Combustion Turbine Component Having Rare-Earth Elements and Associated Methods

Abstract

A method of making a combustion turbine component includes forming a nanosized powder including a plurality of metals and at least one rare-earth element and agglomerating the nanosized powder to form a microsized powder including a plurality of metals and at least one rare-earth element. The microsized powder is processed to form a cohesive metallic mass and a primary aging heat treating is performed on the cohesive metallic mass. A solution heat treating may be performed on the cohesive metallic mass prior to the primary aging heat treating. A secondary aging treating may be performed on the cohesive metallic mass after the primary aging treating.

1 . A method of making a combustion turbine component comprising:
 forming a nanosized powder comprising a plurality of metals and at least one rare-earth element;   agglomerating the nanosized powder to form a microsized powder comprising a plurality of metals and at least one rare-earth element;   processing the microsized powder to form a cohesive metallic mass; and   performing a primary aging heat treating on the cohesive metallic mass.   
     
     
         2 . The method of  claim 1  wherein forming the nanosized powder comprises:
 forming an alloy powder comprising a plurality of metals; forming a metallic powder comprising at least one rare-earth element; and   milling the alloy powder comprising a plurality of metals and the metallic powder comprising at least one rare-earth element together to form the nanosized powder.   
     
     
         3 . The method of  claim 2  wherein forming the metallic powder comprising the at least one rare-earth element comprises atomizing a metallic liquid comprising at least one rare-earth element to form a metallic powder comprising at least one rare-earth element and heat treating the metallic powder comprising at least one rare-earth element to form a metallic powder comprising at least one rare-earth element and at least one oxide thereof. 
     
     
         4 . The method of  claim 1  wherein performing the primary aging heat treating comprises:
 heating the cohesive metallic mass to a primary aging temperature being greater than a secondary carbide phase field temperature of the cohesive metallic mass and less than a solvus temperature of a gamma prime phase of the cohesive metallic mass;   holding the cohesive metallic mass at the primary aging temperature; and   cooling the cohesive metallic to a desired temperature related to the secondary carbide phase field temperature.   
     
     
         5 . The method of  claim 4  wherein the cohesive metallic mass is held at the primary aging temperature for 1.5 to 2.5 hours; wherein the cohesive metallic mass is cooled at a rate of 20° C. to 30° C. per second; and wherein the desired temperature is within 300° C. of the secondary carbide phase field temperature. 
     
     
         6 . The method of  claim 1  further comprising performing a solution heat treating on the cohesive metallic mass prior to the primary aging treating. 
     
     
         7 . The method of  claim 6  wherein performing the solution heat treating comprises:
 heating the cohesive metallic mass at a first heating rate to a temperature below the solvus temperature of a gamma prime phase of the cohesive metallic mass;   heating the cohesive metallic mass at a second heating rate less than the first heating rate to a solution temperature being at least the solvus temperature of the gamma prime phase of the cohesive metallic mass;   holding the cohesive metallic mass at the solution temperature; and   cooling the cohesive metallic mass to a temperature below the solution temperature.   
     
     
         8 . The method of  claim 7  wherein the first heating rate is in a range of 10° C. to 25° C. per minute; wherein the second heating rate is in a range of 1° C. to 3° C. per minute; wherein the cohesive metallic mass is held at the solution temperature for 1.5 to 2.5 hours; and wherein the cohesive metallic mass is cooled at a rate of 20° C. to 30° C. per minute. 
     
     
         9 . The method of  claim 6  further comprising performing a secondary aging heat treating on the cohesive metallic mass after performing the primary aging heat treating. 
     
     
         10 . The method of  claim 9  wherein performing the secondary aging heat treating comprises:
 heating the cohesive metallic mass to a secondary carbide phase field temperature of the cohesive metallic mass;   holding the cohesive metallic mass at the secondary carbide phase field temperature; and   cooling the cohesive metallic mass to below the secondary carbide phase field temperature.   
     
     
         11 . The method of  claim 10  wherein the cohesive metallic mass is heated to the secondary carbide phase field temperature at a rate of less than 25° C. per minute; wherein the cohesive metallic mass is held at the secondary carbide phase field temperature for 15 to 25 hours; and wherein the cohesive metallic mass is cooled at a rate of 20° C. to 30° C. per minute. 
     
     
         12 . A method as in  claim 1  wherein the metallic powder comprising at least one rare-earth element further comprises at least one oxide of the at least one rare-earth element, 
     
     
         13 . A method as in  claim 1  wherein processing the microsized powder to form the cohesive metallic mass comprises compacting the microsized powder to form a cohesive metallic mass. 
     
     
         14 . A method as in  claim 1  wherein processing the microsized powder to form the cohesive metallic mass comprises thermally spraying the microsized powder onto a metallic substrate. 
     
     
         15 . A method as in  claim 1  further comprising forming the combustion turbine component from the cohesive metallic mass. 
     
     
         16 . A method of making a combustion turbine component comprising:
 forming an alloy powder comprising a plurality of metals;   forming a metallic powder comprising at least one rare-earth element;   milling the alloy powder comprising a plurality of metals and the metallic powder comprising at least one rare-earth element together to form a nanosized powder comprising a plurality of metals and at least one rare-earth element;   agglomerating the nanosized powder to form a microsized powder comprising a plurality of metals and at least one rare-earth element;   processing the microsized powder to form a cohesive metallic mass;   performing a solution heat treating on the cohesive metallic mass; and   performing a primary aging heat treating on the cohesive metallic mass.   
     
     
         17 . A method as in  claim 16  wherein the metallic powder comprising at least one rare-earth element further comprises at least one oxide of the at least one rare-earth element. 
     
     
         18 . A method as in  claim 16  wherein forming the metallic powder comprises atomizing a metallic liquid comprising at least one rare-earth element to form a metallic powder comprising at least one rare-earth element and heat treating the metallic powder comprising at least one rare-earth element to form the metallic powder comprising the at least one rare-earth element and at least one oxide thereof. 
     
     
         19 . A method as in  claim 16  wherein forming the alloy powder comprising the plurality of metals comprises atomizing an alloy liquid comprising a plurality of metals to form an alloy powder comprising a plurality of metals. 
     
     
         20 . A method as in  claim 16  wherein processing the microsized powder to form the cohesive metallic mass comprises compacting the microsized powder to form a cohesive metallic mass. 
     
     
         21 . A method as in  claim 16  wherein processing the microsized powder to form the cohesive metallic mass comprises thermally spraying the microsized powder onto a metallic substrate. 
     
     
         22 . A method of making a combustion turbine component comprising:
 forming a nanosized powder comprising a plurality of metals and at least one rare-earth element;   agglomerating the nanosized powder to form a microsized powder comprising a plurality of metals and at least one rare-earth element;   processing the microsized powder to form a cohesive metallic mass; and   performing a solution heat treating on the cohesive metallic mass.   
     
     
         23 . A method as in  claim 22  wherein the metallic powder comprising at least one rare-earth element further comprises at least one oxide of the at least one rare-earth element. 
     
     
         24 . A method as in  claim 22  wherein processing the microsized powder to form the cohesive metallic mass comprises compacting the microsized powder to form a cohesive metallic mass. 
     
     
         25 . A method as in  claim 22  wherein processing the microsized powder to form the cohesive metallic mass comprises thermally spraying the microsized powder onto a metallic substrate.