High performance wrought powder metal articles and method of manufacture
AssigneeROLLS-ROYCE plc
InventorsBruce A. Ewing, Sushil K. Jain, Kenneth A. Green, Randolph C. Helmink, Allister James
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Abstract
A nickel base powder metallurgy superalloy gas turbine engine disk for a compressor or turbine. The wrought powder metallurgy gas turbine engine disk has desirable fatigue crack growth resistance and a superior balance of tensile, creep rupture and low cycle fatigue strength characteristics. In one embodiment the disk defines a segregation free homogenous structure.
Claims39
A composition consisting essentially of, in weight percent, 0.015%-0.035% carbon, 15.5%-16.5% chromium, 14%-15.5% cobalt, 2.75%-3.25% molybdenum, 4.75%-5.25% titanium, 2.25%-2.50% aluminum, 1%-1.5% tungsten, 0.030%-0.090% zirconium, 0.020%-0.030% boron, up to 0.90% hafnium, and the balance nickel plus incidental impurities.
A composition comprising in weight percent, about 0.025% carbon, about 0.020% boron, about 0.035% zirconium, about 16% chromium, about 5% titanium, about 2.5% aluminum, about 14.75% cobalt, about 3% molybdenum, about 1.25% tungsten, about 0.75% hafnium, and the balance nickel plus incidental impurities.
A composition comprising in weight percent, about 0.025% carbon, about 0.030% boron, about 0.070% zirconium, about 16% chromium, about 5% titanium, about 2.5% aluminum, about 14.75% cobalt, about 3% molybdenum, about 1.25% tungsten, about 0.75% hafnium, and the balance nickel plus incidental impurities.
A gas turbine engine disk, comprising:
- a main body member formed of a gamma prime strengthened wrought powder metallurgy composition consisting essentially of, in weight percent, 0.015%-0.035% carbon, 15.5%-16.5% chromium, 14%-15.5% cobalt, 2.75%-3.25% molybdenum, 4.75%-5.25% titanium, 2.25%-2.50% aluminum, 1%-1.5% tungsten, 0.030%-0.090% zirconium, 0.020%-0.030% boron, up to 0.90% hafnium, and the balance nickel plus incidental impurities;
- and
- said main body member has a substantially segregation free homogenous microstructure having an average grain size within a range of about 25 microns to about 3 microns.
A process of preparing a nickel base powder metal superalloy gas turbine engine disk, comprising:
- furnishing a composition consisting essentially of, in weight percent, 0.015%-0.035% carbon, 15.5%-16.5% chromium, 14%-15.5% cobalt, 2.75%-3.25% molybdenum, 4.75%-5.25% titanium, 2.25%-2.50% aluminum, 1%-1.5% tungsten, 0.030%-0.090% zirconium, 0.020%-0.030% boron, up to 0.90% hafnium, and the balance nickel plus incidental impurities;
- consolidating the composition to produce a perform member;
- thermomechanically working the perform to produce a wrought member;
- and
- heat treating the wrought member.
A metal alloy consisting essentially of:
- in weight percent, 0.015%-0.035% carbon, 15.5%-16.5% chromium, 14%-15.5% cobalt, 2.75%-3.25% molybdenum, 4.75%-5.25% titanium, 2.25%-2.75% aluminum, 1%-1.5% tungsten, 0.030%-0.090% zirconium, 0.020%-0.050% boron, up to 0.90% hafnium, and the balance nickel plus incidental impurities, said metal alloy subjected to thermomechanical processing and heat treatment to produce an average grain size in the alloy of between about 3 microns and about 25 microns.
Dependencies are inferred from the claim text.