® 7.4

[0153] It should be understood that the scope of this disclosure is not necessarily limited to the leagues comprising the elementary contents listed in the examples.

[0154] The following numbered clauses refer to various non-limiting arrangements under this disclosure:

[0155] Clause 1. A nickel-based alloy comprising, in weight percent, based on the total weight of the nickel-based alloy: 8% to 24% molybdenum; 0% to 12% tungsten; 3.5% to 10% chromium; 2% to 10% vanadium; 0% to 10% iron; and nickel.

[0156] Clause 2. The nickel-based alloy of clause 1, comprising 14% to 20% molybdenum, by weight percentage, based on the total weight of the nickel-based alloy.

[0157] Clause 3. The nickel-based alloy of any clause 1, comprising 15% to 17% molybdenum, by weight percentage, based on the total weight of the nickel-based alloy.

[0158] Clause 4. The nickel-based alloy of any of clauses 1 to 3, comprising 4% to 11% tungsten, by weight percentage, based on the total weight of the nickel-based alloy.

[0159] Clause 5. The nickel-based alloy of any of clauses 1 to 3, comprising 6% to 11% tungsten, by weight percentage, based on Petition 870250090293, dated 03 / 10 / 2025, p. 44 / 94 39 / 47 total weight of the nickel-based alloy.

[0160] Clause 6. The nickel-based alloy of any of clauses 1 to 5, comprising 5% to 8.5% chromium, by weight percentage, based on the total weight of the nickel-based alloy.

[0161] Clause 7. The nickel-based alloy of any of clauses 1 to 5, comprising 6% to 8% chromium, by weight percentage, based on the total weight of the nickel-based alloy.

[0162] Clause 8. The nickel-based alloy of any of clauses 1 to 7, comprising 3% to 7% vanadium, by weight percentage, based on the total weight of the nickel-based alloy.

[0163] Clause 9. The nickel-based alloy of any of clauses 1 to 7, comprising 3.5% to 6% vanadium, by weight percentage, based on the total weight of the nickel-based alloy.

[0164] Clause 10. The nickel-based alloy of any of clauses 1 to 9, comprising 0.3% to 2% niobium, by weight percentage, based on the total weight of the nickel-based alloy.

[0165] Clause 11. The nickel-based alloy of any of clauses 1 to 9, comprising up to 0.3% niobium, by weight percentage, based on the total weight of the nickel-based alloy.

[0166] Clause 12. The nickel-based alloy of any of clauses 1 to 11, comprising 0.5% to 3% iron, by weight percentage, based on the total weight of the nickel-based alloy.

[0167] Clause 13. The nickel-based alloy of any of clauses 1 to 12, optionally further comprising, in weight percentage based on the total weight of the nickel-based alloy, at least one of: up to 4% titanium; up to 15% cobalt; up to 5% tantalum; up to 2% silicon; up to 5% copper; up to 2% rhenium; up to 1% hafnium; up to 1% zirconium; up to 0.2% magnesium; up to 0.1% boron; up to 0.5 Petition 870250090293, dated 03 / 10 / 2025, p. 45 / 94 40-47% carbon; up to 1% total rare earth elements; up to 2% aluminum; and up to 5% manganese.

[0168] Clause 14. The nickel-based alloy of clause 1, comprising, in weight percentage, based on the total weight of the nickel-based alloy: 14.5% to 17.5% molybdenum; 7.5% to 11% tungsten; 6% to 8% chromium; 4% to 5% vanadium; 0% to 0.3% niobium; 0% to 3% iron; and nickel.

[0169] Clause 15. The nickel-based alloy of clause 1, comprising, in weight percent, based on the total weight of the nickel-based alloy: 14.5% to 17.5% molybdenum; 7.5% to 11% tungsten; 6% to 8% chromium; 3.5% to 5.5% vanadium; 0% to 0.3% niobium; 0% to 3% iron; and nickel; wherein the average coefficient of linear thermal expansion from 21 °C (70 °F) to 760 °C (1400 °F) is not greater than 8.5 pin / in-°F; and wherein the yield strength at 760 °C (1400 °F) is at least 60 ksi (414 MPa).

[0170] Clause 16. A nickel-based alloy comprising, by weight percent, based on the total weight of the nickel-based alloy: 14.5% to 17% molybdenum; 7% to 11% tungsten; 6% to 8% chromium; 3.5% to 5.5% vanadium; 0% to 0.3% niobium; 0.5% to 3% iron; 0% to 2% titanium; 0% to 0.5% cobalt; 0% to 0.5% tantalum; 0.01% to 0.5% silicon; 0% to 0.5% copper; 0% to 0.5% rhenium; 0% to 0.5% hafnium; 0% to 0.5% zirconium; 0 to 0.2% magnesium; 0 to 0.1% boron; 0 to 0.5% carbon; 0 to 1% rare earth elements; 0.05% to 0.5% aluminum; 0.1% to 0.5% manganese; impurities; and nickel.

[0171] Clause 17. The nickel-based alloy of clause 1, comprising, in weight percentage, based on the total weight of the nickel-based alloy: 14.5% to 17.5% molybdenum; 5% to 8% tungsten; 7% to 9% chromium; 3% to 5.5% vanadium; 0% to 2% niobium; 0% to 1.5% iron; and nickel.

[0172] Clause 18. The nickel-based alloy of clause 1, comprising, in weight percentage, based on the total weight of the nickel-based alloy: 13.5% to Petition 870250090293, dated 03 / 10 / 2025, p. 46 / 94 41 / 47 16.5% molybdenum; 5% to 8% tungsten; 7% to 9% chromium; 3% to 5.5% vanadium; 0% to 2% niobium; 0% to 1.5% iron and nickel; wherein the average coefficient of linear thermal expansion from 21 °C (70 °F) to 816 °C (1,500 °F) is not greater than 8 μη / η^; and wherein the yield strength at 816 °C (1,500 °F) is at least 80 ksi (551 MPa).

[0173] Clause 19. The nickel-based alloy of clause 1, comprising, in weight percent, based on the total weight of the nickel-based alloy: 13.5% to 16.5% molybdenum; 5.5% to 7.5% tungsten; 7% to 8.5% chromium; 3.75% to 5.5% vanadium; 0% to 2% niobium; 0.5% to 1.5% iron; 0% to 2% titanium; 0% to 12% cobalt; 0% to 2% tantalum; 0.01% to 0.5% silicon; 0% to 0.5% copper; 0% to 0.5% rhenium; 0% to 0.5% hafnium; 0 to 0.5% zirconium; 0 to 0.2% magnesium; 0 to 0.1% boron; 0 to 0.5% carbon; 0 to 1% rare earth elements; 0.05% to 0.5% aluminum; 0.1% to 0.5% manganese; impurities; and nickel.

[0174] Clause 20. The nickel-based alloy of any of clauses 1 to 19, wherein the molybdenum and tungsten content in the nickel-based alloy satisfies the following equations: < Creq < 33; and Moeq / Creq > 1.8, where: Creq = {[Cr] + 0.54[Mo] + 0.28[W] + 1.02[V] + 0.55[Nb] + 1.09[Ti] + 0.29[Ta]} Moeq = {[Mo] + 1.06[W] + 6.61[V] + 4.14[Nb] + 14.07[Ti] + 4.26[Ta]}

[0175] Clause 21. The nickel-based alloy of any of clauses 1 to 20, wherein the weight ratio of chromium to vanadium is in the range of 0.8 to 5.

[0176] Clause 22. The nickel-based alloy of any of clauses 1 to 20, wherein the weight ratio of chromium to vanadium is 1.5 to 2.5.

[0177] Clause 23. The nickel-based alloy of any of clauses 1 to 22, where the average coefficient of linear thermal expansion is 21 °C (70 °F) to 760 Petition 870250090293, dated 03 / 10 / 2025, p. 47 / 94 42 / 47 °C (1,400 °F) is no greater than 9 μίη / ίη^.

[0178] Clause 24. The nickel-based alloy of any of clauses 1 to 22, wherein the average coefficient of linear thermal expansion from 21 °C (70 °F) to 760 °C (1,400 °F) is not greater than 8 μin / in-°F.

[0179] Clause 25. The nickel-based alloy of any of clauses 1 to 24, wherein the yield strength at 760 °C (1,400 °F) is at least 50 ksi (345 MPa).

[0180] Clause 26. The nickel-based alloy of any of clauses 1 to 24, wherein the yield strength at 760 °C (1,400 °F) is at least 414 MPa (60 ksi).

[0181] Clause 27. The nickel-based alloy of any of clauses 1 to 26, wherein the yield strength at 816 °C (1,500 °F) is at least 30 ksi (207 MPa).

[0182] Clause 28. The nickel-based alloy of any of clauses 1 to 26, wherein the yield strength at 816 °C (1,500 °F) is at least 35 ksi (241 MPa).

[0183] Clause 31. The nickel-based alloy of any of clauses 1 to 30, wherein: an average coefficient of linear thermal expansion from 21 °C (70 °F) to 760 °C (1,400 °F) is not greater than 8.5 pin / in-oF; a yield strength at 760 °C (1,400 °F) is at least 60 ksi (414 MPa); and a yield strength at 816 °C (1,500 °F) is at least 35 ksi (241 MPa).

[0184] Clause 32. A nickel-based alloy comprising, in weight percent, based on the total weight of the nickel-based alloy: 14.5% to 17% molybdenum; 7.5% to 10.5% tungsten; 5% to 8% chromium; 3.5% to 5.5% vanadium; 0% to 0.3% niobium; 0% to 3% iron; and nickel; and wherein an average coefficient of linear thermal expansion from 21 °C (70 °F) to 760 °C (1,400 °F) is not greater than 8.5 pin / in-°F. Petition 870250090293, dated 03 / 10 / 2025, p. 48 / 94 43 / 47

[0185] Clause 33. A nickel-based alloy comprising, in weight percent, based on the total weight of the nickel-based alloy: 13.5% to 16.5% molybdenum; 5% to 8% tungsten; 7% to 9% chromium; 3% to 5.5% vanadium; 0% to 2% niobium; 0% to 1.5% iron; and nickel; and wherein an average coefficient of linear thermal expansion from 21 °C (70 °F) to 816 °C (1,500 °F) is not greater than 8 pin / in-°F.

[0186] Clause 34. An article of manufacture comprising the nickel-based alloy of any of clauses 1 to 33.

[0187] Clause 35. A manufactured article comprising, as a percentage by weight, based on the total weight of the manufactured article: 8% to 24% molybdenum; 0% to 12% tungsten; 3.5% to 10% chromium; 2% to 10% vanadium; 0% to 10% iron; and nickel.

[0188] Clause 36. The article of manufacture of any of clauses 34 and 35, wherein the article of manufacture is selected from the group consisting of a sheet, a plate, a wire, a billet, a block, a casting and a powder.

[0189] Clause 37. The article of manufacture of any of clauses 34 to 36, wherein the article of manufacture is a component of a supersonic or hypersonic vehicle.

[0190] The alloy embodiments according to this disclosure may be produced in forms including, for example, sheet, plate, wire, rod, block, castings, powder and other forms. The alloy embodiments according to this disclosure may have properties that make them useful in certain manufactured articles, including, for example, heat exchangers, gas turbine seals, supersonic or hypersonic vehicles, rockets and additively manufactured parts. For example, the alloy embodiments according to this disclosure may be included in a component of a supersonic or hypersonic vehicle and / or rocket, Petition 870250090293, dated 03 / 10 / 2025, page 49 / 94 44 / 47 such as, for example, a control surface, a nozzle, a skin, a leading edge, a sliding body or a motor inlet.

[0191] Several non-limiting embodiments are described and illustrated in this descriptive report to provide a general understanding of the disclosed inventions. It is understood that the various non-limiting embodiments described and illustrated in this descriptive report are non-limiting and non-exhaustive. Therefore, the invention is not limited to the description of the various non-limiting and non-exhaustive embodiments disclosed in this descriptive report. Instead, the invention sought for patenting is defined solely by the claims. The features and characteristics illustrated and / or described in relation to various non-limiting embodiments may be combined with the features and characteristics of other non-limiting embodiments. Such modifications and variations shall be included within the scope of this descriptive report.Thus, claims may be amended or supplemented to cite any features or characteristics expressly or inherently described or otherwise expressly or inherently supported by this specification. Furthermore, the Applicant reserves the right to amend claims to affirmatively deny features or characteristics that may be present in the prior art. The various non-limiting embodiments disclosed and described in this descriptive report may include, consist of, or consist essentially of, features and characteristics as described herein.

[0192] Any patent, publication or other disclosure material that is incorporated, in whole or in part, by reference to this document is incorporated herein only to the extent that the incorporated material does not conflict with the existing definitions, statements or other disclosure materials set forth in this disclosure. To that extent, and to the extent necessary, the disclosure set forth in this document supersedes any conflicting material incorporated herein. Petition 870250090293, dated 03 / 10 / 2025, page 50 / 94 45 / 47 document by reference. Any material, or part thereof, which is incorporated by reference into this document but which conflicts with existing definitions, statements or other disclosure materials set forth in this document, is incorporated only to the extent that there is no conflict between such incorporated material and the existing disclosure material.

[0193] In this descriptive report, except where otherwise indicated, all numerical parameters should be understood as being preceded and modified in all instances by the term “about”, wherein the numerical parameters possess the characteristic of variability inherent in the underlying measurement techniques used to determine the numerical value of the parameter. At a minimum, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described in this description should, at a minimum, be interpreted in light of the reported number of significant digits and applying common rounding techniques.

[0194] Furthermore, any numerical range cited in this descriptive report is intended to include all sub-ranges of the same numerical precision included within the cited range. For example, a range of “1 to 10” is intended to include all sub-ranges between (and including) the stated minimum value of 1 and the stated maximum value of 10, i.e., with a minimum value equal to or greater than 1 and a maximum value equal to or less than 10, such as, for example, 2.4 to 7.6. Any maximum numerical limitation cited in this descriptive report is intended to include all lower numerical limitations included therein, and any minimum numerical limitation cited in this descriptive report is intended to include all higher numerical limitations included therein. Therefore, the Applicant reserves the right to amend this descriptive report, including the claims, to expressly cite any sub-range included within the ranges expressly cited herein.All of these sub-ranges should be inherently described in this descriptive report, in such a way. Petition 870250090293, dated 03 / 10 / 2025, p. 51 / 94 46 / 47 that the amendment to expressly recite any of these subranges would be in accordance with the requirements of 35 USC §§ 112 and 132(a). Furthermore, as used in this document when referring to elemental composition ranges, the term “up to” includes zero, unless the particular element is an unavoidable impurity.

[0195] The grammatical articles “a / an” and “the,” as used in this descriptive report, are intended to include “at least one” or “one or more,” unless otherwise indicated. Therefore, the grammatical articles are used in this descriptive report to refer to one or more than one (i.e., “at least one”) of the article’s grammatical objects. By way of example only, “a component” means one or more components, and therefore possibly more than one component is contemplated and may be employed or used in an implementation of the modalities described. Furthermore, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of use requires otherwise.

[0196] A person skilled in the art will recognize that the alloys and methods described in this document, as well as the accompanying discussion, are used as examples for the sake of conceptual clarity and that various modifications are contemplated. Consequently, as used in this document, the specific examples / experiments presented and the accompanying discussion are intended to be representative of their more general classes. In general, the use of any specific example is intended to be representative of its class and should not be considered limiting. Although this disclosure provides descriptions of several specific embodiments for the purpose of illustrating various aspects of this disclosure and / or its possible applications, it is understood that variations and modifications will occur for those skilled in the art. Thus, the invention or inventions described in this document should be understood as being, at a minimum, Petition 870250090293, dated 03 / 10 / 2025, page 52 / 94 47 / 47 as broad as claimed and not as being defined more narrowly by particular examples and illustrative modalities provided in this document. Petition 870250090293, dated 03 / 10 / 2025, page 53 / 94

Claims

1 / 9 CLAIMS 1. Nickel-based alloy CHARACTERIZED in that it comprises, in weight percentage, based on the total weight of the nickel-based alloy: 8% to 24% molybdenum; 0% to 12% tungsten; 3.5% to 10% chromium; 2% to 10% vanadium; 0% to 10% iron; and nickel.

2. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 13% to 19% molybdenum, in weight percent, based on the total weight of the nickel-based alloy.

3. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 14% to 18% molybdenum, in weight percent, based on the total weight of the nickel-based alloy.

4. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 4% to 11% tungsten, in weight percent, based on the total weight of the nickel-based alloy.

5. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 6% to 11% tungsten, by weight percent, based on the total weight of the nickel-based alloy.

6. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 5% to 8.5% chromium, in weight percent, based on the total weight of the nickel-based alloy.

7. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 6% to 8% chromium, by weight percentage, based on the total weight of the nickel-based alloy. Petition 870260036985, dated 20 / 04 / 2026, page 15 / 23 2 / 9 8. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 3% to 7% vanadium, in weight percent, based on the total weight of the nickel-based alloy.

9. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 3.5% to 6% vanadium, in weight percent, based on the total weight of the nickel-based alloy.

10. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 0.3% to 3% niobium, in weight percent, based on the total weight of the nickel-based alloy.

11. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises up to 0.3% niobium, by weight percentage, based on the total weight of the nickel-based alloy.

12. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises 0.5% to 3% iron, in weight percent, based on the total weight of the nickel-based alloy.

13. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it further comprises, in weight percentage, based on the total weight of the nickel-based alloy, at least one of: up to 4% titanium; up to 15% cobalt; up to 5% tantalum; up to 2% silicon; up to 5% copper; up to 2% rhenium; up to 1% hafnium; up to 1% zirconium; up to 0.2% magnesium; Petition 870260036985, dated 20 / 04 / 2026, page 16 / 23 3 / 9 up to 0.1% boron; up to 0.5% carbon; up to 1% of the total rare earth elements; up to 2% aluminum; and up to 5% manganese.

14. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises, in weight percent, based on the total weight of the nickel-based alloy: 13% to 16% molybdenum; 8.5% to 12% tungsten; 6% to 8% chromium; 4% to 5% vanadium; 0% to 0.3% niobium; 0% to 3% iron; and nickel.

15. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises, in weight percent, based on the total weight of the nickel-based alloy: 14% to 18% molybdenum; 7.5% to 10.5% tungsten; 6% to 8% chromium; 3.5% to 5.5% vanadium; 0% to 0.3% niobium; 0% to 3% iron; and nickel; wherein an average coefficient of linear thermal expansion from 21 °C (70 °F) to 760 °C (1400 °F) is not greater than 8.5 μϊπ / ϊπ-°P; and Petition 870260036985, dated 20 / 04 / 2026, p. 17 / 23 4 / 9 where a yield strength at 760 °C (1,400 °F) is at least 60 ksi (414 MPa).

16. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it consists, in weight percentage, based on the total weight of the nickel-based alloy: 14.5% to 17% molybdenum; 7% to 11% tungsten; 6% to 8% chromium; 3.5% to 5.5% vanadium; 0% to 0.3% niobium; 0.5% to 3% iron; 0% to 2% titanium; 0% to 0.5% cobalt; 0% to 0.5% tantalum; 0.01% to 0.5% silicon; 0% to 0.5% copper; 0% to 0.5% rhenium; 0% to 0.5% hafnium; 0 to 0.5% zirconium; 0 to 0.2% magnesium; 0 to 0.1% boron; 0 to 0.5% carbon; 0 to 1% rare earth elements; 0.05% to 0.5% aluminum; 0.1% to 0.5% manganese; impurities; and nickel. Petition 870260036985, dated 20 / 04 / 2026, p. 18 / 23 5 / 9 17. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it comprises, in weight percentage, based on the total weight of the nickel-based alloy: 14.5% to 17.5% molybdenum; 5% to 8% tungsten; 7% to 9% chromium; 3% to 5.5% vanadium; 0% to 2% niobium; 0% to 1.5% iron; and nickel.

18. Nickel-based alloy according to claim 1, CHARACTERIZED in that it comprises, in weight percent, based on the total weight of the nickel-based alloy: 13.5% to 16.5% molybdenum; 5% to 8% tungsten; 7% to 9% chromium; 3% to 5.5% vanadium; 0% to 2% niobium; 0% to 1.5% iron; and nickel; wherein an average coefficient of linear thermal expansion from 21 °C (70 °F) to 816 °C (1,500 °F) is not greater than 8 μϊπ / ϊπ-οP; and wherein a yield strength at 816 °C (1,500 °F) is at least 60 ksi (414 MPa).

19. Nickel-based alloy, according to claim 1, CHARACTERIZED in that it consists of, in weight percentage, based on the total weight of the nickel-based alloy Petition 870260036985, dated 04 / 20 / 2026, page 19 / 23 6 / 9 13.5% to 16.5% molybdenum; 5.5% to 7.5% tungsten; 7% to 8.5% chromium; 3.75% to 5.5% vanadium; 0% to 2% niobium; 0.5% to 1.5% iron; 0% to 2% titanium; 0% to 12% cobalt; 0% to 2% tantalum; 0.01% to 0.5% silicon; 0 to 0.5% copper; 0 to 0.5% rhenium; 0 to 0.5% hafnium; 0 to 0.5% zirconium; 0 to 0.2% magnesium; 0 to 0.1% boron; 0 to 0.5% carbon; 0 to 1% rare earth elements; 0.05% to 0.5% aluminum; 0.1% to 0.5% manganese; impurities; and nickel.

20. Nickel-based alloy, according to claim 1, CHARACTERIZED in that the molybdenum and tungsten content in the nickel-based alloy satisfies the following equations: 18 < Creq < 33; and Moeq / Creq > 1.8, Petition 870260036985, dated 20 / 04 / 2026, p. 20 / 23 7 / 9 where: Creq = {[Cr] + 0.54[Mo] + 0.28[W] + 1.02[V] + 0.55[Nb] + 1.09[Ti] + 0.29[Ta]} MOeq = {[Mo] + 1.06[W] + 6.61[V] + 4.14[Nb] + 14.07[Ti] + 4.26[Ta]}.

21. Nickel-based alloy according to claim 1, CHARACTERIZED in that the weight ratio of chromium to vanadium is 0.8 to 5.

22. Nickel-based alloy according to claim 1, CHARACTERIZED in that the weight ratio of chromium to vanadium is 1.5 to 2.

5.

23. Nickel-based alloy according to claim 1, CHARACTERIZED in that an average linear thermal expansion coefficient from 21 °C (70 °F) to 760 °C (1,400 °F) is not greater than 9 μΐπ / ΐπ-T.

24. Nickel-based alloy according to claim 1, CHARACTERIZED in that an average linear thermal expansion coefficient from 21 °C (70 °F) to 760 °C (1,400 °F) is not greater than 8 ^n / in-°F.

25. Nickel-based alloy according to claim 1, CHARACTERIZED in that a yield strength at 760 °C (1,400 °F) is at least 50 ksi (345 MPa).

26. Nickel-based alloy according to claim 1, CHARACTERIZED in that a yield strength at 760 °C (1,400 °F) is at least 414 MPa (60 ksi).

27. Nickel-based alloy according to claim 1, CHARACTERIZED in that a yield strength at 816 °C (1,500 °F) is at least 30 ksi (207 MPa).

28. Nickel-based alloy according to claim 1, CHARACTERIZED in that a yield strength at 816 °C (1,500 °F) is at least 35 ksi (241 MPa). Petition 870260036985, dated 20 / 04 / 2026, p. 21 / 23 8 / 9 29. Nickel-based alloy according to claim 1, CHARACTERIZED in that: an average linear thermal expansion coefficient from 21 °C (70 °F) to 760 °C (1,400 °F) is not greater than 8 μϊπ / ϊπ-οP; a yield strength at 760 °C (1,400 °F) is at least 60 ksi (414 MPa); and a yield strength at 816 °C (1,500 °F) is at least 35 ksi (241 MPa).

30. Nickel-based alloy CHARACTERIZED in that it comprises, in weight percent, based on the total weight of the nickel-based alloy: 14.5% to 17% molybdenum; 7.5% to 10.5% tungsten; 5% to 8% chromium; 3.5% to 5.5% vanadium; 0% to 0.3% niobium; 0% to 3% iron; and nickel; and wherein an average coefficient of linear thermal expansion from 21 °C (70 °F) to 760 °C (1,400 °F) is not greater than 8 μ₀ / ₀.

31. Nickel-based alloy CHARACTERIZED in that it comprises, in weight percent, based on the total weight of the nickel-based alloy: 13.5% to 16.5% molybdenum; 5% to 8% tungsten; 7% to 9% chromium; 3% to 5.5% vanadium; 0% to 2% niobium; 0% to 1.5% iron; and nickel; and in which an average linear thermal expansion coefficient from 21 °C (70 °F) to 816 °C (1,500 °F) is not greater than 8 μΐπZΐπ-°P.

32. Article of manufacture CHARACTERIZED in that it comprises the nickel-based alloy, as defined in claim 1.

33. A manufactured article according to claim 32, CHARACTERIZED in that the manufactured article is selected from the group consisting of a sheet, a plate, a wire, a billet, a block, a casting, and a powder.

34. Article of manufacture, according to claim 32, CHARACTERIZED in that the article of manufacture is a component of a supersonic or hypersonic vehicle. Petition 870260036985, dated 20 / 04 / 2026, p. 23 / 23

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