Corrosion Resistant Alloy Compositions with Enhanced Castability and Mechanical Properties

Abstract

Disclosed are novel nickel-base alloy compositions that may be cast as a single crystal or directionally solidified alloy consisting essentially of, by weight: 8-12% Cr, 10-14% Co, 0.3-0.9% Mo, 3-7% W, 2-8% Ta, 2.0-5.5% Al, 1.5-5.0% Ti, up to 2% Nb, less than 0.1% B, less than 0.1% Zr, 0.05-0.15% C, less than 0.5% Hf, 2-4% Re, 0.05-0.2% Si, up to 0.015% S, up to 0.1% La, up to 0.1% Y, up to 0.1% Ce, up to 0.1% Nd, up to 0.1% Dy, up to 0.1% Pr, up to 0.1% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.001-0.1%. The compositions for the nickel-base superalloy have a balance between oxidation resistance, corrosion resistance, castability, and mechanical properties, such as creep resistance and thermo-mechanical fatigue resistance.

1 . A nickel base alloy composition consisting essentially of, by weight percent, 8-12% Cr, 10-14% Co, 0.3-0.9% Mo, 3-7% W, 2-8% Ta, 2.0-5.5% Al, 1.5-5.0% Ti, up to 2% Nb, less than 0.1% B, less than 0.1% Zr, 0.05-0.15% C, less than 0.5% Hf, 2-4% Re, 0.05-0.2% Si, up to 0.015% S, up to 0.1% La, up to 0.1% Y, up to 0.1% Ce, up to 0.1% Nd, up to 0.1% Dy, up to 0.1% Pr, up to 0.1% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.001-0.1%. 
     
     
         2 . The composition of  claim 1  selected for its thermo-mechanical fatigue resistance and comprising 2-6% Ta, 2-5% Al, and 3-5% Ti. 
     
     
         3 . The composition of  claim 1  selected for its creep resistance and comprising 4-8% Ta, 3.5-5.5% Al, and 1.5-4.0 Ti. 
     
     
         4 . The composition of  claim 1  selected for its thermo-mechanical fatigue resistance, ability to be cast as a single crystal alloy and comprising 9.5-10.5% Cr, 11.5-12.5% Co, 0.45-0.75% Mo, 4.4-5.4% W, 3.4-4.4% Ta, 3.1-4.0% Al, 3.9-4.25% Ti, up to 0.5% Nb, less than 0.02% B, less than 0.02% Zr, 0.05-0.11% C, less than 0.25% Hf, 2.5-3.5% Re, 0.1-0.15% Si, up to 0.015% S, up to 0.05% La, up to 0.05% Y, up to 0.05% Ce, up to 0.05% Nd, up to 0.05% Dy, up to 0.05% Pr, up to 0.05% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.01-0.05%. 
     
     
         5 . The composition of  claim 1  selected for its thermo-mechanical fatigue resistance, ability to be cast as a directionally solidified alloy and comprising 9.5-10.5% Cr, 11.5-12.5% Co, 0.45-0.75% Mo, 4.4-5.4% W, 3.4-4.4% Ta, 3.1-4.0% Al, 3.9-4.25% Ti, up to 0.5% Nb, 0.005-0.015% B, up to 0.02% Zr, 0.05-0.11% C, less than 0.25% Hf, 2.5-3.5% Re, 0.1-0.15% Si, up to 0.015% S, up to 0.05% La, up to 0.05% Y, up to 0.05% Ce, up to 0.05% Nd, up to 0.05% Dy, up to 0.05% Pr, up to 0.05% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.01-0.05%. 
     
     
         6 . The composition of  claim 1  selected for its creep resistance, ability to be cast as a single crystal alloy and comprising 9.5-10.5% Cr, 11.5-12.5% Co, 0.45-0.75% Mo, 4.4-5.4% W, 5.5-6.5% Ta, 4.2-4.8% Al, 2.0-2.8% Ti, up to 0.5% Nb, less than 0.02% B, less than 0.02% Zr, 0.05-0.11% C, less than 0.25% Hf, 2.5-3.5% Re, 0.1-0.15% Si, up to 0.015% S, up to 0.05% La, up to 0.05% Y, up to 0.05% Ce, up to 0.05% Nd, up to 0.05% Dy, up to 0.05% Pr, up to 0.05% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.01-0.05%. 
     
     
         7 . The composition of  claim 1  selected for its creep resistance, ability to be cast as a directionally solidified alloy and comprising 9.5-10.5% Cr, 11.5-12.5% Co, 0.45-0.75% Mo, 4.4-5.4% W, 5.5-6.5% Ta, 4.2-4.8% Al, 2.0-2.8% Ti, up to 0.5% Nb, 0.005-0.015% B, less than 0.02% Zr, 0.05-0.11% C, less than 0.25% Hf, 2.5-3.5% Re, 0.1-0.15% Si, up to 0.015% S, up to 0.05% La, up to 0.05% Y, up to 0.05% Ce, up to 0.05% Nd, up to 0.05% Dy, up to 0.05% Pr, up to 0.05% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.01-0.05%. 
     
     
         8 . The composition of  claim 1  selected for its thermo-mechanical fatigue resistance, ability to be cast as a single crystal alloy and comprising 10.0% Cr, 12.0% Co, 0.6% Mo, 4.9% W, 3.9% Ta, 3.5% Al, 3.9% Ti, less than 0.01% B, less than 0.01% Zr, 0.07% C, less than 0.1% Hf, 3.0% Re, less than 0.12% Si, up to 0.015% S, up to 0.02% La, up to 0.02% Y, up to 0.02% Ce, up to 0.02% Nd, up to 0.02% Dy, up to 0.02% Pr, up to 0.02% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.03%. 
     
     
         9 . The composition of  claim 1  selected for its thermo-mechanical fatigue resistance, ability to be cast as a directionally solidified alloy and comprising 10.0% Cr, 12.0% Co, 0.6% Mo, 4.9% W, 3.9% Ta, 3.5% Al, 3.9% Ti, 0.01% B, 0.0075% Zr, 0.09% C, 0.1% Hf, 3.0% Re, less than 0.12% Si, up to 0.015% S, up to 0.02% La, up to 0.02% Y, up to 0.02% Ce, up to 0.02% Nd, up to 0.02% Dy, up to 0.02% Pr, up to 0.02% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.03%. 
     
     
         10 . The composition of  claim 1  selected for its creep resistance, ability to be cast as a single crystal alloy and comprising 10.0% Cr, 12.0% Co, 0.6% Mo, 4.9% W, 6.0% Ta, 4.5% Al, 2.4% Ti, less than 0.01% B, less than 0.01% Zr, 0.07% C, less than 0.1% Hf, 3.0% Re, less than 0.12% Si, up to 0.015% S, up to 0.02% La, up to 0.02% Y, up to 0.02% Ce, up to 0.02% Nd, up to 0.02% Dy, up to 0.02% Pr, up to 0.02% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.03%. 
     
     
         11 . The composition of  claim 1  selected for its creep resistance, ability to be cast as a directionally solidified alloy and comprising 10.0% Cr, 12.0% Co, 0.6% Mo, 4.9% W, 6.0% Ta, 4.5% Al, 2.4% Ti, 0.01% B, 0.0075% Zr, 0.09% C, 0.1% Hf, 3.0% Re, less than 0.12% Si, up to 0.015% S, up to 0.02% La, up to 0.02% Y, up to 0.02% Ce, up to 0.02% Nd, up to 0.02% Dy, up to 0.02% Pr, up to 0.02% Gd, balance is Ni, and wherein (La+Y+Ce+Nd+Dy+Pr+Gd) is 0.03%.