Nickel-Based Superalloy Composition for Elevated Temperature Resistance

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Solution Overview

Problem

Nickel-based super alloys used in gas turbines face limitations in castability, oxidation resistance, strength, strain, and weldability, necessitating the development of alternative compositions that can maintain mechanical properties at elevated temperatures.

Innovation Solution

A nickel-based super alloy composition with specific weight percentages of chromium, cobalt, aluminum, titanium, tungsten, molybdenum, niobium, carbon, zirconium, and boron, optimized to reduce Eta phase presence and increase gamma prime volume fraction, enhancing strength, fatigue performance, and weldability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If nickel-based super alloys are used to withstand elevated operating temperatures, then temperature resistance is improved, but castability, oxidization resistance, strength, strain, and weldability deteriorate

Engineering Contradiction:

Improveelevated operating temperature resistanceVSAvoidcastability and weldability

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by precisely controlling the composition ranges of multiple alloying elements (Cr: 13-15%, Co: 8-10%, Al: 3.5-5%, Ti: 0.5-2%, W: 4-5%, Mo: 1-2%, Nb: 3-4%, C: 0.05-0.15%, B: 0.005-0.02%, Zr: 0.01-0.05%) to achieve optimal balance between high-temperature performance and manufacturability. This compositional parameter optimization resolves the contradiction by finding the precise chemical composition window where both temperature resistance and ease of manufacture are satisfied

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite microstructure consisting of gamma prime precipitates ( strengthening phase) embedded in a gamma matrix, along with controlled TCP phase distribution. This composite microstructural design enables the alloy to simultaneously achieve high-temperature strength and improved castability/weldability that pure nickel-based alloys cannot provide

Inventive Principle:

Principle #40Composite materials

2Temperature

If nickel-based super alloys are used to withstand elevated operating temperatures, then temperature resistance is improved, but oxidization resistance deteriorates

Engineering Contradiction:

Improveelevated operating temperature resistanceVSAvoidoxidization resistance

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent optimizes the chromium content to 13-15% and adds controlled amounts of aluminum (3.5-5%) and boron (0.005-0.02%) to create a protective oxide scale formation capability. This compositional parameter change enables the alloy to maintain oxidization resistance while withstanding elevated temperatures, resolving the contradiction between temperature resistance and oxidation protection

Inventive Principle:

Principle #35Parameter changes

3Temperature

If nickel-based super alloys are used to withstand elevated operating temperatures, then temperature resistance is improved, but strength deteriorates

Engineering Contradiction:

Improveelevated operating temperature resistanceVSAvoidmechanical strength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent creates a composite microstructure with gamma prime (Ni3Al-Ti-Nb) precipitates distributed in the gamma (Ni-Co-Cr) matrix. The gamma prime phase provides age-hardening strengthening while the matrix maintains ductility and high-temperature stability. This composite microstructural approach enables simultaneous achievement of high strength and elevated temperature resistance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs local quality by creating distinct phases with different functions: the gamma matrix provides ductility and high-temperature stability, while the gamma prime precipitates provide localized strengthening. The controlled TCP phase distribution further optimizes local properties. This spatial differentiation of material properties resolves the contradiction between strength and temperature resistance

Inventive Principle:

Principle #3Local quality

4Temperature

If nickel-based super alloys are used to withstand elevated operating temperatures, then temperature resistance is improved, but strain deteriorates

Engineering Contradiction:

Improveelevated operating temperature resistanceVSAvoidstrain and mechanical stability

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The patent creates a composite microstructure where the ductile gamma matrix surrounds and protects the strengthening gamma prime precipitates. This composite architecture allows the material to maintain mechanical stability and strain tolerance at elevated temperatures, resolving the contradiction between temperature resistance and compositional stability

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4257716A1Compositions, articles and methods for forming the same

Publication Date: 2023.10.11 GENERAL ELECTRIC TECH GMBH

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AI summary

Compositions, and articles (200) and methods (10) for forming articles (200) which include said compositions, are disclosed. The compositions include, by weight percent, about 13.7% to about 14.3% chromium (Cr), about 9.0% to about 9.9% cobalt (Co), about 4.0% to about 5.25% aluminum (Al), about 0.5% to about 3.0% titanium (Ti), about 4.5% to about 5.0% tungsten (W), about 1.4% to about 1.7% molybdenum (Mo), about 3.25% to about 3.75% niobium (Nb), about 0.08% to about 0.12% carbon (C), about 0.005% to about 0.04% zirconium (Zr), about 0.010% to about 0.014% boron (B), and balance nickel (Ni) and incidental impurities.