NICKEL-CHROMIUM ALLOYS HAVING A DISPERSED PHASE

Abstract: An alloy body specifically adapted to be used as an industrial gas turbine structure having an elongated grain structure, gamma prime hardening precipitate and an oxidic yttrium dispersed phase. The alloy contains, in addition to nickel, 19 to 24% chromium, 1 to 3.4% aluminum, 1.75 to 5% titanium and balanced amounts of cobalt, tungsten, tanta­ lum, boron and zirconium.

Description: Nickel-chromium alloy having a dispersed phase The present invention is directed to metallic alloy bodies especially suitable for use as structures in hot sections of an industrial gas turblne.(IGT) and more particularly to nickel-base alloy bodies suitable for such usage. BACKGROUND AND PROBLEM A modern, advanced design industrial gas turbine (IGT) has hot stage blades and vanes which are required to perform for lives of 5 x 10 to 10 hours in a corroding environment resulting from the combustion of relatively low grade fuels and, in the case of blades, under high stress. Naturally, in order to increase efficiency, it is desired to operate such IGT blades and vanes at the highest practical operating temperatures consistent with achieving the design lifetimes. When considering operating temperatures, it is necessary to take into account not only the highest temperature to which a turbine blade is exposed, but also a range of temperatures below that highest temperature. Even at steady-state operation, a turbine blade will experience a variety of temperatures along its length from root to tip and across its width from leading to trailing edge. Over the long design lives of IGT blades and vanes, corrosion resistance and oxidation resistance become more important factors than thev are in the well-developed field of aircraft gas turbine (AGT) alloys. Although in neither the case of AGT nor ICT turbine blades or vanes would it be advisable to select an oxidation or corrosion prone alloy, the longer (by an order of magnitude) time exposure of IGT components to a more corroding atmosphere make oxidation and corrosion resistance very important features of IGT alloy structures. IGT alloy structures such as hot stage blades and vanes can be coated with conventional coatings to enhance oxidation and corrosion resistance but these coatings are subject to cracking, spalling and the like. Over the long design lives of IGT components, it is more likely that coating failures will occur in comparison to such failures with AGT coated components used for shorter time periods. Thus, even if coated, an IGT alloy structure used in the hot stage of an IGT must have the best oxidation and corrosion resistance obtainable commensurate with other required properties and characteristics. In designing alloy structures for IGT turbine blades it is natural to investigate nickel-base alloys which are used conventionally in AGT turbine blades. Even the strongest conventional, a strengthened nickel-base alloys rapidly lose strength at temperatures above about 900"C (see Figure 2 of U.S. Patent No. 4,386,976). It is disclosed in U.S. Patent No. 4,386,976 however that nickel-base alloys combining iY strengthening and strengthening by a uniform dispersion of microfine refractorv oxidic particles can provide adequate mechanical properties in the temperature range of 750"C up to 11000. However, the alloys disclosed in U.S. patent No. 4,386,976 are deemed to have inadequate oxidation and corrosion resistance for use in advanced design IGTs. It is also known1 for example, from U.S. Patent No. 4,039,330 that)( strengthened nickel -base alloys containing in the vicinity of 21 to 24 weight percent chromium along with some aluminum have excellent corrosion resistance, of the character needed for IGT usage. At very high temperatures, e.g. over 10000C, the oxidation resistance of alloys as disclosed in U.S. Patent No. 4,039,330 tends to fall off. Strength at temperatures in excess of 9009C of the alloys disclosed in U.S. Patent No. 4,039,330, as with all 6 strengthened nickel-base alloys is inadequate for components of advanced design TACTS. From the background in the immediatelv preceding paragraph one might be tempted to declare that the solution to providing turbine blades for advanced design IGTs is obvious. Either increase the chromium and/or aluminum content of Y and dispersion strengthened alloys disclosed in U.S. Patent No. 4,386,976 or add dispersion strengthening to the allovs disclosed in U.S. Patent No. 4,039,330. These appealing, seemingly logical solutions to the existing problem are overly simplistic. The first possibility i.e., increasing the chromium and/or the aluminum content of a known &commat; and dispersion strengthened alloy, has two difficulties. Increasing either chromium or aluminum can tend to make a nickel-base alloy sigma prone. Increase of chromium directly dilutes the nickel content of the alloy matrix remaining after & phase precipitation. Increasing the aluminum content increases the amount of dl phase (Ni3Al-Ti) which can form in the nickel-base alloy again diluting the matrix with respect to nickel. Detrimental acicular sigma phase tends to form in nickel-base alloys having low nickel matrix contents after intermediate temperature (e.g., 8000C) exposure resulting in low allov ductility. Because the existence of Y phase is essential to component strength at temperaturas up to about 9000C, it is necessary to carefully control alloy modification to avoid phase instability over the long term usage characteristic of IGTs where a minimum acceptable ductility is essential. From another point of view, indiscriminate alloy modification especially in the realm of increasing aluminum and/or chromium contents presents a difficulty in providing the component microstructure essential to strength of dispersion strengthened alloys at high temperature. Referring again to U.S. Patent No. 4,386,976 Column 1, line 58 et seq., it is disclosed that ODS (oxide dispersion strengthened) alloys must be capable of developing a coarse, elongated grain structure in order to obtain good elevated temperature properties therein. This coarse, elongated grain structure is developed by directional, secondary recrystallization at a temperature above the y solvus temperature and below the incipient melting temperature of the alloy (see Column 6, line 58 et seq. of the U.S. Patent No. 4,386,976) or some temperature close to the incipient melting temperature. If X phase is not solutioned, the secondary crvstallization will not proceed. If the incipient melting temperature of the alloy is exceeded the oxide dispersion will be detrimentally affected. For practical production, the interval between the 'solvus temperature and the temperature of incipient melting must be at least about 200 and advantageously at least about 20 in Celsius units. Because of the complexity of modern 6 strengthened allov compositions and the complex interactions among the alloying elements, there is no wav of predicting the secondary recrystallization interval which is a sine qua non for obtaining the high temperature strength in ODS alloys. The same difficulty applies to the possible idea of providing oxide dispersion strengthening to a known, high strength & oxidation and corrosion-resistant alloy. There is no way of predicting whether nor not the theoretical ODS- & strengthened alloy can be made on a commercial basis. The foregoing makes it clear that the provision of alloy components suitable for hot stage advanced design IGT usage is a problem that requires critical metallurgical balancing to at least provide an adequate window for thermal treatment necessary for practical production of such components. In addition, the alloy composition must be capable of undergoing the practical mechanical and thermomechanical processing required to reach the stage of directional recrystallization. The present invention prpvides alloy bodies suitable for use in advance design IGTs which can be produced in a practical manner. BRIEF DESCRIPTION OF THE DRAWING The figure is a photograph showing the grain structure of an allov body of the invention. SUMMARY OF THE INVENTION The present invention comtemplates an alloy body especially useful as a component in hot stages of industrial gas turbines having improved resistance to long term stress at temperatures in the range 800" to 10000C combined with enhanced oxidation and corrosion resistance. The alloy body comprises at least in part, an aggregation of elongated, essentially parallel metallic crystals having grain boundaries therebetween wherein the average grain aspect ratio of said metallic crystals is at least about 7. These metallic crystals (1) have a Y phase dispersed therein at a temperature lower than about 11600C and (2) have dispersed therethrough particles in the size range of about 5 to 500 nanometers in malor dimension of an oxidic phase stable at temperatures below at least 11000C. The metallic crystal inclusive of dispersed material and grain boundarv material consists essentially in weight percent of about 19 to 24% chromium, about 1 to 3.4% aluminum about 1.75 to 5% titanium, about 0.5 to 3X tantalum, up to, i.e. 0 to IZ niobium, about 1 eo 5% tungsten, up to 4% rhenium in replacement of an equal weight percentage of molybdenum or tungsten, up to 25Z cobalt, up to 2% hafnium, up to 0.2Z carbon, about 0.4 to 0.7Z oxygen, about 0.4 to 1X yttrium, up to about 0.05, e.g. about 0.005 to 0.05% boron, up to 0.5, e.g. about 0.05 to 0.25% zirconium, up to about 1 or 2Z iron, up to about 0.3 or 0.5% nitrogen, up to about 1% molybdenum, the balance except for impurities and incidental elements being nickel. In these alloy bodies, substantially all of the yttrium and a part of the aluminum exist as oxides forming the principal part of the dispersed stable oxidic phase. Depending upon the exact conditions of manufacture and use, the dispersed oxidic phase can comprise yttria and alumina or alumina - yttria mixed oxides such as A1203 . 2Y203, A1203 . Y203 or 5Al 203 3Y203 and comprises about 2.5 to about 4 volume percent of the metallic crystals. Generally speaking, the alloy body of the present invention is produced by mechanically alloying powdered elemental and/or master allov constituents along with oxidic yttrium in an attritor or horizontal ball mill until substantial saturation hardness is obtained along with thorough interworking of the attrited metals one within another and effective inclusion of the oxide containing yttrium within attrited alloy particles to provide homogeneity. For best results, the milling charge should include powder of an omnibus master alloy, i.e., an alloy containing all non-oxidic alloying ingredients in proper proportion except beinR poor in nickel or nickel and cobalt. This omnibus master allov powder is produced by melting and atomization, e.g. gas atomization. The mill charge consists of the omnibus master alloy, yttria or oxidic yttrium and appropriate amounts of nickel, nickel and cobalt or nickel-cobalt alloy powder. The milled powder is then screened, blended and packed into mild steel extrusion cans which are sealed and may be evacuated. The sealed cans are then heated to about 1000"C to 12000C and hot extruded at an extrusion ratio of at least about 5 using a relatively high strain rate. After extrusion or equivalent hot compaction, the thus processed mechanically alloyed material can be hot worked, especially directionally hot worked by rolling or the like. This hot working should be carried out rapidly in order to preserve in the metal a significant fraction of the strain energy induced by the initial extrusion or other hot compaction. Once this is done, the alloy body of the invention is processed by any suitable means, e.g., zone annealing, to provide coarse elongated grains in the body having an average grain aspect ratio (GAR) of at least 7. If required, the thus produced alloy body can be given a solution treatment and a subsequent aging heat treatment to precipitate dr phase in addition to that amount of 6 phase forming on cooling from grain coarsening temperatures. It has been found that for alloys having a composition within the range as disclosed hereinbefore, the overall grain coarsening interval, i.e., Tic (Temperature of incipient melting) T/ ( dsoivus temperature) is at least 20C in Celsius units thereby providing an adequate processing window for commercial production of alloy bodies having coarse elongated grains of high GAR. For alloy bodies of the present invention, solution treatment can be for 1 to 20 hours at 1050 to-1300"C followed by an aging treatment involving maintaining the alloy bodv for 1 to 24 hours at a temperature in the range of 600 to 950"C. An intermediate aging treatment consisting of maintaining the body for 1 to 16 hours in the range of 800 to 11500C between solutioning and final aging can be advantageous. DESCRIPTION OF THE PREFERRED EMBODIMENT Alloy bodies of the present invention advantageously contain, in combination or singly, the following preferred amounts of alloying ingredients: Ingredient % by Wt. Ingredient % by Wt. Cr 19 -23 Co 5 -25 Al 1.5- 3 Hf 0 - 0.7 Ti 2 - 4 C 0 - 0.1 Ta 1 - 2 Zr 0.05 - 0.25 W 1.8- 2.5 B 0.005- 0.05 Fe 0 - 1 Re 0 N 0 - 0.3 The compositions, (except for nickel balance and from 0.2 to 0.25Z N) in weight percent, of inRredients analyzed (assuming all yttrium to be present as yttria), of specific examples of alloys making up allov bodies of the present invention are set forth in Table I. TABLE I Alloy Cr Al Ti Ta W CO Hf C B Zr u Fe p 1 20.8 2.7 3.4 1.7 2.0 9.7 - 0.057 0.014 0.20 0.57 1.4 0.60 2 20.3 2.7 3.6 1.5 2.0 20.0 - 0.044 0.012 0.08 0.58 0.97 0.73 3 22.0 1.74 2.3 1.5 2.116.1 0.49 0.051 0.011 0.05 0.64 2.3 0.48 4 22.9 2.5 3.5 1.5 2.1 19.7 0.5 0.039 0.012 0.17 0.57 1.1 0.69 5 22.3 3.0 3.6 1.5 2.2 9.0 - 0.048 0.012 0.20 0.56 1.05 0.54 6 20.1 2.75 3.5 1.65 2.2 9.0 - 0.047 0.012 0.19 0.55 0.97 0.51 7 20.2 2.7 3.5 1.6 2.214.1 - 0.048 0.015 0.21 0.54 1.15 0.57 8 22.7 2.8 3.4 1.5 2.-2 9.8 - 0.047 0.012 0.21 1.00 0.84 0.67 Each of the alloy compositions was prepared by mechanical alloying of batches in an attritor using as raw material nickel powder Type 123, elemental chromium, tungsten, molybdenum, tantalum and niobium, nickel 47.5% Al master alloy, nickel-28% zirconium master alloy, nickel-16.9Z boron master allov and yttria. In each case the powder was processed to homogeneity. Each powder bath was screened to remove particles exceeding 12 mesh, cone blended two hours and packed into mild steel extrusion cans which were evacuated and sealed. Up to four extrusion cans were prepared for each composition. The cans were heated in the range 10000C to 12000C and extruded into bar at an extrusion ratio of about 7. Extrusion was performed on 750 ton press at about 35 throttle setting. The extruded bar material was subjected to hot rolling at temperatures from 12000C to 13000C and at total reductions up to about 60% (pass reductions of about 20Z) with no difficulties being encountered. Heat treating experiments determined that the extruded bar material would grow a coarse elongated grain and that zone annealing at an elevated temperature, in the range of about 12000C to about 1315 C was an effective grain coarsening procedure. Tensile tests, stress-rupture tests oxidation tests and sulfidation tests were conducted on alloy bodies having a coarse grain structure of high GAR in accordance with the invention with the results shown in the following Tables The tensile and stressrupture tests were all conducted in the longitudinal direction as determined by the grain structure of the alloy body. Prior to testing, the alloys as set forth in Table I were formed into alloy bodies of the invention by the zone annealing treatment set forth in Table II. Particular heat treatments employed are also set forth in Table II. TABLE II Zone Anneal Heat Treatment Alloy Temp ("C) Speed mm/hr hours - C - AC (air cooling) I 1260 76 7.5 - 1160-AC + 16-760-AC 2 1260 76 7.5 - 1160-AC + 16-760-AC 5 1250 76 7 - 1160-AC + 16-760-AC 6 1257 76 7 - 1160-AC + 16-760-AC 7 1257 76 7 - 1160-AC + 16-760-AC 8 1257 76 7 - 1160-AC + 16-760-AC Some of the alloy bodies of the invention as zone annealed and heat treated as set forth in Table II were tensile tested at various temperatures as reported in Table III. TABLE III Y.S. (MPa) U.T.S. El R.A. Alloy Body 0.2% Offset (MPa) (Z) (Z) ROOM TEMPERATURE 1 1367 1424 1.0 3.0 5 1201 1248 3.0 6.0 TABLE III (CONT'D) Y.S. (MPa) U.T.S. El R.A. Alloy Body 0.2% Offset (MPa) (%) (%) 6000C 1 1064 1164 2.0 1.5 5 1041 1098 1.0 1.0 8000C 1 826 935 2.0 2.5 5 626 747 4.0 2.5 1000 C 1 260 292 14.0 25.5 5 255 290 7.0 16.0 1100 C 1 128 138 9.0 29.5 5 126 140 12.0 31.0 Samples of Alloy body 1 tested under stress for creep-rupture exhibited the characteristics as reported in Table IV. TABLE IV Minimum Temperature Stress Life El RA Creep Rate ( C) (MPa) (h) (%) (%) (Z/h) 816 400 13.9 1.5 2.0 0.027 816 350 77.5 3.2 4.0 0.0026 816 325 169.5 1.0 2.8 816 300 807.8 2.5 8.0 982 193 6.4 4.8 12.5 982 172 73.3 5.5 7.0 0.008 982 160 254.2 3.2 6.7 0.0017 982 150 928.9 3.2 3.1 982 135 8953.1 3.4 3.1 Other tests have established the rupture stress capabilities of alloy bodies 2 to 5 as set forth in Table V. TABLE V Rupture Stress Capabilities (MPa) 816"C 982"C Alloy Body No. 102h 103h 10 102h 103h 104h 1 340 280 240 170 150 135 2 340 275 230* 160 140 NA 5 340 280 240* 160 145 135* 6 NA NA 240* 160 145 135* 7 380 315 250 165 140 130* 8 340 280 230 170 150 135* *Extrapolated Value NA - Not Available Yet Alloy bodies of the present invention exhibited results in terms of metal loss and maximum attack along a diameter as set forth in Table VI when subiected to the burner rig hot corrosion tests specified therein. TABLE VI 926 C(1) 843 C(1) 7040C(2) Metal Max. Metal Max. Metal Max Loss Attack Loss Attack Loss Attack Alloy Body mm mm mm mm mm mm -1 0.0025 0.0914 0.0076 0.0406 0.0254 0.0254 5 ND ND 0.0304 0.0304 ND ND (1) Test Conditions: JP-5 fuel + 0.3 Wt Z S, 5ppm sea salt, 30:1 air-to-fuel ratio, 1 cycle/hour (58 min. in flame, 2 min. out in air) 500h test duration. (2) Test Conditions: Diesel #2 fuel + 3.0 wt % S, 10 ppm sea salt 30:1 air-to-fuel ratio, 1 cvcle/day, (1425 minutes in flame, 15 minutes out in air) 500 hour test duration. (3) ND = Not Determined. In addition to the hot corrosion tests specified in Table VI, allov bodies of the invention were subjected to cvclic oxidation tests in which allov body specimens were held at the temperatures specified in Table VII in air containing 5% water for 24 hour cycles and then cooled in air on completion of the cycle. Table VII reports results in terms of descaled weight change (mg/cm2) of these tests. TABLE VIT Descaled Wt. Change (mg/cm2) Alloy Body 1000 C/41 Cycles 1100 C/21 Cvcles 1 4.683* -165.210 2 3.164* -236.501 6 3.895* -143.287 7 3.128* -179.799 8 5.141* - 89.268 *Tight adherent scale In order to assess the stability of allov bodies of the invention, they were exposed, unstressed, to an air atmosphere at 816"C for various times and then examined, either microscopically or by means of a room temperature tensile test. Microscopic examination of alloy bodies 1 and 3 showed no evidence of formation of sigma phase after 6272 hours of exposure. Room temperature tensile test results of alloy bodies of the present invention after specified times of unstressed exposure at 8160C in an air atmosphere are set forth in Table VIII. TABLE VIII Exposure Alloy Body at 8160C YS (MPa) UTS El. RA. Hardness No. (Hours) .2% Offset (MPa) X Z (RC) 1 6000 843 1043 5.3 7.5 36-38 1 8000 925 956 3.6 4.0 38-40 5 6000 861 996 3.5 5.9 36-37 6 6000 852 1012 4.1 6.5 37-38 7 6000 843 1066 5.1 5.9 40 8 6000 918 1025 2.9 2.8 40-42 Tables III through VIII together in comparison to data in U.S. Patent Nos. 4,386,976 and 4,039,330 mentioned hereinbefore show that allov bodies of the present invention are suitable for use as IGT hot staRe blades and other components provided the maximum temperature exposure is about 10000C. For example, Tables III to V show that in strength characteristics, the alloy bodies of the present invention parallel the strength characteristics of INCONEL MA6000 (U.S. Patent No. 3,926,568) whereas Tables VI and VII show that in corrosion and oxidation resistance, the alloy bodies of the present invention exhibit characteristics akin to or better than IN 939 (U.S. Patent No. 4,039,330). The drawing depicts the coarse elongated grain structure of the allov bodies of the invention which is instrumental in providing their advantageous strength characteristics. Referring now thereto, the optical photograph of the Figure shows the etched outline of coarse metallic grains bound together by grain boundary material. In view of the total aluminum and chromium contents of the alloy bodies of the invention, it is expected that these alloy bodies will constitute compatible substrates for both diffused aluminide coatings and for various high aluminum, high chromium deposited coatings, e.g. M-Cr-Al-Y coatings where M is a metallic element such as nickel or cobalt. By use of such coatings the already high corrosion and oxidation resistance of alloy bodies of the invention can be further enhanced. Those skilled in the art will appreciate that alloy bodies of the present invention can include volumes in which the grain structure can deviate from the coarse elongated structure depicted in the drawing provided that such volumes are not required to possess extreme mechanical characteristics at very high temperatures. For example, in a turbine blade structure, part on all of the root portion can have a grain structure differing from the coarse, elongated, longitudinally oriented grain structure of the blade portion. While the present invention has been described with respect to specific embodiments, those skilled in the art will appreciate that alterations and modifications within the scope of the invention can be made. Such alterations and modifications are intended to be within the ambit of the appended claims.

Claims: WE CLAIM: 1. An alloy body esPecially useful in hot stages of industrial gas turbines having improved resistance to long term stress at temperatures in the range 800C to 10000C combined with enhanced oxidation and corrosion resistance comprising, in at least part, an aggregation of elongated, essentially parallel metallic crystals having grain boundaries therebetween wherein the average grain aspect ratio of said metallic crystals is at least about 7, said metallic crystals (1) having a % phase dispersed therein at a temperature lower than about ll6OCC and (2) having dispersed therethrough particles in the range of about 5 to 500 nanometers in major dimension of a stable yttrium-containing oxidic phase1 said metallic crystals and grain boundary material consisting essentially in weight percent of about 19 to about 24% chromium, about 1 to about 3.4% aluminum, about 1.75Z to about 5Z titanium, about 0.5 to about 3Z tantalum, up to about 1% niobium, up to about 1% molybdenum, about 1 to about 5% tungsten, up to about 25% cobalt, up to about 2% hafnium, about 0.4 to about 0.7Z oxygen, about 0.4 to about 1% yttrium, up to about 0.2Z carbon, up to about 0.05Z boron, up to about05% zirconium, up to about 2Z iron, up to about 0.5Z nitrogen, up to about 4Z rhenium in replacement of an equal weight percentage of molybdenum or tungsten, the balance, except for impurities being essentially nickel. 2. An alloy body as in claim 1 containing about 19 to 23Z chromium. 3. An alloy body as in claim 1 containing about 1.5 to 3Z aluminum. 4. An allov body as in claim 1 containing about 2 to 4% titanium. 5. An alloy body as in claim 1 containing about 1 to 2% tantalum. 6. An alloy body as in claim 1 containing about 1.8 to 2.5% tungsten. 7. An allov body as in claim 1 containing about 5 to 25Z cobalt. 8. An alloy body as in claim 1 containing up to about 0.7% hafnium 9. An alloy body as in claim 1 containing up to 0.1% carbon. 10. An alloy body as in claim 1 containing about 0.05 to 0.25Z zirconium and about 0.005 to 0.05Z boron. 11. An alloy body as in claim i containing up to about 1% iron, up to about 0.3% nitrogen and being essentially devoid of rhenium.

Inventors: ANDRYSZAK, KENNETH ROBERT, BENN, RAYMOND CHRISTOPHER, DAVIDSON, JEFFREY MAX
Applicants: INCO ALLOYS INTERNATIONAL, INC.
Application year: 1986
Main classification: C22C32
IPC codes: F01D5, C22C32, C22C19