Component repair materials

Abstract

A composition comprising Ni and the following additional components: (i) Co in an amount in the range from about 4.5 to about 11%; (ii) Cr in an amount in the range from about 7 to about 12%; (iii) Mo in an amount in the range from about 0.5 to about 1.4%; (iv) W in an amount in the range from about 1.8 to about 4.5%; (v) Re in an amount in the range from about 1.0 to about 2.6%; (vi) Al in an amount in the range from about 2.4 to about 5.6%; (vii) Ta in an amount in the range from about 2.4 to about 5.9%; (viii) Hf in an amount in the range from about 0.4% to about 6.0%; (ix) C in an amount up to about 0.1%; (x) B in an amount in the range from 0.2 to about 2.2%; (xi) Zr in the range from to about 0.02%; (xii) Fe in an amount in the range from about 0.07 to about 0.2%; and (xiii) Mn in an amount in the range from about 0.03 to about 0.1% wherein all percentages are by weight based on the total weight of the composition. The composition is particularly suited for braze repair of alloy materials e.g. superalloys in particular single crystal or directionally solidified alloys such as those used in the manufacture of turbine engines of aircraft etc.

1 - 18 . (Canceled).  
     
     
         19 . A composition comprising Ni and the following additional components: 
 (i) Co in an amount in the range from about 4.5 to about 11%;    (ii) Cr in an amount in the range from about 7 to about 12%;    (iii) Mo in an amount in the range from about 0.5 to about 1.4%;    (iv) W in an amount in the range from about 1.8 to about 4.5%;    (v) Re in an amount in the range from about 1.0 to about 2.6%;    (vi) Al in an amount in the range from about 2.4 to about 5.6%;    (vii) Ta in an amount in the range from about 2.4 to about 5.9%;    (viii) Hf in an amount in the range from about 2.5% to about 6.0%;    (ix) C in an amount up to about 0.1%;    (x) B in an amount in the range from 0.2 to about 2.2%;    (xi) Zr in the range from 0 to about 0.02%;    (xii) Fe in an amount in the range from about 0.07 to about 0.2%; and    (xiii) Mn in an amount in the range from about 0.03 to about 0.1%,.    wherein all percentages are by weight based on the total weight of the composition.    
     
     
         20 . A composition according to  claim 19  wherein Ni makes up the balance of the composition which is not taken up by components (i) to (xiii).  
     
     
         21 . A composition according to  claim 19  wherein B is present in an amount from about 0.4 to about 1.2% by weight based on the total weight of the composition.  
     
     
         22 . A composition according to  claim 19  wherein Hf is present in an amount from about 2.5 to about 4.6% by weight based on the total weight of the composition.  
     
     
         23 . A composition according to  claim 19  wherein the composition is in powder form.  
     
     
         24 . A composition according to  claim 19  comprising: 
 (i) Co 6%;    (ii) Cr 10.6%;    (iii) Mo 0.75%;    (iv) W 2.45%;    (v) Re 1.4%;    (vi) Al 3.1%;    (vii) Ta 3.1%;    (viii) Hf 2.75%;    (ix) C in an amount up to about 0.1%;    (x) B 1.26%;    (xi) Zr from 0 to about 0.02%;    (xii) Fe 0.1% and    (xiii) Mn 0.05%.    
     
     
         25 . A composition according to  claim 19  comprising: 
 (i) Co 6%;    (ii) Cr 10.6%;    (iii) Mo 0.75%;    (iv) W 2.45%;    (v) Re 1.4%;    (vi) Al 3.1%;    (vii) Ta 3.1%;    (viii) Hf 2.75%;    (ix) C in an amount up to about 0.1%;    (x) B 1.51%;    (xi) Zr from 0 to about 0.02%;    (xii) Fe 0.1% and    (xiii) Mn 0.05%.    
     
     
         26 . A composition according to  claim 19  comprising: 
 (i) Co 8.3%;    (ii) Cr 8.6%;    (iii) Mo 1.0%;    (iv) W 3.4%;    (v) Re 1.9%;    (vi) Al 4.3%;    (vii) Ta 4.4%;    (viii) Hf 3.0%;    (ix) C in an amount up to about 0.1%;    (x) B 1.0%;    (xi) Zr from 0 to about 0.02%;    (xii) Fe 0.13% and    (xiii) Mn 0.07%.    
     
     
         27 . A composition according to  claim 19  comprising: 
 (i) Co 8.1%;    (ii) Cr 8.5%;    (iii) Mo 1%;    (iv) W 3.3%;    (v) Re 1.9%;    (vi) Al 4.2%;    (vii) Ta 4.3%;    (viii) Hf 4.5%;    (ix) C in an amount up to about 0.1%;    (x) B 1.0%;    (xi) Zr from 0 to about 0.02%;    (xii) Fe 0.13% and    (xiii) Mn 0.07%.    
     
     
         28 . A composition according to  claim 24  wherein the balance of the composition is Ni.  
     
     
         29 . A composition according to  claim 25  wherein the balance of the composition is Ni.  
     
     
         30 . A composition according to  claim 26  wherein the balance of the composition is Ni.  
     
     
         31 . A composition according to  claim 27  wherein the balance of the composition is Ni.  
     
     
         32 . A process of repairing an article comprising the steps of heating a composition according to  claim 19  and/or heating an area of an article to which the compositions is to be applied, to a suitable temperature for a sufficient period of time to accomplish the repair.  
     
     
         33 . A process according to  claim 32  wherein the temperature is in the range from about 1200° C. to about 1250° C.  
     
     
         34 . A process according to  claim 33  wherein at least the repair area is subsequently tempered.  
     
     
         35 . A process according to  claim 34  wherein the tempering is carried out by heating to a temperature in the range from about 1125° C. to about 1175° C.  
     
     
         36 . An article repaired by a process according to  claim 32 .  
     
     
         37 . An article repaired by a process according to  claim 33 .  
     
     
         38 . An article repaired by a process according to  claim 34 .  
     
     
         39 . An article repaired by a process according to  claim 35 .  
     
     
         40 . A composition comprising Ni and the following additional components with the proviso that the composition does not contain Si: 
 (i) Co in an amount in the range from about 4.5 to about 11%;    (ii) Cr in an amount in the range from about 7 to about 12%;    (iii) Mo in an amount in the range from about 0.5 to about 1.4%;    (iv) W in an amount in the range from about 1.8 to about 4.5%;    (v) Re in an amount in the range from about 1.0 to about 2.6%;    (vi) Al in an amount in the range from about 2.4 to about 5.6%;    (vii) Ta in an amount in the range from about 2.4 to about 5.9%;    (viii) Hf in an amount in the range from about 0.4% to about 6.0%;    (ix) C in an amount up to about 0.1%;    (x) B in an amount in the range from 0.2 to about 2.2%;    (xi) Zr in the range from 0 to about 0.02%;    (xii) Fe in an amount in the range from about 0.07 to about 0.2%; and    (xiii) Mn in an amount in the range from about 0.03 to about 0.1%,.    wherein all percentages are by weight based on the total weight of the composition.