Nickel-Based Superalloy Composition for Additive Manufacturing
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Solution Overview
Problem
Existing nickel-based superalloys face challenges in achieving a balance between ease of processing via additive manufacturing (AM) and high performance material properties, particularly in applications requiring high temperature strength and corrosion resistance.
Innovation Solution
A nickel-based alloy composition is designed using the 'Alloys-By-Design' method, optimizing elemental contents within specific ranges to satisfy equations that balance strength, AM processability, and microstructural stability, incorporating elements like aluminum, titanium, niobium, tantalum, tungsten, and others to enhance tensile and creep strength while ensuring AM compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional nickel-based superalloys are migrated from cast or wrought form to additive manufacturing process, then existing material properties are maintained, but processing difficulties increase and structural integrity deteriorates
Solution Approach 1:
The patent modifies the chemical composition parameters of nickel-based superalloys by adjusting the content ranges of alloying elements (Co: 5-30 wt%, Cr: 5-25 wt%, Mo: 0-10 wt%, W: 0-10 wt%, Al: 0-10 wt%, Ti: 0-5 wt%, Nb: 0-10 wt%, Ta: 0-5 wt%) to optimize both AM processability and structural integrity. This parameter optimization resolves the contradiction by enabling successful additive manufacturing while maintaining high strength and creep resistance.
2Strength
If alloy composition is optimized for high strength and creep resistance, then material performance improves, but AM processability deteriorates
Solution Approach 1:
The patent establishes specific composition ranges that balance strength enhancement with AM processability. By controlling element ratios (e.g., Al+Ti+ Nb+Ta content, Mo+W content) within optimized ranges, the alloy achieves high tensile strength and creep resistance while maintaining crack resistance and ease of additive manufacturing.
Solution Approach 2:
The patent creates a composite alloy system combining multiple strengthening mechanisms through carefully selected alloying elements. The interaction between γ' phase formers (Al, Ti, Nb, Ta) and solid solution strengtheners (Co, Cr, Mo, W) produces a composite microstructure that delivers high strength while the controlled composition ensures AM processability.
3Reliability
If multiple alloying elements are added to achieve desired properties, then material performance improves, but alloy complexity and cost increase
Solution Approach 1:
The patent optimizes the number and concentration of alloying elements by establishing specific content ranges. Rather than arbitrarily adding elements, the patent identifies critical elements (Co, Cr, Mo, W, Al, Ti, Nb, Ta) and controls their interactions through defined composition windows, reducing unnecessary complexity while maintaining corrosion resistance and high temperature strength.
Data Source
AI summary
A nickel-based alloy composition consisting, in weight percent, of: between 1.0 and 3.5% aluminium, 0.0 and 3.6% titanium, 0.0 and 6.0% niobium, 0.0 and 4.9% tantalum, 0.0 and 5.4% tungsten, 0.0 and 4.0% molybdenum, 8.9 and 30.0% cobalt, 10.8 and 20.6% chromium, 0.02 and 0.35% carbon, between 0.001 and 0.2% boron, between 0.001 and 0.5% zirconium, 0.0 and 5.0% rhenium, 0.0 and 8.5% ruthenium, 0.0 and 4.6 percent iridium, between 0.0 and 0.5% vanadium, between 0.0 and 1.0% palladium, between 0.0 and 1.0% platinum, between 0.0 and 0.5% silicon, between 0.0 and 0.1% yttrium, between 0.0 and 0.1% lanthanum, between 0.0 and 0.1% cerium, between 0.0 and 0.003% sulphur, between 0.0 and 0.25% manganese, between 0.0 and 6.0% iron, between 0.0 and 0.5% copper, between 0.0 and 0.5% hafnium, the balance being nickel and incidental impurities, wherein the following equations are satisfied in which WNb, WTa, WTi, WMo, WAl, WRe and WRu are the weight percent of niobium, tantalum, titanium, molybdenum, aluminium, rhenium and ruthenium in the alloy respectively4.2≤(WW+0.92WRe+1.58WRu)+WMoWA1+0.5WTi+0.3WNb+0.15WTa≤4.3.≤WA1+0.5WTi+1.5(0.3WNb+0.15WTa)