Abstract: The present invention is a composite welding wire for fusion welding of components manufactured of superalloys. The composite weld wire includes a surface layer applied to the core wire in a green condition and bonded to the core wire. The surface layer includes alloying elements selected from among B and Si, the total bulk content of B and Si representing 0.5 to 4.0 wt. % of the composite welding wire. The boron and silicon alloying elements reduce the melting temperature and increase the solidification range of the weld pool, minimizing the incidence of weld cracking compared to welding without the coating. The green condition surface layer is comprised of more than 80 wt. % of the bulk content of the composite welding wire selected from the combination of B and Si.

Abstract: The present invention is a composite welding wire for fusion welding of components manufactured of superalloys. The composite weld wire includes a surface layer applied to the core wire in a green condition and bonded to the core wire. The surface layer includes alloying elements selected from among B and Si, the total bulk content of B and Si representing 0.5 to 4.0 wt. % of the composite welding wire. The boron and silicon alloying elements reduce the melting temperature and increase the solidification range of the weld pool, minimizing the incidence of weld cracking compared to welding without the coating. The green condition surface layer is comprised of more than 80 wt. % of the bulk content of the composite welding wire selected from the combination of B and Si.

Abstract: The present concept is a method of cladding and fusion welding of superalloys and includes the steps of firstly application of a composite filler powder that comprises 5-50% by weight brazing powder which includes melting point depressants, and 50-95% by weight high temperature welding powder, to a superalloy base material. Secondly there is simultaneous melting of the base material and the composite filler powder by a welding heat source that is movable relative to the base material. There is heating to a temperature that will fully melt the brazing and high temperature welding powder and also melt a surface layer of the base material, thereby forming a weld pool followed by heat treatment with a partial re-melt of interdendritic B based eutectics.

Abstract: The present concept is a method of substantially crack-free cladding, fusion welding and additive manufacturing of superalloys. The method involves the application of a high temperature pre-alloyed filler powder that includes melting point depressants, to a superalloy base material. The base material and pre-alloyed filler powder are heated to a temperature that will fully melt the pre-alloyed filler powder and also melt a surface layer of the base material, thereby forming a weld pool. Upon solidification and cooling of the weld pool, there is coalescence between a weld bead and the base material thereby forming the weld bead which is substantially crack-free. The high temperature pre-alloyed filler powder consists in wt % of the following chemical elements: Co 9-15%; Al 3-6.5%; C 0.1-0.2%; Ti, Zr and Hf with a total content from 1 to 8.5%; Ta and Nb with a total content from 0.5 to 8.5%; W and Mo with a total content from 7 to 20%; Cr and Re with a total content from 6.5 to 18.

Abstract: The present invention is a composite welding wire for fusion welding of components manufactured of superalloys. The composite weld wire includes an inner core wire and a surface layer applied and bonded to the inner core wire. The surface layer includes alloying elements selected from among B and Si with a total bulk content of B and Si in the composite welding wire of 0.1 to 10 wt. %. Preferably the total bulk content of B is less than 4 wt. % and the surface layer comprises from 5 to 95 wt. % of the alloying elements selected from among B and Si.

Abstract: The present concept is a method of cladding and fusion welding of superalloys and includes the steps of firstly application of a composite filler powder that consists of 5-50% by weight brazing powder which includes melting point depressants, and 50-95% by weight high temperature welding powder, to a superalloy base material. Secondly there is simultaneous heating of the base material and the composite filler powder by a welding heat source that is movable relative to the base material. There is heating to a temperature that will fully melt the brazing powder and at least partially melt the high temperature welding powder and also melt a surface layer of the base material, thereby forming a weld pool. Thirdly upon solidification and cooling of the weld pool, there is coalescence between the weld bead and the base material.