Process for welding nickel-based superalloys

Claim 2

A process for preventing crack formation in nickel alloy substrates having a gamma-prime phase, comprising the steps of: (a) providing a substrate to be treated, said substrate comprising a nickel alloy having a gamma-prime phase; (b) exposing a portion of said substrate to a high power energy source and causing a molten pool of said alloy to be formed; (c) dispersing a supply of coating particles within said pool, said particles comprising a nickel alloy; and, (d) effecting rapid relative motion between said source and said pool so that said pool rapidly solidifies and thereby minimizes formation of gamma-prime therein and adjacent thereto.

Claim 3

The process of claim 1, including the step of: (a) providing a substrate comprised of a nickel alloy having gamma-prime forming constituents of a concentration less than 10.5% by weight.

Claim 4

The process of claim 1, including the step of: (a) providing particles comprised of a nickel alloy having gamma-prime forming constituents.

Claim 5

The process of claim 2, including the step of: (a) providing particles comprised of a nickel alloy having gamma-prime forming constituents of a concentration not exceeding 7.5% by weight.

Claim 6

The process of claim 1, including the step of: (a) providing a substrate comprised of an alloy having at least 60% by weight nickel.

Claim 7

The process of claim 1, including the steps of: (a) moving said beam relative to said pool at a speed of from about 10 to about 100 inches per minute; and, (b) shrouding said pool with an inert gas.

Claim 8

The process of claim 6, including the step of: (a) providing particles comprised of a nickel alloy having a nominal chemical composition corresponding substantially with the nominal chemical composition of the nickel alloy of which said substrate is comprised.

Claim 9

A process for repairing the surface of a nickel alloy substrate having a gamma-prime phase, comprising the steps of: (a) providing a substrate having a surface defect, said substrate comprised of a first nickel alloy having a gamma-prime phase; (b) irradiating at least a portion of said defect with a laser beam and causing a molten pool of said alloy to be formed; (c) dispersing a supply of coating particles within said pool, said particles comprised of a second nickel alloy having gamma-prime forming constituents; and, (d) moving said beam relative to said pool so that said pool rapidly solidifies and thereby minimizes formation of gamma-prime therein and adjacent thereto.

Claim 10

A process for repairing the surface of a nickel alloy substrate having a gamma-prime phase, comprising the steps of: (a) providing a substrate having a surface defect, said substrate comprised of a first nickel alloy having a gamma-prime phase; (b) irradiating at least a portion of said defect with a laser beam and causing a molten pool of said alloy to be formed; (c) dispersing a supply of coating particles within said pool, said particles comprised of a second nickel alloy having gamma-prime forming constituents; and, (d) moving said beam relative to said pool so that said pool rapidly solidifies and thereby minimizes formation of gamma-prime therein and adjacent thereto.

Claim 11

The process of claim 8, including the step of: (a) forming a molten pool having a mass substantially less than the mass of said substrate.

Claim 12

The process of claim 9, including the steps of: (a) moving said beam relative to said pool at a speed from about 10 to about 100 inches per minute; and, (b) irradiating said defect with a laser beam having a power of from about 1.0 to about 5.0 kilowatts.

Claim 13

The process of claim 10, including the steps of: (a) pneumatically conveying said coating particles to said pool so that the particles thereby enter said pool and become dispersed therein; and, (b) shrouding said pool with an inert gas.

Claim 14

The process of claim 11, including the step of: (a) pneumatically conveying said particles with an inert gas, said conveying gas corresponding with said shrouding gas.

Claim 15

The process of claim 11, including the step of: (a) providing first and second nickel alloys having gamma-prime forming constituent concentrations not exceeding 7.5% by weight.

Claim 16

A process for coating a nickel alloy substrate having a gamma-prime phase, comprising the steps of: (a) providing a substrate comprised of a first nickel alloy having a gamma-prime phase; (b) focusing a laser beam on said substrate and irradiating a portion of said substrate and forming a molten pool of said first alloy, said pool having a mass substantially less than the mass of said substrate; (c) pneumatically conveying a supply of coating particles to said pool and thereby causing the particles to be introduced into and dispersed throughout said pool, said particles comprised of a second nickel alloy having gamma-prime forming constituents; and, (d) rapidly moving said beam relative to said pool so that said pool rapidly solidifies and thereby substantially minimizes formation of gamma-prime therein and adjacent thereto.

Claim 17

A process for coating a nickel alloy substrate having a gamma-prime phase, comprising the steps of: (a) providing a substrate comprised of a first nickel alloy having a gamma-prime phase; (b) focusing a laser beam on said substrate and irradiating a portion of said substrate and forming a molten pool of said first alloy, said pool having a mass substantially less than the mass of said substrate; (c) pneumatically conveying a supply of coating particles to said pool and thereby causing the particles to be introduced into and dispersed throughout said pool, said particles comprised of a second nickel alloy having gamma-prime forming constituents; and, (d) rapidly moving said beam relative to said pool so that said pool rapidly solidifies and thereby substantially minimizes formation of gamma-prime therein and adjacent thereto.

Claim 18

The process of claim 14, including the steps of: (a) providing coating particles having a mesh size of from about -80 to about +325; and, (b) shrouding said pool in an inert gas, the shrouding gas corresponding chemically with the conveying gas.

Claim 19

The process of claim 15, including the steps of: (a) providing a substrate having a thickness of from about 0.0625 to about 0.5 inches; (b) forming a molten pool having a depth of from about 0.005 to about 0.05 inches; and, (c) providing first and second nickel alloys having substantially corresponding nominal chemical composition.

Claim 20

The process of claim 16, including the steps of: (a) moving said beam relative to said pool at a speed from about 10 to about 100 inches per minute; and, (b) supplying particles at a rate of from about 0.10 to about 0.40 grams per second.

Claim 21

The process of claim 17, including the step of: (a) focusing said beam so that said beam has a diameter at said substrate of from about 0.050 to about 0.25 inches.

Claim 22

The process of claim 16, including the step of: (a) providing first and second alloys having gamma-prime forming constituents of a concentration not exceeding 7.5% by weight.

Claim 23

The process of claim 19, including the step of: (a) moving said beam relative to said pool as a function of the volume of said pool.