METHOD OF BRAZE REPAIR FOR EUTECTIC PHASE REDUCTION

A method of repairing an article having a surface and a defect is provided. The method includes forming a groove in the article at the defect and the top surface. The method further includes providing a superalloy powder to the groove such that the superalloy powder at least partially fills the defect and the groove. The method further includes providing a braze powder on the superalloy powder at the groove and the surface. The method further includes heating the article such that the braze powder becomes a liquified braze material and infiltrates the groove and the defect.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority pursuant to 35 U.S.C. 119 (a) to Polish Application No. P.446083, filed Sep. 12, 2023, which application is incorporated herein by reference in its entirety.

FIELD

The present disclosure relates generally to repairing high temperature performance alloys, e.g. superalloys.

BACKGROUND

Metal and alloy parts may experience various wear instances as a result of application fatigue. For example, cracking, abrasions, erosion or a variety of other acts may cause the removal or wear of original substrate material. To repair the worn parts, filler material may be added (e.g., welded or brazed) to fill in cracks, patch abrasions or otherwise replace material lost to erosion or has become defective during operation. To provide strong uniform mechanical properties across the repaired parts, filler material that is the same as, or substantially similar to, the substrate material can be used.

However, high temperature performance alloys (such as nickel and cobalt based super alloys used in hot gas path components of gas turbine parts) have high melting temperatures that require a significant application of energy before they can be applied to the original substrate material. As a result, the large amount of heat produced by a welding apparatus used to melt such filler materials can also affect the nearby substrate material. For example, heat can cause slumping, melting or other changes to the microstructure of the original substrate material. These changes in the substrate material can reduce the original component's strength, toughness and/or other physical characteristics.

While other filler materials with lower melting temperatures may alternatively be used, they may provide lower performance at high temperatures and/or possess mechanical properties that are increasingly different than the mechanical properties of the original substrate material. Additionally, the filler material may crack and lower the effectiveness of the repair.

BRIEF DESCRIPTION

Aspects and advantages of the methods in accordance with the present disclosure will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the technology.

In accordance with one embodiment, a method of repairing an article having a surface and a defect is provided. The method includes forming a groove in the article at the defect and the top surface. The method further includes providing a superalloy powder to the groove such that the superalloy powder at least partially fills the defect and the groove. The method further includes providing a braze powder on the superalloy powder at the groove and the surface. The method further includes heating the article such that the braze powder becomes a liquified braze material and infiltrates the groove and the defect.

In accordance with another embodiment, a method of repairing a turbomachine component having a surface and a defect is provided. The method includes forming a groove in the article at the defect and the top surface. The method further includes providing a superalloy powder to the groove such that the superalloy powder at least partially fills the defect and the groove. The method further includes providing a braze powder on the superalloy powder at the groove and the surface. The method further includes heating the article to a temperature above a braze powder melting point and below a superalloy powder melting point. As a result, the braze powder becomes a liquified braze material and infiltrates the superalloy powder in the groove and the defect.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the present methods, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation, rather than limitation of, the technology. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present technology without departing from the scope or spirit of the claimed technology. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.

The term “fluid” may be a gas or a liquid. The term “fluid communication” means that a fluid is capable of making the connection between the areas specified.

As used herein, the terms “upstream” (or “forward”) and “downstream” (or “aft”) refer to the relative direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the direction from which the fluid flows, and “downstream” refers to the direction to which the fluid flows. However, the terms “upstream” and “downstream” as used herein may also refer to a flow of electricity. The term “radially” refers to the relative direction that is substantially perpendicular to an axial centerline of a particular component, the term “axially” refers to the relative direction that is substantially parallel and/or coaxially aligned to an axial centerline of a particular component and the term “circumferentially” refers to the relative direction that extends around the axial centerline of a particular component.

The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive—or and not to an exclusive—or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Referring now to the drawings,FIG.1illustrates a schematic diagram of one embodiment of a turbomachine, which in the illustrated embodiment is a gas turbine10. Although an industrial or land-based gas turbine is shown and described herein, the present disclosure is not limited to a land based and/or industrial gas turbine unless otherwise specified in the claims. For example, the invention as described herein may be used in any type of turbomachine including but not limited to a steam turbine, an aircraft gas turbine, or a marine gas turbine.

As shown, gas turbine10generally includes an inlet section12, a compressor section14disposed downstream of the inlet section12, a plurality of combustors (not shown) within a combustor section16disposed downstream of the compressor section14, a turbine section18disposed downstream of the combustor section16, and an exhaust section20disposed downstream of the turbine section18. Additionally, the gas turbine10may include one or more shafts22coupled between the compressor section14and the turbine section18.

The compressor section14may generally include a plurality of rotor disks24(one of which is shown) and a plurality of rotor blades26extending radially outwardly from and connected to each rotor disk24. Each rotor disk24in turn may be coupled to or form a portion of the shaft22that extends through the compressor section14. The compressor section14may further include one or more stator vanes arranged circumferentially around the shaft. The stator vanes may be fixed to a compressor casing or static casing that extends circumferentially around the rotor blades26.

The turbine section18may generally include a plurality of rotor disks28(one of which is shown) and a plurality of rotor blades30extending radially outwardly from and being interconnected to each rotor disk28. Each rotor disk28in turn may be coupled to or form a portion of the shaft22that extends through the turbine section18. The turbine section18further includes a turbine casing33that circumferentially surround the portion of the shaft22and the rotor blades30, thereby at least partially defining a hot gas path32through the turbine section18. The turbine casing33may be configured to support a plurality of stages of stationary nozzles extending radially inwardly from the inner circumference of the turbine casing.

During operation, a working fluid such as air flows through the inlet section12and into the compressor section14where the air is progressively compressed, thus providing pressurized air to the combustors of the combustor section16. The pressurized air is mixed with fuel and burned within each combustor to produce combustion gases34. The combustion gases34flow through the hot gas path32from the combustor section16into the turbine section18, wherein energy (kinetic and/or thermal) is transferred from the combustion gases34to the rotor blades30, causing the shaft22to rotate. The mechanical rotational energy may then be used to power the compressor section14and/or to generate electricity. The combustion gases34exiting the turbine section18may then be exhausted from the gas turbine10via the exhaust section20.

FIGS.2through4each illustrate a cross-sectional view of an article100having a defect102(such as a crack, a void, a separation, or others), in accordance with various aspects of the present disclosure. In exemplary embodiments, the article100may be a turbomachine component101, such as a rotor blade, a stator vane, a portion of the turbine or compressor casing, a portion of the shaft, or other turbomachine component (e.g., any of the components of the gas turbine10discussed above with reference toFIG.1). As shown, the article100may define a vertical direction V, which may extend opposite the direction of gravity. As used herein, “top” and “bottom” may be with reference to the vertical direction V.

As shown, the article100may have a top surface104and a bottom surface106opposite the top surface104. The defect102may extend from the top surface104towards the bottom surface106. The defect102may extend through the top surface104, such that the defect102is exposed to the ambient environment at the top surface104. In many embodiments, the defect102may terminate prior to the bottom surface106, such that the defect102does not extend through the bottom surface106. In other embodiments, the defect102may extend through the bottom surface106.

FIGS.2through4may each illustrate the article100at various stages in a method of repairing the defect102in the article100.FIG.1illustrates the article100prior to being machined and/or filled with superalloy powder and/or braze powder. In this stage, the article100may be cleaned to remove any dirt/debris prior to being machined. For example, the top surface104, the bottom surface106, and any exposed portions of the defect102may be cleaned.

InFIG.3, a groove108may be formed in the article100at the defect102and the top surface104, such that the groove108is connected to the defect102. For example, the groove108may be machined or cut into the component using any suitable process, such as milling, turning, broaching, grinding, Electrical Discharge Machining (EDM), or others. Forming the groove108may include at removing at least a portion of the material surrounding the defect102, thereby removing a portion of the defect102. The groove108may be fluidly coupled to the defect102, such that the void formed by the groove108is connected to the space of the defect102.

In some embodiments, as shown best inFIG.3, the groove108may be generally rectangularly shaped, such that the groove108may be defined collectively by a first side wall110, a first floor112, a second side wall114, and a second floor116. The first side wall110and the second side wall114may be disposed on opposite sides of the defect102. The first floor112may extend from the first side wall110to the defect102, and the second floor116may extend from the second side wall114to the groove108. In other embodiments, the groove108may be curved or generally shaped as a semi-circle.

As shown inFIG.3, the groove108may define a first width124and the defect102may define a second width126. The first width124may be defined between the first side wall110and the second side wall114. The second width126may be the maximum width of the defect102measured in the same direction as the first width124. In exemplary embodiments, as shown, the first width124is larger than the second width126. For example, the first width124may be at least 50% larger than the second width126, or at least 100% larger than the second width126, or at least 150% larger than the second width126, or at least 200% larger than the second width126, or at least 500% larger than the second width126.

Similarly, as shown inFIGS.2and4collectively, the groove108may define a first length125and the defect102may define a second length127. The first length125may be defined between the top surface104and the floor (e.g., the first floor112and/or the second floor116). The first length125may be smaller than the second length127. For example, the first length125may be between about 1% and about 70% of the second length127, or such as between about 5% and about 50% of the second length127, or such as between about 5% and about 25% of the second length127, or such as between about 5% and about 15% of the second length127.

In many embodiments, the article100may be formed from a superalloy material. The superalloy may be a nickel or iron or cobalt based superalloy. Particularly, the article100may be a gas turbine component that is formed from a high gamma prime superalloy. The superalloy may be formed of a conventionally cast (CC), directionally solidified (DS), or single crystal (SX) material. Examples of such high gamma prime superalloys include, but are not limited to, B-1900, GTD-111, Inconel 100, Inconel 713, Inconel 792, MAR-M-246, MAR-M-509, Rene 77, Rene 125, U-500, CMSX single crystal alloys, and others.

As shown inFIG.4, a superalloy powder120may be provided to the groove108and the defect102, such that the superalloy powder120at least partially fills the defect102and the groove108. Notably, the superalloy powder120is not shown to scale, but rather is enlarged for the purpose of discussion and ease of illustration. The superalloy powder120may be the same material as the article100, or the superalloy powder120may be a different material than the article100. In some embodiments, the superalloy powder may be mixed with a binder, such as between about 5% and about 15% of a binder. In many embodiments, the superalloy powder120may be Rene 142 or a similar alloy (e.g., a rhenium-containing nickel-based superalloy). In other embodiments, the superalloy powder120may be CMSx4 or PWA 1426. In various embodiments, the superalloy powder120may be composed of, by weight, between about 6.3% and about 7.3% Chromium (Cr), between about 11% and about 13% Cobalt (Co), between about 1% and about 2% Molybdenum (Mo), between about 2.3% and about 3.3% Rhenium (Re), between about 4.4% and about 5.4% Tungsten (W), between about 5.65% and about 6.65% Aluminum (Al), between about 5.85% about 6.85% Tantalum (Ta), between about 1% and about 2% Hafnium (Hf), between about 0.005% and about 0.025% Boron (B), between about 0.05% and about 0.2% Carbon (C), between about 0.01 and about 0.03% Zirconium (Zr), and a balance (or remainder) of Nickel (Ni). Specifically, in exemplary embodiments, the superalloy powder120may be composed of, by weight, about 6.8% Chromium (Cr), about 12% Cobalt (Co), about 1.5% Molybdenum (Mo), about 2.8% Rhenium (Re), about 4.9% Tungsten (W), about 6.15% Aluminum (Al), about 6.35% Tantalum (Ta), about 1.5% Hafnium (Hf), about 0.015% Boron (B), about 0.12% Carbon (C), about 0.02% Zirconium (Zr), a balance (or remainder) of Nickel (Ni).

In various embodiments, as shown inFIG.4, the superalloy powder120may be provided to the groove108and the defect102until the superalloy powder120is flush with the top surface104of the article100(e.g., not protruding or recessed from the top surface104. This may involve applying an impact force to the article100or subjecting the article to vibrations (such as a shaker table or vibration table) to ensure the superalloy powder120has reached and settled in the entirety of the groove108and the defect102(e.g., the superalloy powder120has reached the bottom of the groove108). This process may be iterated until the superalloy powder120has filled the defect102and the groove108such that the superalloy powder120is flush with the top surface104.

As shown inFIG.5, a braze powder122may be provided on the top surface104and on top of the superalloy powder120that fills the groove108and the defect102. As discussed above, the braze powder122and the superalloy powder120are not shown to scale but instead enlarged for discussion purposes. The braze powder122may be a mixture of a braze material and a superalloy material (which may be the same superalloy material as the article100, a different superalloy material than the article100, or the superalloy powder120). In such embodiments, the braze powder122mixture may include between about 70% and about 100% braze material with a remainder being the superalloy material. Similarly, the superalloy powder120may be a mixture of superalloy material and braze material, such as between about 70% and 100% superalloy material with a remainder being braze material.

In various embodiments, the braze material in the braze powder122may be a nickel-based brazing alloy, which may be used alone, or which may be blended with a powder of a superalloy, such as those discussed above. The brazing powder may also be mixed with binders (e.g., between 5% and 15%). In many embodiments, the braze powder122may be Amdry DF4B or a similar braze alloy (such as Amdry DF-3 or Amdry 775). In various embodiments, the braze powder may be composed of, by weight, between about 13% and about 15% Chromium (Cr), between about 9% and about 11% Cobalt (Co), between about 3.25% and about 3.75% Aluminum (Al), between about 2.25% and about 2.75% Tantalum (Ta), between about 2.5% and about 3.0% Boron (B), between about 0.01% and about 0.10% Yttrium (Y), and balance of Ni. Specifically, in exemplary embodiments, the braze powder122may be composed of, by weight, about 14% Chromium (Cr), about 10% Cobalt (Co), about 3.5% Aluminum (Al), about 2.5% Tantalum (Ta), about 2.75% Boron (B), about 0.05% Yttrium (Y), a balance of Nickel (Ni).

As shown inFIG.6, the article100may be heated, e.g., in a furnace or braze oven200. That is the article may be subjected to a heat treatment known as a braze cycle, which occurs in a high vacuum furnace or braze oven200. The position of the article100within the furnace depends on the cracks' orientation, and generally the parts are positioned in the way that the force of gravity, combined with the capillary force, facilitates the flow of the brazing alloy in most of the cracks to be brazed. During the braze cycle, the braze powder122liquifies and flows into the defect102. Stated otherwise, when the article100is heated, the braze powder122may melt or liquify and infiltrate the groove108and the defect102. That is, during the heating step, the braze powder122may transition to a liquid state and move downward with gravity into the groove108, thereby filling the spaces between the still-solid superalloy powder120and mixing therewith. The liquid braze powder from the top surface104flows to the defect102towards the bottom surface106, thereby infiltrating the superalloy powder120(which are still in a solid phase) in the notch so that the solid-phase superalloy powder120is dissolved in the liquid braze material.

Particularly, in exemplary embodiments, the article100may be heated in the braze oven200to a temperature that is above a braze powder melting point and below a superalloy powder melting point. As a result, the braze powder122becomes a liquified braze material and infiltrates the still-solid superalloy powder120in the groove108and the defect102.

Subsequently, the article100may cool, such that the braze material solidifies within the groove108and the defect102. Post processing procedures may be implemented to finalize the repair of the article100, such as removing excess braze material from the top surface, cleaning the braze joint, or others. For example, a blending tool may be used to smooth the excess braze material and create a blended surface with the top surface104.

Referring now toFIG.7, a flow diagram of one embodiment of a method700of repairing an article having a surface and a defect is illustrated in accordance with embodiments of the present subject matter. In general, the method700will be described herein with reference to the articles100described above with reference toFIGS.2-6. In addition, althoughFIG.7depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement unless otherwise specified in the claims. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

As shown inFIG.7, the method700may include at (702) forming a groove in the article at the defect and the top surface. The groove may be cut or machines in the article using any suitable process, such as milling, turning, broaching, grinding, Electrical Discharge Machining (EDM), or others. Forming the groove may include at removing at least a portion of the material surrounding the defect, thereby removing a portion of the defect from the article. The groove may be fluidly coupled to the defect, such that the groove and the defect form a continuous void in the article. The forming step702may be the first step performed as part of the method700. In some implementations, the article may be cleaned prior to and/or after the forming step702to remove debris.

In many implementations, the method may include forming the groove in the article at the defect and the top surface such that the groove is disposed on either side of the defect. In other embodiments, the groove may only be disposed on one side of the defect but still in fluid communication therewith. Additionally, in various implementations, at least a portion of the defect is removed by forming the groove in the article at the top surface. For example, the portion of the article surrounding and at least partially defining the groove may be removed to form the groove, thereby removing a portion of the defect.

The method700may further include at (704) providing a superalloy powder to the groove such that the superalloy powder at least partially fills the defect and the groove. In various implementations, the superalloy powder may be provided to the groove and the defect until the superalloy powder is flush with the top surface of the article (e.g., not protruding or recessed from the top surface. This may include applying an impact force to the article or subjecting the article to vibrations (such as a shaker table or vibration table), e.g., during the providing step704, to ensure the superalloy powder has reached and settled in the entirety of the groove and the defect (e.g., the superalloy powder120has reached the bottom of the groove). This process may be iterated until the superalloy powder has filled the defect and the groove such that the superalloy powder is flush with the top surface. For example, a first amount of superalloy powder may be provided to the groove and the defect, the article may be subject to an impact force or vibrations, a second amount of powder may be provided to the groove and the defect, and so on.

The method700may further include at (706) providing a braze powder on the superalloy powder at the groove and the surface. Particularly, step706may be after step704, and the braze powder may be provided on top of the superalloy powder that has already been provided to the groove and the defect. In this way, the braze powder may form a mound or protrusion on top of the surface and on top of the superalloy powder in the groove.

The method700may further include at (708) heating the article such that the braze powder becomes a liquified braze material and infiltrates the groove and the defect. Particularly, as shown by the optional dashed box, the heating step (708) may further include at (710) heating the article to a temperature above a braze powder melting point and below a superalloy powder melting point, whereby the braze powder becomes the liquified braze material and infiltrates the superalloy powder in the groove and the defect. The heating steps708and710may be performed within a furnace or braze oven. In many implementations, during the heating step, the liquified braze material may mix with the superalloy powder (which is still in a solid state) in the groove and the defect such that the superalloy powder at least partially dissolves in the liquified braze material. For example, larger particles of the superalloy powder may not dissolve while smaller particles of the superalloy powder will dissolve.

In many embodiments, the method700may further include at (712) cooling the article such that the liquified braze material solidifies. This may include removing the article from the braze oven or furnace, thereby allowing the article and liquified braze material to solidify within the defect and the groove. Additionally, the method700may include at (714) performing one or more post-processing operations on the article. Post-processing operations may be implemented to finalize the repair of the article, such as removing excess braze material from the top surface, cleaning the braze joint, or others.

The method disclosed herein advantageously provides for an increased strength braze repair when compared to prior methods. Specifically, the groove created above the defect provides for a braze joint with increased strength due to the formation of less eutectic chains during the braze repair. For example, the liquid braze material from the upper layer flows to the bottom of the crack in the brazing process, infiltrating the high-melting point superalloy powder in the groove. The small (e.g., smaller than the braze powder particles), solid-phase, particles of the superalloy powder are dissolved in the liquid braze material. The larger particles of the superalloy powder are partially dissolved in the liquid braze material, so the quantity of the liquid phase is reduced in the overall material flowing into the defect (e.g., the liquid braze material and the at least partially dissolved solid-phase superalloy powder). This results in less eutectic chains forming at a midline of the defect, thereby increasing the strength of the braze joint.

A method of repairing an article having a surface and a defect, the method comprising: forming a groove in the article at the defect and the surface; providing a superalloy powder to the groove such that the superalloy powder at least partially fills the defect and the groove; providing a braze powder on the superalloy powder at the groove and the surface; and heating the article such that the braze powder becomes a liquified braze material and infiltrates the groove and the defect.

The method as in any preceding clause, wherein the heating step further comprises: heating the article to a temperature above a braze powder melting point and below a superalloy powder melting point, whereby the braze powder becomes the liquified braze material and infiltrates the superalloy powder in the groove and the defect.

The method as in any preceding clause, wherein, during the heating step, the liquified braze material mixes with the superalloy powder in the groove and the defect such that the superalloy powder at least partially dissolves in the liquified braze material.

The method as in any preceding clause, wherein the article is a formed from a superalloy material.

The method as in any preceding clause, wherein the forming step further comprises: forming the groove in the article at the defect and the surface such that the groove is disposed on either side of the defect.

The method as in any preceding clause, wherein at least a portion of the defect is removed by forming the groove in the article at the surface.

The method as in any preceding clause, wherein the article is a turbomachine component.

The method as in any preceding clause, wherein the groove defines a first width and the defect defines a second width, wherein the first width is larger than the second width.

The method as in any preceding clause, further comprising: cooling the article such that the liquified braze material solidifies; and performing one or more post-processing operations on the article.

The method as in any preceding clause, wherein the superalloy powder comprises, by weight, between about 6.3% and about 7.3% Chromium (Cr), between about 11% and about 13% Cobalt (Co), between about 1% and about 2% Molybdenum (Mo), between about 2.3% and about 3.3% Rhenium (Re), between about 4.4% and about 5.4% Tungsten (W), between about 5.65% and about 6.65% Aluminum (Al), between about 5.85% about 6.85% Tantalum (Ta), between about 1% and about 2% Hafnium (Hf), between about 0.005% and about 0.025% Boron (B), between about 0.05% and about 0.2% Carbon (C), between about 0.01 and about 0.03% Zirconium (Zr), and a balance of Nickel (Ni).

The method as in any preceding clause, wherein the braze powder comprises, by weight, between about 13% and about 15% Chromium (Cr), between about 9% and about 11% Cobalt (Co), between about 3.25% and about 3.75% Aluminum (Al), between about 2.25% and about 2.75% Tantalum (Ta), between about 2.5% and about 3.0% Boron (B), between about 0.01% and about 0.10% Yttrium (Y), and balance of Ni.

A method of repairing a turbomachine component having a surface and a defect, the method comprising: forming a groove in the turbomachine component at the defect and the surface; providing a superalloy powder to the groove such that the superalloy powder at least partially fills the defect and the groove; providing a braze powder on the superalloy powder at the groove and the surface; and heating the turbomachine component to a temperature above a braze powder melting point and below a superalloy powder melting point, whereby the braze powder becomes a liquified braze material and infiltrates the superalloy powder in the groove and the defect.

The method as in any preceding clause, wherein, during the heating step, the liquified braze material mixes with the superalloy powder in the groove and the defect such that the superalloy powder at least partially dissolves in the liquified braze material.

The method as in any preceding clause, wherein the turbomachine component is a formed from a superalloy material.

The method as in any preceding clause, wherein the forming step further comprises: forming the groove in the turbomachine component at the defect and the surface such that the groove is disposed on either side of the defect.

The method as in any preceding clause, wherein at least a portion of the defect is removed by forming the groove in the turbomachine component at the surface.

The method as in any preceding clause, wherein the groove defines a first width and the defect defines a second width, wherein the first width is larger than the second width.

The method as in any preceding clause further comprising: cooling the turbomachine component such that the liquified braze material solidifies; and performing one or more post-processing operations on the turbomachine component.

The method as in any preceding clause, wherein the superalloy powder comprises, by weight, between about 6.3% and about 7.3% Chromium (Cr), between about 11% and about 13% Cobalt (Co), between about 1% and about 2% Molybdenum (Mo), between about 2.3% and about 3.3% Rhenium (Re), between about 4.4% and about 5.4% Tungsten (W), between about 5.65% and about 6.65% Aluminum (Al), between about 5.85% about 6.85% Tantalum (Ta), between about 1% and about 2% Hafnium (Hf), between about 0.005% and about 0.025% Boron (B), between about 0.05% and about 0.2% Carbon (C), between about 0.01 and about 0.03% Zirconium (Zr), and a balance of Nickel (Ni).

The method as in any preceding clause, wherein the braze powder comprises, by weight, between about 13% and about 15% Chromium (Cr), between about 9% and about 11% Cobalt (Co), between about 3.25% and about 3.75% Aluminum (Al), between about 2.25% and about 2.75% Tantalum (Ta), between about 2.5% and about 3.0% Boron (B), between about 0.01% and about 0.10% Yttrium (Y), and balance of Ni.