Nickel Based Alloy with High Fatigue Resistance and Methods of Forming the Same

Abstract

A nickel based alloy, along with methods of its use and manufacture, is provided that may include about 20 wt. % to about 26 wt. % cobalt; about 9 wt. % to about 13 wt. % chromium; about 2 wt. % to about 6 wt. % iron; about 3.5 wt. % to about 6 wt. % aluminum; about 9 wt. % to about 13 wt. % tungsten; about 6 wt. % to about 9 wt. % tantalum; about 0.06 wt. % to about 0.20 wt. % boron; and the balance nickel. The nickel based alloy may have gamma prime precipitates in a plurality of grain interiors and a gamma prime solvus temperature of about 1038° C. or greater. Additionally or alternatively, the nickel based alloy may comprise about 30% by volume or more gamma prime precipitates in the plurality of grain interiors.

What is claimed is: 
     
         1 . A nickel based alloy, comprising:
 about 20 wt. % to about 26 wt. % cobalt;   about 9 wt. % to about 13 wt. % chromium;   about 2 wt. % to about 6 wt. % iron;   about 3.5 wt. % to about 6 wt. % aluminum;   about 9 wt. % to about 13 wt. % tungsten;   about 6 wt. % to about 9 wt. % tantalum;   about 0.06 wt. % to about 0.20 wt. % boron; and   the balance nickel.   
     
     
         2 . The nickel based alloy according to  claim 1 , wherein the nickel based alloy comprises gamma prime precipitates in a plurality of grain interiors and has a gamma prime solvus temperature of about 1038° C. or greater. 
     
     
         3 . The nickel based alloy according to  claim 2 , wherein the nickel based alloy comprises about 30% by volume or more gamma prime precipitates in the plurality of grain interiors. 
     
     
         4 . The nickel based alloy according to  claim 3 , wherein the nickel based alloy has a grain boundary phase fraction of about 20% by volume or more. 
     
     
         5 . The nickel based alloy according to  claim 4 , wherein the nickel based alloy has a grain boundary phase lineal density of about 310 precipitates per mm or greater. 
     
     
         6 . The nickel based alloy according to  claim 2 , wherein the nickel based alloy comprises precipitates of W-bearing phases along one or more grain boundaries. 
     
     
         7 . The nickel based alloy according to  claim 6 , wherein the W-bearing phase comprises Laves phase, mu phase, beta phase, sigma phase, borides, or carbides. 
     
     
         8 . The nickel based alloy according to  claim 1 , wherein the nickel based alloy comprises about 0.065 wt. % to about 0.155 wt. % boron. 
     
     
         9 . The nickel based alloy according to  claim 1 , wherein the nickel based alloy comprises about 22% by weight to about 24% by weight cobalt, about 10% by weight to about 12% by weight chromium, about 3% by weight to about 5% by weight iron, about 4% by weight to about 5.5% by weight aluminum, about 10% by weight to about 12% by weight tungsten, about 7% by weight to about 8% by weight tantalum, and about 0.07% by weight to about 0.15% by weight boron. 
     
     
         10 . The nickel based alloy according to  claim 1 , wherein the nickel based alloy further comprises greater than 0% by weight to about 0.1% by weight carbon. 
     
     
         11 . The nickel based alloy according to  claim 1 , wherein the nickel based alloy further comprises about 0.02% by weight to about 0.08% by weight carbon. 
     
     
         12 . The nickel based alloy according to  claim 1 , wherein the nickel based alloy further comprises greater than 0% by weight to about 0.5% by weight hafnium. 
     
     
         13 . The nickel based alloy according to  claim 1 , wherein the nickel based alloy further comprises greater than 0% by weight to about 0.1% by weight zirconium. 
     
     
         14 . A component for a gas turbine assembly comprising the nickel alloy of  claim 1 . 
     
     
         15 . A nickel based alloy consisting of:
 about 20 wt. % to about 26 wt. % cobalt;   about 9 wt. % to about 13 wt. % chromium;   about 2 wt. % to about 6 wt. % iron;   about 3.5 wt. % to about 6 wt. % aluminum;   about 9 wt. % to about 13 wt. % tungsten;   about 6 wt. % to about 9 wt. % tantalum;   about 0.06 wt. % to about 0.20 wt. % boron; and   the balance nickel.   
     
     
         16 . The nickel based alloy according to  claim 15 , wherein boron is included in an amount of about 0.065 wt. % to about 0.155 wt. % boron. 
     
     
         17 . The nickel based alloy according to  claim 15 , consisting of about 22% by weight to about 24% by weight cobalt, about 10% by weight to about 12% by weight chromium, about 3% by weight to about 5% by weight iron, about 4% by weight to about 5.5% by weight aluminum, about 10% by weight to about 12% by weight tungsten, about 7% by weight to about 8% by weight tantalum, and about 0.07% by weight to about 0.15% by weight boron.