Co-Based Alloy Microstructure Control for High-Temperature Strength
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Solution Overview
Problem
Co-based alloy materials produced at an industrial level often form coarse, undesired heterogeneous phases during manufacturing, leading to degraded mechanical properties and increased production costs due to reduced yield.
Innovation Solution
A Co-based alloy material with a specific chemical composition and microstructure is developed, including Al, W, and O, with γ′ and μ phase grains finely dispersed within γ phase crystal grains, using an additive manufacturing method and aging treatment to control microstructure and prevent coarsening of undesired phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Co-based alloy material is produced at industrial level with conventional manufacturing conditions, then production scale is achieved, but coarse grains of undesired heterogeneous phases (p phase) are formed/precipitated leading to degraded mechanical properties
Solution Approach 1:
The patent applies parameter changes by precisely controlling the oxygen content within 0.007-0.05 mass% and aluminum content within 0.1-10 mass%, along with tungsten content of 3-45 mass%. These compositional parameter changes prevent the formation of coarse unwanted phases while maintaining industrial production scale, thereby preserving mechanical properties
Solution Approach 2:
The patent implements preliminary action by controlling the chemical composition parameters before the manufacturing process begins. By pre-establishing the oxygen and aluminum content ranges, the alloy prevents phase coarsening during subsequent industrial production, avoiding the need for post-processing excision of defective regions
2Productivity
If Co-based alloy material is produced at industrial level, then production volume increases, but production yield decreases due to need to excise regions with coarse undesired phases
Solution Approach 1:
By changing the compositional parameters (oxygen: 0.007-0.05 mass%, aluminum: 0.1-10 mass%, tungsten: 3-45 mass%), the patent prevents the formation of excisable defective regions, thereby maintaining high production yield during industrial-scale production
Solution Approach 2:
The patent takes out the problematic element (excess oxygen leading to p-phase formation) by strictly controlling oxygen content within 0.007-0.05 mass%. This extraction of the harmful factor prevents yield loss from excision operations
3Productivity
If Co-based alloy material is produced at industrial level, then manufacturing cost increases due to reduced production yield
Solution Approach 1:
The patent changes the compositional parameters (particularly oxygen content control at 0.007-0.05 mass% and aluminum at 0.1-10 mass%) to prevent phase coarsening, thereby eliminating the need for costly excision operations and reducing overall production cost at industrial scale
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The alloy exhibits mechanical properties comparable to or superior to conventional materials while maintaining high production yield, with improved high-temperature fatigue and tensile strength, and is suitable for high-temperature applications.
Implementation Method 1
γ′ (gamma prime) phase grains within a size of 0.01 μm or more and 0.5 μm or less including Co, Al and W are dispersively precipitated in the segregation cells
Implementation Method 2
using an additive manufacturing method and aging treatment to control microstructure and prevent coarsening of undesired phases
Data Source
AI summary
There is provided a Co-based alloy material, having a chemical composition including: Al of 0.1 to 10 mass %; W of 3 to 45 mass %, the total content of Al and W being 50 mass % or less; O of 0.007 to 0.05 mass %; and the balance being Co and impurities, wherein in γ phase crystal grains as a matrix phase of the Co-based alloy material, segregation cells within an average size of 0.15 to 1.5 μm are formed, wherein in the segregation cells, γ′ phase grains within a size of 0.01 to 0.5 μm including Co, Al and W are dispersively precipitated, and wherein on boundary regions of the segregation cells and grain boundaries of the γ phase crystal grains, μ phase grains within a size of 0.005 to 2 μm including Co and W are dispersively precipitated.