METALLIC ALLOY

Abstract

An alloy that may include nickel, aluminum from 4.8 wt. % to 5.15 wt. %; cobalt from 18 wt. % to 19 wt. %, chromium from 11.9 wt. % to 12.9 wt. %, molybdenum from 2.8 wt. % to 3.6 wt. %, and niobium from 0.05 wt. % to 0.1 wt. %. The alloy may further include tungsten from 0.05 wt. % to 0.1 wt. %. The alloy may further include tantalum from 0.05 wt. % to 0.1 wt. %.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-In-Part of, and claims priority to and the benefit of, PCT Application No. PCT/US20/61575, filed on Nov. 20, 2020 and entitled “METALLIC ALLOY,” which claims priority to U.S. Provisional Patent Application No. 62/939,106, filed on Nov. 22, 2019 and entitled “METALLIC ALLOY,” both of which are incorporated by reference herein in their entireties.

FIELD

The present disclosure relates to high-temperature alloys, and, more specifically, to various nickel alloys.

BACKGROUND

Aircraft components may be subjected to elevated temperatures during flight. For example, various components of a gas turbine engine may experience operating temperatures in excess of 1000° F. (537° C.). As a result, components used therein should be able to withstand such conditions over time.

SUMMARY

In various embodiments, a nickel alloy is provided, comprising nickel, aluminum from 4.8 wt. % to 5.15 wt. %, cobalt from 18 wt. % to 19 wt. %, chromium from 11.9 wt. % to 12.9 wt. %, molybdenum from 2.8 wt. % to 3.6 wt. %, and niobium from 0.05 wt. % to 0.1 wt. %. In various embodiments, the nickel alloy may further comprise tungsten from 0.05 wt. % to 0.1 wt. %. In various embodiments, the nickel alloy further comprise tantalum from 0.05 wt. % to 0.1 wt. %. In various embodiments, the nickel alloy may further comprise tantalum from 0.05 wt. % to 0.1 wt. %. In various embodiments, the ratio of tungsten to niobium is between 1:1 and 1:3.

In various embodiments, the ratio of tantalum to niobium is between 1:1 and 1:3.

In various embodiments, the ratio of tungsten to tantalum is between 1:1 and 1:3.

In various embodiments, the ratio of tungsten to niobium is between 1:1 and 1:3.

In various embodiments, the ratio of tantalum to niobium is between 1:1 and 1:3.

In various embodiments, the niobium is present at 0.1 wt. %.

In various embodiments, the tantalum is present at 0.1 wt. %.

In various embodiments, the tungsten is present at 0.1 wt. %.

In various embodiments, the nickel alloy further comprises titanium from 4.15 wt. % to 4.5 wt. %.

In various embodiments, a nickel alloy is provided comprising nickel, aluminum from 4.8 wt. % to 5.15 wt. %, cobalt from 18 wt. % to 19 wt. %, chromium from 11.9 wt. % to 12.9 wt. %, molybdenum from 2.8 wt. % to 3.6 wt. %, and tungsten from 0.05 wt. % to 0.1 wt. %. In various embodiments, the nickel alloy further comprises tantalum from 0.05 wt. % to 0.1 wt. %.

In various embodiments, the ratio of tungsten to tantalum is between 1:1 and 1:3.

In various embodiments, a nickel alloy is provided comprising nickel, aluminum from 4.8 wt. % to 5.15 wt. %, cobalt from 18 wt. % to 19 wt. %, chromium from 11.9 wt. % to 12.9 wt. %, molybdenum from 2.8 wt. % to 3.6 wt. %, tantalum from 0.05 wt. % to 0.1 wt. %. In various embodiments, the nickel alloy further comprises niobium from 0.05 wt. % to 0.1 wt. %. In various embodiments, the ratio of tantalum to niobium is between 1:1 and 1:3. In various embodiments, the aircraft component comprised from the nickel alloy.

The forgoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated herein otherwise. These features and elements as well as the operation of the disclosed embodiments will become more apparent in light of the following description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the figures, wherein like numerals denote like elements.

FIG. 1 illustrates a process of making an aircraft component from a nickel alloy, in accordance with various embodiments.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the inventions, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this invention and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. The scope of the invention is defined by the appended claims. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact.

Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Surface shading lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

As used herein, the term “% wt” or “% by weight,” or “wt. %,” used in reference to a nickel alloy, may refer to the percentage weight of the nickel alloy or a constituent of the nickel aluminum alloy or a group of constituents of the nickel alloy over the weight of the entire nickel alloy.

In various embodiments, FIG. 1 depicts a method 100 of making aircraft components using a nickel alloy. A nickel alloy may be formed, for example by casting, such as by heating and melting one or more metals to form a homogenous solution (Step 102). The solution may be cooled to solidify the nickel alloy.

In various embodiments, a nickel alloy comprises at least one of niobium, tungsten, or tantalum. The presence of at least one of niobium, tungsten, or tantalum may lead to enhanced physical properties. For example, nickel alloys in various embodiments have enhanced yield stress and tensile strength than conventional nickel alloys. For example, an unexpected increase in between 3 to 6 ksi (kilpounds per square inch) (˜20,684 kPa to 41,368 kPa) in tensile strength may be observed in nickel alloys in accordance with various embodiments. Moreover reduced susceptibility to creep is observed in nickel alloys in accordance with various embodiments.

In various embodiments, the nickel alloy may be comprised as set forth below in TABLE 1:

	TABLE 1
		Nickel Alloy
		Min, wt.	Max, wt.
	Element	%	%
	Al	4.8	5.15
	Co	18	19
	Cr	11.9	12.9
	Mo	2.8	3.6
	Nb	0.05	0.100
	Ta	0.05	0.100
	Ti	4.15	4.5
	W	0.05	0.1
	B	0.016	0.024
	C	0.015	0.09
	V	0	0.98
	Fe	0	0.12
	Zr	0.04	0.08
	Hf	0	0.9
	Re	0	0.1
	Ni	Balance	Balance

For the avoidance of doubt, the term “Balance” in TABLE 1, and in subsequent TABLES, means that the balance of the composition is nickel, provided the other constituents are present at any point in the ranges recited. In that regard, the nickel alloy comprises nickel, in an amount determined by the proportion of other constituents by weight.

In various embodiments, the nickel alloy may be comprised as set forth below in TABLE 2:

		Nickel Alloy
		Min, wt.	Max, wt.
	Element	%	%
	Al	4.8	5.15
	Co	18	19
	Cr	11.9	12.9
	Mo	2.8	3.6
	Nb	0.05	0.100
	Ti	4.15	4.5
	B	0.016	0.024
	C	0.015	0.09
	V	0	0.98
	Fe	0	0.12
	Zr	0.04	0.08
	Hf	0	0.9
	Re	0	0.1
	Ni	Balance	Balance

In various embodiments, the nickel alloy may be comprised as set forth below in TABLE 3:

	TABLE 3
		Nickel Alloy
		Min, wt.	Max, wt.
	Element	%	%
	Al	4.8	5.15
	Co	18	19
	Cr	11.9	12.9
	Mo	2.8	3.6
	Ti	4.15	4.5
	W	0.05	0.1
	B	0.016	0.024
	C	0.015	0.09
	V	0	0.98
	Fe	0	0.12
	Zr	0.04	0.08
	Hf	0	0.9
	Re	0	0.1
	Ni	Balance	Balance

In various embodiments, the nickel alloy may be comprised as set forth below in TABLE 4:

	TABLE 4
		Nickel Alloy
	Element	Min	Max
	Al	4.8	5.15
	Co	18	19
	Cr	11.9	12.9
	Mo	2.8	3.6
	Ta	0.05	0.100
	Ti	4.15	4.5
	B	0.016	0.024
	C	0.015	0.09
	V	0	0.98
	Fe	0	0.12
	Zr	0.04	0.08
	Hf	0	0.9
	Re	0	0.1
	Ni	Balance	Balance

In various embodiments, the nickel alloy may be comprised as set forth below in TABLE 5:

	TABLE 5
		Nickel Alloy
		Min, wt.	Max, wt.
	Element	%	%
	Al	4.8	5.15
	Co	18	19
	Cr	11.9	12.9
	Mo	2.8	3.6
	Nb	0.05	0.100
	Ta	0.05	0.100
	Ti	4.15	4.5
	B	0.016	0.024
	C	0.015	0.09
	V	0	0.98
	Fe	0	0.12
	Zr	0.04	0.08
	Hf	0	0.9
	Re	0	0.1
	Ni	Balance	Balance

In various embodiments, the nickel alloy may be comprised as set forth below in TABLE 6:

	TABLE 6
		Nickel Alloy
		Min, wt.	Max, wt.
	Element	%	%
	Al	4.8	5.15
	Co	18	19
	Cr	11.9	12.9
	Mo	2.8	3.6
	Nb	0.05	0.100
	Ti	4.15	4.5
	W	0.05	0.1
	B	0.016	0.024
	C	0.015	0.09
	V	0	0.98
	Fe	0	0.12
	Zr	0.04	0.08
	Hf	0	0.9
	Re	0	0.1
	Ni	Balance	Balance

In various embodiments, the nickel alloy may be comprised as set forth below in TABLE 7:

	TABLE 7
		Nickel Alloy
		Min, wt.	Max, wt.
	Element	%	%
	Al	4.8	5.15
	Co	18	19
	Cr	11.9	12.9
	Mo	2.8	3.6
	Ta	0.05	0.100
	Ti	4.15	4.5
	W	0.05	0.1
	B	0.016	0.024
	C	0.015	0.09
	V	0	0.98
	Fe	0	0.12
	Zr	0.04	0.08
	Hf	0	0.9
	Re	0	0.1
	Ni	Balance	Balance

In various embodiments, the nickel alloy may have a ratio of niobium to tantalum of at least one of between 1:0.5 and 1:5 and between 1:1 and 1:3. In various embodiments, the nickel alloy may have a ratio of tungsten to tantalum of at least one of between 1:0.5 and 1:5 and between 1:1 and 1:3. In various embodiments, the nickel alloy may have a ratio of tungsten to niobium of at least one of between 1:0.5 and 1:5 and between 1:1 and 1:3.

In various embodiments, tantalum is present at 0.1 wt. %, tungsten is present at 0.1 wt. %, and niobium is present at 0.1 wt. %. In various embodiments, tantalum is present at 0.5 wt. %, tungsten is present at 0.05 wt. %, and niobium is present at 0.05 wt. %.

As shown in the TABLES, in various embodiments, a nickel alloy may have niobium, tungsten, tantalum, niobium and tungsten, niobium and tantalum, tungsten and tantalum or niobium, tantalum and tungsten. In all such combinations, the tungsten, tantalum, and/or niobium may be present at between 0.05% wt. and 0.1% wt.

In various embodiments, with reference to process 100 in FIG. 1, the nickel alloy may mixed or otherwise formed (Step 102). Then, the nickel alloy can be worked (either forged or cast or other suitable method) into an aircraft component (Step 104). Casting may be used to work the nickel alloy into the desired shape. For example, the nickel alloy may be cast into a disc or any other cast aircraft component for use on an aircraft.

A nickel alloy was prepared, in accordance with various embodiments, comprising tungsten, tantalum, and niobium, and the tensile strength and yield stress of such nickel alloy were tested. The tests were conducted in accordance with ASTM (American Society for Testing and Materials) E21: Standard Test Methods for Elevated Temperature Tension Tests of Metallic Materials, which is hereby incorporated by reference herein. The tensile strength of the nickel alloy is 209.8 pounds per square inch (ksi), and the yield stress of the nickel alloy is 160.7 ksi. These properties are improved over a conventional nickel alloy (having less or no niobium, tungsten, or tantalum than nickel alloys in accordance with various embodiments of this disclosure), the tensile strength for which is 208.6 ksi, and the yield stress is 159.7. Therefore, the presence (or greater presence) of niobium, tungsten, and/or tantalum in a nickel alloy improves the properties of the nickel alloy (e.g., for use in high-stress or heavy-load applications, such as in aircraft components) relative to a conventional nickel alloy.

Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the inventions. The scope of the inventions is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.

Systems, methods and apparatus are provided herein. In the detailed description herein, references to “various embodiments”, “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

Claims

1. A nickel alloy, comprising:

nickel;

aluminum from 4.8 wt. % to 5.15 wt. %;

cobalt from 18 wt. % to 19 wt. %;

chromium from 11.9 wt. % to 12.9 wt. %;

molybdenum from 2.8 wt. % to 3.6 wt. %; and

niobium from 0.05 wt. % to 0.1 wt. %.

2. The nickel alloy of claim 1, further comprising tungsten from 0.05 wt. % to 0.1 wt. %.

3. The nickel alloy of claim 1, further comprising tantalum from 0.05 wt. % to 0.1 wt. %.

4. The nickel alloy of claim 2, further comprising tantalum from 0.05 wt. % to 0.1 wt. %.

5. The nickel alloy of claim 2, wherein the ratio of tungsten to niobium is between 1:1 and 1:3.

6. The nickel alloy of claim 3, wherein the ratio of tantalum to niobium is between 1:1 and 1:3.

7. The nickel alloy of claim 4, wherein the ratio of tungsten to tantalum is between 1:1 and 1:3.

8. The nickel alloy of claim 4, wherein the ratio of tungsten to niobium is between 1:1 and 1:3.

9. The nickel alloy of claim 4, wherein the ratio of tantalum to niobium is between 1:1 and 1:3.

10. The nickel alloy of claim 4, wherein the niobium is present at 0.1 wt. %.

11. The nickel alloy of claim 10, wherein the tantalum is present at 0.1 wt. %.

12. The nickel alloy of claim 11, wherein the tungsten is present at 0.1 wt. %.

13. The nickel alloy of claim 12, further comprising titanium from 4.15 wt. % to 4.5 wt. %.

14. A nickel alloy, comprising:

nickel;

aluminum from 4.8 wt. % to 5.15 wt. %;

cobalt from 18 wt. % to 19 wt. %;

chromium from 11.9 wt. % to 12.9 wt. %;

molybdenum from 2.8 wt. % to 3.6 wt. %; and

tungsten from 0.05 wt. % to 0.1 wt. %.

15. The nickel alloy of claim 14, further comprising tantalum from 0.05 wt. % to 0.1 wt. %.

16. The nickel alloy of claim 15, wherein the ratio of tungsten to tantalum is between 1:1 and 1:3.

17. A nickel alloy, comprising:

nickel;

aluminum from 4.8 wt. % to 5.15 wt. %;

cobalt from 18 wt. % to 19 wt. %;

chromium from 11.9 wt. % to 12.9 wt. %;

molybdenum from 2.8 wt. % to 3.6 wt. %; and

tantalum from 0.05 wt. % to 0.1 wt. %.

18. The nickel alloy of claim 17, further comprising niobium from 0.05 wt. % to 0.1 wt. %.

19. The nickel alloy of claim 19, wherein the ratio of tantalum to niobium is between 1:1 and 1:3.

20. An aircraft component comprised from the nickel alloy of claim 1.