# US 11,440,090 B2 · Composition for material for liquid metal deposition or additive manufacturing, method and product

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- Number: US 11,440,090 B2
- Document ID: US11440090B2
- Status: Granted
- Kind: B2
- Application number: 17/282,306
- Filed: 2019-08-02
- Published: 2021-10-21
- Granted: 2022-09-13
- Earliest claimed: 2018-10-12
- Assignees: Siemens Energy Global GmbH & Co. KG
- Applicants: Siemens Energy Global GmbH & Co. KG
- Inventors: Bernd Burbaum; Henning Hanebuth; Andreas Rucki; Ahmed Kamel
- Web page: https://patentgrep.com/patent/US11440090B2

## CPC

- B23K 35/3033: {Ni as the principal constituent}
- B22F 1/09: {Mixtures of metallic powders}
- B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B23K 15/0086: {welding for purposes other than joining, e.g. build-up welding}
- B23K 15/0093: {characterised by the properties of the materials to be welded}
- B23K 26/0006: {taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence)}
- B23K 26/14: using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor (B23K26/12 takes precedence)
- B23K 26/1476: {Features inside the nozzle for feeding the fluid stream through the nozzle}
- B23K 26/342: Build-up welding
- B23K 35/304: {with Cr as the next major constituent}
- B23K 35/3046: {Co as the principal constituent}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C22C 19/05: with chromium
- C22C 19/055: {with the maximum Cr content being at least 20% but less than 30%}
- C22C 19/056: {with the maximum Cr content being at least 10% but less than 20%}
- C22C 19/057: {with the maximum Cr content being less 10%}
- C22C 30/00: Alloys containing less than 50% by weight of each constituent
- B22F 2301/15: Nickel or cobalt
- B23K 2101/001: {Turbines}
- B23K 2103/26: {Alloys of Nickel and Cobalt and Chromium}
- C22C 19/07: based on cobalt
- Y02P 10/25: Process efficiency
- Y10T 428/12944: Ni-base component
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composition of a nickel based alloy mixture which can be used for welding via especially liquid metal deposition or as a powder bed of an additive manufacturing method. A metallic powder mixture includes (in wt %): a cobalt (Co) or nickel (Ni) based super alloy with a content of 20% to 60%, a NiCoCrAlY-composition with a content of 70% to 30% and a metallic braze material with a content between 10% to 5%. The melting point of the braze material is at least 10K lower than the melting point of the nickel or cobalt based superalloy.

## Claims

### Claim 1

A metallic powder mixture, usable for build up via liquid metal deposition or any additive manufacturing method, comprising (in wt %):
a nickel (Ni) based superalloy with a content of 20% to 60%,
a NiCoCrAlY-composition with a content of 70% to 30% and
a metallic braze material with a content between 10% to 5%,
wherein the melting point of the braze material is at least 10K lower than the melting point of the nickel based superalloy, wherein the nickel (Ni) based superalloy comprises (in wt %):
Cobalt (Co) 18.0%-19.0%
wherein the NiCoCrAlY composition comprises (in wt %):
14%-22% Chromium (Cr)
9.0%-11.5% Aluminum (Al)
0.3%-0.5% Yttrium (Y)
11%-26% Cobalt (Co)
0%-1.0% Silicon (Si),
0%-2.5% Rhenium (Re)
and remainder Nickel (Ni).

### Claim 2 (depends on 1)

The metallic powder mixture according to claim 1, comprising (in wt %):
Nickel (Ni)
from 51.00% to 58.00%
Carbon (C)
from 0.02% to 0.05%
Chromium (Cr)
from 11.00% to 15.00%
Molybdenum (Mo)
from 0.05% to 0.35%
Tungsten (W)
from 1.80% to 5.80%
Titanium (Ti)
from 0.10% to 0.50%
Aluminum (Al)
from 6.50% to 8.50%
Boron (B)
from 0.05% to 0.10%
Tantalum (Ta)
from 0.80% to 2.20%
Hafnium (Hf)
from 0.20% to 0.80%
Yttrium (Y)
from 0.05% to 0.25%
Rhenium (Re)
from 0.40% to 1.10%.

### Claim 3 (depends on 1)

The metallic powder mixture according to claim 1, wherein the nickel (Ni) base superalloy further comprises (in wt %):
Carbon (C)
0.05%-0.20%
Chromium (Cr)
8.0%-23.0%
Tungsten (W)
2.0%-10.0%
Titanium (Ti)
0.6%-5.0%
Aluminum (Al)
1.0%-6.0%
Boron (B)
0.005%-0.02%
optionally
Molybdenum (Mo)
0.0%-4.5%
Tantalum (Ta)
0.0%-4.5%
Hafnium (Hf)
0.6%-1.5%
Zirconium (Zr)
0.02%-0.12%
Niobium (Nb)
0.5%-1.0%
no Yttrium (Y) and/or
no Rhenium (Re),
remainder Nickel (Ni).

### Claim 4

A metallic powder mixture, usable for build up via liquid metal deposition or any additive manufacturing method, comprising (in wt %):
a nickel (Ni) based superalloy with a content of 20% to 60%,
a NiCoCrAlY-composition with a content of 70% to 30% and
a metallic braze material with a content between 10% to 5%,
wherein the melting point of the braze material is at least 10K lower than the melting point of the nickel based superalloy,
wherein the nickel (Ni) based superalloy comprises (in wt %):
Nickel (Ni)
61.6%
Carbon (C)
0.08%
Chromium (Cr)
8.25%
Molybdenum (Mo)
0.50%
Tungsten (W)
9.50%
Titan (Ti)
0.75%
Aluminum (Al)
5.55%
Boron (B)
0.02%
Tantalum (Ta)
3.20%
Hafnium (Hf)
1.30%,
no Yttrium (Y) and/or
no Rhenium (Re)
wherein the NiCoCrAlY composition comprises (in wt %):
14%-22%
Chromium (Cr)
9.0%-11.5%
Aluminum (Al)
0.3%-0.5%
Yttrium (Y)
11%-26%
Cobalt (Co)
0%-1.0%
Silicon (Si),
0%-2.5%
Rhenium (Re)
and remainder Nickel (Ni).

### Claim 5 (depends on 1)

The metallic powder mixture according to claim 1, wherein the braze alloy comprises (in wt %):
Nickel (Ni)
40%-70%
Chromium (Cr)
8.0%-23.0%
Cobalt (Co)
5.0%-20.0%
Aluminum (Al)
1.0%-10.0%
Boron (B)
0.5%-4.00%
optionally
Tantalum (Ta)
1.0%-4.0%
Molybdenum (Mo)
0.0%-5.0%
Hafnium (Hf)
0.05%-0.09%
Tungsten (W)
2.0%-10.0%
Titanium (Ti)
0.5%-5.0%
no Yttrium (Y),
and/or no Rhenium (Re),
and/or no Carbon (C).

### Claim 6 (depends on 1)

The metallic powder mixture according to claim 1, wherein the braze alloy comprises (in wt %):
Nickel (Ni)
69.2%
Chromium (Cr)
14.0%
Cobalt (Co)
10.0%
Aluminum (Al)
3.5%
Boron (B)
0.75%
Tantalum (Ta)
2.5%
Hafnium (Hf)
0.06%,
no Yttrium (Y) and/or
no Tungsten (W),
and/or no Titanium (Ti),
and/or no Molybdenum (Mo),
and/or no Rhenium (Re),
and/or no Carbon (C).

### Claim 7 (depends on 1)

The metallic powder mixture according to claim 1, wherein the metallic braze material comprises:
Silicon (Si) and/or Magnesium (Mg) and/or Manganese (Mn).

### Claim 8 (depends on 1)

The metallic powder mixture according to claim 1,
wherein the braze material is a nickel-based alloy with at least 0.5 wt % Boron (B), and/or
at least 1.0 wt % Silicon (Si),
and/or
at least 2.0 wt % Magnesium (Mg).

### Claim 9 (depends on 1)

The metallic powder mixture according to claim 1,
wherein the NiCoCrAlY composition consists of NiCoCrAlY and optionally Tantalum (Ta), Rhenium (Re), Iron (Fe) and/or Silicon (Si).

### Claim 10 (depends on 1)

The metallic powder mixture according to claim 1,
wherein the NiCoCrALY composition comprises (in wt %):
20%-22%
Chromium (Cr)
10.5%-11.5%
Aluminum (Al)
0.3%-0.5%
Yttrium (Y)
1.5%-2.5%
Rhenium (Re)
11%-13%
Cobalt (Co) and
remainder Nickel.

### Claim 11 (depends on 1)

The metallic powder mixture according to claim 1,
wherein the NiCoCrAlY composition comprises (in wt %):
15%-21%
Chromium (Cr)
24%-26%
Cobalt (Co)
9.0%-11.5%
Aluminum (Al)
0.05%-0.7%
Yttrium (Y)
0.5%-2.0%
Rhenium (Re) and
remainder Nickel.

### Claim 12 (depends on 1)

The metallic powder mixture according to claim 1,
wherein the NiCoCrAlY composition comprises (in wt %):
22%-24%
Cobalt (Co)
14%-16%
Chromium (Cr)
10.5%-11.5%
Aluminum (Al)
0.2%-0.4%
Yttrium (Y), optionally
0.3%-0.9%
Tantalum (Ta) and
remainder Nickel (Ni).

### Claim 13 (depends on 1)

A method to build up metallic material, comprising:
building up a metallic powder mixture of claim 1.

### Claim 14 (depends on 13)

The method according to claim 13,
wherein the building up of the metallic powder mixture is used for welding using powder cladding, wire welding or for additive manufacturing using powder beds.

### Claim 15 (depends on 1)

A product, comprising:
a metallic powder mixture according to claim 1.

### Claim 16 (depends on 15)

The product according to claim 15,
wherein first directly on a substrate a layer of a mixture consisting of a NiCoCrAlY, and
a nickel or cobalt based superalloy is applied on the substrate,
and then layers of the metallic powder mixture are applied.