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WO2018183066A1 - Alliages à base de nickel à haute température - Google Patents

Alliages à base de nickel à haute température Download PDF

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Publication number
WO2018183066A1
WO2018183066A1 PCT/US2018/023677 US2018023677W WO2018183066A1 WO 2018183066 A1 WO2018183066 A1 WO 2018183066A1 US 2018023677 W US2018023677 W US 2018023677W WO 2018183066 A1 WO2018183066 A1 WO 2018183066A1
Authority
WO
WIPO (PCT)
Prior art keywords
nickel
alloy
alloys
gas turbine
properties
Prior art date
Application number
PCT/US2018/023677
Other languages
English (en)
Inventor
Mehmet Gungor
Phillip DRAA
Original Assignee
Siemens Aktiengesellschaft
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens Aktiengesellschaft filed Critical Siemens Aktiengesellschaft
Priority to US16/499,603 priority Critical patent/US20200102628A1/en
Priority to EP18716784.6A priority patent/EP3565914B1/fr
Publication of WO2018183066A1 publication Critical patent/WO2018183066A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/057—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion

Definitions

  • This disclosure relates in general to the field of nickel-based alloys. More particularly, it relates to such alloys that may possess improved high-temperature oxidation resistance, corrosion resistance, castability, and mechanical properties such as creep strength and thermomechanical fatigue resistance.
  • alloys designed to withstand degradation and failure in the gas turbine industry may operate at service temperatures in excess of 1100 °C. Such high temperatures can accelerate oxidation and corrosion processes and microstructural
  • Nickel-based alloys can exhibit and retain desirable physical, mechanical, and chemical properties at high temperatures.
  • Such alloys sometimes referred to as 'superalloys,' are alloys composed primarily of nickel, with the addition of several other elements.
  • High-temperature nickel-based alloys are often used to form components of gas turbines such as, e.g., blades, vanes, and ring segments, which are typically exposed to high temperatures, mechanical forces, oxidation, and corrosive environments during service.
  • gas turbines such as, e.g., blades, vanes, and ring segments, which are typically exposed to high temperatures, mechanical forces, oxidation, and corrosive environments during service.
  • Different alloying elements can provide certain benefits, e.g., by forming and/or stabilizing precipitates (which may be continuous or discontinuous), stabilizing grain boundaries, forming protective coatings when exposed to high temperatures and/or certain environments, etc.
  • the types and amounts of these additive elements can be selected for their ability to improve overall high temperature performance and may focus on one or more beneficial effects, e.g., resistance to creep, oxidation, corrosion, fatigue, and other thermo-mechanical or chemical failure modes at elevated temperatures.
  • discontinuous precipitates, etc. may be related to composition in simple systems. However, with multiple alloying components present the effects become far more complex. Different elements may substitute for others in precipitate phases, preferentially migrate to boundaries, stabilize lattices, alter chemical reactivity, etc.
  • U.S. Patent No. 5,399,313 to Ross et al. describes a nickel- based superalloy that has good tolerance for low-angle grain boundaries when formed as a single crystal, as well as a balance between oxidation and corrosion resistance at high temperatures.
  • Another nickel-based alloy described in U.S. Patent Publication No. US 2014/0241936 of Deschandol et al., modifies a known alloy, Rene 125, by reducing the concentrations of certain components to reduce the appearance of cracks when casting the alloy while maintaining certain desirable properties of Rene 125.
  • Many other examples of nickel-based alloys can be found in the literature, with various combinations of elements and concentrations thereof that may provide certain desirable properties or compromises between such properties.
  • Another nickel-based alloy described in International Patent Publication No. WO 2015/183955 of Gong et al., has relatively low levels of rhenium to provide improved single-crystal processing while maintaining other desirable high-temperature properties.
  • alloys with greater creep resistance often sacrifice good hot corrosion resistance and thermo-mechanical fatigue resistance.
  • alloys exhibiting greater hot corrosion resistance tend to exhibit lower levels of creep resistance and/or thermo-mechanical fatigue resistance.
  • Certain alloy compositions may focus on optimizing one or more of such properties at the expense of others.
  • nickel-based alloys e.g., superalloys
  • exhibit desirable levels of various properties such as creep resistance, oxidation resistance, corrosion resistance, and fatigue resistance, when exposed to temperatures and conditions that may exist in such environments as turbine engines.
  • the herein described exemplary embodiments pertain to new nickel -based alloy compositions that can provide a balance of desirable properties for use in severe environments, including high-temperature environments such as those that may be present gas turbines.
  • a nickel-based alloy that comprises the following elements, with the associated composition ranges provided as a range of approximate weight percents (wt%) in the alloy: Cr: 7.25-7.75; Co: 8.6-9.6; Mo: 0.6-1.0; W: 8.5-9.1; Al: 6.0-6.4; Ti: 0.6-1.0; Ta: 4.0-4.8; C: 0.06-0.10; B: 0.01-0.02; and Hf: 0.4-0.6; with the balance of the alloy consisting of Ni and unavoidable or trace impurities.
  • a nickel-based alloy can be provided that has a nominal composition of: 7.5 wt% Cr; 9.1 wt% Co; 0.8 wt% Mo; 8.8 wt% W; 6.2 wt% Al; 0.8 wt% Ti; 4.4 wt% Ta; 0.08 wt% C; 0.015 wt% B; 0.5 wt% Hf; and the balance of the alloy consisting of Ni and unavoidable or trace impurities.
  • a nickel-based alloy that comprises the following elements, with the associated composition ranges provided as a range of approximate weight percents (wt%) in the alloy: Cr: 7.25-7.75; Co: 8.6- 9.4; Mo: 0.6-1.0; W: 8.5-9.1; Al: 6.0-6.4; Ti: 0.6-1.0; Ta: 3.8-4.4; C: 0.06-0.10; B: 0.01-0.02; Hf: 0.4-0.6; and Re: 0.4-0.6, with the balance of the alloy consisting of Ni and unavoidable or trace impurities.
  • a nickel-based alloy can be provided that has the following nominal composition: 7.7 wt% Cr; 9.0 wt% Co; 0.8 wt% Mo; 8.8 wt% W; 6.2 wt% Al; 0.8 wt% Ti; 4.1 wt% Ta; 0.08 wt% C; 0.015 wt% B; 0.5 wt% Hf; 0.5 wt% Re; and the balance of the alloy consisting of Ni and unavoidable or trace impurities.
  • enclosures can provide components of a gas turbine system, such as blades or vanes, where such components comprise at least one of the alloy compositions described herein.
  • a gas turbine system can be provided in which at least one blade or vane comprises or is made of at least one of the alloy compositions described herein.
  • FIG. 1 is a perspective view of a gas turbine component in accordance with an exemplary embodiment of the present disclosure.
  • Embodiments of the present can provide nickel-based alloys having certain compositions, where such alloys may possess desirable properties such as, e.g., high creep resistance and improved oxidation resistance. Such alloys may also exhibit other desirable properties such as, e.g., good castability, and good corrosion resistance when used in high- temperature environments.
  • embodiments of the disclosure can provide alloys (and components made therefrom) that exhibit desirable properties when solidified as single crystals, directionally solidified, and when cast in a conventional equiaxed solidification process.
  • a nickel-based alloy that comprises the following elements, with the associated composition ranges provided as a range of approximate weight percents (wt%) in the alloy: Cr: 7.25-7.75; Co: 8.6-9.6; Mo: 0.6-1.0; W: 8.5-9.1; Al: 6.0-6.4; Ti: 0.6-1.0; Ta: 4.0-4.8; C: 0.06-0.10; B: 0.01-0.02; and Hf: 0.4-0.6; with the balance of the alloy comprising Ni and unavoidable impurities.
  • a nickel-based alloy can be provided that has the following nominal composition: 7.5 wt% Cr; 9.1 wt% Co; 0.8 wt% Mo; 8.8 wt% W; 6.2 wt% Al; 0.8 wt% Ti; 4.4 wt% Ta; 0.08 wt% C; 0.015 wt% B; 0.5 wt% Hf; and the balance of the alloy consisting of Ni and unavoidable impurities.
  • the total wt% of Cr+Mo+W in these embodiments is 17 wt%, which is higher than the sum of these component weight percentages in many other nickel-based alloys.
  • Such compositions can provide increased solid solution strengthening when the alloy is exposed to higher temperatures.
  • Table 1 Nominal composition and composition ranges for a nickel-based alloy in accordance with certain embodiments of the disclosure.
  • the aluminum composition of 6.20 wt% e.g., between 6.0 and 6.4 wt%) is greater than that in many other nickel-based alloys.
  • This higher level of Al can provide a superior oxidation resistance with lower levels of chromium and titanium present.
  • Such reduction of chromium levels can also allow introduction of higher concentrations of capable refractory metals such as tungsten and molybdenum for further high-temperature
  • the total amount of Al+Cr in the alloy compositions disclosed herein can provide good resistance to oxidation and hot corrosion, e.g., in a temperature range of 600 to 1100° C, which are typical service temperatures for large gas turbine blades and vanes. Such improved properties at elevated temperatures may extend service life of turbine components formed of the alloys disclosed herein to 100,000 hours or more.
  • the disclosed aluminium levels can also enhance gamma prime ( ⁇ ') precipitation, thereby also improving creep stability and strength at high temperatures.
  • Gamma prime is the principal high-temperature strengthening phase that occurs in the nickel- rich gamma ( ⁇ ) phase of such alloys.
  • the enhanced high-temperature strengthening can be achieved with relatively low levels of titanium and tantalum, which also promote gamma prime precipitate formation to improve strength.
  • the total weight percent of the gamma prime formers in a nickel-based alloy in accordance with embodiments of the present disclosure, Al+Ta+Ti, is between 10.6 and 12.2 wt%.
  • Such total composition percentage of these elements can provide suitable amounts of gamma prime phases for creep resistance while balancing the effects of these elements on other material properties of the alloy as described herein.
  • the higher levels of Al in embodiments of the present disclosure allow a reduction in the amount of Ti while maintaining desirable high-temperature strengthening properties. Reduced levels of Ti can also promote a more adherent oxide scale formation in harsh environments, thereby improving environmental protection of the alloy.
  • Certain alloying elements such as tantalum, chromium, molybdenum, and tungsten can form carbides, which segregate to grain boundaries to retard grain boundary sliding. This inhibition of grain boundary displacement (e.g., grain-boundary sliding) at high temperatures can improve creep strength.
  • grain boundary displacement e.g., grain-boundary sliding
  • excessive amounts of carbide particles at grain boundaries can promote nucleation of microcracks at the grain boundaries, e.g., at the matrix- carbide interface, and result in increased material failure by intergranular fracture.
  • embodiments of the present disclosure provide alloys having balanced compositions of refractory elements such as, e.g., Ta, W, Mo, and Cr, to maximize certain high-temperature properties such as creep strength while reducing or avoiding adverse effects such as, e.g., formation of harmful topologically close-packed (TCP) phases and excessive carbides.
  • TCP phases typically form as plates within the matrix, e.g., when sufficiently high levels of such refractory elements are present, and can adversely affect mechanical properties such as ductility and creep resistance.
  • TCP phases can retain elements that strengthen gamma and gamma prime phases in a non-useful form, thereby reducing creep strength, and they can also serve as crack initiators because of their brittle nature.
  • a nickel-based alloy that also includes rhenium.
  • Rhenium can improve creep strength, e.g., based on its low diffusion rates in nickel-based superalloys, which can help to stabilize precipitate phases and structures at elevated temperatures.
  • rhenium can also promote formation of topologically close-packed (TCP) phases in nickel-based alloys when present in sufficiently high concentrations, and such intermetallic TCP phases can degrade certain alloy properties.
  • TCP topologically close-packed
  • a nickel-based alloy that includes the following elements, with the associated composition ranges provided as a range of approximate weight percents (wt%) in the alloy: Cr: 7.25-7.75; Co: 8.6- 9.4; Mo: 0.6-1.0; W: 8.5-9.1; Al: 6.0-6.4; Ti: 0.6-1.0; Ta: 3.8-4.4; C: 0.06-0.10; B: 0.01-0.02; Hf: 0.4-0.6; and Re: 0.4-0.6, with the balance of the alloy consisting of Ni and unavoidable impurities.
  • a nickel-based alloy can be provided that has the following nominal composition: 7.7 wt% Cr; 9.0 wt% Co; 0.8 wt% Mo; 8.8 wt% W; 6.2 wt% Al; 0.8 wt% Ti; 4.1 wt% Ta; 0.08 wt% C; 0.015 wt% B; 0.5 wt% Hf; 0.5 wt% Re; and the balance of the alloy consisting of Ni and unavoidable impurities.
  • nickel-based alloys such as those described herein, certain atoms can substitute for nickel atoms in a unit cell to improve solid solution strengthening.
  • Such strengthening can be more effective with larger elements such as, e.g., molybdenum as compared to, e.g., cobalt.
  • the atomic radius difference between Ni and Mo is +12%, whereas that between Ni and Co is +3%.
  • the large mismatch between Ni and Mo can lead to formation of incoherent precipitates under certain conditions, e.g. at higher concentrations of Mo.
  • Co tends to exhibit greater solubility in the nickel lattice and thus may be more stable at elevated temperatures, in part because the lower lattice mismatch between Ni and Co results in a lower driving force for precipitate coarsening processes at elevated temperatures.
  • Table 2 Nominal composition and composition ranges for a nickel- based alloy in accordance with further embodiments of the disclosure.
  • One of the advantages of the alloy compositions described herein is a limitation of the overall ⁇ / ⁇ ' lattice mismatch.
  • a large lattice mismatch between these phases can increase the rate of precipitate coarsening at high temperatures (e.g., driven by a reduction in the mechanical strain energy that can be achieved by formation of larger, discontinuous precipitates). Accordingly, limiting the overall lattice mismatch can improve long-term stability of the alloy in service, thereby facilitating longer component lifetimes and a reduced likelihood of mechanical failure.
  • embodiments of the present disclosure can provide nickel- based alloys that have effective solid-solution strengthening in the gamma phase while also maintaining desirable levels of the gamma-prime phase.
  • desirable material properties of the alloy such as, e.g., creep resistance, tensile strength, ductility, damage tolerance, and low-cycle fatigue resistance, can be optimized by the presence of high- temperature solid-solution strengthening elements in the alloy composition.
  • Elements that contribute to solid-solution strengthening in nickel -based alloys include, e.g., cobalt, chromium, molybdenum, tantalum, tungsten, and rhenium.
  • the total wt % of W+Ta+Mo+Cr+Co is 30.6 wt%.
  • the total wt % of W+Ta+Mo+Cr+Co+Re is 30.2 wt%.
  • a rotor blade or guide vane used in gas turbines can be provided, where such blade or vane can be formed of an alloy having one of the exemplary compositions described herein.
  • blade or vane can be formed of an alloy having one of the exemplary compositions described herein.
  • third- and fourth-row blades in large gas turbines tend to be exposed to higher temperatures in service as the firing (max inlet temperature increases.
  • Such blades can perform more reliably and safely when formed of nickel-based alloys such as those described herein, e.g., alloys having compositions as shown in Tables 1 and 2.
  • FIG. 1 shows a perspective view of a typical rotor blade 130 of a gas turbine, which extends along a longitudinal axis 121.
  • the gas turbine may be, e.g., a gas turbine of an aircraft or of a power plant for generating electricity, a steam turbine, or a compressor.
  • the blade 130 includes a securing region 400, an adjoining blade platform 403, an airfoil 406, and a blade tip 415.
  • a blade root 183 can be provided in the fastening region 400, which may be used to secure the rotor blade 130 to a shaft or a disk (not shown).
  • the blade 130 has a leading edge 409 and a trailing edge 412 for a medium (e.g., hot combustion gases) to flow past.
  • the blade 130 can be either hollow or solid in form. If the blade 130 is hollow, it can include cooling holes 418 to facilitate flow of internal cooling gases.
  • the blade 130 can be formed of a nickel -based alloy such as those described herein, e.g., using conventional directional solidification or equiaxed casting techniques. Such blade 130 can provide the benefits associated with the alloy compositions described herein, e.g., improved creep resistance and corrosion resistance while in service.
  • a guide vane for a gas turbine can be provided, where the vane is made from an alloy having one of the compositions described herein.
  • the vane can be similar in appearance to the blade 130 shown in FIG. 1, with a further blade platform 403 provided at the blade tip 415.
  • Other specific configurations of turbine vanes and/or blades can be provided in still further embodiments of the disclosure.
  • a gas turbine system in which the gas turbine system includes at least one blade or vane formed using an alloy having one of the compositions described herein.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

La présente invention concerne de nouvelles compositions d'alliage à base de nickel, comprenant 7,25 à 7,75 % en poids de Cr, 0,6 à 1,0 % en poids de Mo, 8,5 à 9,1 % en poids de W, 6,0 à 6,4 % en poids d'Al, 0,6 à 1,0 % en poids de Ti, 0,06 à 0,10 % en poids de C, 0,01 à 0,02 % en poids de B, 0,4 à 0,6 % en poids de Hf, et au moins un constituant parmi : 8,6 à 9,6 % en poids de Co et 4,0 à 4,8 % en poids de Ta ; ou 8,6 à 9,4 % en poids de Co, 3,8 à 4,4 % en poids de Ta, et 0,4 à 0,6 % en poids de Re, le reste étant du nickel et des impuretés à l'état de trace. L'invention concerne également des aubes de turbine à gaz ou des palettes directrices, les aubes ou les palettes étant formées à l'aide d'un alliage possédant de telles compositions.
PCT/US2018/023677 2017-03-31 2018-03-22 Alliages à base de nickel à haute température WO2018183066A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US16/499,603 US20200102628A1 (en) 2017-03-31 2018-03-22 High-temperature nickel-based alloys
EP18716784.6A EP3565914B1 (fr) 2017-03-31 2018-03-22 Alliages à base de nickel à haute température

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201762479573P 2017-03-31 2017-03-31
US62/479,573 2017-03-31

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WO2018183066A1 true WO2018183066A1 (fr) 2018-10-04

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Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4589937A (en) * 1982-09-22 1986-05-20 General Electric Company Carbide reinforced nickel-base superalloy eutectics having improved resistance to surface carbide formation
GB2235697A (en) * 1986-12-30 1991-03-13 Gen Electric Nickel-base superalloys
US5399313A (en) 1981-10-02 1995-03-21 General Electric Company Nickel-based superalloys for producing single crystal articles having improved tolerance to low angle grain boundaries
US5611670A (en) * 1993-08-06 1997-03-18 Hitachi, Ltd. Blade for gas turbine
JPH11310839A (ja) * 1998-04-28 1999-11-09 Hitachi Ltd 高強度Ｎｉ基超合金方向性凝固鋳物
US6054096A (en) * 1982-12-27 2000-04-25 United Technologies Corporation Stable heat treatable nickel superalloy single crystal articles and compositions
US20110076181A1 (en) * 2009-09-30 2011-03-31 General Electric Company Nickel-Based Superalloys and Articles
US20140241936A1 (en) 2011-09-28 2014-08-28 Snecma Nickel alloy
WO2015183955A2 (fr) 2014-05-27 2015-12-03 Questek Innovations Llc Alliages de nickel monocristallin pouvant être très facilement traités

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5399313A (en) 1981-10-02 1995-03-21 General Electric Company Nickel-based superalloys for producing single crystal articles having improved tolerance to low angle grain boundaries
US4589937A (en) * 1982-09-22 1986-05-20 General Electric Company Carbide reinforced nickel-base superalloy eutectics having improved resistance to surface carbide formation
US6054096A (en) * 1982-12-27 2000-04-25 United Technologies Corporation Stable heat treatable nickel superalloy single crystal articles and compositions
GB2235697A (en) * 1986-12-30 1991-03-13 Gen Electric Nickel-base superalloys
US5611670A (en) * 1993-08-06 1997-03-18 Hitachi, Ltd. Blade for gas turbine
JPH11310839A (ja) * 1998-04-28 1999-11-09 Hitachi Ltd 高強度Ｎｉ基超合金方向性凝固鋳物
US20110076181A1 (en) * 2009-09-30 2011-03-31 General Electric Company Nickel-Based Superalloys and Articles
US20140241936A1 (en) 2011-09-28 2014-08-28 Snecma Nickel alloy
WO2015183955A2 (fr) 2014-05-27 2015-12-03 Questek Innovations Llc Alliages de nickel monocristallin pouvant être très facilement traités

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EP3565914B1 (fr) 2020-12-16
US20200102628A1 (en) 2020-04-02
EP3565914A1 (fr) 2019-11-13

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