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Wire for liquid assisted additive manufacturing of a superalloy component

a superalloy and additive manufacturing technology, applied in the direction of additive manufacturing with solid and fluid, metal-working equipment, welding/cutting media/materials, etc., can solve the problems of high ′ forming nickel-base superalloy materials, additively manufactured or welded superalloy components are sensitive to strain-age cracking and other problems

Pending Publication Date: 2022-07-21
SIEMENS ENERGY INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent text describes a method for reducing solidification cracks in a low melt superalloy powder. By using a specific chemistry, the powder is able to fill the cracks in each deposited layer and thus reduce them. This method also results in less microcracking when the powder is cooled to room temperature. On average, this method improves the quality of the resulting low melt superalloy powder.

Problems solved by technology

However, additively manufacturing and / or welding of high γ′ forming nickel-base superalloy materials has been known to be difficult as such superalloys experience solidification and grain boundary liquation cracking problems during such processes.
Further, during subsequent heat treatments such additively manufactured or welded superalloy components are sensitive to strain-age cracking.

Method used

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  • Wire for liquid assisted additive manufacturing of a superalloy component
  • Wire for liquid assisted additive manufacturing of a superalloy component
  • Wire for liquid assisted additive manufacturing of a superalloy component

Examples

Experimental program
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Embodiment Construction

[0111]Various technologies that pertain to systems, methods and materials that facilitate additively manufacturing (and / or welding) components made from superalloy materials will now be described with reference to the drawings, where like reference numerals represent like elements throughout. Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in this description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0112]Example embodiments of one or more inventions described herein are directed to making components comprising nickel-base superalloys including greater than 40%...

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Abstract

A wire is provided for additive manufacturing a superalloy component using a liquid assisted additive manufacturing process. The wire has an elongated body that includes therein a superalloy powder mixture including at least 51% by weight a high melt superalloy powder and at least 5% by weight a low melt superalloy powder. The low melt superalloy powder may have a solidus temperature lower than the solidus temperature of the high melt superalloy powder by between 50° C. and 220° C. Each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture may have an aluminum content by weight of greater than 1.5%. The low melt superalloy powder may include at least 5% by weight of tantalum, and the high melt superalloy powder may include less than half the content by weight percent of tantalum compared to the content by weight percent of tantalum in the low melt superalloy powder.

Description

BACKGROUND[0001]The present disclosure relates generally to the field of additive manufacturing and welding, and more particularly, to additively manufacturing and / or welding components made of difficult-to-weld superalloys used in gas turbines and other high temperature applications.[0002]Nickel-base superalloys are metal alloys capable of being used to form gamma-prime (γ′) precipitation-strengthened metal parts that have a favorable combination of mechanical strength and resistance to thermal fatigue, oxidation, type I or type II corrosion, and thermal creep deformation. High γ′ forming nickel-base superalloys are typically used in high temperature applications (e.g., above 950° C.). For example, parts casted from such superalloys may include blades, guide vanes and other hot gas path components that are used in aerospace, marine, and industrial gas turbine engines. However, additively manufacturing and / or welding of high γ′ forming nickel-base superalloy materials has been known...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B23K35/02B33Y70/00B23K35/30C22C19/05C22C30/00
CPCB23K35/0261B33Y70/00C22C30/00C22C19/057B23K35/304C22C1/0433C22C19/00B22F10/28B22F10/25B22F10/18B23K26/342B22F2998/10B33Y80/00B33Y10/00C22C19/055C22C19/056C22C19/058C22F1/10B23K35/3033B23K26/21B23K2101/001B23K2103/26Y02P10/25B22F3/10B22F2301/15B33Y40/20B22F10/62B22F10/64B22F12/41B22F1/105B22F5/04B22F2301/052B22F2301/205B29C64/165B23K2103/08B22F10/14B22F1/05B22F2304/10B22F1/09C22C2202/00
Inventor OZBAYSAL, KAZIMKAMEL, AHMED
Owner SIEMENS ENERGY INC
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