A process for filling openings, including blind holes, through-holes, and cavities, in high temperature components. The process entails forming a powder mixture by mixing particles of at least a base alloy and a second alloy that contains a sufficient amount of a melting point depressant to have a l
A process for filling openings, including blind holes, through-holes, and cavities, in high temperature components. The process entails forming a powder mixture by mixing particles of at least a base alloy and a second alloy that contains a sufficient amount of a melting point depressant to have a lower melting temperature than the base alloy. The powder mixture is combined with a binder and compacted to form a compacted preform, which is then heated to remove the binder and form a rigid sintered preform. The sintered preform is produced, or optionally is further shaped, to have a cross-sectional shape and dimensions to achieve a clearance of up to 200 micrometers with the opening, after which the preform is placed in the opening and diffusion bonded within the opening to form a brazement comprising the particles of the base alloy dispersed in a matrix formed by the second alloy.
대표청구항▼
1. A process of filling a hole in a surface of a component formed of a nickel- or cobalt-base alloy, the process comprising: forming the hole to have an axial direction, a wall parallel to the axial direction and defining a cross-sectional shape of the hole perpendicular to the axial direction, and
1. A process of filling a hole in a surface of a component formed of a nickel- or cobalt-base alloy, the process comprising: forming the hole to have an axial direction, a wall parallel to the axial direction and defining a cross-sectional shape of the hole perpendicular to the axial direction, and at least one interlocking feature separated from the surface of the component by the wall, the interlocking feature comprising a recess that diverges from the hole in a direction transverse to the axial direction of the hole;forming a powder mixture by mixing particles of at least a base alloy and a second alloy, the base alloy constituting about 30 to about 90 weight percent of the powder mixture, the second alloy containing a sufficient amount of a melting point depressant to have a lower melting temperature than the base alloy;combining the powder mixture with a binder and then compacting the combined powder mixture and binder to form a compacted preform;heating the compacted preform to remove the binder and form a sintered preform;placing the sintered preform within the hole so that a perimeter thereof is surrounded by the wall of the hole, wherein the perimeter defines a cross-sectional shape of the sintered preform that corresponds to the cross-sectional shape of the hole and has dimensions to achieve a clearance of not greater than 200 micrometers between the perimeter of the sintered preform and the wall of the hole; and thendiffusion braze bonding the sintered preform within the hole to form a brazement within the hole comprising the particles of the base alloy dispersed in a matrix formed by the second alloy, wherein during the diffusion braze bonding step the sintered preform flows from the perimeter thereof into the recess and following the diffusion braze bonding step the brazement has a protrusion that extends into the recess and increases the shear surface area of a bond between the brazement and the wall of the hole. 2. The process according to claim 1, wherein the sintered preform has a density of at least 90% of theoretical. 3. The process according to claim 1, wherein the base alloy consists essentially of, by weight, about 2.5 to 11% cobalt, 7 to 9% chromium, 3.5 to 11% tungsten, 4.5 to 8% aluminum, 2.5 to 6% tantalum, 0.02 to 1.2% titanium, 0.1 to 1.8% hafnium, 0.1 to 0.8% molybdenum, 0.01 to 0.17% carbon, up to 0.08% zirconium, up to 0.60 silicon, up to 2.0 rhenium, the balance nickel and incidental impurities. 4. The process according to claim 1, wherein the second alloy consists essentially of, by weight, about 9 to 10% cobalt, 11 to 16% chromium, 3 to 4% aluminum, 2.25 to 2.75% tantalum, 1.5 to 3.0% boron, up to 5% silicon, up to 1.0% yttrium, the balance nickel and incidental impurities. 5. The process according to claim 1, wherein the particles of the base and second alloys are mixed together at a weight ratio of about 30:70 to about 90:10, respectively. 6. The process according to claim 1, wherein the cross-sectional shape and dimensions of the sintered preform are achieved by shaping the sintered preform prior to placing the sintered preform in the hole. 7. The process according to claim 1, wherein the brazement completely closes the hole following the diffusion braze bonding step. 8. The process according to claim 1, further comprising the steps of casting the component to contain an internal cooling passage formed by a core, and creating a cooling hole connected to the internal cooling passage of the component by forming the sintered preform to have a through-hole therein that defines the cooling hole entirely through the brazement following the diffusion braze bonding step. 9. The process according to claim 1, wherein the component is a hot gas path component of a gas turbine. 10. The process according to claim 1, wherein the sintered preform does not protrude into or fill the recess. 11. The process according to claim 1, wherein the sintered preform comprises a protrusion that radially protrudes from the perimeter thereof and protrudes into the recess as a result of the placing step. 12. A process of filling a hole in a surface of a hot gas path component of a gas turbine, the component being cast from a nickel- or cobalt-base alloy and the hole being formed by a rod that supported a core within the component during casting of the component wherein the hole has an axial direction and a wall parallel to the axial direction and defining a cross-sectional shape of the hole perpendicular to the axial direction, the process comprising: forming the hole to have at least one interlocking feature separated from the surface of the component by the wall of the hole, the interlocking feature comprising a recess that diverges from the hole in a direction perpendicular to the axial direction of the hole;forming a powder mixture by mixing particles of at least a base alloy and a second alloy, the base alloy constituting about 30 to about 90 weight percent of the powder mixture, the second alloy containing a sufficient amount of a melting point depressant to have a lower melting temperature than the base alloy;combining the powder mixture with a binder and then compacting the combined powder mixture and binder to form a compacted preform;heating the powder mixture to remove the binder and form a sintered preform having a cross-section larger than the hole;shaping the sintered preform to produce a cross-sectional shape and dimensions to achieve a diametrical clearance of not greater than 200 micrometers with the hole;placing the sintered preform within the hole so that a perimeter thereof is surrounded by the wall of the hole and the sintered preform at least partially fills the hole, wherein the perimeter defines a cross-sectional shape of the sintered preform that corresponds to the cross-sectional shape of the hole and has dimensions to achieve a clearance of not greater than 200 micrometers between the perimeter of the sintered preform and the wall of the hole; and thendiffusion braze bonding the sintered preform within the hole to at least partially fill the hole with a brazement comprising the particles of the base alloy dispersed in a matrix formed by the second alloy, wherein during the diffusion braze bonding step the sintered preform flows from the perimeter thereof into the recess and following the diffusion braze bonding step the brazement has a protrusion that extends into the recess and increases the shear surface area of a bond between the brazement and the wall of the hole. 13. The process according to claim 12, wherein the sintered preform has a density of at least 90% of theoretical. 14. The process according to claim 12, wherein the base alloy consists essentially of, by weight, about 9 to 11% cobalt, 8 to 8.8% chromium, 9.5 to 10.5% tungsten, 5.3 to 5.7% aluminum, 2.8 to 2.3% tantalum, 0.9 to 1.2% titanium, 1.2 to 1.6% hafnium, 0.5 to 0.8% molybdenum, 0.13 to 0.17% carbon, 0.03 to 0.08% zirconium, the balance nickel and incidental impurities. 15. The process according to claim 12, wherein the second alloy consists essentially of, by weight, about 9 to 10% cobalt, 11 to 16% chromium, 3 to 4% aluminum, 2.25 to 2.75% tantalum, 1.5 to 3.0% boron, up to 5% silicon, up to 1.0% yttrium, the balance nickel and incidental impurities. 16. The process according to claim 12, wherein the particles of the base and second alloys are mixed together at a weight ratio of about 40:60 to about 70:30, respectively. 17. The process according to claim 12, wherein the shaping step comprises a machining operation and the sintered preform does not have a recast surface when placed in the hole. 18. The process according to claim 12, wherein the brazement completely closes the hole following the diffusion braze bonding step. 19. The process according to claim 12, wherein the component contains an internal cooling passage formed by the core during casting of the component, the process further comprising creating a cooling hole connected to the internal cooling passage of the component by forming the sintered preform to have a through-hole therein that defines the cooling hole entirely through the brazement following the diffusion braze bonding step. 20. The process according to claim 12, wherein the component is chosen from the group consisting of turbine buckets and turbine nozzles. 21. The process according to claim 12, wherein the sintered preform does not protrude into or fill the recess. 22. The process according to claim 12, wherein the sintered preform comprises a protrusion that radially protrudes from the perimeter thereof and protrudes into the recess as a result of the placing step.
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이 특허에 인용된 특허 (11)
Budinger David E. (Milford OH) Ferrigno Stephen J. (Cincinnati OH) Murphy Wendy H. (Cincinnati OH), Alloy powder mixture for brazing of superalloy articles.
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