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1. (WO2018157228) HIGH GAMMA PRIME NICKEL BASED WELDABLE SUPERALLOY AND METHOD OF REPAIRING AND MANUFACTURING OF TURBINE ENGINE COMPONENTS USING THE SAME
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Claims:

1. A high gamma prime nickel based weldable superalloy comprises of the following alloying elements:

Cobalt from about 10 to 13 wt. %

Chromium from about 5 to 8 wt. %

Molybdenum from about 1.0 to 2.5 wt. %

Tungsten from about 4 to 6 wt. %

Tantalum from about 6 to 7 wt. %

Rhenium from about 1.5 to 3.5 wt. %

Aluminum from about 5.5 to 6.5 wt. %

Hafnium from about 1.2 to 1.8 wt. %

Boron from about 0.01 to 0.02 wt. %

Carbon from about 0.05 to 0.15 wt. %

Zirconium from about 0.01 to 0.02 wt. %

Titanium form about 0.15 to 0.25 wt. %

Silicon from about 0.4 to about 0.5 wt. %, and

Nickel with impurities to balance

2. The high gamma prime nickel based weldable superalloy as per claim 1 wherein the content of the following elements comprises:

Cobalt from about 11 to 13 wt. %

Chromium from about 6 to 8 wt.%

Molybdenum from about 1.0 to 2.0 wt. %

Rhenium from about 2.5-3.5 wt.%

3. The high gamma prime nickel based weldable superalloy as per claim 2 comprises the silicon in a form of selected from among a refractory Ti, Ta and W based silicide and disilicide and preferably titanium disilicide.

4. The high gamma prime nickel based weldable superalloy as per claim 2 comprises the titanium and silicon with a ratio of 0.5 - 0.625 and preferably 0.50 when contents of titanium and silicon are in wt.% adapted to provide preferential formation of Ti disilicide thereby minimizing the silicon content in a nickel based solid solution matrix.

5. The high gamma prime nickel based weldable superalloy as per claim 2 selected from among a welding wire, a welding powder, equiaxed cast material, directionally solidified cast material single crystal cast materials, extruded articles, cast articles, repair sections of a turbine engine components, and 3D additive manufactured materials and articles.

6. Method of repairing and manufacturing of the turbine engine components includes the steps of:

a) weld repair of the blade tip using a fusion welding process selected from among

welding at an ambient temperature or welding with a preheating, and a welding material comprising:

Cobalt from about 10 to 13 wt. %

Chromium from about 5 to 8 wt. %

Molybdenum from about 1.0 to 2.5 wt. %

Tungsten from about 4 to 6 wt. %

Tantalum from about 6 to 7 wt. %

Rhenium from about 1.5 to 3.5 wt. %

Aluminum from about 5.5 to 6.5 wt. %

Hafnium from about 1.2 to 1.8 wt. %

Boron from about 0.01 to 0.02 wt. %

Carbon from about 0.05 to 0.15 wt. %

Zirconium from about 0.01 to 0.02 wt. %

Titanium form about 0.15 to 0.25 wt. %

Silicon from about 0.4 to about 0.5 wt. %, and

Nickel with impurities to balance

b) Post weld heat treatment selected from among an annealing, primary and secondary aging and stress relief or all above.

7. The method of repairing and manufacturing of the turbine engine components as per claim 6 wherein the content of the following elements of the welding material comprises:

Cobalt from about 11 to 13 wt. %

Chromium from about 6 to 8 wt.%

Molybdenum from about 1.0 to 2.0 wt. %

Rhenium from about 2.5-3.5 wt.%

8. Method of repairing and manufacturing of turbine engine components as per claim 6 where in the fusion welding is done with the speed of 1 - 3 inch per minute aiming to allow a formation of the refractory Ti-Ta- W based silicide and disilicide during welding and a solidification of a welding pool.

9. Method of repairing and manufacturing of turbine engine components as per claim 6 wherein the post weld heat treatment comprising the steps of:

a) The primary aging at a temperature of 1975 - 2150°F for 2 - 4 hours

b) The secondary aging at a temperature of 1300 - 1400 °F for 16 - 24 hours, and

c) An additional heat treatment at a temperature 1550 - 1700°F for 4 - 24 hours, which exceeds the temperature of the secondary aging aiming to allow further improvement of a mechanical properties of the weld metal after restoration of properties of the base material.

10. Method of repairing and manufacturing of turbine engine components as per claim 9 wherein the components are manufactured from single crystal material.

11. Method of repairing and manufacturing of turbine engine components as per claim 6 wherein the post weld heat treatment comprising the steps of:

a) Annealing at a temperature of 2190 - 2230°F for 2 - 4 hours

b) Primary aging at a temperature of 1975 - 2040 °F for 2 - 4 hours

c) Secondary aging at a temperature of 1550 - 1625°F for 16 - 24 hours aiming to

maximize properties of welds by optimizing a morphology and volume of gamma prime phase and Ti-Ta-W based silicide and silicide.

12. Method of repairing and manufacturing of turbine engine components as per claim 11 wherein the components are manufactured from equiaxed and directionally solidified materials.

13. Method of repairing and manufacturing of turbine engine components as per claim 6 wherein the tip of the turbine blade is selected from among a squealer, tip cap or combination of above.

14. Method of repairing and manufacturing of turbine engine components as per claim 6 were the tip cap is selected from among of the equiaxed, directionally solidified, single crystal, 3D additive manufactured and preferably extruded materials.

15. Method of repairing and manufacturing of turbine engine components as per cl wherein the pre-weld heat treatment of the tip cap comprises the steps of:

a) Annealing at a temperature of 2190 - 2230°F for 2 - 4 hours,

b) Primary aging at a temperature of 1975 - 2040 °F for 2 - 4 hours,

c) Welding of the tip cap to the tip of the turbine blade, and

d) Secondary aging at the temperature of 1550 - 1625°F for 4 - 24 hours.