Alloy compositions and articles formed from such compositions

Abstract

The invention relates to alloy compositions and articles formed from such compositions. Compositions are described herein, and more particularly, to alloy compositions, methods of using the alloy compositions, and articles formed from the alloy compositions. The alloy compositions are widely useful in applications where superalloys are required, including welding processes, additive manufacturing processes, metal casting processes, coating processes, repair processes, powder metallurgy, and / or combinations thereof.

Description

Background Art

[0001] The field of the present disclosure relates generally to compositions, and more particularly to alloy compositions, methods of using the alloy compositions, and articles formed from the alloy compositions. The alloy compositions are widely suitable for use in applications requiring superalloys, including welding processes, additive manufacturing processes, metal casting processes, coating processes, repair processes, powder metallurgy, and / or combinations thereof.

[0002] Nickel-based superalloys generally include relatively easy-to-weld superalloys with lower aluminum content and difficult-to-weld superalloys with higher aluminum content. The application of difficult-to-weld superalloys is limited due to poor weldability characteristics.

[0003] Nickel-based superalloys are described in U.S. Patent Publication No. 2016 / 0326613, which describes alloys with lower Al content and showing good weldability. However, this alloy system is intended to have a low Al content, which may limit other properties.

[0004] Nickel-based superalloys are also described in U.S. Pat. No. 10,640,849, which describes an alloy having a higher Al content and showing good weldability. However, the alloy system is simple. In order to improve the properties of the alloy, more elements should be added to the alloy system.

[0005] Therefore, there is a need for nickel-based superalloys that provide good weldability and a combination of mechanical properties at elevated temperatures as well as corrosion and oxidation resistance. Summary of the invention

[0006] In one aspect, a composition is provided, comprising about 16 wt % to about 21 wt % chromium, about 3.5 wt % to about 6.0 wt % aluminum, about 0.5 wt % to about 1.95 wt % iron, about 9 wt % to about 12 wt % cobalt, about 0.5 wt % to about 1.5 wt % molybdenum, about 0.03 wt % to about 0.18 wt % carbon, about 0.5 wt % to about 1.5 wt % titanium, about 0.5 wt % to about 2.5 wt % tungsten, about 1.0 wt % to about 3.5 wt % niobium, less than about 0.25 wt % hafnium, and the balance nickel and incidental impurities.

[0007] On the other hand, a method for using a composition is provided. The composition comprises about 16 wt % to about 21 wt % chromium, about 3.5 wt % to about 6.0 wt % aluminum, about 0.5 wt % to about 1.95 wt % iron, about 9 wt % to about 12 wt % cobalt, about 0.5 wt % to about 1.5 wt % molybdenum, about 0.03 wt % to about 0.18 wt % carbon, about 0.5 wt % to about 1.5 wt % titanium, about 0.5 wt % to about 2.5 wt % tungsten, about 1.0 wt % to about 3.5 wt % niobium, less than about 0.25 wt % hafnium, and the remainder of nickel and incidental impurities. The method includes using the composition for a purpose selected from welding, additive manufacturing, metal casting, coating, repairing, powder metallurgy, and combinations thereof.

[0008] In yet another aspect, an article is provided comprising a composition comprising about 16 wt % to about 21 wt % chromium, about 3.5 wt % to about 6.0 wt % aluminum, about 0.5 wt % to about 1.95 wt % iron, about 9 wt % to about 12 wt % cobalt, about 0.5 wt % to about 1.5 wt % molybdenum, about 0.03 wt % to about 0.18 wt % carbon, about 0.5 wt % to about 1.5 wt % titanium, about 0.5 wt % to about 2.5 wt % tungsten, about 1.0 wt % to about 3.5 wt % niobium, less than about 0.25 wt % hafnium, and the balance nickel and incidental impurities. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features, aspects and advantages of the present disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, in which like characters refer to like parts throughout the several views, and in which:

[0010] Figure 1 is an exemplary phase diagram of a composition according to the present disclosure.

[0011] Figure 2 Depicted are exemplary results of metallurgical evaluations of compositions according to the present disclosure.

[0012] Figure 3 Depicted are exemplary results of welding tests utilizing compositions according to the present disclosure. DETAILED DESCRIPTION

[0013] It is surprisingly found in the present disclosure that the composition according to the present disclosure can be used for welding. The composition comprises modified Al, Fe and Nb element contents compared to other alloy compositions. Due to the higher aluminum content, good mechanical properties, high γ' volume fraction and high γ' solvus temperature, the composition exhibits excellent weldability characteristics, excellent castability characteristics, excellent oxidation resistance. The composition according to the present disclosure is widely suitable for use in applications requiring superalloys, including but not limited to welding, additive manufacturing, metal casting, coating, repair, powder metallurgy and combinations thereof.

[0014] Embodiments described herein overcome at least some of the shortcomings of known nickel-based superalloys. Exemplary embodiments described herein include a composition. The composition comprises about 16 wt % to about 21 wt % chromium, about 3.5 wt % to about 6.0 wt % aluminum, about 0.5 wt % to about 1.95 wt % iron, about 9 wt % to about 12 wt % cobalt, about 0.5 wt % to about 1.5 wt % molybdenum, about 0.03 wt % to about 0.18 wt % carbon, about 0.5 wt % to about 1.5 wt % titanium, about 0.5 wt % to about 2.5 wt % tungsten, about 1.0 wt % to about 3.5 wt % niobium, less than about 0.25 wt % hafnium, and the balance of nickel and incidental impurities.

[0015] In some embodiments, the composition may include any suitable amount of chromium (Cr) that is beneficial to the compositions described herein. In some embodiments, the composition includes Cr. In some embodiments, the composition includes about 16 wt % to about 21 wt % chromium.

[0016] In some embodiments, the composition comprises at least about 16.0 wt % Cr, at least about 16.1 wt % Cr, at least about 16.2 wt % Cr, at least about 16.3 wt % Cr, at least about 16.4 wt % Cr, at least about 16.5 wt % Cr, at least about 16.6 wt % Cr, at least about 16.7 wt % Cr, at least about 16.8 wt % Cr, at least about 16.9 wt % Cr, at least about 17.0 wt % Cr, at least about 17. 1 wt % Cr, at least about 17.2 wt % Cr, at least about 17.3 wt % Cr, at least about 17.4 wt % Cr, at least about 17.5 wt % Cr, at least about 17.6 wt % Cr, at least about 17.7 wt % Cr, at least about 17.8 wt % Cr, at least about 17.9 wt % Cr, at least about 18.0 wt % Cr, at least about 18.1 wt % Cr, at least about 18.2 wt % Cr, at least about 18.3 wt % Cr , at least about 18.4 wt % Cr, at least about 18.5 wt % Cr, at least about 18.6 wt % Cr, at least about 18.7 wt % Cr, at least about 18.8 wt % Cr, at least about 18.9 wt % Cr, at least about 19.0 wt % Cr, at least about 19.1 wt % Cr, at least about 19.2 wt % Cr, at least about 19.3 wt % Cr, at least about 19.4 wt % Cr, at least about 19.5 wt % Cr, at least about 19.6 wt % Cr, at least about 19.7 wt % Cr, at least about 19.8 wt % Cr, at least about 19.9 ... 6 wt % Cr, at least about 19.7 wt % Cr, at least about 19.8 wt % Cr, or at least about 19.9 wt % Cr, at least about 20.1 wt % Cr, at least about 20.2 wt % Cr, at least about 20.3 wt % Cr, at least about 20.4 wt % Cr, at least about 20.5 wt % Cr, at least about 20.6 wt % Cr, at least about 20.7 wt % Cr, at least about 20.8 wt % Cr, or at least about 20.9 wt % Cr.In some embodiments, the composition comprises up to about 16.1 wt % Cr, up to about 16.2 wt % Cr, up to about 16.3 wt % Cr, up to about 16.4 wt % Cr, up to about 16.5 wt % Cr, up to about 16.6 wt % Cr, up to about 16.7 wt % Cr, up to about 16.8 wt % Cr, up to about 16.9 wt % Cr, up to about 17.0 wt % Cr, up to about 17.1 wt % Cr, up to about 17.2 wt % Cr. % Cr, up to about 17.3 wt % Cr, up to about 17.4 wt % Cr, up to about 17.5 wt % Cr, up to about 17.6 wt % Cr, up to about 17.7 wt % Cr, up to about 17.8 wt % Cr, up to about 17.9 wt % Cr, up to about 18.0 wt % Cr, up to about 18.1 wt % Cr, up to about 18.2 wt % Cr, up to about 18.3 wt % Cr, up to about 18.4 wt % Cr, up to about 18. 5 wt % Cr, up to about 18.6 wt % Cr, up to about 18.7 wt % Cr, up to about 18.8 wt % Cr, up to about 18.9 wt % Cr, up to about 19.0 wt % Cr, up to about 19.1 wt % Cr, up to about 19.2 wt % Cr, up to about 19.3 wt % Cr, up to about 19.4 wt % Cr, up to about 19.5 wt % Cr, up to about 19.6 wt % Cr, up to about 19.7 wt % Cr, up to about % Cr, up to about 19.8 wt % Cr, up to about 19.9 wt % Cr, up to about 20.0 wt % Cr, up to about 20.1 wt % Cr, up to about 20.2 wt % Cr, up to about 20.3 wt % Cr, up to about 20.4 wt % Cr, up to about 20.5 wt % Cr, up to about 20.6 wt % Cr, up to about 20.7 wt % Cr, up to about 20.8 wt % Cr, up to about 20.9 wt % Cr, or up to about 21.0 wt % Cr.

[0017] In some embodiments, the composition may include any suitable amount of aluminum (Al) that is beneficial to the compositions described herein. In some embodiments, the composition includes about 3.5 wt % to about 6.0 wt % aluminum. In some embodiments, the composition includes about 4.0 wt % to about 5.0 wt % aluminum.

[0018] In some embodiments, the composition comprises at least about 3.5 wt % Al, at least about 3.6 wt % Al, at least about 3.7 wt % Al, at least about 3.8 wt % Al, at least about 3.9 wt % Al, at least about 4.0 wt % Al, at least about 4.1 wt % Al, at least about 4.2 wt % Al, at least about 4.3 wt % Al, at least about 4.4 wt % Al, at least about 4.5 wt % Al, at least about 4.6 wt % Al, , at least about 4.7 wt % Al, at least about 4.8 wt % Al, at least about 4.9 wt % Al, at least about 5.0 wt % Al, at least about 5.1 wt % Al, at least about 5.2 wt % Al, at least about 5.3 wt % Al, at least about 5.4 wt % Al, at least about 5.5 wt % Al, at least about 5.6 wt % Al, at least about 5.7 wt % Al, at least about 5.8 wt % Al, or at least about 5.9 wt % Al. In some embodiments, the composition comprises up to about 3.6 wt % Al, up to about 3.7 wt % Al, up to about 3.8 wt % Al, up to about 3.9 wt % Al, up to about 4.0 wt % Al, up to about 4.1 wt % Al, up to about 4.2 wt % Al, up to about 4.3 wt % Al, up to about 4.4 wt % Al, up to about 4.5 wt % Al, up to about 4.6 wt % Al, up to about 4.7 wt % Al, or up to about 4.8 wt % Al. , up to about 4.8 wt % Al, up to about 4.9 wt % Al, up to about 5.0 wt % Al, up to about 5.1 wt % Al, up to about 5.2 wt % Al, up to about 5.3 wt % Al, up to about 5.4 wt % Al, up to about 5.5 wt % Al, up to about 5.6 wt % Al, up to about 5.7 wt % Al, up to about 5.8 wt % Al, up to about 5.9 wt % Al, or up to about 6.0 wt % Al.

[0019] In some embodiments, the composition can include any suitable amount of iron (Fe) that facilitates the compositions described herein. In some embodiments, the composition includes from about 0.5 wt % to about 1.95 wt % iron.

[0020] In some embodiments, the composition comprises at least about 0.50 wt % Fe, at least about 0.55 wt % Fe, at least about 0.60 wt % Fe, at least about 0.65 wt % Fe, at least about 0.70 wt % Fe, at least about 0.75 wt % Fe, at least about 0.80 wt % Fe, at least about 0.85 wt % Fe, at least about 0.90 wt % Fe, at least about 0.95 wt % Fe, at least about 1.0 wt % Fe, at least about 1.05 wt % Fe, at least about 1.1 wt % Fe, at least about 1.15 wt % Fe. % Fe, at least about 1.2 wt % Fe, at least about 1.25 wt % Fe, at least about 1.3 wt % Fe, at least about 1.35 wt % Fe, at least about 1.4 wt % Fe, at least about 1.45 wt % Fe, at least about 1.5 wt % Fe, at least about 1.55 wt % Fe, at least about 1.6 wt % Fe, at least about 1.65 wt % Fe, at least about 1.7 wt % Fe, at least about 1.75 wt % Fe, at least about 1.8 wt % Fe, at least about 1.85 wt % Fe, or at least about 1.9 wt % Fe. In some embodiments, the composition comprises up to about 0.55 wt % Fe, up to about 0.60 wt % Fe, up to about 0.65 wt % Fe, up to about 0.70 wt % Fe, up to about 0.75 wt % Fe, up to about 0.80 wt % Fe, up to about 0.85 wt % Fe, up to about 0.90 wt % Fe, up to about 0.95 wt % Fe, up to about 1.0 wt % Fe, up to about 1.05 wt % Fe, up to about 1.1 wt % Fe, up to about 1.15 wt % Fe, up to about 1.2 wt % Fe. % Fe, up to about 1.25 wt % Fe, up to about 1.3 wt % Fe, up to about 1.35 wt % Fe, up to about 1.4 wt % Fe, up to about 1.45 wt % Fe, up to about 1.5 wt % Fe, up to about 1.55 wt % Fe, up to about 1.6 wt % Fe, up to about 1.65 wt % Fe, up to about 1.7 wt % Fe, up to about 1.75 wt % Fe, up to about 1.8 wt % Fe, up to about 1.85 wt % Fe, up to about 1.9 wt % Fe, or up to about 1.95 wt % Fe.

[0021] In some embodiments, the composition can include cobalt (Co) in any suitable amount that facilitates the compositions described herein. In some embodiments, the composition includes from about 9 wt % to about 12 wt % cobalt.

[0022] In some embodiments, the composition comprises at least about 9.0 wt % Co, at least about 9.1 wt % Co, at least about 9.2 wt % Co, at least about 9.3 wt % Co, at least about 9.4 wt % Co, at least about 9.5 wt % Co, at least about 9.6 wt % Co, at least about 9.7 wt % Co, at least about 9.8 wt % Co, at least about 9.9 wt % Co, at least about 10.0 wt % Co, at least about 10.1 wt % Co, at least about 10.2 wt % Co, at least about 10.3 wt % Co, at least about 10.4 wt % Co. % Co, at least about 10.5 wt % Co, at least about 10.6 wt % Co, at least about 10.7 wt % Co, at least about 10.8 wt % Co, at least about 10.9 wt % Co, at least about 11.0 wt % Co, at least about 11.1 wt % Co, at least about 11.2 wt % Co, at least about 11.3 wt % Co, at least about 11.4 wt % Co, at least about 11.5 wt % Co, at least about 11.6 wt % Co, at least about 11.7 wt % Co, at least about 11.8 wt % Co, or at least about 11.9 wt % Co. In some embodiments, the composition comprises up to about 9.1 wt % Co, up to about 9.2 wt % Co, up to about 9.3 wt % Co, up to about 9.4 wt % Co, up to about 9.5 wt % Co, up to about 9.6 wt % Co, up to about 9.7 wt % Co, up to about 9.8 wt % Co, up to about 9.9 wt % Co, up to about 10.0 wt % Co, up to about 10.1 wt % Co, up to about 10.2 wt % Co, up to about 10.3 wt % Co, up to about 10.4 wt % Co, up to about 10.5 wt % Co. % Co, up to about 10.6 wt % Co, up to about 10.7 wt % Co, up to about 10.8 wt % Co, up to about 10.9 wt % Co, up to about 11.0 wt % Co, up to about 11.1 wt % Co, up to about 11.2 wt % Co, up to about 11.3 wt % Co, up to about 11.4 wt % Co, up to about 11.5 wt % Co, up to about 11.6 wt % Co, up to about 11.7 wt % Co, up to about 11.8 wt % Co, up to about 11.9 wt % Co, or up to about 12.0 wt % Co.

[0023] In some embodiments, the composition may include any suitable amount of molybdenum (Mo) that facilitates the compositions described herein. In some embodiments, the composition includes about 0.5 wt % to about 1.5 wt % molybdenum.

[0024] In some embodiments, the composition comprises at least about 0.50 wt % Mo, at least about 0.55 wt % Mo, at least about 0.60 wt % Mo, at least about 0.65 wt % Mo, at least about 0.70 wt % Mo, at least about 0.75 wt % Mo, at least about 0.80 wt % Mo, at least about 0.85 wt % Mo, at least about 0.90 wt % Mo, at least about 0.95 wt % Mo, at least about 1.0 wt % Mo, at least about 1.05 wt % Mo, at least about 1.1 wt % Mo, at least about 1.15 wt % Mo, at least about 1.2 wt % Mo, at least about 1.25 wt % Mo, at least about 1.3 wt % Mo, at least about 1.35 wt % Mo, at least about 1.4 wt % Mo, or at least about 1.45 wt % Mo. In some embodiments, the composition comprises up to about 0.55 wt % Mo, up to about 0.60 wt % Mo, up to about 0.65 wt % Mo, up to about 0.70 wt % Mo, up to about 0.75 wt % Mo, up to about 0.80 wt % Mo, up to about 0.85 wt % Mo, up to about 0.90 wt % Mo, up to about 0.95 wt % Mo, up to about 1.0 wt % Mo, up to about 1.05 wt % Mo, up to about 1.1 wt % Mo, up to about 1.15 wt % Mo, up to about 1.2 wt % Mo, up to about 1.25 wt % Mo, up to about 1.3 wt % Mo, up to about 1.35 wt % Mo, up to about 1.4 wt % Mo, up to about 1.45 wt % Mo, or up to about 1.5 wt % Mo.

[0025] In some embodiments, the composition can include any suitable amount of carbon (C) that facilitates the compositions described herein. In some embodiments, the composition includes about 0.03 wt % to about 0.18 wt % carbon.

[0026] In some embodiments, the composition comprises at least about 0.03 wt % C, at least about 0.04 wt % C, at least about 0.05 wt % C, at least about 0.06 wt % C, at least about 0.07 wt % C, at least about 0.08 wt % C, at least about 0.09 wt % C, at least about 0.10 wt % C, at least about 0.11 wt % C, at least about 0.12 wt % C, at least about 0.13 wt % C, at least about 0.14 wt % C, at least about 0.15 wt % C, at least about 0.16 wt % C, or at least about 0.17 wt % C. In some embodiments, the composition comprises at most about 0.04 wt. % C, at most about 0.05 wt. % C, at most about 0.06 wt. % C, at most about 0.07 wt. % C, at most about 0.08 wt. % C, at most about 0.09 wt. % C, at most about 0.10 wt. % C, at most about 0.11 wt. % C, at most about 0.12 wt. % C, at most about 0.13 wt. % C, at most about 0.14 wt. % C, at most about 0.15 wt. % C, at most about 0.16 wt. % C, at most about 0.17 wt. % C, or at most about 0.18 wt. % C.

[0027] In some embodiments, the composition can include any suitable amount of titanium (Ti) that facilitates the compositions described herein. In some embodiments, the composition includes about 0.50 wt % to about 1.5 wt % Ti.

[0028] In some embodiments, the composition comprises at least about 0.50 wt % Ti, at least about 0.55 wt % Ti, at least about 0.60 wt % Ti, at least about 0.65 wt % Ti, at least about 0.70 wt % Ti, at least about 0.75 wt % Ti, at least about 0.80 wt % Ti, at least about 0.85 wt % Ti, at least about 0.90 wt % Ti, at least about 0.95 wt % Ti, at least about 1.0 wt % Ti, at least about 1.05 wt % Ti, at least about 1.1 wt % Ti, at least about 1.15 wt % Ti, at least about 1.2 wt % Ti, at least about 1.25 wt % Ti, at least about 1.3 wt % Ti, at least about 1.35 wt % Ti, at least about 1.4 wt % Ti, or at least about 1.45 wt % Ti. In some embodiments, the composition comprises up to about 0.55 wt % Ti, up to about 0.60 wt % Ti, up to about 0.65 wt % Ti, up to about 0.70 wt % Ti, up to about 0.75 wt % Ti, up to about 0.80 wt % Ti, up to about 0.85 wt % Ti, up to about 0.90 wt % Ti, up to about 0.95 wt % Ti, up to about 1.0 wt % Ti, up to about 1.05 wt % Ti, up to about 1.1 wt % Ti, up to about 1.15 wt % Ti, up to about 1.2 wt % Ti, up to about 1.25 wt % Ti, up to about 1.3 wt % Ti, up to about 1.35 wt % Ti, up to about 1.4 wt % Ti, up to about 1.45 wt % Ti, or up to about 1.5 wt % Ti.

[0029] In some embodiments, the composition can include any suitable amount of tungsten (W) that facilitates the compositions described herein. In some embodiments, the composition includes about 0.50 wt % to about 2.5 wt % W.

[0030] In some embodiments, the composition comprises at least about 0.50 wt % W, at least about 0.55 wt % W, at least about 0.60 wt % W, at least about 0.65 wt % W, at least about 0.70 wt % W, at least about 0.75 wt % W, at least about 0.80 wt % W, at least about 0.85 wt % W, at least about 0.90 wt % W, at least about 0.95 wt % W, at least about 1.0 wt % W, at least about 1.05 wt % W, at least about 1.1 wt % W, at least about 1.15 wt % W, at least about 1.2 wt % W, at least about 1.25 wt % W, at least about 1.3 wt % W, at least about 1.35 wt % W, at least about 1.4 wt % W, at least about 1.4 % W, at least about 2.5 wt % W, at least about 1.50 wt % W, at least about 1.55 wt % W, at least about 1.60 wt % W, at least about 1.65 wt % W, at least about 1.70 wt % W, at least about 1.75 wt % W, at least about 1.80 wt % W, at least about 1.85 wt % W, at least about 1.90 wt % W, at least about 1.95 wt % W, at least about 2.0 wt % W, at least about 2.05 wt % W, at least about 2.10 wt % W, at least about 2.15 wt % W, at least about 2.2 wt % W, at least about 2.25 wt % W, at least about 2.3 wt % W, at least about 2.35 wt % W, at least about 2.4 wt % W, or at least about 2.45 wt % W.In some embodiments, the composition comprises at most about 0.55 wt % W, at most about 0.60 wt % W, at most about 0.65 wt % W, at most about 0.70 wt % W, at most about 0.75 wt % W, at most about 0.80 wt % W, at most about 0.85 wt % W, at most about 0.90 wt % W, at most about 0.95 wt % W, at most about 1.0 wt % W, at most about 1.05 wt % W, at most about 1.1 wt % W, at most about 1.15 wt % W, at most about 1.2 wt % W, at most about 1.25 wt % W, at most about 1.3 wt % W, at most about 1.35 wt % W, at most about 1.4 wt % W, at most about 1.45 wt % W, at most about 1.5 wt % W, at most about 1.6 wt % W, at most about 1.75 wt % W, at most about 1.8 wt % W, at most about 1.9 wt % W, at most about 2.4 wt % W, at most about 2.5 wt % W, at most about 2.6 wt % W, at most about 2.7 wt % W, at most about 2.8 % W, up to about 2.5 wt % W, up to about 2.6 wt % W, up to about 2.8 wt % W, up to about 2.9 wt % W, up to about 3.5 wt % W, up to about 3.0 wt % W, up to about 4.5 wt % W, up to about 5.0 wt % W, up to about 1.2 wt % W, up to about 1.4 wt % W, up to about 1.6 wt % W, up to about 1.7 wt % W, up to about 1.75 wt % W, up to about 1.80 wt % W, up to about 1.85 wt % W, up to about 1.90 wt % W, up to about 1.95 wt % W, up to about 2.0 wt % W, up to about 2.05 wt % W, up to about 2.10 wt % W, up to about 2.15 wt % W, up to about 2.2 wt % W, up to about 2.25 wt % W, up to about 2.3 wt % W, up to about 2.35 wt % W, up to about 2.4 wt % W, up to about 2.45 wt % W, or up to about 2.5 wt % W.

[0031] In some embodiments, the composition can include niobium (Nb) in any suitable amount that facilitates the compositions described herein. In some embodiments, the composition includes about 1.0 wt. % to about 3.5 wt. % Nb.

[0032] In some embodiments, the composition comprises at least about 1.0 wt % Nb, at least about 1.05 wt % Nb, at least about 1.1 wt % Nb, at least about 1.15 wt % Nb, at least about 1.2 wt % Nb, at least about 1.25 wt % Nb, at least about 1.3 wt % Nb, at least about 1.35 wt % Nb, at least about 1.4 wt % Nb, at least about 1.45 wt % Nb, at least about 1.50 wt % Nb, at least about 1.55 wt % Nb, % Nb, at least about 1.60 wt % Nb, at least about 1.65 wt % Nb, at least about 1.70 wt % Nb, at least about 1.75 wt % Nb, at least about 1.80 wt % Nb, at least about 1.85 wt % Nb, at least about 1.90 wt % Nb, at least about 1.95 wt % Nb, at least about 2.0 wt % Nb, at least about 2.05 wt % Nb, at least about 2.10 wt % Nb, at least about 2.15 wt % Nb, at least about 2.2 % Nb, at least about 2.25 wt % Nb, at least about 2.3 wt % Nb, at least about 2.35 wt % Nb, at least about 2.4 wt % Nb, at least about 2.45 wt % Nb, at least about 2.50 wt % Nb, at least about 2.55 wt % Nb, at least about 2.60 wt % Nb, at least about 2.65 wt % Nb, at least about 2.70 wt % Nb, at least about 2.75 wt % Nb, at least about 2.80 wt % Nb, at least % Nb, at least about 3.4 wt % Nb, or at least about 3.45 wt % Nb.In some embodiments, the composition comprises up to about 1.05 wt % Nb, up to about 1.1 wt % Nb, up to about 1.15 wt % Nb, up to about 1.2 wt % Nb, up to about 1.25 wt % Nb, up to about 1.3 wt % Nb, up to about 1.35 wt % Nb, up to about 1.4 wt % Nb, up to about 1.45 wt % Nb, up to about 1.50 wt % Nb, up to about 1.55 wt % Nb, up to about 1.60 wt % Nb. % Nb, up to about 1.65 wt % Nb, up to about 1.70 wt % Nb, up to about 1.75 wt % Nb, up to about 1.80 wt % Nb, up to about 1.85 wt % Nb, up to about 1.90 wt % Nb, up to about 1.95 wt % Nb, up to about 2.0 wt % Nb, up to about 2.05 wt % Nb, up to about 2.10 wt % Nb, up to about 2.15 wt % Nb, up to about 2.2 wt % Nb, up to about 2.2 % Nb, up to about 2.5 wt % Nb, up to about 2.3 wt % Nb, up to about 2.35 wt % Nb, up to about 2.4 wt % Nb, up to about 2.45 wt % Nb, up to about 2.50 wt % Nb, up to about 2.55 wt % Nb, up to about 2.60 wt % Nb, up to about 2.65 wt % Nb, up to about 2.70 wt % Nb, up to about 2.75 wt % Nb, up to about 2.80 wt % Nb, up to about 2.85 wt % Nb, up to about 2.90 wt % Nb, up to about 3.15 wt % Nb, up to about 3.20 wt % Nb, up to about 3.30 wt % Nb, up to about 3.45 wt % Nb, up to about 3.50 wt % Nb, up to about 3.65 wt % Nb, up to about 3.70 wt % Nb, up to about 3.85 wt % Nb, up to about 3.90 wt % Nb % Nb, up to about 3.45 wt % Nb, or up to about 3.5 wt % Nb.

[0033] In some embodiments, the composition may include any suitable amount of hafnium (Hf) that facilitates the compositions described herein. In some embodiments, the composition does not include Hf. In some embodiments, the composition includes less than about 0.25 wt % Hf.

[0034] In some embodiments, the composition comprises at least about 0.01 wt % Hf, at least about 0.05 wt % Hf, at least about 0.10 wt % Hf, at least about 0.15 wt % Hf, or at least about 0.20 wt % Hf. In some embodiments, the composition comprises at most about 0.05 wt % Hf, at most about 0.10 wt % Hf, at most about 0.15 wt % Hf, at most about 0.20 wt % Hf, or at most about 0.24 wt % Hf.

[0035] In some embodiments, the composition may include any suitable amount of nickel (Ni) that is beneficial to the composition described herein. In many embodiments, the composition includes a balance of nickel. In these embodiments, the amount of nickel is sufficient to make the total weight percentage of the composition reach 100 weight %.

[0036] In some embodiments, the composition comprises at least about 49 wt % Ni, at least about 50 wt % Ni, at least about 51 wt % Ni, at least about 52 wt % Ni, at least about 53 wt % Ni, at least about 54 wt % Ni, at least about 55 wt % Ni, at least about 56 wt % Ni, at least about 57 wt % Ni, at least about 58 wt % Ni, at least about 59 wt % Ni, at least about 60 wt % Ni, at least about 61 wt % Ni, at least about 62 wt % Ni, at least about 63 wt % Ni, at least about 64 wt % Ni, at least about 65 wt % Ni, at least about 66 wt % Ni, at least about 67 wt % Ni, at least about 68 wt % Ni, or at least about 69 wt % Ni. In some embodiments, the composition comprises up to about 50 wt % Ni, up to about 51 wt % Ni, up to about 52 wt % Ni, up to about 53 wt % Ni, up to about 54 wt % Ni, up to about 55 wt % Ni, up to about 56 wt % Ni, up to about 57 wt % Ni, up to about 58 wt % Ni, up to about 59 wt % Ni, up to about 60 wt % Ni, up to about 61 wt % Ni, up to about 62 wt % Ni, up to about 63 wt % Ni, up to about 64 wt % Ni, up to about 65 wt % Ni, up to about 67 wt % Ni, up to about 68 wt % Ni, or up to about 69 wt % Ni.

[0037] Generally speaking, the composition may include impurities that do not substantially change the material properties of the composition. In some embodiments, the composition further includes elemental impurities. In some embodiments, the composition further includes incidental impurities.

[0038] In some embodiments, the composition comprises a balance of nickel and incidental impurities. In these embodiments, the amount of nickel and incidental impurities is sufficient to bring the total weight percentage of the composition to 100 weight percent.

[0039] In some embodiments, the composition is an alloy composition. In some embodiments, the composition is a superalloy composition.

[0040] In some embodiments, the composition may have a γ' solvus temperature that facilitates the use of the compositions described herein. In some embodiments, the composition has a γ' solvus temperature of about 1700°F to about 2100°F. In some embodiments, the composition has a γ' solvus temperature of about 1900°F to about 2050°F.

[0041] In some embodiments, the composition has a gamma 'solvus temperature of at least about 1700°F, at least about 1750°F, at least about 1800°F, at least about 1850°F, at least about 1900°F, at least about 1950°F, at least about 2000°F, or at least about 2050°F. In some embodiments, the composition has a gamma 'solvus temperature of at most about 1750°F, at most about 1800°F, at most about 1850°F, at most about 1900°F, at most about 1950°F, at most about 2000°F, at most about 2050°F, or at most about 2100°F.

[0042] In some embodiments, the composition may have a γ' solvus temperature that is beneficial for the use of the composition described herein. In some embodiments, the composition has a γ' volume fraction of about 40% to about 75%. In some embodiments, the composition has a γ' volume fraction of about 45% to about 70%.

[0043] In some embodiments, the composition has a γ' volume fraction of at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, or at least about 70%. In some embodiments, the composition has a γ' volume fraction of at most about 45%, at most about 50%, at most about 55%, at most about 60%, at most about 65%, at most about 70%, or at most about 75%.

[0044] In general, the composition can be used for any suitable purpose known in the art that is conducive to the use of the composition described herein. In some embodiments, the composition is a welding composition, an additive manufacturing composition, a metal casting composition, a coating composition, and / or a repair composition. In some embodiments, the composition is used in a welding composition, an additive manufacturing composition, a metal casting composition, a coating composition, a powder metallurgy composition, and / or a repair composition.

[0045] Also described herein is a method of using the composition, wherein the method includes using the composition for any of, but not limited to, welding, additive manufacturing, metal casting, coating, repairing, powder metallurgy, and combinations thereof.

[0046] Also described herein is an article comprising the composition. Generally, the composition may be included in any suitable article known in the art that facilitates the use of the composition described herein. In some embodiments, the article is produced using, but not limited to, welding processes, additive manufacturing processes, metal casting processes, coating processes, repair processes, powder metallurgy, and combinations thereof.

[0047] In some embodiments, the article is a blade for a gas turbine or a grooved blade tip of a blade of a gas turbine. In some embodiments, the article is a component of a gas turbine, such as but not limited to only a nozzle, a shroud, a diaphragm, a combustion chamber component, and / or a combination thereof.

[0048] Other aspects of the disclosure are provided by the subject matter of the following clauses:

[0049] 1. A composition comprising:

[0050] from about 16 wt % to about 21 wt % chromium;

[0051] about 3.5 wt % to about 6.0 wt % aluminum;

[0052] from about 0.5 wt % to about 1.95 wt % iron;

[0053] from about 9 wt % to about 12 wt % cobalt;

[0054] from about 0.5 wt % to about 1.5 wt % molybdenum;

[0055] from about 0.03 wt % to about 0.18 wt % carbon;

[0056] from about 0.5 wt % to about 1.5 wt % titanium;

[0057] about 0.5 wt % to about 2.5 wt % tungsten;

[0058] from about 1.0 wt. % to about 3.5 wt. % niobium;

[0059] Less than about 0.25 wt. % hafnium; and

[0060] The balance is nickel and incidental impurities.

[0061] 2. A composition according to the preceding clause, wherein the composition comprises from about 4.0% by weight to about

[0062] 5.0 wt% aluminum.

[0063] 3. A composition according to any preceding clause, wherein the composition comprises from about 1.0 wt % to about 1.75 wt % iron.

[0064] 4. The composition of any preceding clause, wherein the composition comprises from about 1.5 wt. % to about 2.5 wt. % niobium.

[0065] 5. A composition according to any preceding clause, wherein the composition comprises from about 4.0 wt % to about 5.0 wt % aluminum, from about 1.0 wt % to about 1.75 wt % iron, and from about

[0066] 1.5 wt. % to about 2.5 wt. % niobium.

[0067] 6. A composition according to any preceding clause, comprising:

[0068] from about 17 wt % to about 19 wt % chromium;

[0069] from about 4.0 wt % to about 5.0 wt % aluminum;

[0070] from about 1.0 wt. % to about 1.75 wt. % iron;

[0071] from about 10 wt % to about 11 wt % cobalt;

[0072] from about 0.5 wt % to about 1.0 wt % molybdenum;

[0073] from about 0.05 wt % to about 0.10 wt % carbon;

[0074] from about 0.5 wt % to about 1.0 wt % titanium;

[0075] about 1.0 wt. % to about 2.0 wt. % tungsten;

[0076] from about 1.5 wt. % to about 2.5 wt. % niobium;

[0077] Less than about 0.25 wt. % hafnium; and

[0078] The balance is nickel and incidental impurities.

[0079] 7. A composition according to any preceding clause, consisting of:

[0080] from about 17 wt % to about 19 wt % chromium;

[0081] from about 4.0 wt % to about 5.0 wt % aluminum;

[0082] from about 1.0 wt. % to about 1.75 wt. % iron;

[0083] from about 10 wt % to about 11 wt % cobalt;

[0084] from about 0.5 wt % to about 1.0 wt % molybdenum;

[0085] from about 0.05 wt % to about 0.10 wt % carbon;

[0086] from about 0.5 wt % to about 1.0 wt % titanium;

[0087] about 1.0 wt. % to about 2.0 wt. % tungsten;

[0088] from about 1.5 wt. % to about 2.5 wt. % niobium;

[0089] Less than about 0.25 wt. % hafnium; and

[0090] The balance is nickel and incidental impurities.

[0091] 8. The composition of any preceding clause, wherein the composition has a gamma prime solvus temperature of about 1700°F to about 2100°F.

[0092] 9. A composition according to any preceding clause, wherein the composition has a

[0093] To a γ' solvus temperature of about 2050°F.

[0094] 10. The composition of any preceding clause, wherein the composition has a γ' volume fraction of about 40% to about 75%.

[0095] 11. A composition according to any preceding clause, wherein the composition has from about 45% to about

[0096] 70% γ' volume fraction.

[0097] 12. The composition according to any preceding clause, wherein the composition is at least one of a welding composition, an additive manufacturing composition, a metal casting composition, a coating composition, and a repair composition.

[0098] 13. A method of using a composition comprising:

[0099] from about 16 wt % to about 21 wt % chromium;

[0100] about 3.5 wt % to about 6.0 wt % aluminum;

[0101] from about 0.5 wt % to about 1.95 wt % iron;

[0102] from about 9 wt % to about 12 wt % cobalt;

[0103] from about 0.5 wt % to about 1.5 wt % molybdenum;

[0104] from about 0.03 wt % to about 0.18 wt % carbon;

[0105] from about 0.5 wt % to about 1.5 wt % titanium;

[0106] about 0.5 wt % to about 2.5 wt % tungsten;

[0107] from about 1.0 wt. % to about 3.5 wt. % niobium;

[0108] Less than about 0.25 wt. % hafnium; and

[0109] The balance of nickel and incidental impurities,

[0110] The method comprises using the composition for a purpose selected from the group consisting of welding, additive manufacturing, metal casting, coating, repairing, powder metallurgy, and combinations thereof.

[0111] 14. The method according to the preceding clause, wherein the composition comprises from about 4.0% by weight to about

[0112] 5.0 wt % aluminum, about 1.0 wt % to about 1.75 wt % iron, and about 1.5 wt %

[0113] to about 2.5 wt. % niobium.

[0114] 15. The method of any preceding clause, wherein the composition has a gamma prime solvus temperature of about 1700°F to about 2100°F.

[0115] 16. An article comprising a composition comprising:

[0116] from about 16 wt % to about 21 wt % chromium;

[0117] about 3.5 wt % to about 6.0 wt % aluminum;

[0118] from about 0.5 wt % to about 1.95 wt % iron;

[0119] from about 9 wt % to about 12 wt % cobalt;

[0120] from about 0.5 wt % to about 1.5 wt % molybdenum;

[0121] from about 0.03 wt % to about 0.18 wt % carbon;

[0122] from about 0.5 wt % to about 1.5 wt % titanium;

[0123] about 0.5 wt % to about 2.5 wt % tungsten;

[0124] from about 1.0 wt. % to about 3.5 wt. % niobium;

[0125] Less than about 0.25 wt. % hafnium; and

[0126] The balance is nickel and incidental impurities.

[0127] 17. An article according to the preceding clause, wherein the article is a blade of a gas turbine or a grooved blade tip of a blade of a gas turbine.

[0128] 18. The article according to any preceding clause, wherein the article is a component of a gas turbine selected from the group consisting of a nozzle, a shroud, a diaphragm, a combustion chamber component, and combinations thereof.

[0129] 19. An article according to any preceding clause, wherein the article is produced using a technique selected from the group consisting of welding, additive manufacturing, metal casting, coating, repairing, powder metallurgy, and combinations thereof.

[0130] 20. An article according to any preceding clause, wherein the composition comprises from about 4.0 wt% to about 5.0 wt% aluminum, from about 1.0 wt% to about 1.75 wt% iron, and from about 1.5 wt% to about 2.5 wt% niobium.

[0131] References to “one embodiment” in the above description are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0132] Example

[0133] Without further detailed description, it is believed that those skilled in the art can make the most of the present invention using the foregoing description. Therefore, the following examples are to be construed as illustrative only and not to limit the present disclosure in any way. The starting materials for the following examples may not necessarily be prepared by a specific preparation run, the procedures of which are described in other embodiments. It should also be understood that any numerical range described herein includes all values ​​from the lower limit to the upper limit. For example, if the range is stated as 10 to 50, it is intended to explicitly list values ​​such as 12 to 30, 20 to 40, or 30 to 50 in this specification. These are only examples of specific intent, and all possible combinations of numerical values ​​between and including the lowest and highest values ​​listed are considered to be explicitly stated in the present application.

[0134] Example 1. Simulation composition .

[0135] Simulated phase diagram of a composition according to the present disclosure. The elemental composition of inventive example El is shown in the table below.

[0136] Table 1. Simulation composition.

[0137] element IE1 (weight %) Cr 18.5 Co 10.5 Al 4.55 Ti 0.75 Fe 1.58 C 0.095 Mo 0.75 W 1.25 Hf 0.1 Nb 2.18 Ni margin total 100

[0138] Figure 1 A phase diagram 110 is shown in FIG. The phase diagram was simulated using Thermo-Calc software based on the chemical composition.

[0139] exist Figure 1 , region 112 is a combined phase of FCC A1 and liquid, region 114 is a phase of liquid, region 116 is a combined phase of FCCA1 and FCC A1#2, region 118 is a combined phase of FCC A1, FCC A1#2 and γ', region 120 is a combined phase of FCC A1, γ' and M23C6, region 122 is a combined phase of FCC A1, FCC A1#2, γ' and M7C3, region 124 is a combined phase of FCCA1, γ' and M7C3, and region 126 is a combined phase of FCC A1, γ', M23C6 and M7C3.

[0140] Example 2. Tested composition .

[0141] A composition according to Inventive Example El was prepared and its properties were measured. Inventive Example El was determined to have a γ' volume fraction of about 52% and a γ' solvus temperature of about 2011°F.

[0142] Example 3. Metallurgical Evaluation .

[0143] A composition according to Example E1 of the present invention was prepared and tested as a welding filler metal. A solder pad was produced using the composition. The solder pad included four layers and was 4.0" long and 1.5" wide. The solder pad passed visual and fluorescent penetrant inspection (FPI) in the as-welded and post-weld heat treated (PWHT) conditions.

[0144] Figure 2 The weld pad is depicted. Surprisingly, the compositions evaluated can produce uniform weld beads without cracks and / or microcracks.

[0145] Figure 3 Results of welding tests are depicted.Surprisingly, no cracks or fissures were observed in the weld material after heat shock PWHT at 2050°F and holding for 2 hours followed by rapid quenching, meaning that the composition exhibits excellent weldability.

[0146] It was surprisingly found in the present disclosure that the composition according to the present disclosure can be used for welding. Due to the higher Al content, good mechanical properties, high γ' volume fraction and high γ' solvus temperature, the composition exhibits excellent weldability, excellent castability, and excellent oxidation resistance. The composition according to the present disclosure is widely suitable for use in applications requiring superalloys, including welding, additive manufacturing, metal casting, coating, repair, powder metallurgy, and combinations thereof.

[0147] Unless otherwise indicated, approximate language as used herein, such as "substantially", "substantially" and "about" indicate that as those of ordinary skill in the art will recognize, the terms so modified may apply only to approximate degrees, rather than absolute or perfect degrees. Therefore, the values ​​modified by one or more terms (such as "about", "approximately" and "substantially") are not limited to the specified exact values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value. In addition, unless otherwise indicated, the terms "first", "second" etc. are only used as marks in this article, and are not intended to impose order, position or hierarchical requirements on the items to which these terms are related. In addition, for example, the reference to the "second" item does not require or exclude the existence of, for example, the "first" or lower numbered items or the "third" or higher numbered items.

[0148] Although specific features of various embodiments of the present invention may be shown in some drawings and not in other drawings, this is for convenience only. In addition, references to "some embodiments" in the above description are not intended to be interpreted as excluding the existence of additional embodiments that also include the described features. In accordance with the principles of the present invention, any feature of a drawing may be referenced and / or claimed in conjunction with any feature of any other drawing.

[0149] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any device or system and performing any combined method. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A composition comprising: from about 16 wt % to about 21 wt % chromium; about 3.5 wt % to about 6.0 wt % aluminum; from about 0.5 wt % to about 1.95 wt % iron; from about 9 wt % to about 12 wt % cobalt; from about 0.5 wt % to about 1.5 wt % molybdenum; from about 0.03 wt % to about 0.18 wt % carbon; from about 0.5 wt % to about 1.5 wt % titanium; about 0.5 wt % to about 2.5 wt % tungsten; from about 1.0 wt. % to about 3.5 wt. % niobium; Less than about 0.25 wt. % hafnium; and The balance is nickel and incidental impurities.

2. The composition of claim 1, wherein the composition comprises from about 4.0 wt. % to about 5.0 wt. % aluminum.

3. The composition of claim 1, wherein the composition comprises from about 1.0 wt% to about 1.75 wt% iron.

4. The composition of claim 1, wherein the composition comprises from about 1.5 wt% to about 2.5 wt% niobium.

5. The composition of claim 1, wherein the composition comprises from about 4.0 wt% to about 5.0 wt% aluminum, from about 1.0 wt% to about 1.75 wt% iron, and from about 1.5 wt% to about 2.5 wt% niobium.

6. The composition according to claim 1, comprising: from about 17 wt % to about 19 wt % chromium; from about 4.0 wt % to about 5.0 wt % aluminum; from about 1.0 wt. % to about 1.75 wt. % iron; from about 10 wt % to about 11 wt % cobalt; from about 0.5 wt % to about 1.0 wt % molybdenum; from about 0.05 wt % to about 0.10 wt % carbon; from about 0.5 wt % to about 1.0 wt % titanium; about 1.0 wt. % to about 2.0 wt. % tungsten; from about 1.5 wt. % to about 2.5 wt. % niobium; Less than about 0.25 wt. % hafnium; and The balance is nickel and incidental impurities.

7. The composition according to claim 1, consisting of: from about 17 wt % to about 19 wt % chromium; from about 4.0 wt % to about 5.0 wt % aluminum; from about 1.0 wt. % to about 1.75 wt. % iron; from about 10 wt % to about 11 wt % cobalt; from about 0.5 wt % to about 1.0 wt % molybdenum; from about 0.05 wt % to about 0.10 wt % carbon; from about 0.5 wt % to about 1.0 wt % titanium; about 1.0 wt. % to about 2.0 wt. % tungsten; from about 1.5 wt. % to about 2.5 wt. % niobium; Less than about 0.25 wt. % hafnium; and The balance is nickel and incidental impurities.

8. The composition of claim 1, wherein the composition has a gamma prime solvus temperature of about 1700°F to about 2100°F or about 1900°F to about 2050°F.

9. The composition of claim 1, wherein the composition has a γ' volume fraction of about 40% to about 75% or about 45% to about 70%.

10. The composition of claim 1, wherein the composition is at least one of a welding composition, an additive manufacturing composition, a metal casting composition, a coating composition, and a repair composition.

11. An article comprising a composition comprising: from about 16 wt % to about 21 wt % chromium; about 3.5 wt % to about 6.0 wt % aluminum; from about 0.5 wt % to about 1.95 wt % iron; from about 9 wt % to about 12 wt % cobalt; from about 0.5 wt % to about 1.5 wt % molybdenum; from about 0.03 wt % to about 0.18 wt % carbon; from about 0.5 wt % to about 1.5 wt % titanium; about 0.5 wt % to about 2.5 wt % tungsten; from about 1.0 wt. % to about 3.5 wt. % niobium; Less than about 0.25 wt. % hafnium; and The balance is nickel and incidental impurities.

12. The article of claim 11, wherein the article is a blade of a gas turbine or a grooved blade tip of a blade of a gas turbine.

13. The article of claim 11, wherein the article is a component of a gas turbine selected from the group consisting of a nozzle, a shroud, a diaphragm, a combustor component, and combinations thereof.

14. The article of claim 11, wherein the article is produced using a technique selected from the group consisting of welding, additive manufacturing, metal casting, coating, repairing, powder metallurgy, and combinations thereof.

15. The article of claim 11, wherein the composition comprises from about 4.0 wt% to about 5.0 wt% aluminum, from about 1.0 wt% to about 1.75 wt% iron, and from about 1.5 wt% to about 2.5 wt% niobium.

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