1770 results about "Superalloy" patented technology

An additive manufacturing process (110) wherein a powder (116) including a superalloy material and flux is selectively melted in layers with a laser beam (124) to form a superalloy component (126). The flux performs a cleaning function to react with contaminants to float them to the surface of the melt to form a slag. The flux also provides a shielding function, thereby eliminating the need for an inert cover gas. The powder may be a mixture of alloy and flux particles, or it may be formed of composite alloy/flux particles.

Large gas turbine blades made from separate cast segments of superalloys are disclosed. The turbine blade is designed such that bond lines between adjacent segments are placed in low stress regions of the blade. The cast superalloy segments of the blades are aligned and fitted together with specified tolerances. The turbine blade segments are then joined by transient liquid phase bonding, followed by a controlled heat treatment which produces the desired microstructure in the bond region. The method allows for the production of large, high quality turbine blades by joining small, high quality cast superalloy sections, in comparison with prior attempts to cast large turbine blades as single pieces which have produced very low yields and high individual component costs.

A method of method of forming or repairing a superalloy article having a columnar or equiaxed or directionally solidified or amorphous or single crystal microstructure includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array corresponding to a pattern of a layer of the article onto a powder bed of the superalloy to form a melt pool; and controlling a temperature gradient and a solidification velocity of the melt pool to form the columnar or single crystal microstructure.

A light weight hybrid heat exchanger core possessing low density and improved thermal conductivity is disclosed. The hybrid core is comprised of a plurality of parting sheets and interposed by a plurality of high thermal conductivity, light weight bridging elements and enclosure bars. These core members are comprised of dissimilar materials. The parting sheets and bridging elements are interconnected by a specially tailored joint which forms form a substantially strong, high thermal conductivity bond. In particular embodiments, carbon-based bridging elements are bonded to metallic parting sheets using a brazed joint. The parting sheets, in certain embodiments, may comprise titanium or Ni-based superalloys or carbon composites, while the carbon-based bridging elements may comprise fiber-reinforced composites. The carbon-based bridging elements reduce the core weight and increase the core thermal conductivity over conventional all-metal designs, while the brazed joint provides for improved leak resistance over all-composite designs.

A method and apparatus for reacting a hydrocarbon containing feed stream by steam methane reforming reactions to form a synthesis gas. The hydrocarbon containing feed is reacted within a reactor having stages in which the final stage from which a synthesis gas is discharged incorporates expensive high temperature materials such as oxide dispersed strengthened metals while upstream stages operate at a lower temperature allowing the use of more conventional high temperature alloys. Each of the reactor stages incorporate reactor elements having one or more separation zones to separate oxygen from an oxygen containing feed to support combustion of a fuel within adjacent combustion zones, thereby to generate heat to support the endothermic steam methane reforming reactions.

The process of making large irregular ring blank of high temperature alloy includes the steps of heating the high temperature alloy rod to deformation temperature and upsetting into solid cake blank, punching the central hole to obtain hollow cake blank, heating the hollow cake blank to deformation temperature and rolling into ring blank with rectangular cross section, heating the ring blank to deformation temperature and setting in to outer expanding mold and on bottom mold plate, applying pressure to extrude the cake blank with the outer expanding mold and the inner expanding mold for deforming to fill the mold cavity, and demolding to obtain the irregular ring blank. The process of the present invention is used mainly for making ring blank of hard-to-deform alloy and with irregular cross section.

A multilayered ceramic topcoat of a thermal barrier coating system is useful for high temperature corrosive applications such as hot section components in gas turbine engines. The ceramic topcoat includes at least two layers, each having generally columnar grain microstructures with different grain orientation directions. A preferred method of producing the multilayered ceramic topcoat includes positioning a superalloy substrate at a first angled orientation relative to a ceramic vapor cloud in an electron beam physical vapor deposition apparatus for a time sufficient to grow a first ceramic layer. The substrate is then reoriented to a second, different angled orientation for a time sufficient to grow a second ceramic layer. The ceramic layers exhibit columnar microstructures having respective grain orientation directions which are related to the first and second substrate orientations. For uniformly coating a complex contoured surface such as a turbine blade airfoil, the blade can be rotated during coating deposition at each angled orientation. Alternatively, the article may be continuously reoriented according to a predetermined speed cycle to produce generally arcuate, sinusoidal, helical, or other columnar grain microstructures.

A hot gas filtration apparatus includes a vessel, a plurality of filter elements mounted within the vessel and positioned such that hot gas flows through said filter elements, with each of said filter elements having a porous body, and a catalytic layer on surfaces of the porous body. The porous body of the filter element may include one of: a porous ceramic monolithic matrix, a continuous fiber reinforced ceramic composite (CFCC) matrix, a metallic matrix, an intermetallic matrix, a superalloy, and a metal-ceramic composite matrix. When the porous body is a nonoxide ceramic, a metallic matrix, an intermetallic matrix, a superalloy, or a metal-ceramic composite matrix, the invention further includes an oxidative resistant layer coating surfaces within the porous body, and the catalytic layer is on the oxidative resistant layer. A porous particulate removal membrane can be positioned on one or more surfaces of the filter element. The porous membrane can also provide a surface for one or more catalysts. The catalysts on the porous surface of the membrane(s) can be the same as or different from the catalysts on surfaces within the porous body.

A method of building or repair of a hollow superalloy component (20, 61) by forming an opening (38, 62) in a wall (28) of the component; filling a cavity (22B, 64) behind the opening with a fugitive support material (34, 52, 54, 68) to support a filler powder (36) across the opening; traversing an energy beam (42) across the filler powder to form a deposit (44) that spans and closes the opening; in which the deposit is fused to the edges (32, 62) of the opening. The filler powder includes at least metal, and may further include flux. The support material may include filler powder, a solid (54), a foam (52) insert, a flux powder (34) and/or other ceramic powder (68). Supporting powder may have a mesh size smaller than that of the filler powder.

Composite materials (2, 8) disclosed herein include a metal alloy (4, 10) and a flux composition (6, 12). The metal alloy may be a superalloy, and a volume ratio of the flux composition to the metal alloy may range from about 30:70 to about 70:30. The composite materials may be in the form of particles (2) containing a core (6) surrounded by a metallic layer (4), in which the core contains the flux composition and the metallic layer contains the metal alloy. The composite materials may also be in the form of fused materials (8) in which the metal alloy (10) and the flux composition (12) are randomly distributed and randomly oriented. Also disclosed are processes involving melting of composite materials to form metal deposits (32).

The invention provides a numerically controlled drilling and milling processing method for a runner of a blisk of an engine. The main technical flow before drilling and milling the runner comprises the following steps: lathing each surface of a blank, performing nondestructive testing, lathing inner and outer cavities of the blisk, finely milling a needed periphery and an axial benchmark, drilling and boring an angular datum hole, drilling and milling the runner and inspecting. A part and a fixture are in peripheral seam allowance fit to limit a radial degree of freedom of the part; an end face gland and a central pull bar axially limit an axial degree of freedom of the part; and a precise positioning pin angularly limits an angular degree of freedom of the part. The method has the advantages that: by applying the drilling and milling processing method to a part machining process of the blisk of the engine having the material removing rate of over 90 percent, the method improves the processing efficiency, shortens the manufacturing period of the product, and provides a new technical means for removing a large amount of remainder materials of the blisk; and the processing of a high-temperature alloy, a titanium alloy and other difficult-to-process materials shows that the material is more difficult to process, the removing rate is bigger and the effect is more obvious.

A gas turbine engine component and coating system including a superalloy substrate having a coating system disposed thereon. A bond coating may be applied to the substrate. An adherent layer of ceramic material forming a thermal barrier coating is present on the bond coat layer. A topcoat layer overlies the thermal barrier coating. The topcoat layer includes greater than about 20 wt % yttria.

A MEMS vapor bubble generator with a chamber for holding liquid and a heater positioned in the chamber for heating the liquid above its bubble nucleation point to form a vapour bubble; wherein, the heater is formed from a superalloy.

A preform (22, 22A-U) containing metal (32, 34) and flux (33) for forming a metal layer to be added to a component being repaired or additively manufactured. The metal may be constrained in the preform in a distribution that forms a shape of a sectional layer or a surface repair of a component in response to an energy beam (58) that melts the preform. The preform is placed on a working surface (42), which may be a previously formed layer (42A-C) in additive manufacturing, or may be an existing component surface (122) for repair The preform is then melted by the energy beam (58) to form a new integrated layer (40A-F) on the component with an over-layer of slag (56) that shields and insulates the melt pool (54) and the solidifying layer The slag is removed, and a subsequent layer may be added.

A method is provided for repairing degraded and/or eroded areas on gas turbine blades and vanes. The method is directed to turbine blades and vanes made of advanced superalloy materials with high elevated-temperature properties. The method uses multiple laser beams to perform steps of preheating the repair area, welding the repair area, and post-welding heating of the repaired area. The method uses an array of two or more lasers to perform the steps of heating, welding, and post-weld heat treatment in nearly simultaneous operation thereby dramatically reducing or eliminating the hot cracking associated with other welding methods used with superalloy materials. The method is further directed to cladding or material buildup of degraded turbine blades where the weld material is the same as the matrix or better superalloy materials.

The invention relates to a method for processing a high-temperature alloy furnace tube, which comprises the following steps: controlling the pressure of low-oxygen partial pressure gas to 0-3 atmospheric pressure; introducing the low-oxygen partial pressure gas into an atmosphere furnace provided with the high-temperature alloy furnace tube after passing through ammonia water; raising the temperature to between 600 and 1,100 DEG C; keeping the temperature for 5 to 80 hours; and forming an oxidized protective layer on the surface of the high-temperature alloy furnace tube to obtain the processed high-temperature alloy furnace tube. The method for processing the high-temperature alloy furnace tube is adopted to process a furnace tube of a hydrocarbon cracking furnace and the like, so that the compact and stable oxidized protective layer on the surface of the furnace tube, and the requirement for long-term use can be met; and the method can inhibit or retard the phenomena of catalysis and coking, reduces the carburization degree of the furnace tube, and prolongs the decoking cycle and the service life of the furnace tube.

The invention relates to a preparation process of a high-temperature alloy multigang hollow turbine blade. The process comprises the following steps of: (1) partitioning the multigang blade into a plurality of blade units and manufacturing a blade body wax mold for each unit blade, wherein a blade body is provided with a ceramic mold core, the unit blade body wax mold with the ceramic mold core is molded in an injection molding way, injection temperature is between 63 and 68 DEG C, the pressure is between 0.3 and 0.5 MPa, the injection time is between 10 and 30 seconds and the pressure is preserved for 10 to 30 seconds; (2) putting each unit blade body wax mold with the ceramic mold core into a multigang mold and injecting wax for primary molding so as to obtain a multigang hollow blade wax mold; and (3) coating, dewaxing, sintering, pouring, clearing and stripping the multigang hollow blade wax mold so as to obtain a high-temperature alloy multigang hollow turbine blade casting.

The invention belongs to the technical field of high-temperature alloy near net shape forming and discloses a method for preparing oxide dispersion strengthened alloy by rapid forming. The method includes: using the mechanical alloying process to obtain oxide dispersion strengthened alloy powder, using CAD (computer-aided design) software to design a three-dimensional solid model of an ODS (oxide dispersion strengthened) alloy part, subjecting the three-dimensional model to layering and slicing to disperse the three-dimensional model into a series of two-dimensional layers, smelting the ODS alloy powder layer by layer according to slicing information to obtain a laser rapidly formed blank in a needed shape, eliminating residue pores in the laser rapidly formed blank by means of hot isostatic pressing, and optimizing structure property by means of subsequent annealing or solid solution and aging heat treatment to obtain an ODS alloy part in a complex shape. Wrap packaging or fixture moulds are not needed, the complexity of shapes of parts is unlimited, and alloy components and structures are easy to control. The prepared ODS alloy is small in oxide dispersed phase, and products are high in compactness and excellent in comprehensive mechanical property.

The invention belongs to the technical field of forging, and relates to a forging method of high-temperature alloy fine-grained bars. According to the invention, a combined breakdown production method of upsetting and stretching, and radial forging is adopted. A deflection is large, deflection directions are changed alternately, carbide is sufficiently crushed, and carbide is distributed in a dispersed state, such that the fatigue property of the alloy is improved. The bar is finally subject to one-heating molding through radial forging, such that grain growing caused by the direct fired bar which is delivered back to a furance is avoided. Also, the method is beneficial for excircle deflection of the bar. Therefore, fine-grained bars with a grain grade difference smaller than 2 grades areobtained. The method is a novel method with a good prospect. The method is suitable for high-temperature alloy fine-grained bar productions. If the method is popularized, good social and economical benefits can be brought in.

According to an embodiment of the invention, a turbine engine rotor component comprises a base metal substrate; and an oxidation and corrosion resistant metal nitride or metal carbide overlay coating applied directly on the base metal substrate of the turbine engine rotor component.

A turbine component contains a substrate (22) such as a superalloy, a basecoat (24) of the type MCrAlY, and a continuous barrier layer (28) between the substrate and basecoat, where the barrier layer (28) is made of an alloy of (Re, Ta, Ru, Os)X, where X can be Ni, Co or their mixture, where the barrier layer is at least 2 micrometers thick and substantially prevents materials from both the basecoat and substrate from migrating through it.

Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot.

The invention relates to a method for melting a nickel-base high temperature alloy with an electro-slag furnace. The method includes the following methods: loading materials, welding a high temperature alloy electrode and a false electrode to be smelted together, and placing slag materials at the bottom of a crystallizer; blowing the welded electrodes with inert gases, and closing a protection cover; protecting a smelting closing smoke exhaust valve, and feeding an Ar gas into the crystallizer and the protection cover; striking an arc and melting slag; cleaning smelting slag materials, starting a smelting period, and swinging a slag resistor for less than 0.5 m omega during the smelting process; adding oxidizing agents, and adding metal aluminum powder continuously or at intervals to serve as deoxidizing agents during an electro-slag re-melting process; adopting feeding thorough three stages, power feeding is decreased rapidly, power feeding is decreased slowly, and finally heat is preserved at constant power; and casting a die, cooling and demolding the die. According to the method for melting the nickel-base high temperature alloy with the electro-slag furnace, the surface of a nickel-base high temperature steel ingot has no slag groove defect, and the burning losses of Al and Ti are less than or equal to 5%.

A method of repairing service-induced surface cracks (92) in a superalloy component (90). A layer of powdered flux material (100) is applied over the cracks and is melted with a laser beam (98) to form a re-melted zone (104) of the superalloy material under a layer of slag (106). The slag cleanses the melt pool of contaminants that may have been trapped in the cracks, thereby eliminating the need for pre-melting fluoride ion cleaning. Optionally, alloy feed material may be applied with the powdered flux material to augment the volume of the melt or to modify the composition of the re-melted zone.

Differing from traditional alloys often containing one primary elemental composition, the present invention reforms a conventional superalloy to a high-entropy superalloy by redesigning the elemental compositions of the conventional superalloy based on a mixing entropy formula. Particularly, this high-entropy superalloy shows advantages of light weight and low cost under the premise of containing a low amount of expensive metal composition. The proposed high-entropy superalloy of the present invention comprises a primary elemental composition and at least one principal strengthening elemental composition, wherein the primary elemental composition has a first element content of at least 35 at % and each of the principal strengthening elemental compositions have a second element content of over 5 at %. Moreover, a variety of experimental results have proved that the high-entropy superalloy simultaneously possesses a variety of excellent high-temperature mechanical properties, such as high mechanical strength, high corrosion resistance, high oxidation resistance, and high creep resistance.

A method of joining metal and ceramic parts, wherein an alumina forming metal part and a ceramic part are provided. A braze material in placed between the alumina forming metal part and the ceramic part, and the combination is then heated in an oxidizing atmosphere, preferably in air at a temperature of between 500° C. and 1300° C. The alumina forming metal parts are selected from the group consisting of high temperature stainless steels, such as Durafoil (alpha-4), Fecralloy, Alumina-coated 430 stainless steel and Crofer-22APU, and high temperature superalloys such as Haynes 214, Nicrofer 6025, and Ducraloy. The braze material is selected as a metal oxide-noble metal mixture, preferably Ag—CuO, Ag—V₂O₅, and Pt—Nb₂O₅, and more preferably between 30.65 to 100 mole % Ag in CuO.

The present invention relates to a low thermal expansion Ni-base superalloy containing, in terms of mass %, C: 0.15% or less; Si: 1% or less; Mn: 1% or less; Cr: 5% or more but less than 20%; at least one of Mo, W and Re, in which Mo+½(W+Re) is 5% or more but less than 20%; W: 10% or less; Al: 0.1 to 2.5%; Ti: 0.10 to 0.95%; Nb+½Ta: 1.5% or less; B: 0.001 to 0.02%; Zr: 0.001 to 0.2%; Fe: 4.0% or less; and a balance of inevitable impurities and Ni, in which the total amount of Al, Ti, Nb and Ta is 2.0 to 6.5% in terms of atomic %. The low thermal expansion Ni-base superalloy of the present invention has a thermal expansion coefficient almost equal to that of 12 Cr ferritic steel, excellent high temperature strength, excellent corrosion and oxidation resistance, good hot-workability, and excellent weldability.

A system and method for laser beam welding at least two adjacent superalloy components involves substantially simultaneous formation of a base weld with a first filler metal placed between the components and cap weld with second filler metal formed over the base weld. A shim is inserted between the components, which may optionally be formed with a groove along the joint surface. A filler wire is fed to a location over the given surface or within the optional groove. Two lasers or a laser and coupled beam splitter supply first and second laser beams that are applied at focal points separated by a predetermined distance (e.g., 0.05-1.5 cm). The first laser beam is used to form a base weld with the first filler metal between the components, and the second laser beam is used to form a cap weld with the second filler metal on top of the base weld.

The invention belongs to the field of metal structural materials, and particularly discloses a high-strength and corrosion-resistant nickel-iron-chromium-based high-temperature alloy and a preparation method for the same. The alloy material is mainly characterized by having the following ingredient range (wt%): 20-30% of Fe, 19-25% of Cr, 0.5-2.5% of Al, 1.0-2.5% of Ti, not greater than 2% of Nb, not greater than 2% of Mo, not greater than 2% of W, not greater than 1% of Ta, not greater than 0.5% of Si, not greater than 1.0% of Mn, not greater than 0.5% of Cu, not greater than 0.05% of C, not greater than 0.01% of B, not greater than 0.03% of Zr and the balance of Ni. The alloy disclosed by the invention is strong in anti-steam-corrosion and anti-fume-corrosion capacities; an ordered-reinforcing phase with dispersed distribution and gamma' phase (Ni3(Al, Ti)) are formed to enhance the high-temperature strength of the alloy; and the content of Fe is increased to the greatest extent on the basis of no influence on the structural stability, the anti-corrosion capacity and the high-temperature strength of the alloy, so as to improve the heat machinability of the alloy and reduce cost. Compared with the prior art, the alloy is low in material cost, excellent in high-temperature strength, heat machinability and corrosion resistance; and in particular, in the case that the alloy is used in the conditions of high temperature, supercritical steam and corrosive fume, the cost performance of the alloy is superior to the cost performances of the existing alloys. The alloy disclosed by the invention can be machined into tube materials, plate materials, bar materials and wire materials.

A friction stir welding system that enables clamping of a pipe to enable friction stir welding around the pipe OD, a movable mandrel that provides a counter-force to the pressure exerted on the outside of a pipe by a tool, and a system for providing friction stir welding and repair inside a nuclear vessel in an underwater environment.