United Technologies Corporation

Power Systems Mfg., LLC

Alstom Technology Limited

United Technology Corporation

Charles M Biondo

Daniel P DeLuca

Chris C Rhemer

William J Gostic

Howard B Jones

Robert J Kraft

Alan David Cetel

David N Duhl

Brian R Mack

J Page Strohl

Mark A Minnich

Bradford A Cowles

Maurice L Gell

Jeffery W Samuelson

Gerhard E Fuchs

James D Formanack

Timothy P Fuesting

Frank Hoegler

John C Tanzola

Christopher D Parmley

Stanley T Wlodek

A nickel-based alloy suitable for casting gas turbine components having a lower density and basic heat treating process while achieving improved strength is disclosed. Multiple embodiments of the alloy are disclosed capable of providing both directionally-solidified and equiaxed castings. Also disclosed is a method of making a cast and heat treated article utilizing the improved nickel-base alloy.

Nickel-base alloy for gas turbine applications

The present invention relates to an improved single crystal nickel base superalloy and a process for making same. The single crystal nickel base superalloy has a composition comprising 3 to 12 wt % chromium, up to 3 wt % molybdenum, 3 to 10 wt % tungsten, up to 5 wt % rhenium, 6 to 12 wt % tantalum, 4 to 7 wt % aluminum, up to 15 wt % cobalt, up to 0.05 wt % carbon, up to 0.02 wt % boron, up to 0.1 wt % zirconium, up to 0.8 wt % hafnium, up to 2.0 wt % niobium, up to 1.0 wt % vanadium, up to 0.7 wt % titanium, up to 10 wt % of at least one element selected from the group consisting of ruthenium, rhodium, palladium, osmium, iridium, platinum, and mixtures thereof, and the balance essentially nickel. The single crystal nickel base superalloy has a microstructure which is pore-free and eutectic &#x3b3;&#x2013;&#x3b3;' free and which has a gamma prime morphology with a bimodal &#x3b3;&#x2032; distribution.

Modified advanced high strength single crystal superalloy composition

A wear reduction means for a fuel nozzle interface of an industrial gas turbine combustor is disclosed. The wear reduction means includes a replaceable insert welded into the engagement location of the fuel nozzle tip. The fuel nozzle tip is coated with a material harder than the replaceable insert, such that any wear due to mechanical contact of the mating components is directed to the replaceable insert.

Means for wear reduction in a gas turbine combustor

A multiple directional axes structural support system for use as the aft end mount for a gas turbine transition duct to a turbine inlet is disclosed. The mounting system is configured to withstand high temperature gradients and mechanical loads associated with gas turbine environments while allowing multiple axes adjustment and interface capability between the transition duct and the turbine inlet casing. A spherical ball joint allows for rotation about multiple (three) axes to compensate for relative thermal growth, manufacturing tolerances, and assembly tolerances between mating surfaces. The ball joint is held in place by fitted spacers, bosses, and a through-bolt, that when torqued will dampen out unwanted vibrations in the multi-axis mounting system.

Three degrees of freedom aft mounting system for gas turbine transition duct

Compositional requirements and processing improvements are disclosed which improve the hydrogen embrittlement resistance and the fatigue resistance in air of nickel base single crystal articles. The compositional requirements enlarge the difference between the &ggr;&prime; solvus temperature and the incipient melting temperature, thus enabling the solution of &ggr;/&ggr;&prime; eutectic islands without causing incipient melting, while hot isostatic pressing and careful melt practice eliminate porosity and carbides, borides and nitrides, all of which act as crack initiation sites.

Nickel base superalloy single crystal articles with improved performance in air and hydrogen

A nickel base superalloy, having either columnar or equiaxed grain structure, which has significantly improved resistance to hydrogen embrittlement, and to fatigue in air. The material is processed so as to be essentially free of script type carbides, .gamma./.gamma.' eutectic islands and porosity. The processing includes heat treating above the .gamma.' solvus temperature to solution the script type carbides and eutectic islands, followed by HIP to eliminate the porosity.

Method for making a hydrogen embrittlement resistant .gamma.'

A nickel base superalloy, having either columnar or equiaxed grain structure, which has significantly improved resistance to hydrogen embrittlement, and to fatigue in air is disclosed. The superalloy consists essentially of, in weight percent, about 0.006-0.17 carbon, about 6.0-22.0 chromium, up to about 17.0 cobalt, up to about 9.0 molybdenum, up to about 12.5 tungsten, up to about 5.0 titanium, up to about 6.7 aluminum, up to about 4.5 tantalum, up to about 2.5 hafnium, up to about 18.5 iron, up to about 3.25 rhenium, up to about 1.25 columbium, remainder nickel. The microstructure of the superalloy consists essentially of a plurality of fine, discrete carbide particles, .gamma.' precipitates in a .gamma. matrix, and is essentially free of script carbides, .gamma./.gamma.' eutectic islands and porosity.

Nickel base superalloy columnar grain and equiaxed materials with

The present invention relates to a method for making a gamma prime precipitation strengthened nickel base alloy having an improved resistance to hydrogen embrittlement, particularly crack propagation. The alloy is cast, heat treated to dissolve substantially all the gamma-gamma prime eutectic islands and script carbides without causing incipient melting, cooled to below 1000.degree. C., HIP'ed to eliminate porosity, precipitation treated and aged. The alloy has a microstructure which is essentially free of script carbides, gamma-gamma prime eutectic islands and porosity. The microstructure further includes a plurality of regularly occurring large barrier gamma prime precipitates and a continuous field of fine cuboidal gamma prime precipitates surrounding the large barrier gamma prime precipitates.

Method for making a nickel base alloy having improved resistance to

A repaired nickel-based superalloy substrate that has applied thereon a nickel-based polycrystalline repair alloy comprising 0.03-2.5 weight % hafnium, 0.003-0.32% boron, 0.02-0.16% yttrium and 0.007-0.35% zirconium. The present invention further provides a repaired single crystal alloy substrate that has applied thereon a repair alloy wherein the repair alloy's composition is similar to or the same as the single crystal alloy composition except that the repair alloy additionally comprises at least one grain boundary strengthener element and at least one element that enhances oxidation resistance.

Repaired nickel based superalloy

The present invention relates to a heat treated, gamma prime precipitation strengthened nickel base alloy having an improved resistance to hydrogen embrittlement, particularly crack propagation. The alloy has a microstructure which is essentially free of script carbides, gamma--gamma prime eutectic islands and porosity. The microstructure further includes a plurality of regularly occurring large barrier gamma prime precipitates and a continuous field of fine cuboidal gamma prime precipitates surrounding the large barrier gamma prime precipitates.

Nickel base superalloy articles with improved resistance to crack

Superalloy castings having large variations in section thickness are heat treated using a cyclic stress relief procedure, with the temperature being cycled between about 50.degree. F. (28.degree. C.) and 150.degree. F. (83.degree. C.) below the second phase particle solvus temperature, to relieve the residual stresses incurred during cooling within the mold following casting, followed by a solution cycle at a temperature about 25.degree. F. (14.degree. C.) below the second phase particle solvus temperature to dissolve some or all of the second phase particles.

Cyclic heat treatment for controlling grain size of superalloy castings

An abrasive, wear resistant layer is applied to the tip surface of a superalloy gas turbine blade by high temperature sintering operation which produces a high strength bond between the layer and the blade, minimizes gamma prime phase growth, and prevents recrystallization in the blade. Important features of the invention include the use of an inductively heated graphite susceptor to heat the blade, and a refractory metal shield which surrounds the airfoil and root portions of the blade while leaving the tip portion exposed to the heat source.

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Jupiter, FL, United States of America

Charles M Biondo