Oxidation-resistant nickel-based alloys and methods

Abstract

Oxidation-resistant nickel-based alloys and methods. The present invention provides, in weight %, , , , , , , , , , , , , 2.0% to 10.0% cobalt (Co), 3.0% to 10.0% iron (Fe), 14.0% to 18.0% chromium (Cr) 4.5% to 5.3% aluminum (Al), 3.0% to 7.0% tantalum (Ta), 0.01% to 0.05% carbon (C), 0.01% to 0.05% zirconium (Zr), 0.05% to 1.0% hafnium (Hf), 0.3% to 0.7% silicon (Si), a total of 0.01% to 0.3% of rare earth elements such as scandium (Sc), yttrium (Y), actinides and / or lanthanides, nickel, optionally, up to 3.0% tungsten (W), and / or [[ID=二十九]] up to 2.0% molybdenum (Mo), and / or up to 2.0% rhenium (Re), and / or up to 0.05% boron (B) relates to nickel-based superalloys containing the above.

Description

Technical Field

[0001] The present invention relates to nickel-based γ-prime strengthened superalloys. The present invention further relates to using this alloy to manufacture high-temperature components such as, but not limited to, blades, vanes, thermal barrier coatings, seal members, and combustor components in gas turbines. The present invention further relates to its use as a cladding (overlaying) and repair filler metal for components such as, but not limited to, blades, vanes, thermal barrier coatings, and combustor components in gas turbines. Furthermore, it is related to its use in a single crystal form. The present invention further relates to its use in cladding of the single crystal substrate such that the single crystal structure is maintained throughout the volume of the added or clad portion.

Background Art

[0002] Blade alloys are essential for important components in aircraft and land-based gas turbines, but are also used in other applications. The differences between blade alloys depend on the level of knowledge and manufacturing technology available at the time they were developed, and also on the relative importance of properties such as hot corrosion resistance, oxidation resistance, weldability, phase stability, and creep strength.

[0003] Blade alloys are used in single-crystal (SX), directional solidification (columnar, DS), or equiaxed (CC) forms. Each grain is primarily composed of a gamma phase matrix, which is essentially nickel (Ni) with solid solutions of elements such as cobalt (Co), iron (Fe), chromium (Cr), molybdenum (Mo), tungsten (W), and rhenium (Re). The gamma-prime phase particles are essentially Ni3Al with solid solutions of elements such as titanium, tantalum (Ta), and niobium (Nb). Each grain is a two-phase crystal where the gamma matrix and gamma-prime particles have the same crystal orientation, and the matrix-particle boundaries are aligned. Where grain boundaries exist, they are usually decorated with carbides and / or borides, which impart cohesive strength. Zirconium (Zr) also contributes to grain boundary cohesion.

[0004] Creep strength is imparted by elements such as molybdenum (Mo), tungsten (W), and rhenium (Re), which provide solid solution strengthening of the gamma matrix, and by elements such as titanium (Ti), tantalum (Ta), and niobium (Nb), which provide solid solution strengthening of gamma prime particles. Aluminum (Al) imparts creep strength by increasing the amount of gamma prime particles, and furthermore, the presence of gamma prime particles also imparts creep strength by concentrating the concentration levels of molybdenum (Mo), tungsten (W), and rhenium (Re) within the matrix.

[0005] Efficiently achieving internal cooling of the edges and tips of high-temperature stage gas turbine components is difficult. Therefore, a significant portion of the cooling air used in the gas turbine is spent as diluting air, mixed with the high-temperature gas flow near the tips and edges, locally lowering the temperature of the high-temperature gas flow and avoiding excessive oxidative damage. Consequently, any improvement in the heat resistance of metals leads to a reduction in the amount of diluting air used, resulting in improved gas turbine thermal efficiency and consequently, a reduction in CO2 emissions.

[0006] IN738LC is adopted as the standard for high-temperature corrosion resistance. It is commonly chosen as the blade alloy for gas turbines when high-temperature corrosion resistance is required.

[0007] CM247CC is manufactured using a low-sulfur treatment with a sulfur (S) content of less than 5 ppm. It forms a protective alumina and effectively suppresses sulfur-induced oxide peeling, making it a standard for high oxidation resistance. It is a commonly chosen blade alloy when high oxidation resistance is required.

[0008] Edge14 is manufactured using a low-sulfur treatment and is adopted as a benchmark for superior oxidation resistance due to its ability to form protective alumina and its ability to highly efficiently suppress oxide scale peeling through a sophisticated blend of reactive elements (rhenium (Re)) based on hafnium (Hf), silicon (Si), zirconium (Zr), and yttrium (Y). Furthermore, its extremely high aluminum (Al) activity means a large margin against loss of protective alumina reforming ability. This extremely high aluminum (Al) activity also enables rapid selective oxidation of Al2O3, resulting in a thin oxide scale with better resistance to peeling.

[0009] STAL18SiLaY is recognized as a benchmark for high crack-free cladding ability, with its single-crystal structure maintained within and in the single-crystal substrate. This is achieved through a moderate gamma prime content and a significant addition of silicon (Si) that provides good wettability between cladding layers.

[0010] STAL18SiLaY has been recognized as a useful standard for phase stability because, when used to repair oxidatively damaged single-crystal blades, no brittle phase formation was observed in actual use.

[0011] STAL18SiLaY is recognized as a useful standard for creep resistance based on its moderate reinforcing element content, 37 mol% gamma prime content, beneficial single-crystal structure obtained through cladding, and its proven track record in repairing oxidatively damaged single-crystal blades.

[0012] High-temperature corrosion resistance is provided by chromium (Cr) and strengthened by silicon (Si). It is also important to keep the molybdenum (Mo) level moderate, at most.

[0013] Non-patent document 1 teaches that the hot corrosion resistance of blade alloy SC16, which contains 16 wt% chromium (Cr) and 3 wt% molybdenum (Mo), is significantly inferior to that of blade alloy IN738LC, which contains 16 wt% chromium (Cr) and 1.8 wt% molybdenum (Mo).

[0014] When the amount of alloying elements is excessive, unwanted phases (UPs), such as the sigma phase and Laves phase, form during use. Therefore, when increasing the amount of alloying elements other than chromium (Cr), the amount of chromium (Cr) must be reduced to avoid excessive UP formation, which means a trade-off between corrosion resistance and other properties. One specific effect of UP precipitation is a decrease in creep strength. Another is embrittlement of the blade alloy. Furthermore, when chromium (Cr) is incorporated into chromium-rich UPs, oxidation resistance and corrosion resistance are reduced.

[0015] In the field of high-temperature combustion gas turbines, high oxidation resistance is generally understood to mean the ability to form a dense and continuous Al2O3 layer in the oxide scale, which is necessary to withstand metallic temperatures of over 1000°C. Furthermore, oxide scale peeling caused by the always-present sulfur contamination must be suppressed. In addition, since aluminum (Al) is lost each time protective alumina is reformed, a margin is needed for the loss of reforming ability. Moreover, the use of alloying elements such as titanium causes contamination of the Al2O3 layer and reduces its protectiveness, as titanium partially replaces the aluminum (Al) in the Al2O3 layer. Furthermore, enabling rapid and selective oxidation of Al2O3 is advantageous because it reduces the thickness of the oxide scale and makes it less prone to peeling.

[0016] The ability to form protective Al2O3 and the margin against aluminum (Al) loss due to scale detachment are complex functions of the aluminum (Al) content and the combination of other alloying elements that synergistically enhance or reduce this ability. In the term CALPHAD, this ability is related to the predicted aluminum (Al) activity. In the context of blade alloys, CALPHAD refers to the prediction of various quantities, such as the distribution of alloying elements between the gamma and gamma-prime phases; the liquidus, solidus, and sorbus temperatures of the gamma-prime phase; the gamma-prime content; the risk of UP precipitation; and the aluminum (Al) activity, using thermodynamic software such as Thermocalc. An increase in aluminum (Al) activity also implies rapid selective oxidation of protective Al2O3.

[0017] The following observations regarding the addition of alloying elements to improve oxidation resistance can be found in the literature:

[0018] Non-patent document 2 shows that the ability to form protective Al2O3 is conferred by aluminum (Al), strengthened by chromium (Cr) and tantalum (Ta), slightly reduced by molybdenum (Mo) and tungsten (W), and significantly reduced by titanium (Ti) and niobium (Nb). This is based on large-scale correlation studies of commercial alloys and experimental blade alloys. This means that when the chromium (Cr) and tantalum (Ta) content is increased, or the titanium (Ti) and niobium (Nb) content is reduced, less aluminum (Al) is needed to form the protective Al2O3 layer.

[0019] Non-patent document 3 indicates that scale adhesion is significantly reduced by impurity elements such as sulfur (S), but this effect can be neutralized by a combination of clean casting and the quantitative addition of a small amount of reactive element (rhenium (Re)). If rhenium (Re) is not added, sulfur (S) must be well below 1 ppmw to avoid harmful effects on scale adhesion.

[0020] Non-patent document 4 emphasizes the importance of sulfur (S) and further demonstrates the beneficial effect of rhenium (Re) when hafnium (Hf) and the rare earth element yttrium (Y) are combined at low levels.

[0021] Non-patent document 5 teaches the beneficial effect of rhenium (Re) when hafnium (Hf) and silicon (Si) are combined at low levels.

[0022] Non-patent document 6 teaches that a significant rhenium (Re) effect can be obtained when using a composition consisting of multiple rhenium (Re) elements. As an example, excellent cyclic oxidation resistance was confirmed in tests of Haynes-214, which contains small amounts of zirconium (Zr), silicon (Si), and yttrium (Y).

[0023] Non-Patent Document 7 shows that in the cyclic oxidation resistance of CMSX-4, the combination of "hafnium (Hf) and lanthanum and yttrium (Y)" has a beneficial effect rather than the combination of "hafnium (Hf) and lanthanum or yttrium (Y)".

Prior Art Documents

Non-Patent Documents

[0024]

Non-Patent Document 1

Non-Patent Document 2

Non-Patent Document 3

Non-Patent Document 4

Non-Patent Document 5

Non-Patent Document 6

Non-Patent Document 7

[0025] It is generally acknowledged that in additive manufacturing processes such as laser cladding or powder bed melting, the risk of high-temperature cracking and subsequent strain-aging cracking during solution treatment increases with increasing gamma-prime content. It is also generally acknowledged that maintaining a single-crystal structure during cladding presents a significant challenge. The cladding process itself generates a high temperature gradient from the molten pool to the relatively low-temperature substrate, thus, in principle, enabling single-crystal growth. However, in practice, it is difficult to suppress the formation of stray grains (crystal grains that deviate from the single-crystal structure) during the process. Furthermore, it is difficult to suppress strain-aging cracking in filler alloys with high gamma-prime content, and most filler alloys with high oxidation resistance, related to their ability to form protective Al2O3, also have high gamma-prime content.

[0026] Most blade alloys can be characterized as classic industrial gas turbine (IGT) alloys, aerospace alloys, or novel IGT alloys (see Table 1).

[0027] The classical IGT alloy classification includes the polycrystalline IN738LC, GTD-111, and IN792, and the single-crystal SCA425 (see Table 1).

[0028] [Table 1] Table 1: Elemental addition amount (wt%), gamma-prime phase content at 850°C (mol%), and aluminum (Al) activity at 1273K (relative value). Yttrium (Y) on Cr2O3 means that protective Cr2O3 can be formed. "na" means "not applicable (not applicable)".

[0029] These alloys contain enough chromium (Cr) to form protective Cr2O3.

[0030] Blade alloys lacking this ability have relatively low corrosion resistance. Classical IGT blade alloys do not have the ability to form protective Al2O3. However, SCA425, containing 4 wt% aluminum (Al) and supported by 16 wt% Cr, lies on the borderline. In-house oxidation tests at 1273 K showed that SCA425 forms continuous Al2O3 on most of its surface, but unfortunately not across its entire surface. The aluminum (Al) activity at 1273 K measured by Thermocalc, using TTNi8 as the database, was 3.1e -8 Conventional IGT alloys do not meet our objectives because they cannot form protective Al2O3.

[0031] The classification of aerospace alloys includes polycrystalline CM247CC, single-crystal CMSX-4, and ReneN5 used in CC and DS castings (see Table 1). These have poor high-temperature corrosion resistance due to their low chromium (Cr) content. Most of these can form protective Al2O3 despite containing high levels of aluminum (Al) and tantalum (Ta), as well as low levels of chromium (Cr). Aerospace alloys do not meet our objectives due to their poor corrosion resistance. Furthermore, their high gamma prime content, typically in the range of 60 mol% to 70 mol%, means they are difficult to process by laser cladding.

[0032] The new IGT alloy class includes polycrystalline STAL125CC1, single-crystal STAL15SX, the laser cladding alloy STAL18SiLaY for cladding single-crystal substrates, and the laser cladding alloy Edge14 for cladding polycrystalline and oriented solidification blade alloys (see Table 1). These alloys contain enough chromium (Cr) to produce protective Cr2O3 at low and medium temperatures (typically up to about 1173K). Furthermore, these alloys form protective Al2O3 at high temperatures (typically above about 1123K) with moderate to high levels of aluminum (Al) aided by substantial amounts of chromium (Cr) and tantalum (Ta).

[0033] STAL18SiLaY forms a protective Cr2O3 layer on top of the protective Al2O3 layer.

[0034] STAL18SiLaY achieves the requirements of extremely high temperature corrosion resistance, high oxidation resistance, good SX cladding properties, high phase stability, and at least moderate creep resistance. This is achieved by using moderate amounts of aluminum (Al) and tantalum (Ta), high amounts of chromium (Cr), multiple rhenium (Re) alloys, moderate amounts of matrix strengthening elements molybdenum (Mo) and tungsten (W), specially limited amounts of molybdenum (Mo), and silicon (Si) to improve corrosion and oxidation resistance while maintaining the single-crystal structure up to the cladding region. The idea was that the effects of high concentrations of chromium (Cr), multiple rhenium (Re), and the removal of harmful elements such as titanium (Ti) and niobium (Nb) were sufficient to enable the formation of a tightly adhering, continuous Al2O3 scale with moderate amounts of aluminum (Al) and tantalum (Ta). Therefore, the gamma prime content can be kept low enough to enable good weldability. Furthermore, the moderate amount of gamma prime and the reinforcing elements in both the matrix and gamma prime provided sufficient creep strength for the intended application. In addition, the addition of high-quality chromium (Cr), low-quality molybdenum (Mo), and silicon (Si) resulted in extremely high-temperature corrosion resistance. Moreover, because the gamma prime content and matrix reinforcing element amounts are moderate, high levels of chromium (Cr) can be tolerated from a phase stability perspective.

[0035] With STAL18SiLaY, crack-free cladding can be achieved within a surprisingly wide process window, even when using relatively large weld seams ranging from 1mm to 2mm in width and height. One reason for this is the moderate gamma prime content. Another reason is based on in-house testing conducted using the same process parameters with variants that are otherwise similar to STAL18SiLaY but have different silicon (Si) content. This testing showed that silicon (Si) improves interlayer wetting, and this wetting plays a crucial role in maintaining the single-crystal structure. When the silicon (Si) content is low, even with similar gamma prime particle and reinforcing element content, new grains and cracks develop in the intermediate phase between cladding layers, and these cracks propagate along the thus formed grain boundaries.

[0036] Edge14, a recently developed novel IGT clad alloy, was developed with the goal of achieving superior oxidation resistance. Compared to the novel IGT alloys mentioned above, it excludes cobalt (Co) and includes iron (Fe). The high aluminum (Al) content of Edge14 would normally result in a high gamma prime content, making crack-free cladding extremely difficult. However, the addition of iron (Fe) affects the distribution of aluminum (Al), resulting in more aluminum (Al) being present in the gamma matrix. This means that a higher aluminum (Al) content can be tolerated while preventing the gamma prime content from becoming too high, making the alloy suitable for cladding. This also means an increase in the aluminum (Al) concentration in the gamma matrix. In CALPHAD terminology, this translates to an increase in aluminum (Al) activity. The aluminum (Al) activity of Edge15 at 1273K is 8.2 × 10⁻⁶. -8 This is the aluminum (Al) activity of STAL18SiLaY, which is 4.9 × 10⁻⁶. -8 STAL15SX aluminum (Al) activity 4.3 × 10 -8, and the aluminum (Al) activity of SCA425 is 3.1 × 10⁻⁶. -8 It is compared to CMSX-4. STAL1SX showed comparable oxidation resistance to CMSX-4 in laboratory tests and actual use, and it should be noted that when the skiler tip of a CMSX-4 blade was repaired with STAL18SiLaY, it suffered less oxidation damage than the original CMSX-4 tip. The predicted difference in aluminum (Al) activity from STAL18SiLaY to Edge14 may be observed to be significantly higher than the significant difference from STAL15SX to STAL18SLaY, and the difference from SCA425 to STAL15SX, which is on the borderline where high oxidation resistance has been proven in laboratory tests and actual use.

[0037] Edge14 was successfully applied to CM247CC by cladding, and oxidation tests were conducted using specimens with Edge14 clad-bonded to a CM247CC substrate. It was found that it was extremely difficult to induce oxidative damage with Edge14. Finally, a 1000-hour test was performed, with holding at 14523K for 1 hour (because higher temperature levels are thought to cause initial dissolution of CM247CC). The Edge15 material remained only slightly affected, while the CM247CC substrate was significantly damaged. Therefore, Edge14 offers excellent oxidation resistance. This excellent oxidation resistance can be observed to correlate well with a very high aluminum (Al) activity.

[0038] Of these new IGT alloys, only STAL18SiLaY has a combination of at most moderate gamma prime content and a large amount of silicon (Si) doping, which enables high cladding performance without cracking, such that the single-crystal structure in the single-crystal substrate is maintained within the cladding region. However, STAL18SiLaY does not provide the aluminum (Al) activity that matches the excellent oxidation resistance observed in Edge14.

[0039] Therefore, the objective of the present invention is to overcome these problems.

[0040] This problem is solved by the alloy described in claim 1, the component described in claim 14, and the method described in claim 17.

[0041] The object of the present invention is to provide a gamma-prime reinforced nickel-based superalloy (hereinafter referred to as "blade alloy") that possesses a unique combination of high high-temperature corrosion resistance, excellent oxidation resistance, high ability to achieve crack-free cladding that preserves the single-crystal structure in the substrate, useful phase stability, and useful creep resistance. This combination is useful for the manufacture of hybrid single-crystal components used to repair oxidatively damaged single-crystal components and to prevent oxidative damage. The clad region also has high resistance to high-temperature corrosion caused by corrosive substances such as corrosive biofuels and sea salt in the inhaled air. Furthermore, the clad region does not crack due to the formation of a brittle phase. The clad region can also withstand moderate creep loads commonly found in areas such as the edges and tips of single-crystal components that are prone to oxidative damage.

[0042] The object of the present invention is to provide a combination of high high-temperature corrosion resistance, excellent oxidation resistance, good cladding performance without cracking that preserves the SX structure in the SX substrate, useful phase stability, and useful creep resistance. In particular, the aim is to significantly improve oxidation resistance while maintaining equivalent levels of SX cladding properties, phase stability, and creep resistance compared to STAL18SiLaY. In this context, a moderate decrease in high-temperature corrosion resistance to the "IN738LC level" is acceptable.

[0043] This invention relates to a nickel-based gamma-prime reinforced superalloy, comprising 2.0 wt% to 9.0 wt% cobalt (Co), 3.0 wt% to 9.0 wt% iron (Fe), 14.0 wt% to 18.0 wt% chromium (Cr), 2.0 wt% to 5.0 wt% molybdenum (Mo) + tungsten (W) + rhenium (Re), where molybdenum (Mo) is limited to a maximum of 2.0 wt%, 4.5 wt% to 5.3 wt% aluminum (Al), and 3.0 wt% to 7.0 wt% tungsten (W). It contains tal (Ta), 0.02 wt% to 0.3 wt% of carbon (C) + zirconium (Zr) + boron (B), where carbon (C) is at least 0.01 wt% and zirconium (Zr) is at least 0.01 wt%, 0.05 wt% to 1.0 wt% of hafnium (Hf), 0.3 wt% to 0.7 wt% of silicon (Si), and a total of 0.05 wt% to 0.3 wt% of rare earth elements such as scandium (Sc), yttrium (Y), actinides, and lanthanides.

[0044] In this invention, the oxidation resistance is significantly improved compared to STAL18SiLaY by using a clever combination of iron (Fe) and cobalt (Co) through a greatly increased aluminum (Al) activity. The addition of iron (Fe) and cobalt (Co) allows for an increase in aluminum (Al) while maintaining the same level of gamma prime content, thanks to the iron (Fe) + cobalt (Co) addition ability that influences the distribution of aluminum (Al). Thus, when aluminum (Al) is forced into the gamma matrix, it is necessary to moderately reduce chromium (Cr) to avoid an increased tendency toward UP phase formation. This is exemplified by the embodiments in Table 1, STAL17FeSiLaY, STAL16FeSiLaY, and STAL15FeSiLaY. ThermoCalc simulations predict that for all clad alloys in Table 1, the gamma prime content at equilibrium temperature of 1123K is 37 mol%. This is low enough to suggest good workability by cladding, but not low enough to suggest low creep strength. Furthermore, creep strength benefits from the SX structure. It should be noted that the "cobalt (Co) replaced with Fe" formulation used to design Edge14 has been updated in this invention to a more efficient "cobalt (Co) replaced with a clever combination of cobalt (Co) and Fe" formulation. As the cobalt (Co) + iron (Fe) content increases, the expected aluminum (Al) activity also increases. Chromium (Cr) is reduced compared to STAL18SiLaY. Nevertheless, the chromium (Cr) content is still far above the classic 12.0 wt% chromium (Cr) limit, and high high-temperature corrosion resistance is achieved by adding silicon (Si) while keeping molybdenum (Mo) low.

[0045] This invention also includes (by weight %) the following: 2.0% to 10.0% cobalt (Co), 3.0% to 10.0% iron (Fe), 14.0%~18.0% chromium (Cr) 4.5% to 5.3% aluminum (Al), 3.0% to 7.0% tantalum (Ta), 0.01% to 0.05% carbon (C), 0.01% to 0.05% zirconium (Zr), 0.05% to 1.0% hafnium (Hf), 0.3% to 0.7% silicon (Si), The total amount of rare earth elements such as scandium (Sc), yttrium (Y), actinides and / or lanthanides is 0.01% to 0.3%. Nickel (Ni), Includes, optionally: Up to 3.0% tungsten (W), In particular, 0.5% to 3.0% tungsten (W), and / or Up to 2.0% molybdenum (Mo), In particular, 0.4% to 2.0% molybdenum (Mo), and / or Up to 2.0% rhenium (Re), Especially 0.3% to 2.0% rhenium (Re) and / or Up to 0.05% boron (B), In particular, 0.01% to 0.05% boron (B), Includes.

[0046] Compared to Edge14, the sole addition of yttrium (Y) has been replaced with the addition of multiple rare earth elements. Furthermore, the silicon (Si) content has been significantly increased. In addition, by using cobalt (Co) + iron (Fe) more efficiently, a very high aluminum (Al) activity was achieved despite a lower aluminum (Al) content. This reduction in aluminum (Al) leads to a decrease in the gamma prime content required to favor cladding of the single crystal substrate, resulting in the formation of a single crystal cladding region.

[0047] It may seem surprising that moderately increasing the aluminum (Al) content can potentially increase aluminum (Al) activity. However, oxidation resistance and aluminum (Al) activity are related to the aluminum (Al) content in the gamma matrix, and since most of the aluminum (Al) is usually distributed to gamma prime particles, this content is relatively low even in blade alloys that can form protective Al2O3. Cobalt (Co) and iron (Fe) push more aluminum (Al) into the gamma matrix, so a relative increase in the aluminum (Al) content of the gamma matrix becomes substantial.

[0048] According to the present invention, the alloy contains between 2.0 wt% and 10.0 wt% cobalt (Co), between 14.0 wt% and 18.0 wt% chromium (Cr), between 2.0 wt% and 5.0 wt% molybdenum (Mo) + tungsten (W) + rhenium (Re), up to 2.0 wt% molybdenum (Mo), between 4.5 wt% and 5.3 wt% aluminum (Al), between 3.0 wt% and 7.0 wt% tantalum (Ta), and between 0.01 wt% and 0.3 wt% It may contain carbon (C) + zirconium (Zr) + boron (B), at least 0.01 wt% carbon (C), at least 0.01 wt% zirconium (Zr), between 0.05 wt% and 1.0 wt% hafnium (Hf), between 0.3 wt% and 0.7 wt% silicon (Si), and a total of between 0.01 wt% and 0.3 wt% rare earth elements such as scandium (Sc), yttrium (Y), actinides and lanthanides.

[0049] Furthermore, the alloy contains 2.0 wt% to 4.0 wt% cobalt (Co), 3.0 wt% to 4.5 wt% iron (Fe), 16.5 to 18.0 wt% chromium (Cr), 0.6 wt% to 1.0 wt% molybdenum (Mo), 2.0 wt% to 3.0 wt% tungsten (W), 4.5 wt% to 4.9 wt% aluminum (Al), and 3.5 wt% to 5.5 wt% tan It may contain tal (Ta), 0.01 wt% to 0.05 wt% carbon (C), 0.01 wt% to 0.05 wt% zirconium (Zr), 0.05 wt% to 0.15 wt% hafnium (Hf), 0.3 wt% to 0.7 wt% silicon (Si), 0.03 to 0.13 wt% lanthanum (La), and 0.03 to 0.13 wt% yttrium (Y).

[0050] In a preferred embodiment called STAL17FeSiLaY, the alloy may contain 3.0 wt% cobalt (Co), 4.0 wt% iron (Fe), 17.0 wt% chromium (Cr), 0.8 wt% molybdenum (Mo), 2.5 wt% tungsten (W), 4.7 wt% aluminum (Al), 4.5 wt% tantalum (Ta), 0.03 wt% carbon (C), 0.03 wt% zirconium (Zr), 0.1 wt% hafnium (Hf), 0.5 wt% silicon (Si), 0.1 wt% lanthanum (La), and 0.1 wt% yttrium (Y).

[0051] Alternatively, the alloy may contain 3.0 wt% to 5.5 wt% cobalt (Co), 5.5 wt% to 6.5 wt% iron (Fe), 15.5 wt% to 17.5 wt% chromium (Cr), 0.6 wt% to 1.0 wt% molybdenum (Mo), 2.0 wt% to 3.0 wt% tungsten (W), 4.6 wt% to 5.1 wt% aluminum (Al), and 3.5 wt% to 5.5 wt% It may contain tantalum (Ta) between 0.01 wt% and 0.05 wt%, carbon (C) between 0.01 wt% and 0.05 wt%, zirconium (Zr) between 0.01 wt% and 0.05 wt%, hafnium (Hf) between 0.05 wt% and 0.15 wt%, silicon (Si) between 0.3 wt% and 0.7 wt%, lanthanum (La) between 0.03 wt% and 0.13 wt%, and yttrium (Y) between 0.03 wt% and 0.13 wt%.

[0052] In a preferred embodiment called STAL16FeSiLaY, the alloy may contain 4.0 wt% cobalt (Co), 6.0 wt% iron (Fe), 16.0 wt% chromium (Cr), 0.8 wt% molybdenum (Mo), 2.5 wt% tungsten (W), 4.9 wt% aluminum (Al), 4.5 wt% tantalum (Ta), 0.03 wt% carbon (C), 0.03 wt% zirconium (Zr), 0.1 wt% hafnium (Hf), 0.5 wt% silicon (Si), 0.1 wt% lanthanum, and 0.1 wt% yttrium (Y).

[0053] Alternatively, the alloy may contain 6.0 wt% to 9.0 wt% cobalt (Co), 7.5 wt% to 9.0 wt% iron (Fe), 14.5 wt% to 15.5 wt% chromium (Cr), 0.5 wt% to 1.0 wt% molybdenum (Mo), 2.0 wt% to 3.0 wt% tungsten (W), 4.8 wt% to 5.2 wt% aluminum (Al), and between 3.5 wt% and 5.5 wt% It may contain tantalum (Ta), carbon (C) between 0.01 wt% and 0.05 wt%, zirconium (Zr) between 0.01 wt% and 0.05 wt%, hafnium (Hf) between 0.05 wt% and 0.15 wt%, silicon (Si) between 0.3 wt% and 0.7 wt%, lanthanum (La) between 0.03 wt% and 0.13 wt%, and yttrium (Y) between 0.03 wt% and 0.13 wt%.

[0054] In a preferred embodiment called STAL15FeSiLaY, the alloy may contain 8.0 wt% cobalt (Co), 8.0 wt% iron (Fe), 15.0 wt% chromium (Cr), 0.8 wt% molybdenum (Mo), 2.5 wt% tungsten (W), 5.0 wt% aluminum (Al), 4.5 wt% tantalum (Ta), 0.03 wt% carbon (C), 0.03 wt% zirconium (Zr), 0.1 wt% hafnium (Hf), 0.5 wt% silicon (Si), 0.1 wt% lanthanum, and 0.1 wt% yttrium (Y).

[0055] The blade alloy according to the present invention is preferably processed in a clean manufacturing process. To ensure the best results, the blade alloy should contain less than 5 ppm of sulfur (S), preferably less than 1 ppm of sulfur (S).

[0056] This alloy is preferably used in the manufacture of blades, vanes, heat shields, or discs.

[0057] This alloy is suitable for casting (e.g., equiaxial casting) and is preferably cast into a single-crystal (SX) or columnar (DS) microstructure. In the latter case, a temperature gradient is used.

[0058] This alloy can be used as a powder for additive manufacturing. This may involve welding using powder or wire made from this alloy, or, more commonly, cladding (e.g., welding) may be used. Furthermore, the powder bed method is also preferably used. Therefore, this alloy can be used to manufacture all or part of a component. This can be preferably used in the manufacture of new parts.

[0059] Furthermore, a method for repairing parts using this alloy is also preferable. In this case, the alloy is added to the substrate. The substrate may preferably have an SX structure or a DS structure. In particular, in this case, the added materials (powder bed, cladding) are also laminated onto the SX or DS structure.

[0060] Alternatively, when this alloy is used as a base alloy, further embodiments can be designed to optimize compatibility with specific coatings. Alternatively, when this alloy is used as a filler alloy for cladding or weld repair, further embodiments can be designed to optimize compatibility with specific base alloys and coatings.

Claims

1. In weight percentage, 2.0% to 10.0% cobalt (Co), 3.0% to 10.0% iron (Fe), 14.0% to 18.0% chromium (Cr), 4.5% to 5.3% aluminum (Al), 3.0% to 7.0% tantalum (Ta), 0.01% to 0.05% carbon (C), 0.01% to 0.05% zirconium (Zr), 0.05% to 1.0% hafnium (Hf), 0.3% to 0.7% silicon (Si), A total of 0.01% to 0.3% of rare earth elements such as scandium (Sc), yttrium (Y), actinides and / or lanthanides. nickel, In particular, the remaining nickel (Ni), Optional: Up to 3.0% tungsten (W), In particular, 0.5% to 3.0% tungsten (W), and / or Up to 2.0% molybdenum (Mo), In particular, 0.4% to 2.0% molybdenum (Mo), and / or Up to 2.0% rhenium (Re), In particular, 0.3% to 2.0% rhenium (Re) and / or Up to 0.05% boron (B), In particular, 0.01% to 0.05% boron (B), A nickel-based superalloy containing [a specific component].

2. 2.0% to 5.0% molybdenum (Mo) and / or tungsten (W) and / or rhenium (Re), In particular, it contains molybdenum (Mo) and tungsten (W), but does not contain rhenium (Re). The alloy according to claim 1.

3. 0.02% to 0.2% carbon (C) and / or zirconium (Zr) and / or boron (B), In particular, carbon (C) and zirconium (Zr), In particular, carbon (C), zirconium (Zr), and boron (B), The alloy according to claim 1 or 2.

4. 2.0% to 4.0% cobalt (Co), 3.0% to 4.5% iron (Fe), 16.5% to 18.0% chromium (Cr), 0.6% to 1.0% molybdenum (Mo), 2.0% to 3.0% tungsten (W), 4.5% to 4.9% aluminum (Al), 3.5% to 5.5% tantalum (Ta), 0.01% to 0.05% carbon (C), 0.01% to 0.05% zirconium (Zr), 0.05% to 0.15% hafnium (Hf), 0.3% to 0.7% silicon (Si), 0.03% to 0.13% lanthanum (La), and 0.03% to 0.13% yttrium (Y), The alloy according to any one of claims 1, 2, or 3.

5. 3.0% cobalt (Co), 4.0% iron (Fe), 17.0% chromium (Cr), 0.8% molybdenum (Mo), 2.5% tungsten (W), 4.7% aluminum (Al), 4.5% tantalum (Ta), 0.03% carbon (C), 0.03% zirconium (Zr), 0.1% hafnium (Hf), 0.5% silicon (Si), 0.1% lanthanum (La), 0.1% yttrium (Y), The alloy according to any one of claims 1, 2, 3, or 4.

6. 3.0% to 5.0% cobalt (Co), 5.5% to 6.5% iron (Fe), 15.5% to 17.5% chromium (Cr), 0.6% to 1.0% molybdenum (Mo), 2.0% to 3.0% tungsten (W), 4.6% to 5.1% aluminum (Al), 3.5% to 5.5% tantalum (Ta), 0.01% to 0.05% carbon (C), 0.01% to 0.05% zirconium (Zr), 0.05% to 0.15% hafnium (Hf), 0.3% to 0.7% silicon (Si), 0.03% to 0.13% lanthanum (La), and 0.03% to 0.13% yttrium (Y), The alloy according to claim 1, 2, or 3.

7. 4.0% cobalt (Co), 6.0% iron (Fe), 16.0% chromium (Cr), 0.8% molybdenum (Mo), 2.5% tungsten (W), 4.9% aluminum (Al), 4.5% tantalum (Ta), 0.03% carbon (C), 0.03% zirconium (Zr), 0.1% hafnium (Hf), 0.5% silicon (Si), 0.1% lanthanum (La), and 0.1% yttrium (Y), The alloy according to claim 1 or 6.

8. 6.0% to 9.0% cobalt (Co), 7.5% to 9.0% iron (Fe), 14.5% to 15.5% chromium (Cr), 0.5% to 1.0% molybdenum (Mo), 2.0% to 3.0% tungsten (W), 4.8% to 5.2% aluminum (Al), 3.5% to 5.5% tantalum (Ta), 0.01% to 0.05% carbon (C), 0.01% to 0.05% zirconium (Zr), 0.05% to 0.15% hafnium (Hf), 0.3% to 0.7% silicon (Si), 0.03% to 0.13% lanthanum (La), and 0.03% to 0.13% yttrium (Y), The alloy according to any one of claims 1, 2, or 3.

9. 8.0% cobalt (Co), 8.0% iron (Fe), 15.0% chromium (Cr), 0.8% molybdenum (Mo), 2.5% tungsten (W), 5.0% aluminum (Al), 4.5% tantalum (Ta), 0.03% carbon (C), 0.03% zirconium (Zr), 0.1% hafnium (Hf), 0.5% silicon (Si), 0.1% lanthanum (La), and 0.1% yttrium (Y) The alloy according to any one of claims 1, 2, 3, or 8, comprising

10. In weight percentage, 6.0% to 9.0% cobalt (Co), 7.5% to 9.0% iron (Fe), 14.5% to 15.5% chromium (Cr), 0.6% to 1.0% molybdenum (Mo), 2.0% to 3.0% tungsten (W), 4.8% to 5.2% aluminum (Al), 3.5% to 5.5% tantalum (Ta), 0.01% to 0.05% carbon (C), 0.01% to 0.05% zirconium (Zr), 0.005% to 0.015% boron (B), 0.05% to 0.15% hafnium (Hf), 0.3% to 0.7% silicon (Si), 0.03% to 0.13% lanthanum (La), 0.03% to 0.13% yttrium (Y) The alloy according to any one of claims 1, 2, or 3, including

11. In weight percentage, 8.0% cobalt (Co), 8.0% iron (Fe), 15.0% chromium (Cr), 0.8% molybdenum (Mo), 2.5% tungsten (W), 5.0% aluminum (Al), 4.5% tantalum (Ta), 0.03% carbon (C), 0.03% zirconium (Zr), 0.01% boron (B), 0.1% hafnium (Hf), 0.5% silicon (Si), 0.1% lanthanum (La), 0.1% yttrium (Y) The alloy according to claim 10, including the alloy described in claim 10.

12. In weight percentage, 6.0% to 9.0% cobalt (Co), 7.5% to 9.0% iron (Fe), 14.5% to 15.5% chromium (Cr), 0.6% to 1.0% molybdenum (Mo), 2.0% to 3.0% tungsten (W), 4.65% to 5.05% aluminum (Al), 3.5% to 5.5% tantalum (Ta), 0.01% to 0.05% carbon (C), 0.01% to 0.05% zirconium (Zr), 0.35% to 0.65% hafnium (Hf), 0.3% to 0.7% silicon (Si), 0.03% to 0.13% lanthanum (La), 0.03% to 0.13% yttrium (Y) The alloy according to any one of claims 1, 2, or 3, including

13. In weight percentage, 8.0% cobalt (Co), 8.0% iron (Fe), 15.0% chromium (Cr), 0.8% molybdenum (Mo), 2.5% tungsten (W), 4.85% aluminum (Al), 4.5% tantalum (Ta), 0.03% carbon (C), 0.03% zirconium (Zr), 0.5% hafnium (Hf), 0.5% silicon (Si), 0.1% lanthanum (La), 0.1% yttrium (Y) The alloy according to claim 12, including the alloy described in claim 12.

14. The alloy comprises the alloy described in any one of claims 1 to 13. In particular, gas turbine components.

15. It is a blade, vane, heat shield, or disc. The component according to claim 14.

16. Having a single crystal (SX) structure or columnar (DS) microstructure, The component according to claim 14 or 15.

17. The alloy according to any one of claims 1 to 13 is used. A method for manufacturing a component, particularly the component described in claim 14, 15, or 16.

18. The aforementioned components are cast, and in particular, a temperature gradient is used. The method according to claim 17.

19. Additive manufacturing lamination is used, particularly cladding or powder bed lamination. The method according to claim 17.

20. A method for repairing component parts, Using the alloy described in any of claims 1 to 13 for repairing the base material, In particular, the substrate has an SX structure or a DS structure, and In particular, an SX structure or a DS structure is constructed. The method according to claim 17 or 19.

Images