Cast nickel-iron-base alloy component and process of forming a cast nickel-iron-base alloy component

Abstract

A cast nickel-iron-base alloy component having by weight about 12.0% to about 16.5% Cr, about 1.0% to about 2.0% Al, about 2.0% to about 3.0% Ti, about 2.0% to about 3.0% W, about 3.0 to about 5.0% Mo, up to about 0.1% Nb, up to about 0.2% Mn, up to about 0.1% Si, about 0.05% to about 0.10% C, about 0.003 to about 0.010% B, about 35% to about 37% Fe, and balance essentially Ni and inevitable impurities. The nickel-iron-base alloy component has a creep rupture life greater than about 1000 hours at about 25 ksi to about 30 ksi at about 1400° F. A method for forming the cast nickel-iron-base alloy component is also disclosed.

1 . A cast nickel-iron-base alloy component comprising by weight:
 about 12.0% to about 16.5% Cr;   about 1.0% to about 2.0% Al;   about 2.0% to about 3.0% Ti;   about 2.0% to about 3.0% W;   about 3.0 to about 5.0% Mo;   up to about 0.1% Nb;   up to about 0.2% Mn;   up to about 0.1% Si;   about 0.05% to about 0.10% C;   about 0.003 to about 0.010% B;   about 35% to about 37% Fe; and   balance essentially Ni and inevitable impurities;   wherein the component has a creep rupture life greater about 1000 hours at about 25 ksi to about 30 ksi at about 1400° F.   
     
     
         2 . The cast nickel-iron-base alloy component of  claim 1 , comprising about 12.0% to about 14% Cr, about 1.35% to about 1.65% Al, about 2.25% to about 2.75% Ti, about 2.0% to about 2.7% W, about 3.2 to about 4.0% Mo, up to about 0.1% Nb, up to about 0.2% Mn, up to about 0.1% Si, about 0.07% to about 0.09% C, about 0.005 to about 0.008% B, about 35% to about 37% Fe, and balance essentially Ni and inevitable impurities. 
     
     
         3 . The cast nickel-iron-base alloy component of  claim 1 , comprising about 12.5% Cr, about 1.5% Al, about 2.5% Ti, about 2.5% W, about 3.5% Mo, up to about 0.1% Nb, up to about 0.2% Mn, up to about 0.1% Si, about 0.08% C, about 0.006% B, about 36% Fe, and balance essentially Ni and inevitable impurities. 
     
     
         4 . The cast nickel-iron-base alloy component of  claim 1 , wherein the composition is devoid of Co. 
     
     
         5 . The cast nickel-iron-base alloy component of  claim 1 , wherein the nickel-iron-base alloy component has a creep rupture life of greater than about 1400 hours at about 25 ksi to about 30 ksi at about 1400° F. 
     
     
         6 . The cast nickel-iron-base alloy component of  claim 1 , wherein the nickel-iron-base alloy component has a creep rupture life of greater than about 1800 hours at about 25 ksi to about 30 ksi at about 1400° F. 
     
     
         7 . The cast nickel-iron-base alloy component of  claim 1 , wherein the nickel-iron-base alloy component has a resistance to oxidation of greater than about 48,000 hours. 
     
     
         8 . The cast nickel-iron-base alloy component of  claim 1 , wherein the nickel-iron-base alloy component is a nozzle. 
     
     
         9 . The cast nickel-iron-base alloy component of  claim 1 , wherein the nickel-iron-base alloy component is a shroud. 
     
     
         10 . A process of forming a cast nickel-iron-base alloy component, the process comprising:
 casting an alloy comprising by weight:   about 12.0% to about 16.5% Cr;   about 1.0% to about 2.0% Al;   about 2.0% to about 3.0% Ti;   about 2.0% to about 3.0% W;   about 3.0 to about 5.0% Mo;   up to about 0.1% Nb;   up to about 0.2% Mn;   up to about 0.1% Si;   about 0.05% to about 0.10% C;   about 0.003 to about 0.010% B;   about 35% to about 37% Fe; and   balance essentially Ni and inevitable impurities to form a cast ingot;   homogenizing the cast ingot at a temperature from about 2000° F. to about 2200° F. to form a homogenized ingot;   heat treating the homogenized ingot at a temperature from about 1700° F. to about 1850° F. to form a heat treated ingot; and   aging the heat treated ingot at a first aging temperature from about 1200° F. to about 1500° F. and then at a second aging temperature from about 1000° F. to about 1200° F. to form an aged ingot;   wherein the aged ingot has a creep rupture life greater than about 1000 hours at about 25 ksi to about 30 ksi at about 1400° F.   
     
     
         11 . The process of  claim 10 , wherein the alloy comprises about 12.0% to about 14% Cr, about 1.35% to about 1.65% Al, about 2.25% to about 2.75% Ti, about 2.0% to about 2.7% W, about 3.2 to about 4.0% Mo, up to about 0.1% Nb, up to about 0.2% Mn, up to about 0.1% Si, about 0.07% to about 0.09% C, about 0.005 to about 0.008% B, about 35% to about 37% Fe, and balance essentially Ni and inevitable impurities. 
     
     
         12 . The process of  claim 10 , wherein the alloy comprises about 12.5% Cr, about 1.5% Al, about 2.5% Ti, about 2.5% W, about 3.5% Mo, up to about 0.1% Nb, up to about 0.2% Mn, up to about 0.1% Si, about 0.08% C, about 0.006% B, about 36% Fe, and balance essentially Ni and inevitable impurities. 
     
     
         13 . The process of  claim 10 , wherein the alloy is devoid of Co. 
     
     
         14 . The process of  claim 10 , wherein the homogenizing includes heating the cast ingot to a temperature of from about 2050° F. to about 2150° F. 
     
     
         15 . The process of  claim 10 , wherein the heat treating includes heating the homogenized ingot to a temperature of from about 1750° F. to about 1800° F. 
     
     
         16 . The process of  claim 10 , wherein the aging includes heating the heat-treated ingot to a first temperature of from about 1300° F. to about 1400° F. and a second temperature of from about 1050° F. to about 1150° F. 
     
     
         17 . The process of  claim 10 , wherein the aged ingot has a creep rupture life greater than about 1400 hours at about 25 ksi to about 30 ksi at about 1400° F. 
     
     
         18 . The process of  claim 10 , wherein the aged ingot has a creep rupture life greater than about 1800 hours at about 25 ksi to about 30 ksi at about 1400° F. 
     
     
         19 . The process of  claim 10 , wherein the nickel-iron-base alloy component is a nozzle. 
     
     
         20 . The process of  claim 10 , wherein the nickel-iron-base alloy component is a shroud.