Directionally solidified superalloy weld wire
AssigneeGeneral Electric Company
InventorRussell W. Smashey
Life of this patent
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Abstract
A method for producing superalloy weld wire and weld wire having fewer inclusions, and specifically fewer hafnia inclusions, and superalloy weld wire, particularly hafnium-containing superalloy weld wire, produced by this method. The method includes producing directionally solidified cast rod in a diameter of less than about ½ inch. The rod preferably is produced by investment casting or by continuous casting. The directional solidification process results in rod having inclusions such as oxides and dirt segregated into portions of the casting where they are easily removed. The cast rod can then be formed into semi-finished weld wire using a single extrusion step, followed by grinding to the final required diameter.
Claims20
A method of producing weld wire having low inclusion content, comprising the steps of:
- casting a molten metal alloy having a preselected composition into a mold having at least one ingot cavity in the shape of a rod of a preselected diameter;
- directionally solidifying the rod-shaped ingot while feeding an advancing solidification interface with molten metal to eliminate creation of shrinkage cavities while forming grains substantially parallel to the axial direction of the rod-shaped ingot;
- removing an end of the rod-shaped ingot having inclusions and impurities;
- cutting the rod-shaped ingot into a plurality of preselected lengths;
- placing a plurality the preselected cut lengths into a container;
- filling the remaining volume of the container with an inert material;
- capping the container;
- sealing the capped container;
- extruding the container so as to form wire for welding having a preselected diameter;
- and
- removing the wire from the container.
A method of producing weld wire having low inclusion content, comprising the steps of;
- casting a molten superalloy having a preselected composition into a mold having at least one ingot cavity in the shape of a rod having a diameter of less than about ½ inch;
- directionally solidifying the rod-shaped ingot by feeding an advancing solidification interface with molten metal to eliminate creation of shrinkage cavities and simultaneously causing impurities and inclusions to segregate as slag to the top and sides of the ingot during solidification, while growing grains into the molten metal substantially parallel to the axial direction of the rod-shaped ingot;
- following completion of solidification, removing a portion of the rod-shaped ingot having inclusions and impurities;
- cutting the rod-shaped ingot into a plurality of preselected lengths;
- placing a plurality the preselected cut lengths of rod into a container;
- filling the remaining volume of the container with an inert oxide;
- capping the container;
- sealing the capped container;
- extruding the rod-filled container so as to form wire for welding having a preselected diameter;
- and
- removing the wire from the container.
Superalloy weld wire having low inclusion content manufactured by a process comprising the steps of:
- casting a molten superalloy having a preselected composition into a mold having at least one ingot cavity in the shape of a rod having a diameter of less than about ½ inch;
- directionally solidifying the rod-shaped ingot by feeding an advancing solidification interface with molten metal to eliminate creation of shrinkage cavities and simultaneously causing impurities and inclusions to segregate as slag to the top of the unsolidified ingot, while growing grains into the molten metal parallel to the axial direction of the rod-shaped ingot;
- following completion of solidification, removing a portion of the rod-shaped ingot having inclusions and impurities;
- cutting the rod-shaped ingot into a plurality of preselected lengths;
- placing a plurality the preselected cut lengths of rod into a container;
- filling the remaining volume of the container with an inert oxide;
- capping the container;
- sealing the capped container;
- extruding the rod-filled container so as to form wire for welding having a preselected diameter;
- removing the wire from the container;
- grinding to remove impurities from the exterior of the wire and to achieve the final preselected diameter.
Dependencies are inferred from the claim text.