Nickel-based alloy

Abstract

A nickel-based alloy comprising, in weight percent based on the total alloy weight: 11 to 18 chromium; 16 to 28 cobalt; 1.5 to 7.0 of molybdenum; from 0 to 6.5 tungsten; from 0 to 1.0 niobium; 1.0 to 2.5 parts of aluminum; 2.0 to 6.0 of titanium; 0 to 2.0 tantalum; 0 to 4.0 of iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.02% of boron; 0.001 to 0.1 part of zirconium; nickel; and impurities. Also disclosed is a nickel-based alloy comprising, in weight percent based on the total alloy weight: 11 to 18 chromium; 24 to 28 cobalt; 1.5 to 7.0 of molybdenum; 2.0 to 6.0 tungsten; from 0 to 1.0 niobium; 1.0 to 2.5 parts of aluminum; 2.0 to 6.0 of titanium; 0 to 2.0 tantalum; 0 to 4.0 of iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.02% of boron; 0.001 to 0.1 part of zirconium; nickel; and impurities.

Description

[0001] Cross-references

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 367,170, filed on June 28, 2022. The contents of which are hereby incorporated by reference into this specification. Technical Field

[0003] The present invention relates to the field of metallurgy, and more particularly to nickel-based alloys. Embodiments of nickel-based alloys according to the present disclosure are suitable for structural applications subjected to high temperatures, such as greater than 1200°F (649°C). Background Art

[0004] Various commercially available nickel-based alloys are suitable for static structural applications subjected to temperatures up to about 1200°C (649°C). Certain of these available alloys are used in static parts of turbine engines, including, for example, compressor exhaust nozzle (CDN) casings, combustor casings, and high / low pressure turbine (HPT / LPT) casing components. For example, Waspaloy alloy (UNS N07001) is used in the CDN and low pressure turbine casings of the GE9X aircraft turbofan engine of the Boeing 777X aircraft. Waspaloy alloy has the following broad weight percentage composition: 18.00-21.00 chromium, 3.50-5.00 molybdenum, 12.00-15.00 cobalt, 1.20-1.60 aluminum, 2.75-3.25 titanium, 0.003-0.01 boron, 0.02-0.10 carbon, 0.02-0.08 zirconium, up to 2.00 iron, up to 0.10 manganese, up to 0.15 silicon, up to 0.015 phosphorus, up to 0.015 sulfur, up to 0.10 copper, balance nickel. The static turbine housing component is a seamless component and can be formed by a series of steps, including forging, stamping and ring rolling at high temperatures of about 2000°F (1093°C).

[0005] In next generation turbine engine designs, the goal is to increase component temperatures to improve engine efficiency. In some designs under consideration, the temperature may approach 1500°F (816°C). At these higher operating temperatures, the mechanical properties of current commercial nickel-base alloys may not meet the design requirements. Methods that have been considered to increase the high temperature properties of nickel-base alloys include increasing the γ' phase and / or alloying element content. However, these methods can make the resulting alloy more susceptible to microstructural instabilities.

[0006] Therefore, there is a need for new nickel-based alloys having properties suitable for high temperature environments, such as temperatures approaching 1500°F (816°C). In particular, there is a need for new nickel-based alloys having properties suitable for structural components of turbine engines and subjected to temperatures approaching 1500°F (816°C). Summary of the invention

[0007] In terms of weight percentage based on the total alloy weight, one embodiment of a nickel-based alloy according to the present disclosure includes: 11 to 18 chromium; 16 to 28 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 2.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.02 boron; 0.001 to 0.1 zirconium; nickel; and impurities. Certain non-limiting embodiments of the nickel-based alloy of this embodiment include 16 to 19 weight percent cobalt. In certain non-limiting embodiments of the nickel-based alloy of this embodiment, the aluminum equivalent number (Al2O3) of the alloy is ... eq ) is in the range of 3.6 to 4.5. Certain nickel-base alloys of this embodiment include a combined concentration of aluminum and titanium of no greater than 7.0 wt. % based on the total alloy weight.

[0008] Additional embodiments of the nickel-based alloys according to the present disclosure include, in weight percentage based on the total alloy weight: 11 to 16 chromium; 16 to 28 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 2.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; at least 36 nickel; and impurities. Certain non-limiting embodiments of the nickel-based alloys of this embodiment include 16 to 19 weight percent cobalt. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloys of this embodiment is ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments of the nickel-based alloy of this embodiment, the combined concentration of aluminum, niobium, and titanium does not exceed 7.0 weight percent.

[0009] Additional embodiments of nickel-based alloys according to the present disclosure include, in weight percentage based on the total alloy weight: 11 to 18 chromium; 24 to 28 cobalt; 1.5 to 7.0 molybdenum; 2.0 to 6.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 2.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.02 boron; 0.001 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.1 to 1.8 chromium; 2.4 to 2.5 ...4 to 2.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 2.0 to 6.0 eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum and titanium of no more than 7.0 wt % based on the total alloy weight.

[0010] Additional embodiments of nickel-based alloys according to the present disclosure include, in weight percent based on the total alloy weight: 14 to 16 chromium; 24 to 27 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.7 to 2.0 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2.0 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of no more than 7.0 wt % based on the total alloy weight.

[0011] Additional embodiments of nickel-based alloys according to the present disclosure include, in weight percentage based on the total alloy weight: 13 to 17 chromium; 16 to 25 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 36 nickel; and impurities. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes an aluminum equivalent number (Al2O3) in the range of 3.6 to 4.5. eq ). In certain non-limiting embodiments, the nickel-base alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent, based on the total alloy weight.

[0012] Additional embodiments of nickel-based alloys according to the present disclosure include, in weight percentage based on the total alloy weight: 13 to 17 chromium; 16 to 19 cobalt; 1.5 to 7.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 2 ...antalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0013] Additional embodiments of nickel-based alloys according to the present disclosure include, in weight percentage based on the total alloy weight: 14 to 17 chromium; 19 to 25 cobalt; 2.0 to 4.0 molybdenum; 0 to 6.5 tungsten; 0 to 0.8 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0014] Additional embodiments of nickel-based alloys according to the present disclosure include, in weight percentage based on the total alloy weight: 14 to 17 chromium; 16 to 19 cobalt; 2.0 to 4.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; greater than 0 to 2.0 tantalum; 1.0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0015] Additional embodiments of nickel-based alloys according to the present disclosure include, in weight percentage based on the total alloy weight: 15 to 17 chromium; 22 to 26 cobalt; 2.0 to 4.0 molybdenum; 0 to 2.0 tungsten; 0 to 1.0 niobium; 1.0 to 4.0 aluminum; 1.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 0.1 to 0.2. eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0016] Additional embodiments of nickel-based alloys according to the present disclosure include, in weight percentage based on the total alloy weight: 14 to 17 chromium; 15 to 18 cobalt; 2.0 to 4.0 molybdenum; 1.0 to 4.0 tungsten; 0 to 1.0 niobium; 1.0 to 3.0 aluminum; 2.0 to 4.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 0.1 to 0.2. eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0017] The present disclosure also relates to methods of preparing alloys having compositions according to the present disclosure and to rolled products, powders, and other articles consisting of or comprising the alloys according to the present disclosure.

[0018] Other areas of applicability of the present invention will be apparent from the detailed description provided below.It should be understood that the detailed description and any specific examples herein, while indicating certain embodiments of the present invention, are intended for illustrative purposes only and are not intended to limit the scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will be more fully understood from the following detailed description and the accompanying drawings, which are not necessarily drawn to scale, in which:

[0020] Figure 1 is a photograph showing a dual VIM mold setup used to cast a 25 lb heater in Example 1 herein;

[0021] Figure 2 The dimensions of the VIM mold apparatus used to cast a 25 pound heater in Example 1 herein are shown;

[0022] Figure 3 is a photograph showing a cast 25 pound heater produced in Example 1 herein;

[0023] Figure 4 is a graph of yield strength (ksi) as a function of test temperature for certain alloy heaters and certain commercial nickel-base alloys;

[0024] Figure 5 is a graph of ultimate tensile strength (ksi) as a function of test temperature for certain alloy heaters and certain commercial nickel-base alloys;

[0025] Figure 6 is a graph of the elongation of several alloy heating pieces versus the test temperature;

[0026] Figure 7-9is a graph of stress rupture results under various determined test conditions;

[0027] Fig.10 is an electron microscope image of the alloy of Example P2F02; and

[0028] Fig.11 is an electron microscope image of the alloy of Example P2F07. DETAILED DESCRIPTION

[0029] The reader will appreciate the foregoing details, as well as other details, upon considering the following detailed description of various non-limiting and non-exhaustive embodiments according to the present disclosure.

[0030] Various non-limiting embodiments are described and illustrated in this specification to provide an overall understanding of the disclosed invention. It should be understood that the various non-limiting embodiments described and illustrated in this specification are non-limiting and non-exhaustive. Therefore, the present invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed in this specification. The features and characteristics illustrated and / or described in conjunction with the various non-limiting embodiments can be combined with the features and characteristics of other non-limiting embodiments. Such modifications and changes are intended to be included in the scope of this specification. Therefore, the claims can be amended or supplemented to list any features or characteristics that are clearly or inherently described in this specification or that are clearly or inherently supported by this specification. In addition, the applicant reserves the right to amend the claims to explicitly deny the features or characteristics that may exist in the prior art. The various non-limiting embodiments disclosed and described in this specification may include the features and characteristics described differently herein, consist of the features and characteristics, or consist essentially of the features and characteristics.

[0031] Unless otherwise indicated herein, all percentages of alloy compositions provided herein are based on the total weight of the particular alloy composition.

[0032] Any patent, publication, or other public material that is claimed to be incorporated by reference herein in whole or in part is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other public materials set forth in the present disclosure. Therefore, and to the extent necessary, the disclosure set forth herein supersedes any conflicting material incorporated by reference herein. Any material or portion thereof that is claimed to be incorporated by reference herein but conflicts with existing definitions, statements, or other public materials set forth herein is incorporated only to the extent that there is no conflict between the incorporated material and the existing public materials.

[0033] In this specification, unless otherwise indicated, all numerical parameters should be understood as being preceded and modified in all instances by the term "about", wherein the numerical parameter is characterized by the inherent variability of the underlying measurement technology employed to determine the numerical value of the parameter. At the very least, 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 specification should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0034] In addition, any numerical range described in this specification is intended to include all sub-ranges of the same numerical precision within the described range. For example, the range of "1 to 10" is intended to include all sub-ranges between (and including) the described minimum value 1 and the described maximum value 10, that is, the minimum value is equal to or greater than 1 and the maximum value is equal to or less than 10, such as 2.4 to 7.6. Any maximum numerical limit described in this specification is intended to include all lower numerical limits included therein, and any minimum numerical limit described in this specification is intended to include all higher numerical limits included therein. Therefore, the applicant reserves the right to amend this specification (including claims) to explicitly describe any sub-ranges included in the range explicitly described herein. All such sub-ranges are intended to be inherently described in this specification, so that amendments to explicitly describe any such sub-ranges will meet the requirements of 35 U.S.C. §§ 112 and 132 (a). In addition, as used herein, when referring to the range of constituent elements, the term "up to" includes zero unless the specific element is an unavoidable impurity.

[0035] Unless otherwise indicated, the grammatical articles "one," "a," "an," and "the" used in this specification are intended to include "at least one" or "one or more." Thus, grammatical articles are used in this specification to refer to one or more than one (i.e., "at least one") of the grammatical objects of the article. By way of example only, "a component" means one or more components, and thus, more than one component may be contemplated and may be employed or used in the implementation of the described embodiments. Furthermore, unless the context requires otherwise, the use of a singular noun includes the plural, and the use of a plural noun includes the singular.

[0036] Reference herein to a nickel-based alloy "comprising" a particular ingredient is intended to encompass alloys "consisting essentially of" or "consisting of" the stated ingredients. It should be understood that the nickel-based alloy compositions described herein as "consisting essentially of" or "consisting essentially of" a particular ingredient may also include impurities.

[0037] Nickel-base alloys suitable for use in turbine engine static structural components that are subjected to operating temperatures approaching 1500°F (816°C) must maintain suitable mechanical properties at these operating temperatures. Suitable nickel-base alloys must exhibit sufficient ductility to allow for damage tolerance and contained fatigue crack growth rates. Tensile properties must also be sufficient, but not at the expense of providing adequate low cycle fatigue (LCF) properties. The alloy should also exhibit suitable high temperature creep properties, fracture toughness, and fatigue crack growth (FCGR) properties. In addition, for example, if the alloy is used in turbine casing applications, it should be formable by ring rolling. Importantly, the alloy should also be inspectable by non-destructive testing methods, weldable to allow repair and reforming, and preferably, should meet the cost requirements of the application. We address some of these requirements in more detail below.

[0038] Alloys according to the present disclosure should exhibit suitable tensile properties. In various embodiments, alloys according to the present disclosure exhibit various tensile properties that are at least as high as the tensile properties of Waspaloy alloy (UNS N07001). A higher γ' volume fraction can enhance tensile performance characteristics. The γ' volume fraction can be adjusted, for example, by adjusting the total content of the alloying elements titanium, aluminum, niobium, and tantalum. Generally, increasing the total content of those elements in the alloy will increase the γ' volume fraction. The γ' content of the alloy can be determined by examining the alloy microstructure. The γ' fraction can also be determined by Al eq Approximately, Al eq The number is calculated for the purposes of this disclosure by the following equation:

[0039] Al eq =[Al]+0.56x[Ti]+0.3x[Nb]+0.15x[Ta]

[0040] Where [Al], [Ti], [Nb], and [Ta] are the weight percent concentrations of the elements in the alloy. However, a higher γ' volume fraction reduces forgeability and also reduces fatigue crack growth resistance. The chemistry of the γ' portion of the alloy can be adjusted by varying the titanium / aluminum ratio, and adjustment to the ratio can change the coherent strain and dislocation-particle interactions in the alloy. Antiphase boundary (APB) energy controls the cutting of precipitates by dislocations and can be controlled by γ' chemistry, and the introduction of elements such as niobium into the alloy can change the APB energy. Smaller grain size can improve tensile properties. Thermomechanical parameters, subsolvus and supersolvus heat treatments, and carbide / γ' content can control grain growth at high temperatures. The matrix chemistry can be changed by solid solution strengthening and by adding matrix strengthening elements such as molybdenum and tungsten, which are partitioned into the γ phase matrix.

[0041] Alloys according to the present disclosure should exhibit suitable creep properties. Larger grain size can improve creep properties, but this may be done at the expense of tensile properties. Higher γ' volume fractions can also improve creep properties. Increased content of refractory elements such as tungsten and molybdenum can also improve creep properties due to their low diffusion rates.

[0042] In various non-limiting embodiments, alloys according to the present disclosure exhibit low cycle fatigue properties that are at least as favorable as Waspaloy alloys. Smaller grain sizes can provide better low cycle fatigue properties. For acceptable low cycle fatigue performance, when the grain size is, for example, about ASTM 10 to 12, carbonitrides can act as crack initiation sites. Nickel-based alloys for turbine engine casing applications are generally required to have a grain size of ASTM 4 to 5, and it is generally not known whether carbonitrides may be harmful to low cycle fatigue. The balance of γ' volume fraction may also be important in providing suitable low cycle fatigue properties. In certain non-limiting embodiments, nickel-based alloys according to the present disclosure may include a grain size within the range of ASTM 2 to 12, such as ASTM 2 to 3, ASTM 5 to 12, ASTM 4 to 8, ASTM 4 to 5, ASTM 5 to 6, ASTM 5 to 10, or ASTM 6 to 12.

[0043] In various embodiments, alloys according to the present disclosure exhibit acceptable fracture toughness and fatigue crack growth rate characteristics. Larger grain size can improve (reduce) fatigue crack growth rate. In order to improve the fatigue crack growth resistance of nickel-based alloys that are subjected to high temperature conditions in use, the alloy can be heat treated above its γ' solvus temperature (commonly referred to as supersolvus heat treatment) to produce significant uniform grain coarsening. Larger grains can also improve retention time fatigue performance, which has a creep component in the matrix. The fine γ' size in the matrix during loading can cause cutting of precipitates, resulting in planar slip, which reduces the fatigue crack growth rate. Increasing the γ' phase content can reduce the K1C (plane strain) fracture toughness, and the γ' phase content has the same effect on the fatigue crack growth rate.

[0044] In various embodiments, alloys according to the present disclosure may be forged by ring rolling. Ring rolling is particularly important in turbine engine casing applications where the annular component is preferably seamless. The larger the forging window of the alloy, the better the forging performance. In turn, the forging window can be adjusted by changing the γ' solvus temperature (a function of the γ' chemical properties) and the solidus temperature (a function of the matrix chemical properties). The carbonitride content (which is a result of the balance of the content of carbon and carbide-forming elements (e.g., niobium, titanium) and the γ' content) may also affect the ring rolling forgeability of the alloy.

[0045] In various embodiments, alloys according to the present disclosure exhibit acceptable long-term microstructural stability. In order to inhibit the formation of topologically close packed (TCP) phases, the chromium content should be limited, and balancing heavy elements (e.g., tungsten, molybdenum, and niobium) may be required. Excessive chromium can destabilize the microstructure and form σ phases. Alloys according to the present disclosure also preferably exhibit acceptable degradation of mechanical properties over time. The main causes of degradation of nickel-based superalloy properties are the formation of secondary phases (such as σ phases) and the coarsening of γ' phases. Improved γ' stability can be achieved by including a higher aluminum content in the γ' chemistry. The alloy chemistry should also preferably be controlled to have lower lattice mismatch and stable carbides.

[0046] Alloys according to the present disclosure are also preferably inspectable using non-destructive testing (NDT) techniques. Generally, smaller grain size improves the NDT inspectability of the alloy. In addition, avoiding the formation of bands of carbonitrides ("carbonitride bands") improves NDT inspectability.

[0047] Alloys according to the present disclosure preferably also have acceptable weldability, for example, so that parts formed from the alloy can be repaired and overhauled without unacceptably degrading the mechanical characteristics and other important characteristics of the alloy. Generally, the easier it is to weld a high temperature alloy, the more difficult it is to establish satisfactory creep strength. This problem is particularly severe in alloys used for gas turbine applications. Weldability can be improved by reducing the γ' content, however, this may adversely affect certain other characteristics of the alloy.

[0048] In view of the foregoing observations and purposes, a non-limiting embodiment of a nickel-based alloy suitable for high temperature applications according to the present disclosure comprises, in weight percentage based on the total alloy weight, 11 to 18 chromium, 16 to 28 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. Certain non-limiting embodiments of the nickel-based alloy of this embodiment comprise 16 to 19 weight % cobalt. In certain non-limiting embodiments, the nickel-based alloy of this embodiment comprises a combined concentration of aluminum and titanium of no more than 7.0 weight % based on the total alloy weight. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 0.01 to 0.2. eq ) is in the range of 3.6 to 4.5.

[0049] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, by weight percentage based on total alloy weight: 11 to 18 chromium, 16 to 28 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. Certain non-limiting embodiments of the nickel-based alloys of this embodiment include 16 to 19 weight percent cobalt. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloys of this embodiment is ... eq ) is in the range of 3.6 to 4.5.

[0050] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on total alloy weight: 11 to 18 chromium, 16 to 28 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. Certain non-limiting embodiments of the nickel-based alloy of this embodiment include 16 to 19 weight % cobalt. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is ... eq ) is in the range of 3.6 to 4.5.

[0051] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percentage based on the total alloy weight, 11 to 16 chromium, 16 to 28 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.015 boron, 0.001 to 0.1 zirconium, at least 36 nickel, and impurities, and wherein the nickel-based alloy includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent. Certain non-limiting embodiments of the nickel-based alloy of this embodiment include 16 to 19 weight percent cobalt. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is ... eq ) is in the range of 3.6 to 4.5.

[0052] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, in weight percentage based on total alloy weight: 11 to 16 chromium, 16 to 28 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.015 boron, 0.001 to 0.1 zirconium, at least 36 nickel, and impurities, and wherein the nickel-based alloy includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent. Certain non-limiting embodiments of the nickel-based alloy of this embodiment include 16 to 19 weight percent cobalt. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 2.5% by weight. eq ) is in the range of 3.6 to 4.5.

[0053] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on total alloy weight: 11 to 16 chromium, 16 to 28 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.015 boron, 0.001 to 0.1 zirconium, at least 36 nickel and impurities, and wherein the combined concentration of aluminum, niobium and titanium is 5.0 to 7.0 weight %. Certain non-limiting embodiments of the nickel-based alloy of this embodiment include 16 to 19 weight % cobalt. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is ... eq ) is in the range of 3.6 to 4.5.

[0054] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percent based on the total alloy weight, 11 to 18 chromium, 24 to 28 cobalt, 1.5 to 7.0 molybdenum, 2.0 to 6.0 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2.0 chromium, 24 to 28 cobalt, 1.5 to 7.0 molybdenum, 2.0 to 6.0 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. eq ) is in the range of 3.6 to 4.5.

[0055] Additional non-limiting embodiments of nickel-base alloys suitable for high temperature applications according to the present disclosure consist essentially of, by weight percentage based on total alloy weight: 11 to 18 chromium, 24 to 28 cobalt, 1.5 to 7.0 molybdenum, 2.0 to 6.0 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-base alloy of this embodiment is 1.5 to 1.0 chromium, 24 to 28 cobalt, 1.5 to 7.0 molybdenum, 2.0 to 6.0 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. eq ) is in the range of 3.6 to 4.5.

[0056] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on the total alloy weight: 11 to 18 chromium, 24 to 28 cobalt, 1.5 to 7.0 molybdenum, 2.0 to 6.0 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.1 to 18 chromium, 24 to 28 cobalt, 1.5 to 7.0 molybdenum, 2.0 to 6.0 tungsten, 0 to 1.0 niobium, 1.0 to 2.5 aluminum, 2.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.02 boron, 0.001 to 0.1 zirconium, nickel, and impurities. eq ) is in the range of 3.6 to 4.5.

[0057] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percent based on the total alloy weight, 14 to 16 chromium, 24 to 27 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.7 to 2.0 aluminum, 3.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.015 boron, 0.001 to 0.1 zirconium, at least 46 nickel, and impurities, and wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 7.0 weight percent. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2.0 .... eq ) is in the range of 3.6 to 4.5.

[0058] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, in weight percent based on the total alloy weight, 14 to 16 chromium, 24 to 27 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.7 to 2.0 aluminum, 3.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.015 boron, 0.001 to 0.1 zirconium, at least 46 nickel, and impurities, and wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 7.0 weight percent. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2.0 tungsten. eq ) is in the range of 3.6 to 4.5.

[0059] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on total alloy weight: 14 to 16 chromium, 24 to 27 cobalt, 1.5 to 7.0 molybdenum, 0 to 6.5 tungsten, 0 to 1.0 niobium, 1.7 to 2.0 aluminum, 3.0 to 6.0 titanium, 0 to 2.0 tantalum, 0 to 4.0 iron, 0 to 0.5 hafnium, 0.01 to 0.2 carbon, 0.001 to 0.015 boron, 0.001 to 0.1 zirconium, at least 46 nickel, and impurities, and wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 7.0 weight %. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2.0 .... eq ) is in the range of 3.6 to 4.5.

[0060] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percent based on the total alloy weight: 13 to 17 chromium; 16 to 25 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 36 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2.0 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0061] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, in weight percent based on the total alloy weight: 13 to 17 chromium; 16 to 25 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 36 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2.0 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0062] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on the total alloy weight: 13 to 17 chromium; 16 to 25 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 36 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2.0 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0063] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percentage based on the total alloy weight: 13 to 17 chromium; 16 to 19 cobalt; 1.5 to 7.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0064] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, in weight percentage based on the total alloy weight: 13 to 17 chromium; 16 to 19 cobalt; 1.5 to 7.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0065] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on the total alloy weight: 13 to 17 chromium; 16 to 19 cobalt; 1.5 to 7.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.5 to 2 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0066] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percent based on the total alloy weight: 14 to 17 chromium; 19 to 25 cobalt; 2.0 to 4.0 molybdenum; 0 to 6.5 tungsten; 0 to 0.8 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.4 to 1.6 chromium; 1.5 to 2.0 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0067] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, in weight percentage based on the total alloy weight: 14 to 17 chromium; 19 to 25 cobalt; 2.0 to 4.0 molybdenum; 0 to 6.5 tungsten; 0 to 0.8 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 2.5 chromium; ...3.0 chromium; 0 to 2.5 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 2.5 chromium; 1.0 to eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0068] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on the total alloy weight: 14 to 17 chromium; 19 to 25 cobalt; 2.0 to 4.0 molybdenum; 0 to 6.5 tungsten; 0 to 0.8 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.4 to 1.7 chromium; 1.9 to 2.0 ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0069] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percent based on the total alloy weight: 14 to 17 chromium; 16 to 19 cobalt; 2.0 to 4.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; greater than 0 to 2.0 tantalum; 1.0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1. ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0070] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, in weight percentage based on the total alloy weight: 14 to 17 chromium; 16 to 19 cobalt; 2.0 to 4.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; greater than 0 to 2.0 tantalum; 1.0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1. ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0071] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on the total alloy weight: 14 to 17 chromium; 16 to 19 cobalt; 2.0 to 4.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; greater than 0 to 2.0 tantalum; 1.0 to 3.0 iron; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; optional trace elements; at least 46 nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1. ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0072] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percent based on the total alloy weight: 15 to 17 chromium; 22 to 26 cobalt; 2.0 to 4.0 molybdenum; 0 to 2.0 tungsten; 0 to 1.0 niobium; 1.0 to 4.0 aluminum; 1.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 1.0. eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0073] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, in weight percentage based on the total alloy weight: 15 to 17 chromium; 22 to 26 cobalt; 2.0 to 4.0 molybdenum; 0 to 2.0 tungsten; 0 to 1.0 niobium; 1.0 to 4.0 aluminum; 1.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 1.0. eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0074] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on the total alloy weight: 15 to 17 chromium; 22 to 26 cobalt; 2.0 to 4.0 molybdenum; 0 to 2.0 tungsten; 0 to 1.0 niobium; 1.0 to 4.0 aluminum; 1.0 to 6.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 1.0. eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0075] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure include, in weight percent based on the total alloy weight: 14 to 17 chromium; 15 to 18 cobalt; 2.0 to 4.0 molybdenum; 1.0 to 4.0 tungsten; 0 to 1.0 niobium; 1.0 to 3.0 aluminum; 2.0 to 4.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 3.0 chromium ... eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0076] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist essentially of, in weight percentage based on the total alloy weight: 14 to 17 chromium; 15 to 18 cobalt; 2.0 to 4.0 molybdenum; 1.0 to 4.0 tungsten; 0 to 1.0 niobium; 1.0 to 3.0 aluminum; 2.0 to 4.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 3.0. eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0077] Additional non-limiting embodiments of nickel-based alloys suitable for high temperature applications according to the present disclosure consist of, in weight percentage based on the total alloy weight: 14 to 17 chromium; 15 to 18 cobalt; 2.0 to 4.0 molybdenum; 1.0 to 4.0 tungsten; 0 to 1.0 niobium; 1.0 to 3.0 aluminum; 2.0 to 4.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 3.0 chromium; 1.0 to 4.0 cobalt; 0 to 2.0 molybdenum; 1.0 to 4.0 tungsten; 0 to 1.0 niobium; 1.0 to 3.0 aluminum; 2.0 to 4.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; and impurities. In certain non-limiting embodiments, the aluminum equivalent number (Al2O3) of the nickel-based alloy of this embodiment is 1.0 to 3.0 chromium; 1.0 to 3.0 tungsten; 0 to 1.0 niobium; 1.0 to 3.0 aluminum; 2.0 to 4.0 titanium; 0 to 2.0 tantalum; 0 to 4.0 iron; 0 to 0.5 hafnium; 0 to 0.2 eq ) is in the range of 3.6 to 4.5. In certain non-limiting embodiments, the nickel-based alloy of this embodiment includes a combined concentration of aluminum, niobium, and titanium of 5.0 to 7.0 weight percent based on the total alloy weight.

[0078] In embodiments of the alloys of the present invention, a suitable minimum level of chromium is included to provide acceptable oxidation resistance and corrosion resistance. However, excessive levels of chromium in combination with cobalt can lead to matrix instability and the possibility of sigma phase formation. In certain embodiments of alloys according to the present disclosure, the chromium content is in the range of 11 wt % to 18 wt %, and for example, in certain such alloys, the chromium content may be in a narrower range of 11 wt % to 16 wt %, 11 wt % to 15 wt %, 11 wt % to 14 wt %, 12 wt % to 16 wt %, 12 wt % to 15 wt %, 12 wt % to 14 wt %, 13 wt % to 18 wt %, 13 wt % to 17 wt %, 14 wt % to 17 wt %, 15 wt % to 17 wt %, or 14 wt % to 16 wt %. In certain other embodiments of the alloys herein, the chromium content is 11 wt % to 16 wt %, and in some embodiments 14 wt % to 16 wt %.

[0079] Cobalt reduces the γ' solvus line. Cobalt also reduces the stacking fault energy and can therefore increase the number of annealing twins. However, the combination of excessive levels of chromium and cobalt may result in the precipitation of harmful second phases (e.g., σ phases), which may result in reduced mechanical properties. To balance these results, in certain embodiments of alloys according to the present disclosure, the cobalt content is in the range of 15 wt % to 28 wt %, and for example, in certain such alloys, the cobalt content may be in a narrower range of 16 wt % to 28 wt %, 15 wt % to 18 wt %, 16 wt % to 27 wt %, 16 wt % to 26 wt %, 17 wt % to 27 wt %, 17 wt % to 26 wt %, 18 wt % to 26 wt %, 16 wt % to 25 wt %, 19 wt % to 25 wt %, 20 wt % to 25 wt %, 22 wt % to 26 wt %, or 19 wt % to 24 wt %. In certain other embodiments, the cobalt content is in the range of 16 wt % to 19 wt %, and, for example, in certain such alloys, may be in the narrower range of 16 wt % to 18 wt %, 16 wt % to 17 wt %, 17 wt % to 18 wt %, 17 wt % to 19 wt %, or 18 wt % to 19 wt %. In certain other embodiments of the alloys herein, the cobalt content is 24 wt % to 28 wt %, and in some embodiments, in the narrower range of 24 wt % to 27 wt %, 24 wt % to 26 wt %, 25 wt % to 28 wt %, 25 wt % to 27 wt %, 26 wt % to 28 wt %, or 26 wt % to 27 wt %.

[0080] Molybdenum is primarily distributed into the matrix and can strengthen the matrix by a solid solution mechanism. However, excessive molybdenum may result in excessive levels of TCP phase in use. The molybdenum content in certain alloys according to the present disclosure is 1.5 to 7.0 weight %, and for example, in certain such alloys, the molybdenum content may be in a narrower range of 2.0 to 6.0, 2.0 to 5.5, 2.0 to 5.0, 2.0 to 4.0, 3.0 to 5.0, 3.0 to 6.0, 4.0 to 6.0, 4.0 to 5.0, 4.5 to 5.5, 3.0 to 7.0, or 4.0 to 7.0 weight %. Molybdenum contents below 2.0 weight % may not result in the desired combination of creep resistance, machinability, and weldability.

[0081] Tungsten is primarily distributed to the gamma matrix phase. The addition of tungsten and / or molybdenum increases the lattice parameter of the matrix and can minimize the lattice mismatch (or it can even become negative), which can reduce the gamma 'coarsening rate and can strengthen the matrix through a solid solution mechanism. This increases creep resistance. However, excessive tungsten may result in excessive levels of TCP phase in use, increasing density and may result in the formation of less favorable primary and secondary carbides if added in very large amounts. Tungsten may be present in certain alloys according to the present disclosure at a concentration of 0 to 6.5 weight percent, and, for example, may be within a narrower range of greater than 0 to 6.5, 0 to 5.0, greater than 0 to 5.0, 0 to 0.5, greater than 0 to 0.5, 0 to 2.0, greater than 0 to 2.0, 1.0 to 6.5, 1.0 to 4.0, 1.5 to 6.5, 1.5 to 5.0, 2.5 to 6.5, 2.5 to 5.0, 3.5 to 5.0, 4.0 to 6.0, or 5.0 to 6.5 weight percent in certain such alloys. In various embodiments of the alloys herein, the tungsten content is 2.0 wt % to 6.0 wt %, and for example, in certain such alloys, the tungsten content may be within a narrower range of 2.0 wt % to 5.0 wt %, 2.0 wt % to 4.5 wt %, 3.0 wt % to 5.0 wt %, 4.0 wt % to 6.0 wt %, 2.0 wt % to 4.0 wt %, or 5.0 wt % to 6.0 wt %.

[0082] As used herein, an alloy composition described as including an element in a concentration of "0 to," "0 up to," or simply "up to" some specified upper weight percent limit means that in certain embodiments of the alloy, the element may not be present or may be present in a non-zero concentration up to the specified upper weight percent limit. Applicants reserve the right to amend the claims herein to affirmatively recite a non-zero lower weight percent limit (e.g., "greater than 0") for any element that may not be present in certain other embodiments of alloys according to the present disclosure.

[0083] In various non-limiting embodiments of the nickel-based alloys according to the present disclosure, the concentrations of molybdenum and tungsten in the alloys satisfy the limit 3% < [Mo] + 0.52 × [W] < 8%, where [Mo] and [W] are the weight percent concentrations of molybdenum and tungsten in the alloys, respectively. In certain non-limiting embodiments of the nickel-based alloys according to the present disclosure, the concentrations of molybdenum and tungsten in the alloys satisfy the limit 3% < [Mo] + 0.52 × [W] < 5%, where [Mo] and [W] are the weight percent concentrations of molybdenum and tungsten in the alloys, respectively.

[0084] Niobium preferentially distributes to the γ' phase and improves creep resistance and high temperature strength by increasing the activation energy of dislocation motion in the γ' phase. Embodiments of alloys according to the present disclosure may include up to 2.0% by weight of niobium. It is known that niobium strongly segregates during solidification, and therefore, in various non-limiting embodiments of the alloys of the present invention, niobium is not present or its content is kept to a minimum. Preferably, the niobium content does not exceed 1.5%, 1.0%, 0.8%, or 0.1% by weight. In certain embodiments, a niobium content greater than 0.2, 1.0, or 1.5% by weight may be used to offset a certain amount of titanium, aluminum, cobalt, molybdenum, and / or tungsten. In various non-limiting embodiments, niobium may be present in certain alloys according to the present disclosure at a concentration of 0 to 2.0% by weight, such as greater than 0 to 2.0% by weight or 0.2 to 1.0% by weight.

[0085] The ratios between aluminum, titanium, niobium, and tantalum, and the combined contents of these elements, control the solvus temperature of the γ' phase, which is particularly important for alloys used in structural applications, such as turbine engine casings. Titanium, on an atomic basis, is more effective than aluminum in raising the solvus temperature. However, excess levels of titanium can result in the formation of an η phase rather than a γ' phase. Turbine engine casings are currently manufactured by steps including ring rolling, which typically limits the alloy to a γ' solvus temperature of no more than about 1900-2000°F (1038-1093°C) in order to maintain sufficient hot workability to allow large plastic strains to be generated during forming. At aluminum concentrations greater than 3.5 weight percent, the solvus temperature of the alloy is too high, or the amount of γ' is too high to support acceptable ring rolling capability and / or weldability for certain structural applications, such as for turbine engine casings. Aluminum can be present in certain alloys according to the present disclosure at a concentration of 1.0 wt % to 4.0 wt %, and for example, in certain alloy embodiments, the aluminum can be within a narrower range of 1.0 wt % to 3.0 wt %, 1.0 wt % to 2.5 wt %, 1.25 wt % to 2.0 wt %, 1.25 wt % to 1.9 wt %, 1.3 wt % to 1.8 wt %, 1.5 wt % to 2.5 wt %, 1.0 wt % to 2.0 wt %, or 1.5 wt % to 2.0 wt %. In various embodiments of the alloys herein, the aluminum content is 1.7 to 2.0 wt %.

[0086] Titanium strengthens the γ' phase, increases the resistance of the γ' relative shear, and improves the solvus temperature and coherence of the γ' phase. These factors strongly affect the strength and creep resistance of the alloy. Titanium is present in certain alloys according to the present disclosure at a concentration of 1.0 wt % to 6.0 wt %, and for example, in certain alloy embodiments, it can be in a narrower range of 2.0 wt % to 6.0 wt %, 2.0 wt % to 5.0 wt %, 2.0 wt % to 4.5 wt %, 2.0 wt % to 4.0 wt %, 2.0 wt % to 3.5 wt %, 2.0 wt % to 3.0 wt %, 2.5 wt % to 3.5 wt %, 3.0 wt % to 5.5 wt %, 3.0 wt % to 4.0 wt %, 4.5 wt % to 5.5 wt %, or 3.0 wt % to 6.0 wt %. In various embodiments of the alloys herein, the titanium content is 3.0 to 4.5 wt %.

[0087] Tantalum can be used to control the solvus temperature and the coherence of the γ' phase with the matrix. It is also a strong carbide stabilizer, can be beneficial for oxidation resistance, and can improve the creep resistance of the γ matrix at high temperatures. Alloys according to the present disclosure may include up to 2.0 weight % tantalum, up to 0.5 weight % tantalum, or up to 0.2 weight % tantalum. In various non-limiting embodiments of alloys according to the present disclosure, tantalum is absent. In various embodiments, the tantalum content is greater than 0 to 2.0, greater than 0 to 1.0, greater than 0 to 0.8, 0.2 to 2.0, 0.6 to 2.0, or 1.0 to 2.0 weight %.

[0088] Increasing the iron content increases the type and amount of recovery allowed in the alloy, which helps to reduce the production cost of the alloy. The alloy according to the present disclosure may include up to 4.0% by weight of iron or greater than 0 to 4.0% by weight of iron. In various non-limiting embodiments of alloys according to the present disclosure, iron is not present. In other alloy embodiments, the iron content may be up to 3.0% by weight, up to 2.0% by weight, or up to 1.0% by weight. In various embodiments of the alloys herein, the iron content is greater than 0 to 3.0 or 1.0 to 3.0% by weight.

[0089] Hafnium is a strong carbide stabilizer and improves creep resistance at high temperatures at levels according to the present disclosure. Like zirconium, hafnium may also adversely affect weldability due to its strong segregation during solidification. Alloys according to the present disclosure may include up to 0.5 wt % hafnium. In various non-limiting embodiments of alloys according to the present disclosure, hafnium is absent. In other alloy embodiments, hafnium may be present in a concentration greater than 0 to 0.5 wt % or greater than 0 to 0.25 wt %.

[0090] Alloys according to the present disclosure include up to 0.2 wt. % carbon, greater than 0 to 0.2 wt. % carbon, or 0.01 to 0.2 wt. % carbon. Higher concentrations of carbon can produce smaller average grain sizes and narrower grain size distributions, but can also reduce forgeability and low cycle fatigue properties due to the formation of carbonitride stringers. In certain non-limiting embodiments of alloys according to the present disclosure, the carbon content is at least 0.02 to 0.2 wt. %, or at least 0.03 to 0.2 wt. %. It has been observed that a carbon concentration of about 0.03 wt. % results in a carbon content of at least 0.02 to 0.2 wt. %, or at least 0.03 to 0.2 wt. %. 23 The presence of C6 carbides is minimized, which otherwise may form during high temperature exposure and produce internal oxidation damage caused by their decomposition. In certain preferred embodiments, the carbon content is 0.02 wt % to 0.1 wt %, or in some embodiments 0.03 wt % to 0.06 wt % or 0.025 wt % to 0.05 wt %, to ensure good high temperature processability and low risk of deleterious melt structure. The carbon content in the aforementioned range balances the ability to produce fine grain size for good high cycle fatigue and fatigue crack growth resistance while ensuring good low cycle fatigue and ultrasonic detectability.

[0091] Grain boundary elements zirconium and boron may be present in embodiments of alloys according to the present disclosure. Zirconium can act as a scavenger of oxygen and sulfur in the alloy. However, zirconium may adversely affect weldability, and its maximum content should be controlled. In certain embodiments of alloys according to the present disclosure, the zirconium content is 0 to 0.1 wt %, greater than 0 to 0.1 wt %, or 0.001 wt % to 0.1 wt %. In various embodiments, the zirconium content of the alloy herein is 0.001 wt % to 0.05 wt %, 0.001 wt % to 0.04 wt % or 0.001 wt % to 0.03 wt %. Boron can improve grain boundary cohesion and high temperature ductility. However, boron can promote the formation of grain boundary films, particularly when high temperature solution treatment temperature is required when processing the alloy. In addition, due to the increased risk of harmful melt structures, it is known that high boron concentrations reduce the ability of alloys to be manufactured by ingot metallurgical practices. In certain embodiments of alloys according to the present disclosure, the boron content is 0 to 0.02 wt%, greater than 0 to 0.02 wt%, or 0.001 to 0.02 wt%. In various embodiments, the boron content of the alloys herein is 0.001 to 0.015 wt%, 0.001 to 0.1 wt%, 0.02 to 0.04 wt%, or 0.002 to 0.01 wt%.

[0092] In various embodiments of alloys according to the present disclosure, the balance of the alloy includes nickel, trace elements, and impurities. Certain alloy embodiments include at least 33% nickel by weight. Certain embodiments of alloys according to the present disclosure include at least 36% nickel by weight, while other embodiments include at least 46% nickel by weight or at least 48% nickel by weight. Impurities may also be present, for example, by inclusion in the starting materials or as a result of alloy processing.

[0093] Various non-limiting embodiments of alloys according to the present disclosure include one or more trace elements. As used herein, a "trace element" is an element that can be present in a concentration of less than 5% by weight, or in some cases less than 2% by weight, or less than 1% by weight, and it provides some additional advantageous features or characteristics to the alloy, or does not significantly affect the important characteristics or performance of the alloy. Trace elements may not be present in various embodiments of the alloys herein. Examples of trace elements and corresponding maximum contents that may optionally be present in non-limiting embodiments of alloys according to the present disclosure include up to 5.0% by weight (e.g., up to 4.0, up to 3.0, up to 2.0% by weight, or greater than 0 to 5.0% by weight) of manganese; up to 0.1% by weight (e.g., up to 0.05, up to 0.001, up to 0.05% by weight, greater than 0 to 0.1% by weight, greater than 0 to 0.05% by weight, or 0.0001 to 0.1% by weight) of magnesium; up to 1.0% by weight (e.g., up to 0. 8, up to 0.6, up to 0.5 wt %, or greater than 0 to 1.0 wt %) of silicon; up to 5.0 wt % (e.g., up to 4.0, up to 3.0, up to 2.0 wt %, or greater than 0 to 5.0 wt %) of copper; up to 2 wt % (e.g., up to 1.5, up to 1.0, up to 0.5 wt %, or greater than 0 to 2 wt %) of vanadium; and / or up to a total of 0.2 wt % (e.g., up to 0.1, up to 0.05, up to 0.03 wt %, or greater than 0 to 0.2 wt %) of rare earth metals, scandium, and yttrium. Magnesium can improve melt cleanliness and hot workability.

[0094] Examples of elements that may be present as impurities in alloys according to the present disclosure include, for example, but not limited to, sodium, magnesium, potassium, calcium, antimony, tin, arsenic, lead, phosphorus, sulfur, fluorine, sulfur, chlorine, oxygen, nitrogen, zinc, and gallium. These impurity elements, if present, are typically present in individual concentrations of no more than about 0.1% by weight, and the total content of such impurities typically does not exceed 5.0% by weight.

[0095] Increasing the content of the γ' phase can increase the microstructural stability of the alloy, which is a very important feature in the alloys according to the present disclosure. However, increasing the γ' content above a certain level will reduce the forgeability of the alloy to an unacceptably low level. The γ' content can be adjusted by, for example, selecting a suitable combined content of aluminum, titanium, tantalum, and niobium in the alloy. For example, a nickel-based alloy according to the present disclosure may include a combined concentration of aluminum, niobium, and titanium in the range of 5.0 to 7.0 weight %, such as 5.0 to 6.0 or 6.0 to 7.0 weight %. In various non-limiting embodiments, a nickel-based alloy according to the present disclosure may include a combined concentration of aluminum and titanium not greater than 7.0 weight %. For example, a nickel-based alloy according to the present disclosure may include a combined concentration of aluminum and titanium in the range of 5.0 to 7.0 weight %, such as 5.0 to 6.0 or 6.0 to 7.0 weight %. In certain non-limiting embodiments, the aluminum equivalent number (Al ) of the nickel-based alloy according to the present disclosure is preferably 0.1% to 0.2%; eq ) is in the range of 3.6 to 4.5, for example, 3.6 to 4.2 or 4.0 to 4.5.

[0096] The chemical properties of the γ' phase may also be important in the alloys of the present invention. For example, changing the γ' chemistry can change the lattice parameters of the phase and thereby affect the γ' stability. The titanium / aluminum atomic ratio can affect the properties of the γ' phase. Higher titanium levels are generally beneficial to mechanical properties, and higher aluminum levels can promote alloy stability. However, a higher titanium / aluminum atomic ratio can increase η phase formation. In order to balance the effects of titanium and aluminum on the γ' phase in the present alloy, in various embodiments, the titanium / aluminum atomic ratio corresponds to a titanium / aluminum weight percentage of 1.2 to 4.0, and in some embodiments, the titanium / aluminum weight percentage is 1.5 to 4.0, 2.0 to 4.0, 2.5 to 4.0, 1.5 to 3.0, 1.5 to 2.4, 1.3 to 2.4, 1.7 to 2.2, 3.0 to 4.0, or 1.0 to 2.0.

[0097] Niobium additions may also affect the γ' chemistry. Niobium tends to partition into the γ' phase, increasing the γ' phase fraction and promoting γ' formation by reducing the solubility of aluminum in the matrix. Niobium may also increase the γ' antiphase boundary energy and subsequently improve the creep and tensile properties of the alloy. However, the combination of higher niobium contents with high titanium contents may increase the tendency to form eta phase or other detrimental phases containing niobium and titanium.

[0098] Likewise, the addition of tantalum may affect the γ' chemistry. Tantalum tends to partition into the γ' phase, increasing the γ' phase fraction and promoting γ' formation by reducing the solubility of aluminum in the matrix. Tantalum may also increase the γ' antiphase boundary energy and subsequently improve the creep and tensile properties of the alloy. However, the combination of higher tantalum content with high titanium content may increase the tendency to form η phase or other phases containing titanium and tantalum.

[0099] The inventors have observed that providing a combined concentration of aluminum, niobium, tantalum, and titanium within a certain range in an alloy according to the present disclosure can provide a particularly advantageous combination of workability and strength at high temperatures. In certain non-limiting embodiments, the aluminum equivalent number (Al 2 O 2 ) of the nickel-based alloy of this embodiment is eq ) is in the range of 3.6 to 4.5, for example, 3.6 to 4.2 or 4.0 to 4.5.

[0100] For alloys according to the present disclosure, the titanium equivalent / aluminum equivalent ratio (Ti eq / Al eq ) can be calculated by the following equation:

[0101] Ti eq / Al eq =([Ti]+1.07x[Nb]+0.54x[Ta]) / ([Al]+0.56x[Ti]+0.3x[Nb]+0.15x[Ta])

[0102] Wherein [Ti], [Nb], [Ta] and [Al] are the weight percentage contents of the aforementioned elements in the alloy. It has been observed that Ti eq / Al eq The ratio can be used to track the relative stability, shear resistance, and lattice parameters of the γ' phase between alloy chemistries. In various embodiments of the nickel-based alloys according to the present disclosure, Ti eq / Al eq 0.9 to 1.25, for example 0.9 to 1.0 or 1.0 to 1.25.

[0103] Certain non-limiting embodiments of nickel-based alloys according to the present disclosure may be solution treated and / or aged. For example, the nickel-based alloy may be solution treated at a temperature in the range of 1800°F (982°C) to 2150°F (1176°C) for up to 168 hours, such as 1 hour to 24 hours or 4 hours to 12 hours. In various non-limiting embodiments, the nickel-based alloy may be aged in one or more steps at a temperature in the range of 1400°F (760°C) to 1800°F (982°C) for up to 72 hours, such as 1 to 12 hours. The aging parameters may be selected based on the desired properties of the nickel-based alloy after heat treatment without undue experimentation.

[0104] As understood in the art, "creep" refers to the time-dependent strain that occurs under a continuous stress below the yield strength of the material, such as at an elevated temperature under load. As used herein in conjunction with creep properties, "elevated temperature" refers to temperatures in excess of 200°F (93.3°C). "Stress rupture" is understood to be the time it takes for a metal article to rupture when subjected to a given sustained load at a given temperature. "Creep strength," also known as the "creep limit," is a measure of a material's resistance to creep. It can also be described as the stress that causes a specific creep rate under specific conditions. In other words, creep strength can be viewed as a combination of stress, temperature, and time required to achieve a specific creep or rupture percentage. The stress rupture of an alloy article generally indicates its creep strength. A higher stress rupture value indicates a higher creep strength of the alloy article. An embodiment of a nickel-based alloy according to the present disclosure may have enhanced stress rupture at 1500°F (816°C).

[0105] Certain non-limiting embodiments of nickel-based alloys according to the present disclosure have a yield strength of at least 120 ksi (827 MPa) at room temperature (e.g., 72°F + / - 2°F) under aged conditions, such as at least 125 ksi (862 MPa), at least 130 ksi (896 MPa), at least 135 ksi (931 MPa), at least 140 ksi (965 MPa), or at least 145 ksi (1000 MPa) at room temperature. The tensile properties at room temperature can be determined according to ASTM E8 / E8M-16.

[0106] Certain non-limiting embodiments of nickel-based alloys according to the present disclosure may exhibit a yield strength under an aged condition at 1500°F (816°C) of at least 90 ksi (621 MPa), such as at least 95 ksi (655 MPa), at least 100 ksi (689 MPa), or at least 105 ksi (724 MPa). The yield strength at 1500°F (816°C) may be measured according to ASTM E21-20.

[0107] Certain non-limiting embodiments of nickel-based alloys according to the present disclosure may exhibit an ultimate tensile strength under aged conditions of at least 180 ksi (1241 MPa), such as at least 190 ksi (1310 MPa), at least 195 ksi (1344 MPa), at least 200 ksi (1378 MPa), or at least 205 ksi (1413.43 MPa). The ultimate tensile strength may be measured according to ASTM E8 / E8M-22.

[0108] Certain non-limiting embodiments of nickel-based alloys according to the present disclosure may exhibit an ultimate tensile strength under aging conditions at 1500°F (816°C) of at least 90 ksi (621 MPa), e.g., at least 95 ksi (655 MPa), at least 100 ksi (689 MPa), at least 105 ksi (724 MPa), at least 110 ksi (758 MPa), or at least 120 ksi (827 MPa). The ultimate tensile strength at 1500°F (816°C) may be measured according to ASTM E21-20.

[0109] Certain non-limiting embodiments of nickel-based alloys according to the present disclosure may exhibit an elongation percentage under aging conditions at room temperature of 15% to 40%, such as 20% to 35% or 25% to 35%. The elongation at room temperature may be measured according to ASTM E8 / E8M-22.

[0110] Certain non-limiting embodiments of nickel-based alloys according to the present disclosure may exhibit an elongation percentage at 1500°F (816°C) of 5% to 30%, such as 5% to 25%, 10% to 25%, or 15% to 20%. The elongation at 1500°F (816°C) may be measured according to ASTM E8 / E8M-22.

[0111] The alloys according to the present disclosure can be made using conventional ingot metallurgy techniques used in the production of nickel-based superalloys and are known to those of ordinary skill. Such techniques include, for example, vacuum induction melting, electroslag remelting, vacuum arc remelting, argon oxygen decarburization melting, vacuum oxygen decarburization melting, arc furnace and ladle furnace melting. Other embodiments of the alloys of the present invention can be produced in powder form using processes such as vacuum melt inert gas atomization (VIGA), electrode induction gas atomization (EIGA), close-coupled gas atomization, cold wall inert gas atomization, and rotating electrode process atomization. Subsequent billeting of the ingot can occur by thermomechanical processing, including heat treatment for homogenization, retaining sufficient heat for deformation, and refining the microstructure. Mechanical processing techniques in the thermomechanical processing that can be applied include, but are not limited to, press forging, radial forging, rotary forging, extrusion, pilgering, die forging, rolling, and stretching. Processing of the alloys according to the present disclosure can be performed at temperatures above 1500°F (816°C) and below the solidus of the material.

[0112] Certain non-limiting embodiments of the nickel-based alloys of the present invention can be additively manufactured to produce additively manufactured parts. Additive manufacturing refers to the process of joining materials from three-dimensional model data to manufacture an object, usually layer by layer, as opposed to subtractive manufacturing methods, and is defined in ASTM F2792-12a, "Standard Terminology for Additively Manufacturing Technologies". Non-limiting examples of additive manufacturing processes that can be used to produce products from metal raw materials include, for example, DMLS (direct metal laser sintering), SLM (selective laser melting), SLS (selective laser sintering), laser powder bed melting (LPBF) and EBM (electron beam melting), etc. Any suitable raw material can be used, including powders, wires, and combinations thereof. In some embodiments, the additive manufacturing raw material consists of powder.

[0113] Additively manufactured parts that may be made from suitable powder forms of alloys according to the present disclosure may include, but are not limited to, heat exchangers, nose cones, scramjet engine components, vehicle leading edges, heat pipes, reentry structures, actively or passively cooled controlled surfaces, vehicle skins, components of ramjets, components of rocket engines, components of combined cycle engines, components of rotating detonation engines, components of gasification equipment, components of chemical processing equipment, and components of fastening systems.

[0114] Non-limiting examples follow.

[0115] Example 1

[0116] Several experimental "button" samples, each weighing approximately 500 grams, were prepared, rolled, heat treated, and tested for tensile properties. Table 1 provides the target compositions for the experimental samples referred to as W6, W11-W13, W20-W22, and W24-W26, as well as the target composition of Waspaloy sample W0 prepared for comparative purposes. The samples will also include incidental impurities. Table 1 also lists the predicted values ​​for density, γ' volume percent content at 1000℉ (538℃) and 1500℉ (816℃), and γ' solvus temperature, all calculated using JMatPro software version 4-1.

[0117] Each button was cold rolled to a thickness of about 0.15 inches and heat treated as follows. No button cracking was observed during rolling. The rolled buttons were solution treated at 2000°F (1093°C) for 2 hours and water quenched separately. The solutionized buttons were subjected to a first aging step at 1650°F (890°C) for 4 hours, air cooled, and then subjected to a second aging step at 1550°F (843°C) for 12 hours and air cooled. The tensile properties of the solution treated and aged rolled buttons were tested at room temperature according to ASTM E8-16ae1, and the tensile properties were also tested at 1500°F (816°C) according to ASTM E21-17e1. The properties tested included ultimate tensile strength, 0.2% yield strength, elongation, and area reduction. The tensile test results are reported in Table 2 (tensile test samples at room temperature) and Table 3 (tensile test samples at 1500°F (816°C)). Prior to tensile testing, the heated tensile test specimens were soaked at 1500°F (816°C) for 30 minutes.

[0118] The tensile test sample of sample W12 tested at 1500°F (816°C) had a questionable test strain and therefore yield could not be reported. However, the reported UTS for sample W12 tested at 1500°F (816°C) was considered valid and reported. The tensile test sample of sample W13 tested at 1500°F (816°C) was stuck in the U-clip after testing and was damaged during its removal, and the elongation and reduction in area (RA) were not obtained for the sample.

[0119] Table 1: Chemical composition of button samples

[0120]

[0121] Table 2: Tensile test results (room temperature)

[0122]

[0123] Table 3: Tensile test results (1500°F)

[0124]

[0125] Example 2

[0126] Several 25 pound heating pieces of nickel-based alloy of different chemical compositions were melted via vacuum induction melting and poured into a conical bimetallic mold. The chemical composition of each heating piece is shown in Table 3. The values ​​in Table 3 are weight percentages based on the total weight of the alloy. Figure 1 is a photograph showing the dual VIM mold setup used to cast the 25 lb heater in this example. Figure 2 The dimensions of the VIM mold setup used to cast a 25 lb heater in this example are shown. Figure 3 is a photograph showing a representative cast 25 lb. heater made in this example. Each heater was homogenized at a higher temperature to equalize any possible chemical changes that may occur during solidification.

[0127] Table 3: Chemical composition of the 25 lb heating element

[0128]

[0129]

[0130] The chemical composition of each heating element listed in Table 3 is selected to include alloying elements that adjust the γ' content to a level greater than that of certain conventional high temperature nickel-base alloys (e.g., Waspaloy, 718, and GTD222 alloys), and to control the Al content of the alloy. eq To ensure that the γ' content is low enough to ensure acceptable machinability. In heating piece numbers P0F00 to P0F03, the contents of molybdenum, tungsten, tantalum and niobium are varied. Molybdenum and tungsten are substitute elements that can improve high temperature mechanical properties. Tungsten and molybdenum can also increase the lattice parameter of the matrix phase, and thus minimize the lattice mismatch between the γ' phase and the matrix phase, which in turn reduces the coarsening rate of the γ' phase. However, tantalum and niobium can form carbides and distribute into the γ' precipitates, and can improve stress rupture properties. Adding too high a content of tantalum and / or niobium may increase the sensitivity of the alloy to form η phase (NiTi3) or other harmful secondary phases. In heating piece numbers P0F04 and P0F05, the aluminum and titanium contents are reduced, and the molybdenum and tungsten contents are adjusted to avoid TCP phase formation. In order to better ensure that the alloy is ring-rollable and has good machinability, the γ' solvus line is kept below or near 2050℉ (1121℃).

[0131] Chromium is included in the heating element to provide oxidation resistance, but the chromium is limited so that the alloy microstructure does not become unstable and cause the formation of TCP phase. Cobalt can reduce the stacking fault energy and also increase the solubility of aluminum and titanium in the matrix, thereby improving the machinability of the alloy. The presence of grain boundary elements including boron and zirconium improves the fatigue crack growth rate, high temperature ductility and weldability of the alloy. Boron and zirconium content is limited because excessive amounts of those elements may lead to the formation of grain boundary films at higher temperatures during solution treatment.

[0132] The carbon level in the heating element is selected so that M 23The presence of C6 carbides, which can form during high temperature exposure and produce possible internal oxidation damage when they decompose, is minimized. It has been observed, for example, that controlling the carbon content to 0.040 wt. % to 0.05 wt. % during supersolvus solution heat treatment is effective in controlling grain growth through grain boundary pinning. Although increasing the carbon content in the alloy composition can produce a smaller average grain size, it can also reduce the machinability and low cycle fatigue performance of the alloy due to the formation of carbonitride stringers.

[0133] Table 4 provides the γ' solvus temperature and aluminum equivalent number of the heated pieces listed in Table 3. The γ' solvus temperature was measured by differential thermal analysis (DTA) technique. In order to better ensure adequate workability, the γ' solvus temperature is preferably below 2050°F, more preferably below 1950°F, so that no γ' precipitation occurs on the surface of the material when the material is ring rolled. The γ' content of the alloy according to the present disclosure can be affected by appropriately adjusting the aluminum equivalent number of the alloy. For the purposes of the present disclosure, the aluminum number (Al eq ) is calculated by the following equation, where [Al], [Ti], [Nb], and [Ta] are the weight percent concentrations of the elements in the alloy:

[0134] Al eq =[Al]+0.56[Ti]+0.3[Nb]+0.15[Ta]

[0135] The inventors have determined that alloys according to the present disclosure having an aluminum equivalent number in the range of 3.6 to 4.5 can have advantageous machinability characteristics and gamma prime content at high temperatures (e.g., greater than 1200°F (649°C)), which is advantageous in structural components that are subjected to stress at those high temperatures.

[0136] Table 4: γ' solvus temperature

[0137]

[0138] The VIM samples were forged and then subjected to supersolvus solution treatment and two-step aging. After heat treatment, samples were prepared from each heating piece and subjected to tensile and stress rupture tests under various test conditions. The test conditions are shown in Table 5 below, and the test results are shown in Tables 6-10 below. Table 6 lists the tensile test results (yield strength, ultimate tensile strength, elongation percentage (%El) and area reduction percentage (%RA)) evaluated at room temperature. Table 7 lists the tensile test results evaluated at 1500℉ (816.6℃). Table 8 lists the stress rupture test results of certain heating pieces evaluated at 1500℉ (816.6℃) and 40ksi (275.8MPa).

[0139] Table 5: Mechanical test conditions

[0140]

[0141] Table 6: Tensile properties at room temperature

[0142]

[0143]

[0144] Table 7: Tensile properties at 1500°F (816.6°C)

[0145]

[0146] Table 8: Stress rupture results at 1500°F (816.6°C) / 40 ksi (275.8 MPa)

[0147]

[0148]

[0149] The yield strength and ultimate tensile strength of certain 25 pound heaters in this Example 2 were determined at 1400°F (760.0°C) and 1600°F (871.1°C). The elongation and reduction in area of ​​certain heaters were measured at 1400°F (760.0°C). The tensile properties of certain 25 pound heaters measured at 1400°F (760.0°C) are included in Table 9.

[0150] Table 9: Tensile properties at 1400°F (760.0°C)

[0151]

[0152] Figure 4 is a graph of the yield strength (ksi) of heated pieces (lot numbers provided) as a function of test temperature (measured at room temperature and 1400°F (760.0°C), 1500°F (816.6°C), and 1600°F (871.1°C)), as well as a graph of the yield strength of the commercial nickel-based alloys Haynes Waspaloy alloy, ATI Waspaloy alloy, and Haynes 282 alloy at various temperatures. Figure 5 is a graph showing the ultimate tensile strength (ksi) as a function of test temperature for the heaters (lot numbers provided) made in this Example 1, as well as a graph of the ultimate tensile strength at various temperatures for Haynes Waspaloy alloy, ATI Waspaloy alloy, and Haynes 282 alloy (UNS N07208). The alloys are observed to be similar to Waspaloy alloy in forgeability, while exhibiting significant advantages over Waspaloy alloy at 1500°F (816.6°C).

[0153] In addition to testing at room temperature and 1500°F (816.6°C), the elongation of the 25 lb heater was evaluated at 1400°F (760.0°C). Figure 6 The elongation for each heater (lot number listed) was plotted versus the test temperature.

[0154] Due to the very long stress rupture time, only certain heaters were stress rupture tested at 1500°F (816.6°C) and 40 ksi (275.8 MPa). After stress rupture testing of certain chemicals at 1500°F (816.6°C) and 40 ksi (275.8 MPa), the stress rupture test conditions were changed to 1500°F (816.6°C) / 50 ksi (344.7 MPa) and 1500°F (816.6°C) / 60 ksi (413.7 MPa). The test results under these additional conditions are shown in Tables 10 and 11, respectively. Figure 7-9 The stress rupture results for each test condition are plotted. As expected, the stress rupture time is generally shorter at higher stresses. Tables 10 and 11 also provide the stress rupture time and elongation results for Waspaloy alloy production material under the specified test conditions, which has been heat treated by the following sequence of steps: (1) heating at 1975°F (1079°C) for 4 hours and air cooling; (2) heating at 1550°F (843°C) for 24 hours and air cooling; and (3) heating at 1400°F (760°C) for 16 hours and air cooling.

[0155] Table 10: Stress rupture results at 1500°F (816.6°C) / 50 ksi (344.7 MPa)

[0156] Heating element number Break time (hr) ％El P0F00 68.9 30.5 P0F01 134 11.6 P0F02 141.7 8 P0F03 139 7.4 P0F05 56 9.9 P0F07 41.1 14.9 P0F12 74.3 11.8 P0F13 46.6 No data Waspaloy 53.4 38.2

[0157] Table 11: Stress rupture results at 1500°F (816.6°C) / 60 ksi (413.7 MPa)

[0158]

[0159] Example 3

[0160] After considering the mechanical and microstructural results of the 25 lb heating piece of Example 2, seven 300 lb experimental heating pieces (POF15 to POF19) were melted by vacuum induction melting and then remelted using vacuum arc remelting. Table 12 provides the chemical composition of each 300 lb heating piece, where all contents are weight percentages based on the total weight of the alloy heating piece.

[0161] Table 12: Chemical composition of 300 lb heating element

[0162] Heating element batch number Al B C Co Cr Fe Mo Nb Ni Si Ta Ti W Zr P0F14 455 1.741 0.0049 0.014 26.262 15.051 2.02 3.513 0.002 44.8936 0.01 0.008 3.994 2.456 0.031 P0F15 456 1.745 0.0058 0.028 18.271 15.864 2.03 5.98 0.004 50.4552 0.013 0.015 3.581 1.99 0.031 P0F16 457 1.714 0.0055 0.026 16.131 15.102 2.019 3.099 0.474 54.0562 0.015 0.935 3.457 2.951 0.028 P0F17 459 1.957 0.0058 0.017 17.916 13.899 2.02 2.544 0.725 52.8962 0.019 1.404 3.079 3.49 0.031 P0F18 460 3.372 0.006 0.018 17.712 11.665 1.958 2.937 0.704 51.8678 0.02 1.264 2.803 5.653 0.025 P0F18 460 1.923 0.0056 0.02 17.906 11.923 1.98 3.022 0.732 52.732 0.021 1.395 2.516 5.806 0.024 P0F19 461 1.697 0.0059 0.022 18.018 14.054 1.974 2.045 0.715 52.5589 0.019 1.393 3.457 4.013 0.032

[0163] Heater POF14 includes a relatively high cobalt content, which increases the solubility of titanium, preventing it from participating in TCP phase formation. This also allows for a relatively high titanium / aluminum ratio, which provides favorable tensile properties (high strength and ductility at room temperature). The tungsten content in heater POF18 is relatively high and the chromium content is reduced compared to POF14. The lower chromium content reduces the likelihood of sigma phase precipitation and increases the solubility limit of tungsten and molybdenum in heater POF18. Heater POF19 is similar to heater POF16, but includes a higher tungsten and lower molybdenum content, which can improve creep properties and potentially reduce the tendency to form TCP phases.

[0164] The γ' solvus temperatures of Heat Nos. P0F14 to P0F19 were determined by DTA, and the results are shown in Table 13. As previously stated, the preferred γ' solvus for alloys according to the present disclosure is at or below 2050°F, and in Table 10, all results except for the result for Heat No. P0F19 meet the preferred characteristics.

[0165] Table 13: γ' solvus temperature

[0166]

[0167] After homogenization, the alloy samples were heat treated. Table 14 provides the steps of the heat treatment applied to the heated pieces. "AC" refers to air cooling in Table 14.

[0168] Table 14: Heat treatment

[0169]

[0170] Test specimens were prepared from the heat treated alloys and tested for tensile and formability properties at various test specimen temperatures. The tensile and formability test results are listed in Table 15. Heat treated production samples of Waspaloy alloy were also tested and the results are shown in Table 15.

[0171] Table 15: Tensile and formability test results

[0172]

[0173]

[0174] a Room temperature (about 75°F)

[0175] b Fracture outer gauge length

[0176] c No YS obtained; fractured before reaching 0.2% deflection

[0177] Samples of the heat treated alloy and Waspaloy alloy production material were also tested for high temperature stress rupture time and elongation at a sample temperature of 1500°F (816°C) and an applied stress of 50 ksi (345 MPa) or 60 ksi (414 MPa). The test results are shown in Table 16.

[0178] Table 16: Stress rupture and elongation test results

[0179]

[0180]

[0181] All experimental alloys in this example exhibit significantly improved creep rupture properties and tensile strength relative to Waspaloy.

[0182] Example 4

[0183] Nickel-based alloy heating pieces having the chemical compositions listed in Table 17 were prepared by vacuum induction melting of feed materials. The values ​​in Table 17 are weight percentages based on the total alloy weight. "NM" means unmeasured content. Each alloy heating piece also includes incidental impurities and excess nickel. The heating piece is atomized to form a metallurgical powder.

[0184] Table 17: Atomized Powder Chemistry

[0185] Heating element Al B C Co Cr Fe Mo Nb Ta Ti W Zr R1 1.34 0.004 0.049 24.11 16.16 2 3.58 NM NM 4.97 NM 0.03 B1 1.538 0.0049 0.047 24.137 16.603 2.058 3.666 0.059 0.12 5.004 0.383 0.031 R2 1.68 0.006 0.053 17.97 15.94 2 2.99 0.51 1.02 3.54 3.04 0.02 B2 1.779 0.0048 0.051 18.235 16.028 1.995 3.034 0.46 0.954 3.551 3.011 0.032

[0186] Example 5

[0187] Nickel-based alloy ingots having the chemical compositions listed in Table 18 were prepared by vacuum induction melting and vacuum arc remelting. Each heated piece weighed approximately 300 pounds. The values ​​in Table 18 are weight percentages based on the total alloy weight. Each alloy also included incidental impurities.

[0188] Table 18: Alloy heating element chemistry

[0189] Heating element Al B C Co Cr Fe Mo Nb Ni Si Ta Ti W Zr P2F00 1.731 0.0064 0.05 18.105 15.96 2.016 6.265 <0.01 50.1737 0.027 0.011 3.493 2.163 0.028 P2F01 1.73 0.0037 0.049 18.034 16.012 2.027 6.007 <0.01 50.5747 0.026 0.01 3.492 2.018 0.044 P2F02 1.743 0.0059 0.048 18.005 15.997 2.028 5.998 <0.01 50.6387 0.02 0.011 3.48 2.019 0.034 P2F03 1.734 0.0062 0.049 15.997 14.979 2.001 3.105 0.497 53.7043 0.018 1.205 3.749 2.958 0.03 P2F04 1.722 0.0059 0.046 25.848 15.022 2.014 3.474 0.023 45.2581 0.011 0.056 4.007 2.513 0.03 P2F05 1.96 0.0057 0.042 18.499 13.949 2.033 2.51 0.724 52.2888 0.016 1.475 3.023 3.474 0.029 P2F06 1.966 0.0062 0.046 17.967 12.045 2.04 2.975 0.75 52.2732 0.023 1.473 2.492 5.943 0.031 P2F07 1.747 0.0061 0.043 18.13 13.98 2.014 2.069 0.749 52.154 0.017 1.497 3.482 4.11 0.03

[0190] The yield strength, ultimate yield strength and percent elongation of the samples of the heat treated alloy were tested at room temperature and elevated temperature. In addition, the stress rupture time and elongation at failure of the samples were tested at a sample temperature of 1500°F (816°C) and an applied stress of 50 ksi (345 MPa). Stress rupture testing was performed according to ASTM E139-11. Room temperature tensile testing was performed according to ASTM E8 / E8M-22. High temperature tensile testing was performed according to ASTM E21-20. The test results are shown in Table 19.

[0191] Table 19: Mechanical test results

[0192]

[0193] In addition, the microstructural characteristics of the samples of heating elements P2F02 and P2F07 were analyzed, such as Figure 10-11 shown. Fig.10 The particle size of P2F02 is 8.1 ASTM particle size. Fig.11 The particle size of P2F07 is 8.2 ASTM particle size.

[0194] Example 6

[0195] Nickel-based alloy heaters having the chemical compositions listed in Table 20 were prepared by vacuum induction melting of feed material and subsequent gas atomization to produce metal powder. After gas atomization, the powder heaters were screened for LPBF printing. The values ​​in Table 20 are weight percentages based on the total alloy weight. "NM" means not measured content. Each alloy heater also includes incidental impurities and excess nickel.

[0196] Metallurgical powders were used to additively manufacture test bars for mechanical testing. An SLM 125HL LPBF machine (SLM Solutions, Lübeck, Germany) and an EOS M290 LPBF machine (EOS GmbH, Krailling, Germany) were used to print test bars using various orientations of the test bars. The SLM machine has a build volume of 125 mm × 125 mm × 125 mm, and the EOS machine has a build volume of 250 mm × 250 mm × 325 mm. Both machines use similar laser and inert gas (argon) systems. After printing, the test bars were tensile tested at different temperatures and stress fracture tested at different temperatures and stresses. The processing and mechanical testing results of the test bars are shown in Tables 21 and 22.

[0197] Table 20: Powder heating element chemistry

[0198] Powder heating element Al B C Co Cr Fe Mo Nb Ta Ti W Zr O N Si Mn Cu P S 523-107 1.34 0.004 0.049 24.11 16.16 2 3.58 - - 4.97 - 0.03 0.0048 0.0068 NM NM NM NM NM 523-108 1.68 0.006 0.053 17.97 15.94 2 2.99 0.51 1.02 3.54 3.04 0.027 0.015 0.001 NM NM NM NM NM AMABA1C025 1.538 0.0049 0.047 24.137 16.603 2.058 3.666 0.059 0.12 5.004 0.383 0.031 0.0137 0.0012 <0.01 <0.01 <0.01 <0.003 0.0004 AMABB1C024 1.779 0.0048 0.051 18.235 16.028 1.995 3.034 0.46 0.954 3.551 3.011 0.032 0.0139 0.0013 <0.01 <0.01 <0.01 <0.003 0.0004

[0199] Table 21: Tensile testing of additively manufactured parts

[0200]

[0201]

[0202]

[0203] Table 22: Stress rupture testing of additively manufactured parts

[0204]

[0205] The following numbered clauses are directed to various non-limiting embodiments according to the present disclosure:

[0206] Clause 1. A nickel-based alloy comprising, in weight percentage based on the total alloy weight: 11 to 18 chromium;

[0207] 16 to 28 cobalt;

[0208] 1.5 to 7.0 molybdenum;

[0209] 0 to 6.5 tungsten;

[0210] 0 to 1.0 niobium;

[0211] 1.0 to 2.5 aluminum;

[0212] 2.0 to 6.0 titanium;

[0213] 0 to 2.0 Tantalum;

[0214] 0 to 4.0 Fe;

[0215] 0 to 0.5 hafnium;

[0216] 0.01 to 0.2 carbon;

[0217] 0.001 to 0.02 boron;

[0218] 0.001 to 0.1 zirconium;

[0219] Nickel; and

[0220] Impurities.

[0221] Clause 2. The nickel-based alloy according to clause 1, wherein the aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5.

[0222] Clause 3. The nickel-based alloy of any one of Clauses 1 and 2, wherein the combined concentration of aluminum and titanium does not exceed 7.0 weight percent, based on the total alloy weight.

[0223] Clause 4. The nickel-based alloy of any one of Clauses 1 and 2, wherein the combined concentration of aluminum and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0224] Clause 5. The nickel-based alloy of any one of clauses 1-4, comprising 11 to 16 wt. % chromium, based on the total alloy weight.

[0225] Clause 6. The nickel-based alloy of any of Clauses 1-5, comprising 0.001 to 0.015 wt. % boron, based on the total alloy weight.

[0226] Clause 7. The nickel-based alloy of any of Clauses 1-6, comprising at least 36 weight percent nickel, based on the total alloy weight.

[0227] Clause 8. The nickel-based alloy of any one of clauses 1-7, comprising 16 to 19 weight percent cobalt, based on the total alloy weight.

[0228] Clause 9. The nickel-based alloy of any one of clauses 1-8, comprising 2.0 to 4.5 wt. % titanium, based on the total alloy weight.

[0229] Clause 10. The nickel-based alloy of any one of clauses 1-7, comprising, in weight percentage based on the total alloy weight:

[0230] 11 to 16 Cr;

[0231] 16 to 28 cobalt;

[0232] 1.5 to 7.0 molybdenum;

[0233] 0 to 6.5 tungsten;

[0234] 0 to 1.0 niobium;

[0235] 1.0 to 2.5 aluminum;

[0236] 2.0 to 6.0 titanium;

[0237] 0 to 2.0 Tantalum;

[0238] 0 to 4.0 Fe;

[0239] 0 to 0.5 hafnium;

[0240] 0.01 to 0.2 carbon;

[0241] 0.001 to 0.015 boron;

[0242] 0.001 to 0.1 zirconium;

[0243] At least 36 nickel; and

[0244] Impurities;

[0245] wherein the combined concentration of aluminum, niobium and titanium does not exceed 7.0% by weight; and

[0246] The aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5.

[0247] Clause 11. The nickel-based alloy of any one of Clause 10, wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0248] Clause 12. A nickel-based alloy comprising, in weight percentage based on the total alloy weight:

[0249] 11 to 18 chromium;

[0250] 24 to 28 cobalt;

[0251] 1.5 to 7.0 molybdenum;

[0252] 2.0 to 6.0 tungsten;

[0253] 0 to 1.0 niobium;

[0254] 1.0 to 2.5 aluminum;

[0255] 2.0 to 6.0 titanium;

[0256] 0 to 2.0 Tantalum;

[0257] 0 to 4.0 Fe;

[0258] 0 to 0.5 hafnium;

[0259] 0.01 to 0.2 carbon;

[0260] 0.001 to 0.02 boron;

[0261] 0.001 to 0.1 zirconium;

[0262] Nickel; and

[0263] Impurities.

[0264] Clause 13. The nickel-based alloy according to clause 12, wherein the aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5.

[0265] Clause 14. The nickel-based alloy of any of Clauses 12-13, wherein the combined concentration of aluminum and titanium does not exceed 7.0 weight percent, based on the total alloy weight.

[0266] Clause 15. The nickel-based alloy of any of Clauses 12-14, wherein the combined concentration of aluminum and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0267] Clause 16. The nickel-based alloy of any of Clauses 12-15, comprising 14 to 16 wt. % chromium, based on the total alloy weight.

[0268] Clause 17. The nickel-based alloy of any one of clauses 12-16, comprising 24 to 27 weight percent cobalt, based on the total alloy weight.

[0269] Clause 18. The nickel-based alloy of any of Clauses 12-17, comprising 3.0 to 4.5 wt. % titanium, based on the total alloy weight.

[0270] Clause 19. The nickel-based alloy of any of Clauses 12-18, comprising 1.7 to 2.0 wt. % aluminum, based on the total alloy weight.

[0271] Clause 20. The nickel-based alloy of any of Clauses 12-19, comprising 0.001 to 0.015 wt. % boron, based on the total alloy weight.

[0272] Clause 21. The nickel-based alloy of any of Clauses 12-20, comprising at least 46 wt. % nickel based on the total alloy weight.

[0273] Clause 22. The nickel-based alloy according to Clause 12, comprising, in weight percentage based on the total alloy weight:

[0274] 14 to 16 chromium;

[0275] 24 to 27 cobalt;

[0276] 1.5 to 7.0 molybdenum;

[0277] 0 to 6.5 tungsten;

[0278] 0 to 1.0 niobium;

[0279] 1.7 to 2.0 aluminum;

[0280] 3.0 to 4.5 titanium;

[0281] 0 to 2.0 Tantalum;

[0282] 0 to 4.0 Fe;

[0283] 0 to 0.5 hafnium;

[0284] 0.01 to 0.2 carbon;

[0285] 0.001 to 0.015 boron;

[0286] 0.001 to 0.1 zirconium;

[0287] At least 46 nickel; and

[0288] Impurities;

[0289] wherein the combined concentration of aluminum, niobium and titanium does not exceed 7.0% by weight; and

[0290] The aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5.

[0291] Clause 23. The nickel-based alloy of Clause 22, wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0292] Clause 24. A nickel-based alloy comprising, in weight percentage based on the total alloy weight:

[0293] 11 to 18 chromium;

[0294] 16 to 28 cobalt;

[0295] 1.5 to 7.0 molybdenum;

[0296] 0 to 6.5 tungsten;

[0297] 0 to 1.0 niobium;

[0298] 1.0 to 2.5 aluminum;

[0299] 2.0 to 6.0 titanium;

[0300] 0 to 2.0 Tantalum;

[0301] 0 to 4.0 Fe;

[0302] 0 to 0.5 hafnium;

[0303] 0.01 to 0.2 carbon;

[0304] 0.001 to 0.02 boron;

[0305] 0.001 to 0.1 zirconium;

[0306] Nickel; and

[0307] Impurities.

[0308] Clause 25. The nickel-based alloy according to Clause 24, wherein the aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5.

[0309] Clause 26. The nickel-based alloy of any of Clauses 24-25, wherein the combined concentration of aluminum and titanium does not exceed 7.0 wt. %, based on the total alloy weight.

[0310] Clause 27. The nickel-based alloy of any one of Clauses 24-26, wherein the combined concentration of aluminum and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0311] Clause 28. The nickel-based alloy of any one of Clauses 24-27, comprising 13 to 17 wt. % chromium, based on the total alloy weight.

[0312] Clause 29. The nickel-based alloy of any one of Clauses 24-28, comprising 0.001 to 0.015 wt. % boron, based on the total alloy weight.

[0313] Clause 30. The nickel-based alloy of any one of Clauses 24-29, comprising at least 36 wt. % nickel based on the total alloy weight.

[0314] Clause 31. The nickel-based alloy of any one of Clauses 24-30, comprising 16 to 25 wt. % cobalt, based on the total alloy weight.

[0315] Clause 32. The nickel-based alloy of any one of Clauses 24-31, comprising 3.0 to 6.0 wt. % titanium, based on the total alloy weight.

[0316] Clause 33. The nickel-based alloy of any one of Clauses 24-32, comprising 13 to 17 wt. % chromium, based on the total alloy weight.

[0317] Clause 34. The nickel-based alloy of any one of Clauses 24-33, comprising 1 to 6.5 wt. % tungsten, based on the total alloy weight.

[0318] Clause 35. The nickel-based alloy of any one of Clauses 24-34, comprising 0 to 0.05 wt. % magnesium, based on the total alloy weight.

[0319] Clause 36. The nickel-based alloy according to Clause 24, comprising, in weight percentage based on the total alloy weight:

[0320] 13 to 17 chromium;

[0321] 16 to 25 cobalt;

[0322] 1.5 to 7.0 molybdenum;

[0323] 0 to 6.5 tungsten;

[0324] 0 to 1.0 niobium;

[0325] 1.0 to 2.5 aluminum;

[0326] 3.0 to 6.0 titanium;

[0327] 0 to 2.0 Tantalum;

[0328] 0 to 4.0 Fe;

[0329] 0 to 0.5 hafnium;

[0330] 0.01 to 0.2 carbon;

[0331] 0.001 to 0.015 boron;

[0332] 0.001 to 0.1 zirconium;

[0333] Optional trace elements;

[0334] At least 36 nickel; and

[0335] Impurities.

[0336] Clause 37. The nickel-based alloy of Clause 36, wherein the combined concentration of aluminum, niobium, and titanium does not exceed 7.0 weight percent.

[0337] Clause 38. A nickel-based alloy according to any one of clauses 36-37, wherein the aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5.

[0338] Clause 39. The nickel-based alloy of any of Clauses 36-38, wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0339] Clause 40. The nickel-based alloy of any of Clauses 36-39, comprising 16 to 19 weight percent cobalt, based on the total alloy weight.

[0340] Clause 41. The nickel-based alloy of any of Clauses 36-39, comprising 19 to 25 weight percent cobalt, based on the total alloy weight.

[0341] Clause 42. The nickel-based alloy of any one of Clauses 36-41, comprising 2.0 to 4.0 wt. % molybdenum, based on the total alloy weight.

[0342] Clause 43. The nickel-based alloy of any of Clauses 36-41, comprising 4.0 to 6.0 wt. % molybdenum, based on the total alloy weight.

[0343] Clause 44. The nickel-based alloy of any one of Clauses 36-43, comprising 0 to 0.5 wt. % tungsten, based on the total alloy weight.

[0344] Clause 45. The nickel-based alloy of any one of Clauses 36-43, comprising 2.0 to 5.0 wt. % tungsten, based on the total alloy weight.

[0345] Clause 46. The nickel-based alloy of any of Clauses 36-45, comprising 1.25 to 1.9 wt. % aluminum, based on the total alloy weight.

[0346] Clause 47. The nickel-based alloy of any of Clauses 36-46, comprising 1.0 to 3.0 wt. % iron, based on the total alloy weight.

[0347] Clause 48. The nickel-based alloy of any of Clauses 36-47, comprising 0.6 to 2.0 wt. % tantalum, based on the total alloy weight.

[0348] Clause 49. The nickel-based alloy of any of Clauses 36-47, comprising 0 to 0.5 wt. % tantalum, based on the total alloy weight.

[0349] Clause 50. The nickel-based alloy of any of Clauses 36-49, comprising 3.0 to 4.0 wt. % titanium, based on the total alloy weight.

[0350] Clause 51. The nickel-based alloy of any of Clauses 36-49, comprising 4.5 to 5.5 wt. % titanium, based on the total alloy weight.

[0351] Clause 52. The nickel-based alloy of any one of clauses 36-51, comprising 14 to 17 weight percent chromium, based on the total alloy weight.

[0352] Clause 53. The nickel-based alloy of any of Clauses 36-52, comprising 0.2 to 1.0 wt. % niobium, based on the total alloy weight.

[0353] Clause 54. The nickel-based alloy of any of Clauses 36-53, comprising at least 46 wt. % nickel based on the total alloy weight.

[0354] Clause 55. A nickel-based alloy according to any one of clauses 36-54, wherein the aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.2.

[0355] Clause 56. A nickel-based alloy according to any one of clauses 36-55, wherein the aluminum equivalent number (Al eq ) is in the range of 4.0 to 4.5.

[0356] Clause 57. The nickel-based alloy of any of Clauses 36-56, wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 6.0 weight percent, based on the total alloy weight.

[0357] Clause 58. The nickel-based alloy of any of Clauses 36-57, wherein the combined concentration of aluminum, niobium, and titanium is 6.0 to 7.0 weight percent, based on the total alloy weight.

[0358] Clause 59. The nickel-based alloy of any one of Clauses 36-58, wherein the trace elements comprise 0 to 0.05 wt. % magnesium, based on the total alloy weight.

[0359] Clause 60. A nickel-based alloy comprising, by weight percentage based on the total alloy weight:

[0360] 13 to 17 chromium;

[0361] 16 to 19 cobalt;

[0362] 1.5 to 7.0 molybdenum;

[0363] 2.0 to 5.0 tungsten;

[0364] 0 to 1.0 niobium;

[0365] 1.0 to 2.5 aluminum;

[0366] 3.0 to 6.0 titanium;

[0367] 0 to 2.0 Tantalum;

[0368] 0 to 3.0 Fe;

[0369] 0 to 0.5 hafnium;

[0370] 0.01 to 0.2 carbon;

[0371] 0.001 to 0.015 boron;

[0372] 0.001 to 0.1 zirconium;

[0373] Optional trace elements;

[0374] At least 46 nickel; and

[0375] Impurities;

[0376] The aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5, and wherein the combined concentration of aluminum, niobium and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0377] Clause 61. A nickel-based alloy comprising, by weight percentage based on the total alloy weight:

[0378] 14 to 17 chromium;

[0379] 19 to 25 cobalt;

[0380] 2.0 to 4.0 molybdenum;

[0381] 0 to 6.5 tungsten;

[0382] 0 to 0.8 niobium;

[0383] 1.0 to 2.5 aluminum;

[0384] 3.0 to 6.0 titanium;

[0385] 0 to 2.0 Tantalum;

[0386] 0 to 3.0 Fe;

[0387] 0 to 0.5 hafnium;

[0388] 0.01 to 0.2 carbon;

[0389] 0.001 to 0.015 boron;

[0390] 0.001 to 0.1 zirconium;

[0391] Optional trace elements;

[0392] At least 46 nickel; and

[0393] Impurities;

[0394] The aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5, and wherein the combined concentration of aluminum, niobium and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0395] Clause 62. A nickel-based alloy comprising, in weight percentage based on the total alloy weight:

[0396] 14 to 17 chromium;

[0397] 16 to 19 cobalt;

[0398] 2.0 to 4.0 molybdenum;

[0399] 2.0 to 5.0 tungsten;

[0400] 0 to 1.0 niobium;

[0401] 1.0 to 2.5 aluminum;

[0402] 3.0 to 6.0 titanium;

[0403] greater than 0 to 2.0 tantalum;

[0404] 1.0 to 3.0 Fe;

[0405] 0 to 0.5 hafnium;

[0406] 0.01 to 0.2 carbon;

[0407] 0.001 to 0.015 boron;

[0408] 0.001 to 0.1 zirconium;

[0409] Optional trace elements;

[0410] At least 46 nickel; and

[0411] Impurities;

[0412] The aluminum equivalent number (Aleq ) is in the range of 3.6 to 4.5, and wherein the combined concentration of aluminum, niobium and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

[0413] Clause 63. An additively manufactured part comprising the nickel-based alloy of any one of clauses 24-62.

[0414] Clause 64. The additively manufactured part of clause 63, wherein the additively manufactured part comprises at least one part selected from the group consisting of: a heat exchanger, a nose cone, a scramjet engine component, an aircraft leading edge, a heat pipe, a reentry structure, an actively or passively cooled controlled surface, an aircraft skin, a ramjet engine component, a rocket engine component, a combined cycle engine component, a rotating detonation engine component, a gasification equipment component, a chemical processing equipment component, and a fastening system component.

[0415] Clause 65. The nickel-based alloy of any one of clauses 24-62, wherein the nickel-based alloy exhibits:

[0416] Yield strength of at least 120 ksi (827 MPa) under aged conditions at room temperature;

[0417] A yield strength of at least 90 ksi (621 MPa) after aging at 1500°F (816°C);

[0418] An ultimate tensile strength of at least 180 ksi (1241 MPa) under aged conditions at room temperature;

[0419] An ultimate tensile strength of at least 90 ksi (621 MPa) after aging at 1500°F (816°C); and

[0420] The percent elongation under aging conditions at room temperature ranges from 15% to 40%.

[0421] Clause 66. The nickel-based alloy of any one of clauses 24-62, wherein the nickel-based alloy exhibits:

[0422] Yield strength of at least 125 ksi (862 MPa) under aged conditions at room temperature;

[0423] A yield strength of at least 100 ksi (689 MPa) at 1500°F (816°C) aged;

[0424] An ultimate tensile strength of at least 195 ksi (1344 MPa) under aged conditions at room temperature;

[0425] An ultimate tensile strength of at least 105 ksi (724 MPa) after aging at 1500°F (816°C); and

[0426] The percent elongation under aging conditions at room temperature is in the range of 25% to 35%.

[0427] Clause 67. A nickel-based alloy comprising, by weight percentage based on the total alloy weight:

[0428] 15 to 17 chromium;

[0429] 22 to 26 cobalt;

[0430] 2.0 to 4.0 molybdenum;

[0431] 0 to 2.0 tungsten;

[0432] 0 to 1.0 niobium;

[0433] 1.0 to 4.0 aluminum;

[0434] 1.0 to 6.0 Titanium;

[0435] 0 to 2.0 Tantalum;

[0436] 0 to 4.0 Fe;

[0437] 0 to 0.5 hafnium;

[0438] 0 to 0.2 carbon;

[0439] 0 to 0.02 boron;

[0440] 0 to 0.1 zirconium;

[0441] Nickel; and

[0442] Impurities.

[0443] Clause 68. A nickel-based alloy comprising, by weight percentage based on the total alloy weight:

[0444] 14 to 17 chromium;

[0445] 15 to 18 cobalt;

[0446] 2.0 to 4.0 molybdenum;

[0447] 1.0 to 4.0 tungsten;

[0448] 0 to 1.0 niobium;

[0449] 1.0 to 3.0 aluminum;

[0450] 2.0 to 4.0 titanium;

[0451] 0 to 2.0 Tantalum;

[0452] 0 to 4.0 Fe;

[0453] 0 to 0.5 hafnium;

[0454] 0 to 0.2 carbon;

[0455] 0 to 0.02 boron;

[0456] 0 to 0.1 zirconium;

[0457] Nickel; and

[0458] Impurities.

[0459] Those skilled in the art will readily appreciate that the present invention allows for extensive practicality and application. Without departing from the essence or scope of the present invention, in addition to those described herein, many embodiments and adaptations of the present invention and many variations, modifications and equivalent arrangements will be apparent from the present invention and its foregoing description or reasonably suggested by the present invention and its foregoing description. Therefore, although the present invention has been described in detail herein with respect to its preferred embodiments, it should be understood that this disclosure is only an illustration and example of the present invention and is only used for the purpose of providing a complete and feasible disclosure of the present invention. The foregoing disclosure is not intended to or should not be interpreted as limiting the present invention or otherwise excluding any such other embodiments, adaptations, variations, modifications and equivalent arrangements.

Claims

1. A nickel-based alloy comprising, in weight percentage based on the total alloy weight: 11 to 18 chromium; 16 to 28 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 2.0 to 6.0 titanium; 0 to 2.0 Tantalum; 0 to 4.0 Fe; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.02 boron; 0.001 to 0.1 zirconium; Nickel; and Impurities.

2. The nickel-based alloy according to claim 1, wherein the aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.

5.

3. The nickel-base alloy of claim 1 , wherein the combined concentration of aluminum and titanium does not exceed 7.0 weight percent, based on the total alloy weight.

4. The nickel-based alloy of claim 1, wherein the combined concentration of aluminum and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

5. The nickel-based alloy of claim 1 comprising 13 to 17 wt. % chromium based on the total alloy weight.

6. The nickel-based alloy of claim 1 comprising 0.001 to 0.015 wt. % boron based on the total alloy weight.

7. The nickel-based alloy of claim 1 comprising at least 36 weight percent nickel based on total alloy weight.

8. The nickel-based alloy of claim 1 comprising 16 to 25 weight percent cobalt based on the total alloy weight.

9. The nickel-based alloy of claim 1 comprising 3.0 to 6.0 wt. % titanium based on the total alloy weight.

10. The nickel-based alloy of claim 1 comprising 1 to 6.5 wt. % tungsten based on the total alloy weight.

11. The nickel-based alloy of claim 1 comprising 0 to 0.05 wt. % magnesium based on the total alloy weight.

12. The nickel-based alloy of claim 1, comprising, by weight percentage based on the total alloy weight: 13 to 17 chromium; 16 to 25 cobalt; 1.5 to 7.0 molybdenum; 0 to 6.5 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 Tantalum; 0 to 4.0 Fe; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; Optional trace elements; At least 36 nickel; and Impurities.

13. The nickel-based alloy of claim 12, wherein the combined concentration of aluminum, niobium and titanium does not exceed 7.0 weight percent.

14. The nickel-based alloy according to claim 12, wherein the aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.

5.

15. The nickel-based alloy of claim 12, wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

16. The nickel-based alloy of claim 12 comprising 16 to 19 weight percent cobalt based on the total alloy weight.

17. The nickel-based alloy of claim 12 comprising 19 to 25 weight percent cobalt based on the total alloy weight.

18. The nickel-based alloy of claim 12 comprising 2.0 to 4.0 wt. % molybdenum based on the total alloy weight.

19. The nickel-based alloy of claim 12 comprising 4.0 to 6.0 wt. % molybdenum based on the total alloy weight.

20. The nickel-based alloy of claim 12, comprising 0 to 0.5 wt. % tungsten based on the total alloy weight.

21. The nickel-based alloy of claim 12, comprising 2.0 to 5.0 wt. % tungsten based on the total alloy weight.

22. The nickel-based alloy of claim 12 comprising 1.25 to 1.9 wt. % aluminum based on the total alloy weight.

23. The nickel-based alloy of claim 12 comprising 1.0 to 3.0 wt. % iron based on the total alloy weight.

24. The nickel-based alloy of claim 12 comprising 0.6 to 2.0 wt. % tantalum based on the total alloy weight.

25. The nickel-based alloy of claim 12 comprising 0 to 0.5 wt. % tantalum based on the total alloy weight.

26. The nickel-based alloy of claim 12 comprising 3.0 to 4.0 wt. % titanium based on the total alloy weight.

27. The nickel-based alloy of claim 12 comprising 4.5 to 5.5 weight percent titanium based on the total alloy weight.

28. The nickel-based alloy of claim 12 comprising 14 to 17 wt. % chromium based on the total alloy weight.

29. The nickel-based alloy of claim 12 comprising 0.2 to 1.0 wt. % niobium based on the total alloy weight.

30. The nickel-based alloy of claim 12 comprising at least 46 weight percent nickel based on total alloy weight.

31. The nickel-based alloy according to claim 12, wherein the aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.

2.

32. The nickel-based alloy according to claim 12, wherein the aluminum equivalent number (Al eq ) is in the range of 4.0 to 4.

5.

33. The nickel-base alloy of claim 12, wherein the combined concentration of aluminum, niobium, and titanium is 5.0 to 6.0 weight percent, based on the total alloy weight.

34. The nickel-base alloy of claim 12, wherein the combined concentration of aluminum, niobium, and titanium is 6.0 to 7.0 weight percent, based on the total alloy weight.

35. The nickel-based alloy of claim 12, wherein the trace elements comprise 0 to 0.05 wt. % magnesium based on the total alloy weight.

36. The nickel-based alloy of claim 1, comprising, by weight percentage based on the total alloy weight: 13 to 17 chromium; 16 to 19 cobalt; 1.5 to 7.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 Tantalum; 0 to 3.0 Fe; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; Optional trace elements; At least 46 nickel; and Impurities; The aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5, and wherein the combined concentration of aluminum, niobium and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

37. The nickel-based alloy of claim 1, comprising, by weight percentage based on the total alloy weight: 14 to 17 chromium; 19 to 25 cobalt; 2.0 to 4.0 molybdenum; 0 to 6.5 tungsten; 0 to 0.8 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; 0 to 2.0 Tantalum; 0 to 3.0 Fe; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; Optional trace elements; At least 46 nickel; and Impurities; The aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5, and wherein the combined concentration of aluminum, niobium and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

38. The nickel-based alloy of claim 1, comprising, by weight percentage based on the total alloy weight: 14 to 17 chromium; 16 to 19 cobalt; 2.0 to 4.0 molybdenum; 2.0 to 5.0 tungsten; 0 to 1.0 niobium; 1.0 to 2.5 aluminum; 3.0 to 6.0 titanium; Tantalum greater than 0 to 2.0; 1.0 to 3.0 Fe; 0 to 0.5 hafnium; 0.01 to 0.2 carbon; 0.001 to 0.015 boron; 0.001 to 0.1 zirconium; Optional trace elements; At least 46 nickel; and Impurities; The aluminum equivalent number (Al eq ) is in the range of 3.6 to 4.5, and wherein the combined concentration of aluminum, niobium and titanium is 5.0 to 7.0 weight percent, based on the total alloy weight.

39. An additively manufactured part comprising the nickel-based alloy of claim 37.

40. The additively manufactured part of claim 39, wherein the additively manufactured part comprises at least one part selected from the group consisting of: a heat exchanger, a nose cone, a scramjet engine component, an aircraft leading edge, a heat pipe, a reentry structure, an actively or passively cooled controlled surface, an aircraft skin, a ramjet engine component, a rocket engine component, a combined cycle engine component, a rotating detonation engine component, a gasification plant component, a chemical processing plant component, and a fastening system component.

41. An additively manufactured part comprising the nickel-based alloy of claim 38.

42. The additively manufactured part of claim 41, wherein the additively manufactured part comprises at least one part selected from the group consisting of: a heat exchanger, a nose cone, a scramjet engine component, an aircraft leading edge, a heat pipe, a reentry structure, an actively or passively cooled controlled surface, an aircraft skin, a ramjet engine component, a rocket engine component, a combined cycle engine component, a rotating detonation engine component, a gasification plant component, a chemical processing plant component, and a fastening system component.

43. The nickel-based alloy of claim 1, wherein the nickel-based alloy exhibits: Yield strength of at least 120 ksi (827 MPa) under aged conditions at room temperature; A yield strength of at least 90 ksi (621 MPa) after aging at 1500°F (816°C); An ultimate tensile strength of at least 180 ksi (1241 MPa) under aged conditions at room temperature; An ultimate tensile strength of at least 90 ksi (621 MPa) after aging at 1500°F (816°C); and The percent elongation under aging conditions at room temperature ranges from 15% to 40%.

44. The nickel-based alloy of claim 1, wherein the nickel-based alloy exhibits: Yield strength of at least 125 ksi (862 MPa) under aged conditions at room temperature; A yield strength of at least 100 ksi (689 MPa) at 1500°F (816°C) aged; An ultimate tensile strength of at least 195 ksi (1344 MPa) under aged conditions at room temperature; An ultimate tensile strength of at least 105 ksi (724 MPa) after aging at 1500°F (816°C); and The percent elongation under aging conditions at room temperature is in the range of 25% to 35%.

45. A nickel-based alloy comprising, in weight percentage based on the total alloy weight: 15 to 17 chromium; 22 to 26 cobalt; 2.0 to 4.0 molybdenum; 0 to 2.0 tungsten; 0 to 1.0 niobium; 1.0 to 4.0 aluminum; 1.0 to 6.0 Titanium; 0 to 2.0 Tantalum; 0 to 4.0 Fe; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; as well as Impurities.

46. ​​A nickel-based alloy comprising, in weight percentage based on the total alloy weight: 14 to 17 chromium; 15 to 18 cobalt; 2.0 to 4.0 molybdenum; 1.0 to 4.0 tungsten; 0 to 1.0 niobium; 1.0 to 3.0 aluminum; 2.0 to 4.0 titanium; 0 to 2.0 Tantalum; 0 to 4.0 Fe; 0 to 0.5 hafnium; 0 to 0.2 carbon; 0 to 0.02 boron; 0 to 0.1 zirconium; nickel; as well as Impurities.

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