US20070044869A1 - Nickel-base superalloy - Google Patents

Nickel-base superalloy Download PDF

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US20070044869A1
US20070044869A1 US11/162,221 US16222105A US2007044869A1 US 20070044869 A1 US20070044869 A1 US 20070044869A1 US 16222105 A US16222105 A US 16222105A US 2007044869 A1 US2007044869 A1 US 2007044869A1
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alloy
tantalum
rhenium
crystal casting
tungsten
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Ramgopal Darolia
William Walston
Kevin O'Hara
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General Electric Co
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General Electric Co
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Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: O'HARA, KEVIN SWAYNE, WALSTON, WILLIAM SCOTT, DAROLIA, RAMGOPAL (NMN)
Priority to EP06254484A priority patent/EP1760164B1/en
Priority to DE602006003964T priority patent/DE602006003964D1/en
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C19/00Alloys based on nickel or cobalt
    • C22C19/03Alloys based on nickel or cobalt based on nickel
    • C22C19/05Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/057Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
    • CCHEMISTRY; METALLURGY
    • C30CRYSTAL GROWTH
    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B29/00Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
    • C30B29/10Inorganic compounds or compositions
    • C30B29/52Alloys

Definitions

  • the present invention generally relates to nickel-base alloys. More particularly, this invention relates to a nickel-base superalloy capable of being cast as a single-crystal article and exhibiting desirable properties for use in gas turbine engine applications.
  • René N6 The superalloy commercially known as René N6, disclosed in commonly-assigned U.S. Pat. No. 5,455,120, has a nominal composition of, by weight, about 12.5% Co, 4.2% Cr, 7.2% Ta, 5.75% Al, 5.8% W, 5.4% Re, 1.4% Mo, 0.2% Hf, 0.05% C, 0.004% B, 0.01% Y, the balance nickel and incidental impurities.
  • N6 is well known to have a number of very desirable properties for gas turbine engine applications, such as the high pressure turbine blades and vanes of aircraft gas turbine engines.
  • the composition of N6 is characterized by controlled concentrations of certain critical alloying elements to achieve a desired mix of properties.
  • properties include high temperature creep strength, oxidation and corrosion resistance, resistance to low and high cycle fatigue (LCF and HCF), and single-crystal castability.
  • LCF and HCF low and high cycle fatigue
  • N6 performs well in applications within gas turbine engines, improvements would be desirable.
  • Often of interest is the desire to reduce weight and cost, the latter of which is due in part to alloying constituents such as tantalum and rhenium.
  • obtaining such reductions is difficult in view of the desire to maintain or often improve other properties of the alloy, including oxidation resistance and microstructural stability.
  • TCP phases topologically close-packed phases that, if present at sufficiently high levels, reduce the load-carrying capability of the alloy.
  • TCP phases have been associated with superalloys that contain significant amounts of refractory elements such as rhenium, tungsten, tantalum, hafnium, molybdenum, niobium, and zirconium.
  • the present invention provides a nickel-base alloy that exhibits a desirable balance of high-temperature strength (including creep resistance), oxidation and corrosion resistance, resistance to low and high cycle fatigue, castability, and microstructural stability so as to be suitable for components of gas turbine engines, such as the high pressure turbine blades and vanes of gas turbine engines. These properties are achieved with an alloy that is lower in density than the superalloy known as René N6, and in which relatively higher levels of aluminum, tungsten, molybdenum, niobium (columbium), titanium, and hafnium are present and relatively lower levels of tantalum and rhenium are present as compared to N6.
  • the nickel-base alloy is in the form of a single-crystal casting consisting of, by weight, 5.75% to 6.5% aluminum, 4% to 5% tantalum, 2% to 6% chromium, 5.5% to 7% tungsten, 1.5% to 3% molybdenum, 4% to 5% rhenium, up to 1.0% niobium, 10% to 16% cobalt, up to 1% titanium, 0.01% to 0.05% carbon, up to 0.005% boron, up to 0.01% yttrium, 0.5% to 1.0% hafnium, the balance nickel and incidental impurities.
  • the density of the alloy is not more than and preferably less than 0.320 lbs/in 3 (about 8.87 g/cm 3 ).
  • molybdenum is present in an amount greater than 1.5 weight percent
  • molybdenum is present in an amount greater than 1.5 weight percent
  • rhenium and tantalum are each present in an amount less than 5 weight percent
  • hafnium is present in an amount greater than 0.5 weight percent.
  • the nickel-base alloy of the present invention nominally contains more aluminum, tungsten, molybdenum, niobium, titanium, and hafnium and less tantalum and rhenium than N6.
  • these groups of alloys are designated as “delta addition” and “delta reduction” elements, respectively.
  • delta ratio the ratio of delta addition to delta reduction elements
  • the limitation that the value of the delta ratio is less than unity reflects the determination of this invention that, contrary to conventional wisdom, the combination of (Al+Mo+W+Ti+Hf+Nb) is, by weight, a more potent strengthener than (Re+Ta).
  • the alloy of this invention is believed to have properties comparable to, and in some instances better than, those of the N6 alloy, particularly with the above-noted restriction on the delta ratio, which allows for lower tantalum and rhenium contents. Consequently, the alloy of this invention provides an excellent lower density (weight) and potentially lower-cost alternative to N6.
  • FIG. 1 depicts a high pressure turbine blade that can be formed from the nickel-base superalloy of the present invention.
  • FIGS. 2 through 7 are graphs plotting yield strength, tensile strength, 1800° F. rupture, 2000° F. rupture, 2100F rupture, and 1600° F. high cycle fatigue life of alloys prepared during investigations leading to the present invention.
  • FIG. 1 depicts a high pressure turbine (HPT) blade 10 having an airfoil 12 , a dovetail 14 by which the blade 10 is anchored to a turbine disk (not shown), and a platform 16 therebetween. While the advantages of this invention will be described with reference to components of a gas turbine, such as the high pressure turbine blade 10 shown in FIG. 1 , the teachings of this invention are generally applicable to other components that require high temperature capabilities.
  • HPT high pressure turbine
  • alloys having the approximate chemistries set forth in Table I below were formulated. Specimens of various sizes were machined from single crystal slab castings that had been solution heat treated at about 2370° F. (about 1300° C.) for about six hours and then aged at about 1975° F. (about 1080° C.) for about four hours. The densities of the alloys were in the range of about 0.315 to 0.319 lbs/in 3 (about 8.73 to about 8.84 g/cm 3 ), which is significantly less than the density of N6 (0.323 lbs/in 3 ; about 8.95 g/cm 3 ). For reference, Table I also includes the nominal composition for N6.
  • the above alloying levels were selected to evaluate the affects of adding the relatively lighter elements titanium and niobium, increasing the levels of tungsten, hafnium, and relatively lighter elements such as aluminum and molybdenum, and reducing the levels of heavier elements such as tantalum and rhenium in alloys based on N6.
  • the approach of the investigation was also to maintain the total gamma-prime precipitation hardening phase while evaluating the affects of altering the amounts of rhenium, molybdenum, and tungsten that go into the gamma phase.
  • the high-temperature strength of a nickel-base superalloy is directly related to the volume fraction of the gamma-prime phase, which in turn is directly related to the total amount of the gamma prime-forming elements (aluminum, titanium, tantalum, niobium, and hafnium) present. Based on these relationships, the composition and volume fraction of the gamma-prime phase and the amounts of the gamma prime-forming elements required to maintain a given strength level can be approximately estimated based on the starting chemistry of the alloy and some basic assumptions about the phases that form.
  • an alloy having the desired level of creep strength for a HPT blade should contain at least as much gamma prime-forming elements (about 15.8 atomic percent of aluminum, tantalum, niobium, titanium, and hafnium combined) and as much gamma-forming elements (about 4.7 atomic percent of rhenium, molybdenum, and tungsten combined) as nominally contained in N6.
  • gamma prime-forming elements about 15.8 atomic percent of aluminum, tantalum, niobium, titanium, and hafnium combined
  • gamma-forming elements about 4.7 atomic percent of rhenium, molybdenum, and tungsten combined
  • FIGS. 4-6 are graphs plotting time to stress rupture for Alloys 1-14 in comparison to historical averages for N6 (“N6 avg”). Samples from each alloy were machined to form conventional creep test specimens and stress rupture tested in accordance with ASTM E139 at stress and temperature combinations of about 40 ksi (about 276 MPa) and about 1800° F. (about 980° C.), about 20 ksi (about 138 MPa) and about 2000° F. (about 1090° C.), and about 13 ksi (about 90 MPa) and about 2100° F. (about 1150° C.). Specimens from all but one alloy exhibited stress rupture strength approaching N6 at 1800° F., and Alloys 9, 10, and 11 exhibited the best overall stress rupture performance at the three test temperatures.
  • FIG. 7 is a graph plotting axial-axial high cycle fatigue (HCF) life at about 1600° F. (about 870° C.) for Alloys 9, 10, and 11 in comparison to N6 baseline data.
  • HCF tests were conducted under the stress-controlled condition and about 60 Hz cyclic loading. The data indicate that the HCF lives of Alloys 9, 10, and 11 were equal or better than the N6 baseline at the temperature tested.
  • alloys 9, 10, 11 On the basis of Alloys 9, 10, 11, an alloy having the approximate broad and nominal compositions (by weight) summarized in Table II is believed to have properties similar to N6 and therefore suitable for use as an alloy for hot gas path components of gas turbine engines, as well as other applications in which similar properties are required.
  • the densities of Alloys 9, 10, and 11 were about 0.319 lbs/in 3 (about 8.82 g/cm 3 ), about 0.316 lbs/in 3 (about 8.74 g/cm 3 ), and about 0.317 lbs/in 3 (about 8.77 g/cm 3 ), respectively. It is believed that an alloy within the ranges set forth in Table II can be satisfactorily heat treated using the treatment described above.
  • niobium, tantalum, tungsten, and rhenium appeared to be particularly important for both strength and microstructural stability (resistance to TCP formation).
  • data obtained with the alloys of Table I coated with diffusion aluminide coatings showed that certain alloys of Table I appeared to exhibit lower incidence of TCP phases if they contained, by weight, 0.75% (e.g., less than 1%) niobium, 6% (e.g., less than 7%) tungsten, and 4% (e.g., less than 5%) tantalum.
  • strength and microstructural stability could be further promoted by adjusting the compositions set forth in Table 11 to contain, by weight, about 4.0% tantalum, about 6.0% tungsten, and about 5.0% rhenium.
  • Alloys 9, 10, and 11 were further characterized on the basis of, in comparison to the nominal composition of N6 (Table 1), their nominal decreases in the levels of the relatively heavy elements tantalum and rhenium and their nominal increases in the levels of aluminum, tungsten, molybdenum, niobium, titanium, and hafnium levels (of which all but tungsten and hafnium are significantly less dense than tantalum and rhenium).
  • delta additions and delta reductions are summarized for Alloys 9, 10, and 11 in Table III, as is the ratio of delta additions to delta reductions for each alloy (delta ratio).
  • ALLOY 9 ALLOY 10 ALLOY 11 ALLOY 14 ⁇ Al 0.25 0.50 0.25 0.375 ⁇ W 1.2 0.2 0.2 0.7 ⁇ Mo 0.1 0.1 0.1 0.1 ⁇ Nb 0.75 0.75 0.75 1.13 ⁇ Ti 0.3 0.3 0.3 0.3 ⁇ Hf 0.4 0.4 0.4 0.4 Delta Addition 3.0 2.25 2.0 3.005 ⁇ Ta 3.2 3.2 2.2 1.7 ⁇ Re 0.4 0.4 1.4 0.9 Delta Reduction 3.6 3.6 3.6 2.6 Delta Ratio 0.83 0.62 0.55 1.15
  • Alloys 15-25 in Table IV below were selected to evaluate the affects of limiting tantalum and niobium levels to the minimum present in Alloys 9, 10, and 11, reducing the tungsten content, and increasing the molybdenum content.
  • the approach taken with Alloys 15-25 is to approximately maintain levels of gamma prime-forming elements similar to that nominally contained in N6 (about 15.8 atomic percent of aluminum, tantalum, niobium, titanium, and hafnium combined) without increasing density. Alloys 15-25 also reflect the intent to maintain a delta ratio of less than one.
  • Alloys 15-25 can generally be summarized as covering the ranges and nominal compositions (by weight) summarized in Table V below.
  • Table V TABLE V RANGE NOMINAL Al 6.00 to 6.25 6.1 Ta 4.0 to 5.0 4.0 Cr 2.0 to 6.0 4.2 W 6.0 to 7.0 6.0 Mo 1.5 to 3.0 2.25 Re 4.0 to 5.0 4.75 Nb 0.5 to 1.0 0.75 Co 10.0 to 12.0 10.0 Ti 0.25 to 1.0 0.3 C 0.01 to 0.05 0.03 B 0.001 to 0.005 0.004 Y 0 to 0.01 0.004 Hf 0.5 to 1.0 0.60 Ni balance balance

Abstract

A nickel-base alloy that exhibits a desirable balance of mechanical properties, environmental properties, and microstructural stability suitable for gas turbine engine applications. The nickel-base alloy is in the form of a single-crystal casting consisting of, by weight, 5.75% to 6.5% aluminum, 4% to 5% tantalum, 2% to 6% chromium, 5.5% to 7% tungsten, 1.5% to 3% molybdenum, 4% to 5% rhenium, up to 1.0% niobium, 10% to 16% cobalt, up to 1% titanium, 0.01% to 0.05% carbon, up to 0.005% boron, up to 0.01% yttrium, 0.5% to 1.0% hafnium, the balance nickel and incidental impurities. The alloy has a density of not more than 0.320 lbs/in3 (about 8.87 g/cm3), and contains a combined amount of aluminum, tungsten, molybdenum, niobium, titanium, and hafnium specified relative to the combined amount of tantalum and rhenium.

Description

    BACKGROUND OF THE INVENTION
  • The present invention generally relates to nickel-base alloys. More particularly, this invention relates to a nickel-base superalloy capable of being cast as a single-crystal article and exhibiting desirable properties for use in gas turbine engine applications.
  • The superalloy commercially known as René N6, disclosed in commonly-assigned U.S. Pat. No. 5,455,120, has a nominal composition of, by weight, about 12.5% Co, 4.2% Cr, 7.2% Ta, 5.75% Al, 5.8% W, 5.4% Re, 1.4% Mo, 0.2% Hf, 0.05% C, 0.004% B, 0.01% Y, the balance nickel and incidental impurities. N6 is well known to have a number of very desirable properties for gas turbine engine applications, such as the high pressure turbine blades and vanes of aircraft gas turbine engines.
  • As with the formulation of other superalloys, the composition of N6 is characterized by controlled concentrations of certain critical alloying elements to achieve a desired mix of properties. For use in gas turbine engine applications, such properties include high temperature creep strength, oxidation and corrosion resistance, resistance to low and high cycle fatigue (LCF and HCF), and single-crystal castability. While N6 performs well in applications within gas turbine engines, improvements would be desirable. Often of interest is the desire to reduce weight and cost, the latter of which is due in part to alloying constituents such as tantalum and rhenium. However, obtaining such reductions is difficult in view of the desire to maintain or often improve other properties of the alloy, including oxidation resistance and microstructural stability. With regard to the latter issue, microstructural instability is known to occur in various high strength superalloys when protected with coatings containing relatively high levels of aluminum, such as a diffusion aluminide environmental coating or bond coat. In particular, aluminum migration out of such coatings and into the underlying superalloy substrate can result in the formation of topologically close-packed (TCP) phases that, if present at sufficiently high levels, reduce the load-carrying capability of the alloy. The incidence of TCP phases has been associated with superalloys that contain significant amounts of refractory elements such as rhenium, tungsten, tantalum, hafnium, molybdenum, niobium, and zirconium.
  • BRIEF SUMMARY OF THE INVENTION
  • The present invention provides a nickel-base alloy that exhibits a desirable balance of high-temperature strength (including creep resistance), oxidation and corrosion resistance, resistance to low and high cycle fatigue, castability, and microstructural stability so as to be suitable for components of gas turbine engines, such as the high pressure turbine blades and vanes of gas turbine engines. These properties are achieved with an alloy that is lower in density than the superalloy known as René N6, and in which relatively higher levels of aluminum, tungsten, molybdenum, niobium (columbium), titanium, and hafnium are present and relatively lower levels of tantalum and rhenium are present as compared to N6.
  • According to the invention, the nickel-base alloy is in the form of a single-crystal casting consisting of, by weight, 5.75% to 6.5% aluminum, 4% to 5% tantalum, 2% to 6% chromium, 5.5% to 7% tungsten, 1.5% to 3% molybdenum, 4% to 5% rhenium, up to 1.0% niobium, 10% to 16% cobalt, up to 1% titanium, 0.01% to 0.05% carbon, up to 0.005% boron, up to 0.01% yttrium, 0.5% to 1.0% hafnium, the balance nickel and incidental impurities. Importantly, the density of the alloy is not more than and preferably less than 0.320 lbs/in3 (about 8.87 g/cm3). In preferred embodiments, molybdenum is present in an amount greater than 1.5 weight percent, molybdenum is present in an amount greater than 1.5 weight percent, rhenium and tantalum are each present in an amount less than 5 weight percent, and hafnium is present in an amount greater than 0.5 weight percent.
  • As noted above, the nickel-base alloy of the present invention nominally contains more aluminum, tungsten, molybdenum, niobium, titanium, and hafnium and less tantalum and rhenium than N6. For the purpose of characterizing the alloy, these groups of alloys are designated as “delta addition” and “delta reduction” elements, respectively. According to the present invention, the ratio of delta addition to delta reduction elements (hereinafter, delta ratio) is less than 1.0. The limitation that the value of the delta ratio is less than unity reflects the determination of this invention that, contrary to conventional wisdom, the combination of (Al+Mo+W+Ti+Hf+Nb) is, by weight, a more potent strengthener than (Re+Ta).
  • The alloy of this invention is believed to have properties comparable to, and in some instances better than, those of the N6 alloy, particularly with the above-noted restriction on the delta ratio, which allows for lower tantalum and rhenium contents. Consequently, the alloy of this invention provides an excellent lower density (weight) and potentially lower-cost alternative to N6.
  • Other objects and advantages of this invention will be better appreciated from the following detailed description.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 depicts a high pressure turbine blade that can be formed from the nickel-base superalloy of the present invention.
  • FIGS. 2 through 7 are graphs plotting yield strength, tensile strength, 1800° F. rupture, 2000° F. rupture, 2100F rupture, and 1600° F. high cycle fatigue life of alloys prepared during investigations leading to the present invention.
  • DETAILED DESCRIPTION OF THE INVENTION
  • The present invention was the result of an effort to develop a nickel-base alloy having properties comparable to the nickel-base alloy commercially known as René N6, but with a chemistry that reduces the density and cost of the alloy while maintaining or improving high temperature strength (including creep resistance), oxidation resistance, fatigue resistance, castability, and microstructural stability (resistance to TCP formation) for use in such applications as the hot gas flow path of gas turbine engines. As an example, FIG. 1 depicts a high pressure turbine (HPT) blade 10 having an airfoil 12, a dovetail 14 by which the blade 10 is anchored to a turbine disk (not shown), and a platform 16 therebetween. While the advantages of this invention will be described with reference to components of a gas turbine, such as the high pressure turbine blade 10 shown in FIG. 1, the teachings of this invention are generally applicable to other components that require high temperature capabilities.
  • In a first round of investigations, alloys having the approximate chemistries set forth in Table I below were formulated. Specimens of various sizes were machined from single crystal slab castings that had been solution heat treated at about 2370° F. (about 1300° C.) for about six hours and then aged at about 1975° F. (about 1080° C.) for about four hours. The densities of the alloys were in the range of about 0.315 to 0.319 lbs/in3 (about 8.73 to about 8.84 g/cm3), which is significantly less than the density of N6 (0.323 lbs/in3; about 8.95 g/cm3). For reference, Table I also includes the nominal composition for N6.
    TABLE I
    Al Ta Cr W Mo Re Nb Co Ti C B Y Hf Ni
    N6 5.75 7.2 4.2 5.8 1.4 5.4 12.5 0.05 0.004 0.01 0.2 bal.
    1 6.25 4.0 4.2 6.0 1.5 4.0 1.50 10.0 0.3 0.03 0.004 0.004 0.6 61.6
    2 6.25 5.0 4.2 7.0 1.5 4.0 0.75 10.0 0.3 0.03 0.004 0.004 0.6 60.4
    3 6.00 5.0 4.2 6.0 1.5 5.0 1.50 10.0 0.3 0.03 0.004 0.004 0.6 59.9
    4 6.25 4.0 4.2 7.0 1.5 4.0 1.50 10.0 0.3 0.03 0.004 0.004 0.6 60.6
    5 6.25 5.0 4.2 7.0 1.5 5.0 0.75 10.0 0.3 0.03 0.004 0.004 0.6 59.4
    6 6.25 5.0 4.2 6.0 1.5 5.0 1.50 10.0 0.3 0.03 0.004 0.004 0.6 59.6
    7 6.00 5.0 4.2 7.0 1.5 4.0 1.50 10.0 0.3 0.03 0.004 0.004 0.6 59.9
    8 6.00 4.0 4.2 7.0 1.5 5.0 1.50 10.0 0.3 0.03 0.004 0.004 0.6 59.9
    9 6.00 4.0 4.2 7.0 1.5 5.0 0.75 10.0 0.3 0.03 0.004 0.004 0.6 60.6
    10  6.25 4.0 4.2 6.0 1.5 5.0 0.75 10.0 0.3 0.03 0.004 0.004 0.6 61.4
    11  6.00 5.0 4.2 6.0 1.5 4.0 0.75 10.0 0.3 0.03 0.004 0.004 0.6 61.6
    12  6.00 4.0 4.2 6.0 1.5 4.0 0.75 10.0 0.3 0.03 0.004 0.004 0.6 62.6
    13  6.125 4.5 4.2 6.5 1.5 4.5 1.13 10.0 0.3 0.03 0.004 0.004 0.6 60.6
    14  6.125 5.5 4.2 6.5 1.5 4.5 1.13 10.0 0.3 0.03 0.004 0.004 0.6 59.6
  • The above alloying levels were selected to evaluate the affects of adding the relatively lighter elements titanium and niobium, increasing the levels of tungsten, hafnium, and relatively lighter elements such as aluminum and molybdenum, and reducing the levels of heavier elements such as tantalum and rhenium in alloys based on N6. The approach of the investigation was also to maintain the total gamma-prime precipitation hardening phase while evaluating the affects of altering the amounts of rhenium, molybdenum, and tungsten that go into the gamma phase. As known in the art, the high-temperature strength of a nickel-base superalloy is directly related to the volume fraction of the gamma-prime phase, which in turn is directly related to the total amount of the gamma prime-forming elements (aluminum, titanium, tantalum, niobium, and hafnium) present. Based on these relationships, the composition and volume fraction of the gamma-prime phase and the amounts of the gamma prime-forming elements required to maintain a given strength level can be approximately estimated based on the starting chemistry of the alloy and some basic assumptions about the phases that form. It was initially viewed that an alloy having the desired level of creep strength for a HPT blade should contain at least as much gamma prime-forming elements (about 15.8 atomic percent of aluminum, tantalum, niobium, titanium, and hafnium combined) and as much gamma-forming elements (about 4.7 atomic percent of rhenium, molybdenum, and tungsten combined) as nominally contained in N6. However, other properties important to HPT blades and other hot gas flow path components, such as fatigue life, castability, metallurgical stability, and oxidation resistance, cannot be predicted from amounts of these and other elements.
  • Tensile and yield strengths of the alloys are summarized in FIGS. 2 and 3, in which “N6 avg” identifies historical averages for N6. The data indicate that yield and tensile strengths of the specimens were similar to and generally higher than, respectively, N6.
  • FIGS. 4-6 are graphs plotting time to stress rupture for Alloys 1-14 in comparison to historical averages for N6 (“N6 avg”). Samples from each alloy were machined to form conventional creep test specimens and stress rupture tested in accordance with ASTM E139 at stress and temperature combinations of about 40 ksi (about 276 MPa) and about 1800° F. (about 980° C.), about 20 ksi (about 138 MPa) and about 2000° F. (about 1090° C.), and about 13 ksi (about 90 MPa) and about 2100° F. (about 1150° C.). Specimens from all but one alloy exhibited stress rupture strength approaching N6 at 1800° F., and Alloys 9, 10, and 11 exhibited the best overall stress rupture performance at the three test temperatures.
  • FIG. 7 is a graph plotting axial-axial high cycle fatigue (HCF) life at about 1600° F. (about 870° C.) for Alloys 9, 10, and 11 in comparison to N6 baseline data. The HCF tests were conducted under the stress-controlled condition and about 60 Hz cyclic loading. The data indicate that the HCF lives of Alloys 9, 10, and 11 were equal or better than the N6 baseline at the temperature tested.
  • On the basis of Alloys 9, 10, 11, an alloy having the approximate broad and nominal compositions (by weight) summarized in Table II is believed to have properties similar to N6 and therefore suitable for use as an alloy for hot gas path components of gas turbine engines, as well as other applications in which similar properties are required. The densities of Alloys 9, 10, and 11 were about 0.319 lbs/in3 (about 8.82 g/cm3), about 0.316 lbs/in3 (about 8.74 g/cm3), and about 0.317 lbs/in3 (about 8.77 g/cm3), respectively. It is believed that an alloy within the ranges set forth in Table II can be satisfactorily heat treated using the treatment described above.
    TABLE II
    BROAD PREFERRED NOMINAL
    Al 5.75 to 6.5 6.00 to 6.5 6.125
    Ta 4.0 to 5.0 4.0 to 5.0 4.5
    Cr 2.0 to 6.0 2.0 to 6.0 4.2
    W 5.5 to 7.0 5.5 to 7.0 6.5
    Mo 1.5 to 3.0 1.5 to 3.0 1.5
    Re 4.0 to 5.0 4.0 to 5.0 4.5
    Nb 0 to 1.0 0.5 to 1.0 0.75
    Co 10.0 to 16.0 10.0 to 12.0 10.0
    Ti 0 to 1.0 0.25 to 1.0 0.3
    C 0.01 to 0.05 0.01 to 0.05 0.03
    B 0 to 0.005 0.001 to 0.005 0.004
    Y 0 to 0.01 0 to 0.01 0.004
    Hf 0.5 to 1.0 0.5 to 1.0 0.60
    Ni balance balance balance
  • It should be noted that the relative amounts of niobium, tantalum, tungsten, and rhenium appeared to be particularly important for both strength and microstructural stability (resistance to TCP formation). Specifically, data obtained with the alloys of Table I coated with diffusion aluminide coatings showed that certain alloys of Table I appeared to exhibit lower incidence of TCP phases if they contained, by weight, 0.75% (e.g., less than 1%) niobium, 6% (e.g., less than 7%) tungsten, and 4% (e.g., less than 5%) tantalum. On this basis, it was theorized that strength and microstructural stability could be further promoted by adjusting the compositions set forth in Table 11 to contain, by weight, about 4.0% tantalum, about 6.0% tungsten, and about 5.0% rhenium.
  • Because of their excellent mechanical properties and low densities, Alloys 9, 10, and 11 were further characterized on the basis of, in comparison to the nominal composition of N6 (Table 1), their nominal decreases in the levels of the relatively heavy elements tantalum and rhenium and their nominal increases in the levels of aluminum, tungsten, molybdenum, niobium, titanium, and hafnium levels (of which all but tungsten and hafnium are significantly less dense than tantalum and rhenium). The sums of these increased and decreased levels, designated herein as delta additions and delta reductions, respectively, are summarized for Alloys 9, 10, and 11 in Table III, as is the ratio of delta additions to delta reductions for each alloy (delta ratio).
    TABLE III
    ALLOY 9 ALLOY 10 ALLOY 11 ALLOY 14
    ΔAl 0.25 0.50 0.25 0.375
    ΔW 1.2 0.2 0.2 0.7
    ΔMo 0.1 0.1 0.1 0.1
    ΔNb 0.75 0.75 0.75 1.13
    ΔTi 0.3 0.3 0.3 0.3
    ΔHf 0.4 0.4 0.4 0.4
    Delta Addition 3.0 2.25 2.0 3.005
    ΔTa 3.2 3.2 2.2 1.7
    ΔRe 0.4 0.4 1.4 0.9
    Delta Reduction 3.6 3.6 3.6 2.6
    Delta Ratio 0.83 0.62 0.55 1.15
  • From the above, it can be seen that the delta ratios of Alloys 9, 10, and 11 were less than one. For comparison, the delta ratio of Alloy 14 is also calculated in Table Ill. In view of these results, it was concluded that the delta ratios of the alloys could be used as indicators of their abilities to exhibit desirable mechanical properties relative to their densities, with lower delta ratios evidencing lower densities as compared to N6. Based on the nominal composition of N6 as set forth in Table I, the calculation of the delta ratio for alloys within the scope of this invention can be made using the following formulas:
    Delta Ratio=(Al-5.75+W-5.8+Mo-1.4+Nb+Ti+Hf-0.2)/(7.2-Ta+5.4-Re)
    or (Al+W+Mo+Nb+Ti+Hf−13.15)/(12.6−Ta—Re)
  • A second round of alloys was then identified for further testing based on the knowledge gained from the first round. The alloying levels for the second round of alloys identified as Alloys 15-25 in Table IV below were selected to evaluate the affects of limiting tantalum and niobium levels to the minimum present in Alloys 9, 10, and 11, reducing the tungsten content, and increasing the molybdenum content. In part, the approach taken with Alloys 15-25 is to approximately maintain levels of gamma prime-forming elements similar to that nominally contained in N6 (about 15.8 atomic percent of aluminum, tantalum, niobium, titanium, and hafnium combined) without increasing density. Alloys 15-25 also reflect the intent to maintain a delta ratio of less than one.
    TABLE IV
    Al Ta Cr W Mo Re Nb Co Ti Ru C B Y Hf
    N6 5.7 7.2 4.2 5.5 1.4 5.4 12.5 0.0 0.004 0.01 0.2
    15 6.1 4.0 4.2 5.5 2.25 4.5 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
    16 6.1 4.0 4.2 6.0 3.00 4.5 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
    17 6.1 4.0 4.2 6.0 2.25 4.5 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
    18 6.1 4.0 4.2 5.5 3.00 5.0 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
    19 6.1 4.0 4.2 5.5 2.25 5.0 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
    20 6.1 4.0 4.2 6.0 3.00 5.0 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
    21 6.1 4.0 4.2 6.0 2.25 5.0 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
    22 6.1 4.0 4.2 6.0 3.00 5.0 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
    23 6.1 4.0 4.2 6.0 1.50 5.0 0.4 10.0 0.5 0.0 0.0 0.004 0.004 0.6
    24 6.1 4.0 4.2 6.0 1.50 5.0 0.7 10.0 0.5 0.0 0.0 0.004 0.004 0.6
    25 6.1 4.0 4.0 6.5 2.25 5.0 0.7 10.0 0.3 0.0 0.0 0.004 0.004 0.6
  • Alloys 15-25 can generally be summarized as covering the ranges and nominal compositions (by weight) summarized in Table V below.
    TABLE V
    RANGE NOMINAL
    Al 6.00 to 6.25 6.1
    Ta 4.0 to 5.0 4.0
    Cr 2.0 to 6.0 4.2
    W 6.0 to 7.0 6.0
    Mo 1.5 to 3.0 2.25
    Re 4.0 to 5.0 4.75
    Nb 0.5 to 1.0 0.75
    Co 10.0 to 12.0 10.0
    Ti 0.25 to 1.0  0.3
    C 0.01 to 0.05 0.03
    B 0.001 to 0.005 0.004
    Y   0 to 0.01 0.004
    Hf 0.5 to 1.0 0.60
    Ni balance balance
  • Preparation of Alloys 15-25 for testing is currently underway.
  • While the invention has been described in terms of a preferred embodiment, it is apparent that other forms could be adopted by one skilled in the art. Therefore, the scope of the invention is to be limited only by the following claims.

Claims (20)

1. A single-crystal casting formed of a nickel-base alloy consisting of, by weight:
5.75% to 6.5% aluminum;
about 4.0% up to 5.0% tantalum;
2.0% to 6.0% chromium;
5.5% to 7.0% tungsten;
1.5% to 3.0% molybdenum;
4.0% to about 5.0% rhenium;
up to 1.0% niobium;
10.0% to 16.0% cobalt;
up to 1.0% titanium;
0.01% to 0.05% carbon;
up to 0.005% boron;
up to 0.01% yttrium;
0.5% to 1.0% hafnium;
the balance nickel and incidental impurities;
where in the density of the alloy is not greater than 3.20 lb/in3 and the alloy has a delta ratio of less than one calculated with the formula

(Al+W+Mo+Nb+Ti+Hf−13.15)/(12.6−Ta—Re)
wherein Al, W, Mo, Nb, Ti, Hf, Ta, and Re are the levels of aluminum, tungsten, molybdenum, niobium, titanium, hafnium, tantalum, and rhenium, respectively, in weight percent.
2. The single-crystal casting according to claim 1, wherein the alloy consists of, by weight, 6.0 to 6.25% aluminum, 4.0 to 5.0% tantalum, 2.0 to 6.0% chromium, 5.5 to 7.0% tungsten, 1.5 to 3.0% molybdenum, 4.0 to 5.0% rhenium, 0.5 to 1.0% niobium, 10.0 to 12.0% cobalt, 0.25 to 1.0% titanium, 0.01 to 0.05% carbon, 0.001 to 0.005% boron, 0 to 0.01% yttrium, 0.5 to 1.0% hafnium, the balance nickel and incidental impurities.
3. The single-crystal casting according to claim 1, wherein the alloy consists of, by weight, 6.0 to 6.25% aluminum, 4.0 to 5.0% tantalum, about 4.2% chromium, 6.0 to 7.0% tungsten, about 1.5% molybdenum, 4.0 to 5.0% rhenium, about 0.75% niobium, about 10.0% cobalt, about 0.3% titanium, about 0.03% carbon, about 0.004% boron, about 0.004% yttrium, about 0.6% hafnium, the balance nickel and incidental impurities.
4. The single-crystal casting according to claim 1, wherein the alloy contains of, by weight, about 4.0% tantalum, about 6.0% tungsten, and about 5.0% rhenium.
5. The single-crystal casting according to claim 1, wherein the alloy has a density of 0.315 to 0.319 lb/in3.
6. The single-crystal casting according to claim 1, wherein the alloy has a delta ratio of less than 0.9.
7. The single-crystal casting according to claim 1, wherein the casting is a gas turbine engine component.
8. A single-crystal casting formed of a nickel-base alloy consisting of, by weight:
6.00% to 6.25% aluminum;
about 4.0% up to 5.0% tantalum;
2.0% to 6.0% chromium;
about 6.0% up to 7.0% tungsten;
1.5% to 3.0% molybdenum;
4.0% to about 5.0% rhenium;
0.5% to 1.0% niobium;
10.0% to 12.0% cobalt;
0.25% to 1.0% titanium;
0.01% to 0.05% carbon;
0.001% to 0.005% boron;
up to 0.01% yttrium;
0.5% to 1.0% hafnium;
the balance nickel and incidental impurities;
where in the density of the alloy is less than 3.20 lb/in3 and the alloy has a delta ratio of less than one calculated with the formula

(Al+W+Mo+Nb+Ti+Hf−13.15)/(12.6−Ta—Re)
wherein Al, W, Mo, Nb, Ti, Hf, Ta, and Re are the levels of aluminum, tungsten, molybdenum, niobium, titanium, hafnium, tantalum, and rhenium, respectively, in weight percent.
9. The single-crystal casting according to claim 8, wherein the molybdenum content in the alloy is greater than 2.0 weight percent.
10. The single-crystal casting according to claim 8, wherein the molybdenum content in the alloy is greater than 2.25 weight percent.
11. The single-crystal casting according to claim 8, wherein the alloy has a density of 0.315 to 0.318 lbs/in3.
12. The single-crystal casting according to claim 8, wherein the alloy has a delta ratio of less than 0.9.
13. The single-crystal casting according to claim 8, wherein the alloy contains of, by weight, about 4.0% tantalum, about 6.0% tungsten, and about 5.0% rhenium.
14. The single-crystal casting according to claim 8, wherein the casting is a gas turbine engine component.
15. The single-crystal casting according to claim 8, wherein the alloy consists of, by weight, about 6.1% aluminum, about 4.0% tantalum, 4.0 to 4.2% chromium, 5.5 to 6.5% tungsten, 1.50 to 3.0% molybdenum, 4.5 to 5.0% rhenium, about 0.75% niobium, about 10.0% cobalt, 0.3 to 0.5% titanium, about 0.03% carbon, about 0.004% boron, about 0.004% yttrium, about 0.6% hafnium, the balance nickel and incidental impurities.
16. The single-crystal casting according to claim 15, wherein the molybdenum content in the alloy is greater than 2.0 weight percent.
17. The single-crystal casting according to claim 15, wherein the molybdenum content in the alloy is greater than 2.25 weight percent.
18. The single-crystal casting according to claim 15, wherein the alloy has a density of 0.315 to 0.318 lbs/in3.
19. The single-crystal casting according to claim 15, wherein the alloy has a delta ratio of less than 0.9.
20. The single-crystal casting according to claim 15, wherein the casting is a gas turbine engine component.
US11/162,221 2005-09-01 2005-09-01 Nickel-base superalloy Abandoned US20070044869A1 (en)

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