Braze materials and processes therefor

Abstract

Braze materials and processes for using braze materials, such as for use in the manufacturing, coating, repair, and build-up of superalloy components. The braze material contains a plurality of first particles of a metallic material having a melting point, and a plurality of second particles comprising at least one nonmetallic material chosen from the group consisting of oxides, carbides, and nitrides of at least one metal. The nonmetallic material is more susceptible to heating by microwave radiation than the metallic material of the first particles, and the nonmetallic material is present in the braze material in an amount sufficient to enable the first particles to completely melt when the first and second particles are subjected to heating by microwave radiation.

1 . A process, comprising:
 applying a braze material to a surface of at least a first substrate, the braze material comprising
 a plurality of first particles of a metallic material having a melting point, and 
 a plurality of second particles comprising at least one nonmetallic material chosen from the group consisting of oxides, carbides, and nitrides of at least one metal, the nonmetallic material of the second particles being more susceptible to heating by microwave radiation than the metallic material of the first particles, and the nonmetallic material being present in the braze material in an amount sufficient to enable the first particles to completely melt when the first and second particles are subjected to heating by microwave radiation; 
   heating the braze material with microwave radiation to sufficiently heat at least the second particles to cause the first particles to completely melt; and then   allowing the molten first particles to cool, solidify, and form a solid brazement.   
     
     
         2 . The process according to  claim 1 , wherein the first substrate does not melt and the first particles completely melt when the first and second particles are subjected to heating by microwave radiation. 
     
     
         3 . The process according to  claim 1 , wherein the braze material comprises layers containing different amounts of the first and second particles, and one of the layers contains the greatest amount of the second particles and does not contact the first substrate. 
     
     
         4 . The process of  claim 1 , wherein the solid brazement contains a dispersion of the second particles. 
     
     
         5 . The process according to  claim 1 , wherein the solid brazement contains a dispersion of the nonmetallic material. 
     
     
         6 . The process according to  claim 1 , wherein the solid brazement is a braze joint that metallurgically bonds the first substrate surface to a second substrate surface. 
     
     
         7 . The process according to  claim 1 , wherein the solid brazement is a coating on the first substrate surface. 
     
     
         8 . The process according to  claim 1 , wherein at least some of the second particles are formed entirely of the nonmetallic material. 
     
     
         9 . The process according to  claim 1 , wherein the nonmetallic material of the second particles is present at only an outer surface region of at least some of the second particles and is substantially absent from a core region of the at least some of the second particles. 
     
     
         10 . The process according to  claim 9 , wherein the core regions of the at least some of the second particles are formed of a second metallic material and the nonmetallic material is an oxide, carbide, or nitride of the second metallic material. 
     
     
         11 . The process according to  claim 10 , wherein the nonmetallic material is formed in situ on the second particles. 
     
     
         12 . The process according to  claim 1 , wherein the second particles have a particle size of about −325 mesh. 
     
     
         13 . The process according to  claim 1 , wherein the first particles have a particle size of about −325 mesh. 
     
     
         14 . The process according to  claim 1 , wherein the second particles constitute up to about 50 weight percent of the first and second particles combined. 
     
     
         15 . The process according to  claim 1 , wherein the metallic material of the first particles is a superalloy. 
     
     
         16 . The process according to  claim 1 , wherein the nonmetallic material is an oxide, carbide, or nitride of at least one material chosen from the group consisting of manganese, nickel, copper, tungsten, tantalum, chromium, and iron. 
     
     
         17 . The process according to  claim 1 , wherein the nonmetallic material is at least one of nickel oxide and manganese dioxide. 
     
     
         18 . The process according to  claim 1 , wherein the braze material consists essentially of the first and second particles and a binder. 
     
     
         19 . The process according to  claim 1 , wherein the braze material comprises layers, and at least one of the layers does not contain any of the second particles.