Method of manufacturing an airfoil

Abstract

Disclosed is a method of manufacturing an airfoil. The method includes establishing an Argon (Ar)-free environment, providing a bed within the Argon free environment, providing a set of data instructions for manufacturing the airfoil, and providing a powdered Nickel (Ni)-based alloy on the bed. In one example, the powdered Nickel (Ni)-based alloy consists essentially of about 4.8 wt. % Iron (Fe), about 21 wt. % Chromium (Cr), about 8.6 wt. % Molybdenum (Mo), about 0.07 wt. % Titanium (Ti), about 0.40% Aluminum (Al), about 5.01 wt. % Niobium (Nb), about 0.03 wt. % Carbon (C), about 0.14 wt. % Silicon (Si), and a balance Nickel (Ni). The method further includes fusing the powdered Nickel (Ni)-based alloy with an electron beam with reference to the data instructions to form the airfoil.

What is claimed is: 
     
         1 . A method of manufacturing an airfoil, the method comprising:
 forming an airfoil using a powdered Nickel (Ni)-based alloy in an additive manufacturing process, wherein the powdered Nickel (Ni)-based alloy includes Molybdenum (Mo) within a range of 7.7 to 9.5 wt. %, Titanium (Ti) within a range of 0.06 to 0.08 wt. %, Aluminum (Al) within a range of 0.3 to 0.5 wt. %, Niobium (Nb) within a range of 4.5 to 5.5 wt. %, Carbon (C) within a range of 0.02 to 0.04 wt. %, and a balance Nickel (Ni) and alloy elements.   
     
     
         2 . The method as recited in  claim 1 , further including establishing an Argon (Ar)-free environment, providing a bed within the Argon free environment, and positioning the powdered Nickel (Ni)-based alloy on the bed. 
     
     
         3 . The method as recited in  claim 2 , further including providing data instructions for manufacturing the airfoil, and fusing the powdered Nickel (Ni)-based alloy using an electron beam with reference to the data instructions. 
     
     
         4 . The method as recited in  claim 1 , wherein the airfoil is a turbine airfoil. 
     
     
         5 . The method as recited in  claim 4 , wherein the airfoil is one of a rotor blade and a stator vane. 
     
     
         6 . The method as recited in  claim 1 , wherein the alloy elements include about 4.9 wt. % Iron (Fe), about 21 wt. % Chromium (Cr), and about 0.14 wt. % Silicon (Si). 
     
     
         7 . The method as recited in  claim 1 , wherein the powdered Nickel (Ni)-based alloy consists of about 4.8 wt. % Iron (Fe), about 21 wt. % Chromium (Cr), about 8.6 wt. % Molybdenum (Mo), about 0.07 wt. % Titanium (Ti), about 0.40 wt. % Aluminum (Al), about 5.01 wt. % Niobium (Nb), about 0.03 wt. % Carbon (C), about 0.14 wt. % Silicon (Si), and a balance Nickel (Ni). 
     
     
         8 . The method as recited in  claim 1 , wherein the powdered Nickel (Ni)-based alloy consists essentially of about 4.8 wt. % Iron (Fe), about 21 wt. % Chromium (Cr), about 8.6 wt. % Molybdenum (Mo), about 0.07 wt. % Titanium (Ti), about 0.40 wt. % Aluminum (Al), about 5.01 wt. % Niobium (Nb), about 0.03 wt. % Carbon (C), about 0.14 wt. % Silicon (Si), and a balance Nickel (Ni). 
     
     
         9 . The method as recited in  claim 1 , wherein the airfoil exhibits a tensile ductility within a range of 33% to 38% at 1400° F. 
     
     
         10 . The method as recited in  claim 1 , wherein the powdered Nickel (Ni)-based alloy is substantially free of Aluminum (Al)-based oxides. 
     
     
         11 . A method of manufacturing an airfoil, the method comprising:
 establishing an Argon (Ar)-free environment;   providing a bed within the Argon free environment;   providing a set of data instructions for manufacturing the airfoil;   providing a powdered Nickel (Ni)-based alloy on the bed, wherein the powdered Nickel (Ni)-based alloy consists essentially of about 4.8 wt. % Iron (Fe), about 21 wt. % Chromium (Cr), about 8.6 wt. % Molybdenum (Mo), about 0.07 wt. % Titanium (Ti), about 0.40% Aluminum (Al), about 5.01 wt. % Niobium (Nb), about 0.03 wt. % Carbon (C), about 0.14 wt. % Silicon (Si), and a balance Nickel (Ni); and   fusing the powdered Nickel (Ni)-based alloy with an electron beam with reference to the data instructions to form the airfoil.   
     
     
         12 . The method as recited in  claim 11 , wherein the powdered Nickel-based alloy consists of about 4.8 wt. % Iron (Fe), about 21 wt. % Chromium (Cr), about 8.6 wt. % Molybdenum (Mo), about 0.07 wt. % Titanium (Ti), about 0.40% Aluminum (Al), about 5.01 wt. % Niobium (Nb), about 0.03 wt. % Carbon (C), about 0.14 wt. % Silicon (Si), and a balance Nickel (Ni). 
     
     
         13 . The method as recited in  claim 11 , further including removing excess, unfused powdered Nickel (Ni)-based alloy from the bed. 
     
     
         14 . A turbine airfoil comprising:
 an electron beam formed component with a chemical composition consisting essentially of approximately 4.9 wt. % Iron (Fe), approximately 21 wt. % Chromium (Cr), approximately 8.6 wt. % Molybdenum (Mo), approximately 0.07 wt. % Titanium (Ti), approximately 0.4 wt. % Aluminum (Al), approximately 5.01 wt. % Niobium (Nb), approximately 0.03 wt. % Carbon (C), approximately 0.14 wt. % Silicon (Si), and a balance Nickel (Ni).   
     
     
         15 . The turbine airfoil as recited in  claim 14 , wherein the component provides one of a turbine rotor blade and a turbine stator vane. 
     
     
         16 . The turbine airfoil as recited in  claim 14 , wherein the component exhibits a tensile ductility within a range of 33% to 38% at 1400° F.