cu») United States (2) Patent Application Publication (0) Pub. No.: US 2015/0125282 Al Georgieva et al. US 2015012528241 oa oy @ ay @y oy BRAZE ALLOY COMPOSITIONS AND BRAZING METHODS FOR SUPERALLOYS Applicants: Petya M. Georgieva, Oviedo, FL (US) ames A. Yarbrough, Spring, TX (US) Inventors: Petya M. Georgieva, Oviedo, FL (US): ames A. Yarbrough, Spring, TX (US) Appl. Now 141070,664 Filed: Now. 4, 2013 Publication Classification Int cl. Fob sn Fo 92 FID s/12 23K 35/30 23K 100 (2006.01) (2006.01), (2006.01) (2006.01) (2006.01) (43) Pub. Date: May 7, 2015, (2) US.Cl cee FOLD $7005 (2013.01), B23K 382304 (2013.01); 823K 1/9018 (2013.01); ForD S12 (2013.01); FOLD 02 (2013.01): B23K 201/001 (2013.01); FOSD 2230/237 (2013.01); ‘FUSD 2230/80 (2013001): FOSD 2300175, (2013.01), FUSD 2300/17 201301) 6 ABSTRACT A multi-component braze filler allay comprising 60-70% by ‘weight CM247 superalloy and BRB braze alloy is diffusion brazed toa CM247 alloy base substrate, such asa pas turbine blade or vane. The substratelbraze interface may be subse- quently weld-repired without de-meling and migrating the braze alloy from the interface. The weld zone and surround- ing area are solidification crack resistant. After he alloy com- position is brazed the base substrate the component may be returned to service. Thereafter the component remains rep able by welding or re-brazing, if needed to comet fithre in-tervice defectsPatent Application Publication © May 7,2015 Sheet 1of13 US 2015/0125282 A1 TEST BRAZE ALLOY ALLOY MDXTURE. FURNACE CYCLE CHI247A-G4 [NarMMGO9A \MarKiS096 | 50150 Crack Repair Paste | 2050 VAC CLEAN 2200 BRAZE| CA247A-G5 | MarMISOGA \ MarK450B | 60/40 Crack Repair Paste | 2050 VAC CLEAN 2200 BRAZE| (CH247A-06 | MarM5O8A \ MarMS08B | 70/30 Crack Repair Paste | 2050 VAC CLEAN 2200 BRAZE| (CH1247A-07 | MarS0GA \ MartAS096 | 5050 Remett Evaluation | 2200 BRAZE CN247A-G8 [MarMSOGA \ Marl1S00B | 60/40 Remelt Evaluation | 2200 BRAZE (CM247A-08 [MarMGOA \MarMS09B | 70/30 Remelt Evaluation | 2200 BRAZE CA2A7A-10 [MarMSOGA \ MartASOGE | Post Braze Weld Evaluation| 2200 BRAZE FIG. 1 VACUUM CLEAN FURNACE CYCLE ‘Avvacuum cf 10¢ for (minimum) shal! be maintained during the entire cleaning cycle 4) Ramp up at 20°F/min to 1200°F and hold for 10 minutes b) Ramp up at 30°F/min and hold at 1800°F for 10 minutes } Ramp up at 30°F/min to 2120°F (225°F) and hold for three (3) hours d) Gas fan cool at 40°Fimin minimum FIG. 2Patent Application Publication May 7,2015 Sheet 20f13 US 2015/0125282 AL FIG. 3 FIG. 4Patent Application Publication © May 7,2015 Sheet 3 of 13 US 2015/0125282 Al Heat @ T?Fimin to T100°F + 25°F and hold for 30 minutes Heat @ 17°F/min to 1600°F + 25°F and hold for 30 minutes Heat @ 22°F/min to 1950°F + 25°F and hold for 30 minutes Heat @ 22°Fimin to 2050°F + 10°F and hold for 30 minutes Heat @ 35°F /min to 2200°F + 10°F and hold for 40 minutes Cool @ 22°F min to 2050°F + 10°F and hold for 240 minutes Argan Coal @ 40°Fimin to 150°F and hold for 30 minutes COMBINED BRAZE & DIFFUSION CYCLE FIG. 5 v Loe 2 or ae ee i ee eee Hee Le ooPatent Application Publication © May 7,2015 Sheet 4 of 13 US 2015/0125282 AL FIG. 11Patent Application Public cation May 7,2015 Sheet Sof13 US 2015/0125282 Al FIG. 14 ‘one7e-14 [C247 \BRB 60440 Crack Repat Paste ‘CMa7B.15 |" CMe7\ BRB [7080 Crack Repai Paste 27818 80/20 Crack Repai Paste ‘CM247B-17 66/40 RemettEvaliaton ‘Gwioe7e-18 | C247 BRE 76G0 Reet Evaluation ‘CM247B-19 | CMO47\ BRB 80/20 Remet Evaluaton ‘CM247B-20_| ~ CH247\ BAB 66149 Prefom Braze ‘CMe47B.21 [C247 BRB 75/05 Preorm raze ‘cMge7e.22 | CMo«7\ BRB 80020 Pref Brazo ‘GN2478-24 | CMOAT) BRB Post Weld Evaluation ‘CH2A7ADS | ~ WerMlSDOA arM6008 | ~ 6040 Crack Repair Paste ‘CM247AG0 |" WarNlS00A \MaWM008 | 700 Crack Rpatr Paste ‘CMRA7ASI | MarllS00A \MatM008— | 6020 Crack Repar Paste ‘CM2A7AGD |" NarMB00A \Manis008 | 6040 Ramelt Evauaton ‘CMA7AGS |" WaiNS00A \MarM008 | 7030 Ramet Evauaton CHZE7A-G4 | MasMS0GA\ MerMtS008 | "86720 Remit Evaluation ‘CM47AL35 | ~ MarBlS00A \MaME008 | 60140 Prefoo Braze (0,100) ‘CMOSTACGE | — NarMCOA \MartdS098 | 7000 Preform Brae (0.030) ‘CMRA7AST | — WanlS00A \MaN6098 | 60/20 reform Braze (0.030), [_CM2a7A- sMGCOA\ Mar FIG. 15 FIG. 16Patent Application Publication © May 7,2015 Sheet 6 of 13. US 2015/0125282 A1 FIG. 17 2) Inorease fumace temperature to 1800°F 425°F at 28°F per minute maximum under partial pressure (vacuum of 5X10* or less acceptable) 'b) Decrease the pressure of the furnace pressure to 5X10* or less and hold for stabilization 0} Increase furnace temperature to 2270°F +12°F at a rate no greater than 10°F per minute and hold for 240-255 minutes for braze and diffusion cycle time combined. ‘The tumace pressure of 5X10 or less must be maintained 'd} Vacuum coo! furnace temperature to 1975°F 225°F in <8 minutes ¢} Rapid cool by back purging with argon gas down to room temperature COMBINED BRAZE & DIFFUSION CYCLE FIG. 18Patent Application Publication © May 7,2015 Sheet 7of 13 US 2015/0125282 AL FIG. 20Patent Application Publication © May 7,2015 Sheet 8 of 13 US 2015/0125282 AL FIG. 22 FIG. 23 FIG. 24Patent Application Publication May 7,2015 Sheet 9 of 13 US 2015/0125282 AL FIG. 25 FIG. 26 FIG. 27‘US 2015/0125282 AL May 7, 2015 Sheet 10 of 13 Patent Application Publication FIG. 28 ees pe ee _ _ FIG. 29 FIG. 30Patent Application Publication May 7,2015 Sheet 11 of 13 US 2015/0125282 AL ‘oM2a7B-26 (CMaT) (0M2478-26 (C247 FIG. 31Patent Application Publication May 7,2015 Sheet 12 of 13 US 2015/0125282 AL ‘ - 0M247 8-39 (MARME09 AB) -_OM47 899 (MARES AB) CHET B59 (MBANS0O AB) 2.50 (MARWSOO AB) (8267 8-99 (MARIE AB) FIG. 32Patent Application Publication May 7, 2015 Sheet 13 of 13 US 2015/0125282 AL Tea Targets: 00 ‘Metcut Test | Specimen: 8 i ‘O2KYS | Blong. Stost Ho... identification ‘Test Materiat Description gnc | desi} | tks) | tte) Tassie ‘m3] sur | 108 a aa TT a| ms | es sons 83. 7995024, 8 [Brags MarMSOaAiE 70/30, 87 | 4a Taso | a) ie GET a 52 yegsosa | ET [trate CM2478RB 20°30 5 | sia] gee | 32 Tassara | _st__ [bw untae a0 POST FS ea [sar] oes 18 s9sies_|___8t_ [eee uaerane roves rc seas] eae Aral Gage Deer 025 wh 0402 eC 8 no ‘Testing Specification: ASTM £-21{09) ftescmeter Cage Leng in: 4.0 ‘tai Raehagh 20 yl 0.5 Head Rae ence fab: O05 nin, FIG. 33US 2015/0125282 AI BRAZE ALLOY COMPOSITIONS AND BRAZING METHODS FOR SUPERALLOYS BACKGROUND OF THE INVENTION [0001] 1. Field ofthe Invention 10002} The invention relates 10 the brazing snd repair of superalloy components, snd in particular to brazing eompo- sitlons and methods for brazing superalloy blade and vane ‘components used in ans turbines, with braze compositions and brazing procedures that consistently provide good braz~ ing of test samples, some embodiments of whieh permit post braze welding without substantial degradation of structural properties [0003] 2. Description ofthe Prior Art 10003} Structural repsie or new fabrication of nickel and cobalt based superalloy materials that are used to manufie~ ture turbine components, such as cast turbine blades, are ‘challenging, due in part tothe metallurgie properties oF the ‘superalloy material. For example, a superalloy having more than about 6% aggregate aluminum or titanium conten, seh 8 nickel-base superalloys with low carbon content ©. ‘CM247, is typically more susceptible to solidification crack Jing when subjected to high-temperstre welding than a lower aluminum-ttanium content superalloy, ex, X-750, Superal~ loys used in finishes turbine blades ae typically strengsened ‘during post casting heat treatments, which render them dif ‘ull materials upon which to perform subsequent structural ‘wold Currently use welding processes for super alloy fabrication or repair generally involve substantial melt- Jing of the substrate adjoining the weld preparation, and com- plete melting of the added welding filler material. When blade constructed of such a material is welded with filler of the same or similar alloy, e., for structural repair, the blade js suscepibe to solidification cracking (aka liquation erack- 12) Within and proximate to the weld, Post weld soiditiea- tion cracked superalloy vanes and blades are generally scrapped as unrepaimale, alter coasiderable time andexpense ‘was already expended to attempt torepairthe bade. Given the shortcomings of superalloy structural repair welding often the only commercially acceptable solution i to serap dame ‘aged turbine blades tat require siuetural repair, Because past ‘experience has shown limited success of such structural repairs. Thus repairs have been limited to those particular materials, components and types of strctural damage that have in the past been proven enable o suecessful repair by ‘cosmetic welding, employing more ductile welding filler materials with reduced structural strength, Blades needing ‘veld strtural repairs with known relatively high risk of post weld solidification erackingare generally strapped. Pro- Viding brazing compositions and methods that ean withstand post braze Welding Without significant solidification cracking ‘or other degradation of srictural, mechanical or other prop= ‘erties would permit repair and reuse of such components, an Jmportant esonomie benefit [0005] | Non-structral repair or fabrication of metal com ponents, including superalloy components typically inwolves replacing damaged material (or joining two components of nes fabricated material) with mismatched alloy material of lessor strcturl properties, where the superior structural per- formance ofthe original substate material is not needed in the localized region, For example, such non-structural oF “cosmetic” repair may be used in order to restore the repaired ‘components original pile geometry. Far the reps of gs turbine components, sn example of cosmetic repaie is the May 7, 2015 {ling of surtee pits, cracks or other voids ona turbine blade airfoil inorder to restore its orignal aerodynamic profile, for cases in which the mechanical propeties ofthe blade's heal ied exterior surface are not erilca forthe structural integrity ofthe entire blade. Cosmetic repair or fabrication is often ‘achieved by using oxidation resistant Weld or braze alloys of lower strength than te blade body superalloy substrate, but faving higher doctility and employing a lower application temperate that does not degrade the structural or material properties ofthe superalloy substrate 0006] Diffusion brazing hus been utilized to join superal- Joy components for repair or fabrication by intrposing braz- ing allay between ther abutting surfaces to be joined, and hating those components in @ furnace (often isolated from ‘ambient sir under vacuum or within an inert atmosphere) unt the brazing alloy Fguefies and diffuses within the substrates of the to-be-conjoined components. Diffusion brazing can also be used to ill surface defects, such as localized surface and/or son-sructural cracks, in superalloy components by inserting brazing ally into the defect and heating the com poneat in a furnace 1 liquefy the brazing alloy and thus fll the crack. In some types of repairs # torch rather than @ Turmace can be used as a localized heat source to melt the brazing alloy. Binze repaid superalloy blades and vanes are ‘ypically returned to service [0007] Ina subsequent gas turbine inspection cycle, blades for vanes that are identified as having defects in previowsly ‘braze-repaired surfaces risk remit and migration of old braze material if the component were agin heated for repairs. (Oien for commercial cost saving reasons blades with defects in previously brazed portions are serapped rather than sk potential repair failure ateibutable to remelt migration of old braze material [0008] raze material with the commercial designation ‘Mar-M-5090 (A registered trademark of Martin Marieta Co, and commercially available, for example, from Praxair Sar Tice Technologies, Ie. Indianapolis, Ind. under their desig- nations CO-222, CO-333) isa igh chrome contest supera- Joy braze material that has commonly been wsed for repair oF (CM247 alloy turbine blade and vane components. Products ith similar performance charaeteristies are also commer- cially aailable Irom Sulzer Metco as Amdry MMSO9 and Amary MMSO9B, However, it would be desirable to uilize a ‘braze material including CM247, so tht the braze material ‘and the component substrate have more closely’ matehed ‘matedal properties. commercial designation for CM247 is -MAR-M.247, one form of which is available from Praxair Surface Technologies under their designation NIA3S-S, 0009] ‘Thus, aneedexists in the art fora braze composition ‘having. material properties more closely matching those of (CM247 superalloy components, such as yas turbine Blades And vanes, that can be reweed without melt migration from the weld zone and that resists solidification eracking at the ‘weld interface or surrounding areas. SUMMARY OF THE INVENTION [0010] Some embodiments of the present invention relate to braze alloy compositions comprising a range of approxi mately 60%-70% by weight of CM247 hase alloy aid the balance of BRR braze alloy. When applied to a CM247 alloy substrate componeat by diffusion brazing, such compositions donot significantly demel and migmte when rowelded in a subsequent weld repair. Even after performing a post weldUS 2015/0125282 AI solution eyee the braze material resists solidification cracks the weld interface and surrounding areas [0011] Ics also demonstrated herein tht diferent braze processing can improve the performance of MarMS09.A MaeMS09B thraze alloy mixtutes ovee tht typically expee- ‘enced in prior art brazing using these materials, 10012] Thus, the present invention includes compositions ‘of matter and braze processes suitable for improved brazing ‘of superalloy components wherein, pursuant to some ‘embodiments ofthe invention, the brazed regions are capable ‘ofpost braze welding repair without substantial solidification ‘carcking andulso ineludes superalloy components so brazed nd subsequently repaired by welding. [0013] "The featuresof the present invention may be applied Jointly or severally in any combination or sub-combination hy those skilled in the ar. BRIEF DESCRIPTION OF THE DRAWINGS. [0014] Theteschingsof he preset invention canbe really understood by considering the following detailed descriptio Jn oajunetion with the sccompanying drawings, in which: [0015] FIG. 1: Tabular enumeration of some braze tests Performed pursuant to some embodiments of the present invention: [0016] "FIG. 2: Typical vacuum cleaning furnace eye pure ‘ant to some embrdimens ofthe present invention: [0017] FIG. 3: Photomicrograph of typical racks created for braze tests; 10018) FIG. 4: Photomicrograph of typical cracks created Jor braze tests following the introduction of paste into the cracks by regulated compressed air behind a piston forcing the paste through an application needle, which was used 10 ‘work the paste into the cracks as required, The paste com= prises a liguidbindcr mixed with a braze alloy: [0019] FIG. §:Braze cycle used forsome of the braze tests ‘conducted herein, representing a typical braze eycle with ‘multiple stop points in the ramp up to bnize temperature, short dwell at braze temperature and then a drop in temipera- ture, an hold fr alloy diffusion; 10020] FIG. 6: Photomicrograph after completion of braze Turaace eycle forte $050 alloy mix MarMS00.'B; [0021] FIG. 7: Photomicrograph after completion of braze Tmace eycle forthe 60150 alloy mix MarMS00 A/D; 10022] FIG. 8: Photomicrograph after completion of braze fimace eye forthe 70°30 alloy mix MarMS00 A/D: 10023] FIG. 9: Photomicrograph at 80x after completion of braze furnace eyele forthe 50150 alloy mix MarMSO9A/2 (ciched) 10024] "FIG. 10: Photomicrograph at 50x afer completion ‘oftbaze fumacecyele for the 6040 alloy mix Mar (509.35, 10025] FIG. 11: Photomicrograph at 50x afer completion ‘of raze furnace cycle forthe 70/30 alloy mix MarMS09A/2. (etched) [0026] FIG. 12: Re-melt Evaluation. Photomicrograph fol- lowing a solution heat twat eyele after completion of the braze finace eycle 10 evaluate the alfet on the braze of possible nomal repair processes following brazing. Tree mixtures of MarM/A/B are depicted (lft to right), 70/30, 60140, 50/50; 10027] FIG. 13: Tabular enumeration of some braze tests performed pursuant 10 some embodiments of the present [0028] FIG. 14: Photomicrograph of cracks created ia samples for braze tests May 7, 2015 [0029] FIG. 18: Photomicrowraph of eracks create samples for brize test prior to HP cleaning: [0030] FIG. 16: Photomicrograph of eracks created in samples for braze test following FIC eleaing aad brazing: [0031] FIG. 17: Alloy Application, Photomicrograph of ‘ypcal cracks created for braze tests following the inrodne- tion of paste info the cracks by regulated compressed air behind a piston foreing the paste through an application ‘needle, which Was used to work the past ino the cracks as required. The paste comprises a liquid binder mixed with a braze alloy: [0032] FIG. 18: Typical braze eyele as employed for some ‘embodiments herein: [0033] FIG. 19: Photomicrograph after complesionofbraze Trnace eycle forthe 60/0 alloy mix MarMS09.\73; [0034] FIG. 20: Photomicrograph after completion of braze urmace eyele forthe 7030 alloy mix MarMS09/B: [0035] FIG. 21: Photomicrograph after completion of braze Turmace eyce forthe $020 alloy mix MarMS094/B:; [0036] FIG. 22: Photomicrograph after compleionofbraze furnace eye forthe 60140 alloy mix CM247/BRB: [0037] "FIG. 23: Photomicrograph aller completion at braze furnace eye forthe 70/30 alloy mix CM247/BRB: [0038] FIG. 24: Photomicrograph after completion of braze furnace eyee forthe $0120 alloy mix CM247/ARB: [039] FIG. 25; Photomicrograph at 0 after completion ‘oftraze furnace eyele fr the 60140 alloy mix MarMSO9A/B:; [040] FIG. 26: Photomicrograph at 0 after eompletion ‘ofbraze farace eye forthe 70/30 allay mix Mat M509, [041] FIG. 27: Photomierograph at 0% after completion ‘ofbraze farace eye forthe 80120 allay mix MatMS09,/B; [0042] FIG, 28; Photomicrograph at 50x after completion ‘of raze fumaceeyele forthe 60140 alloy mix CM247/BRD: [043] FIG. 29: Photomicrograph at 0x after completion of braze furnace eycle for the 70/30 alloy mix CM247/BRB: [044] FIG. 30: Photomicrograph at 0x after completion ‘of braze fumaceeyele for the 80/20 alloy mix CM247/BRD: [045] FIG. 31: Perspective and cross sectional photomi ‘rograph follving a solution heat treat eyele (2250 deg. F.) fier completion of the braze fumace eyele w evaluate the affect on the braze of possible normal repair processes fl- lowing brazing of CMB47/BRB on a CMEST substrate with IN625 filler material; [0046] FIG. 32: Phowmicropraph followings solution heat ‘wea eyele(2250 deg. Falter completionof thebraze furnace cyele to evaluate the affect on the braze of possible normal repair processes following brazing of MarMSO9A/B on (CM247 substrate with IN62S filler material. [nthe drawings and in the specification, "MarMS09 or “509” isan abbreviae tion of MazMSO9A or SO9A respectively: and [047] FIG. 33: Results of mechanical testing for various ‘braze materials and mixtures DETAILED DESCRIPTION [0048] Improved high temperature repair braze compo ‘ions and methods are described, some embodiments of ‘whiehachieve compositions, mechanical and structural prop- erties nearer o that ofthe base meta In some embodiments, the brized region is subsequently weldable without incurring serious degradation of properties. After considering the fol lowing detailed description, those skilled in the art will clearly realize thatthe teachings ofthe present invention an be readily utilized in a multi-component braze filler alloy comprising various compositions of CM247 ally,US 2015/0125282 AI MaeMS09A, MarMS00B and BRB braze alloy that are suite able for diffusion brazing to nickel-based superalloy sub- strate such as CM247, suc as typically used ina gs turbine blade or vane. The subsiatebraze interfce purstant fo some ‘embodiments of the present invention i shown to be ame rable to subsexquent welding repair without incurring damog- ing demeting and/or migration ofthe braze alloy from the interface region, The weld zone and sumounding area are resistant to solidification cracking After the alloy composi tion is brazed to the base substrate the component may be returned to service. Thereafter, the component remains repairable by welding, ifneeded to core future in-service fects rather than seraping the component, wth the weld repaired component hiving reduced risk of solidification ‘racking a8 a consequence of the welding operation. This, represents.an important improvement over conventional biz- ing compositions and methods in which post braze welding ‘ypieally degrades structural properties to such an extent that the component is no longer suitable for nomad use, capa [0049] Alloy 247 isan exemplary material for the fbrica- tionof gasturbine components, and thus, to be concrete nour descriptions, specie formulations aad procedures for the repair of alloy 247 components are deseribed herein. Flom ‘ever, the compositions and procedures described herein are not inherently limited to alloy 247, butcan be advantageousiy used forthe epair of other superalloys as apparent to those having ordinary skillsin hear of superalloy material science ‘and superalloy component repair. [0050] The following composition has been found to be among those advantageous a5 braze fille alloy for use with alloy 247, and comprises approximately 60-70% by weight ‘CM247 silo with the remainder being BRB braze alloy. All Percents are weight percents and are intended to be appeoxi- ‘mate, in which slight deviations about the quoted values are not expected to cause dramatic changes in performance oF properties. A more precise range of applicability ean realy be determined by routine experimentation, [0081] | CM 247 has atypical composition as follows rom Huang and Koo, Mal, Transactions, 45, 562-568 (2004), the ‘entire contents of which is incorporated herein by reference forall purposes) Nip) €PKe)O0Ko) Coen) Al DB {Ra} Wm Moya TNT Bag 2) jn which the weight percentages X_ are approximately as follows for CM247 alloy in Ba. 1 May 7, 2015 2X00 eX) mat [0052] Slipht variations in these proportions are within nor- ‘mal commercial usage. For example, the commercial CM247 ‘known as MAR-M-247 has the compesition given in Fg. 2as provided by the vendor corXe 0.0% Eye 159% NEXythluee) 2, [0053] ‘Thus in view ofthis data, we use CM 247 herein to ‘denote a superalloy having a composition in approximately the following ranges as yiven in Eg 3 [oosa) cM 247 coxa 921008 Hn yrtAne NE Xythlee) BS, [008] ‘The results reported herein employ AIMRO CM 247, substantially the same as CM247 described herein. For ecortomy of language, we use “CM247" herein to denote a ‘material having a composition substantially within the ranges sven by Fg. 3. iretionaly solidified CM 247 (CM247DS). However, itisUS 2015/0125282 AI not expected thatthe use of single erst, polyerystalline or clher forms of CM 247 will have a significant effect on the results BRB 10057] BRB is nickel-based diffasion braze alloy, such as ‘commercially available through Sulzer Metco as Amdry BRB. The BRP material used herein has substantially the {ollowing composition: in which the weight percentages X, are approximately in the following ranges: [0088] BRB With a particle size distibution having @ nominal range— 150445 jm (micrometers), mesh (ASTM)—100+325 mesh. For economy of language, we use “BRB” herein to denote & ‘material having a composition substantially within the ranges iven by Fa. 4 MaeM509A/MarMSO9B 10089] Brazing tests and improved brazing results ar also {described herein for cobalt based supenlloys containing rea tively large amoonis of chromium and nickel commercially Known under the trade names MarMS09 (MarMSO9A, oF briefly “S094, MarM509B ('S09B"), “The particular MéeMS09.VB materials used herein were obiained from Sulzer Metco under the trade names Amdry MMS09 (S09) tnd Amey MMSO013 (5099), The compositions provided by the vendor are as follows: TENE Song So [0060] Studios werecaried out wsng several ofthe present braze composition alloys pursuant to some embodiments of the present invention to repair eracks on an alloy 247 blade substrates and subsequently weld the brazed blades with the results described herein. Its apparent that these results dem- ‘onstrate an improvement over prior art brazing compositions May 7, 2015 ‘and methods, leading towards more effective, less expensive, Service-eady repairs of superalloy components following brazing Resulls: CM247 DS Base Material Braze with CM247/BRB And MarMS09A/MarMS09B. [0061] Improvements btsinable pursuant io some embodi- ‘ments ofthe present invention, employing different mixtures ‘ofCM247/1ARB and MarMf509 A/MsrMSO91 under different processing conditions are presented. To be concrete in our ‘scussion, we consider brazing a CM247 substrate material, ‘more paricularly, 2 component comprising service run row 1 ‘turbine blades from the WSO1G engine made of CM247 DS castings. These examples are intended to be illustrative, not Timiting, as one skilled ia the art can readily adapt these ‘compositions and mothods to other substrate materials andior components without undue experimentation. That is, these tests are typial examples of results obtainable and do not Timit the Seope ofthe present invention t specific compos ‘ions oF process conditions disclosed. However, this particu- Jar example of turbine blades hus considerable practical and ‘commercial importance in its, [0062] The tests deseribed herein were conducted in sepa- rate rounds consisting of different braze base alloys of ml- tiple mixtures with one braze alloy, different braze furnace cycles and different substrate preparation methods [0063] Several criteria were used to evaluate the results of | those tests: [0064] 1. General visual appearance of the braze. [0065] 2. Metallograpic evaluation of the interfce, crack fil and porosity 0066] 3. Remeltofthebrazeduringa postbraze solution eat reat evele [0067] 4. Post braze weldabilty. [0068] 5. Mechanical testing including surface hardness, UTS (ultimate tensile strength), yield snd elongation Examples A “Mari1S09.A/MarMS00B (*MarMSO9A/B") Mixtures [0069] “MarMS09A/R™ denotes « mixture of 509A and ODE materials having the compositions substantially as agivea in Pgs. 5A and SB respectively Example A ‘Surface Preparation 0070] ‘Two methods of surface preparation were combined Tor this west. A mechanical cleaning of the area was per- formed, using earide blend tools to create a similated crack approximately 0.050" (inches) in width by approximately ‘0.0507 in depth typical example is shown in FIG. 3. Fale Jowing the mechanical cleaning and the eeation ofthe sau lated cracks, the lace material was subjected to a vacimm cleaning furnace eycle according tothe procedures given FIG.2, Example A. Alloy Application [0071] Thrce different mixturesofa singlebase anda single braze alloy were tested. [all oF these cases, the brave alloy was MarMS0923 ("S098") and the base was MarMS00A (°S00A"), The base was mixed with braze alloy with weightUS 2015/0125282 AI ratios $09/509B of 50/50, 60/40, 70/30 and thea combined ‘vith liguid binder inthe amount of about 10%-15% by vole "ume te forma paste, The paste was then worked into aplastic ‘cartridge with regulated compressed air behind a piston (0 ore the paste through an application needle that was.sed t0 work the paste into the ergks at roquited, Stop off ean be applied as required to the base material around the braze to fsssure tha the alloy does not rn outside the intended rep zone. A typical result ofthis lloy-applicaion,erack-filling step is shown in FIG. 4 Example AIL Braze Cycle [0072] The braze eycle employed in this Example A repre- ents a typical braze cyele with moltiple stop points in the amp up to braze temperature, a dwell at braze temperature followed by a drop in temperature and a holding period for alloy diffusion. typical eyele is given in FIG. 5. tis impor- tant to note that 2200 deg. F isthe highest temperature applied during all braze cycles employed in these Examples-A for MarMS09AVB, Example AV Results 10073] _ Results from seven tests are reported herein, identi fied as Example A-O4 0 Example A-10 in FIG. 1 Al [0074] A visual inspection was performed after dhe braze Jumace cyele was completed. The results for MarMSO9A/B (Examples. A-04,4.08, A-D6 of PIG. 1 are shawn as follows: [0075] FIG. 6isa photomicrograph of results obtained with the S0/S0 alloy mixture. This S0/30 alloy mixture appears hot (that is, close to or exceeding ts melting point and perhaps has a slight undercut around the braze exlges, although this ‘cannot he definitively detemnined from this micrograph [0076] _ FIG. Tisa photomicrograph ofesults obtained with the 60140 alloy mixture. This 60140 alloy mixture sppeaes have a reasonably smooth appearance and apparently shows ‘continous flow at the edges [0077] FIG. 8isa photomicrograph of results obtained with the 70/30 allay mixture. This 70/30 alloy mixture apparcatly shows a sluggish flow resulting in signifieant transition at the braze edges. V() Post Braze Visual Evaluation, AcIVGi) Metallographic Evaluation 0078}. Metllogrphic evaluation ws performed at 80x foe flow, interface quality, porosity and other defects. The results foeMarNtS09.VB (Examples A, 4-08, 4-06 of FIG. 1) are shown follows 0079] FIG. 9 isthe metallogrphie result for the $0'S0 braze mixture. This photomicrograph apparently indicates 00d flow into the base mater, providing smoth tans thon from the braze repr ate. The interlace appears to be substataly acceptable but with hint being bt Poewsty ‘was blow 19% of the measured area ofthe repair. 0080] FG. 10 isthe metallographic result forthe 60440 braze mixture. This photomicrograph apparently indicates ood lw ino the tase mater, poviing a smooth eas May 7, 2015 ‘ion from the braze repair area The interface appears t0 be ‘excellent and porosity was below I% ofthe measured area of the repair [0081] FIG. 11 is the metallographic result for the 70/30 braze mixture. This photomicrograph apparently indicates sluggish flow into thease material with sharp contas rom the blaze alloy. The interface appears to be substantially acceptable bu he porosity was rather high with severe void- ing arising from a lack of adequate alloy flow. A-IVGi) Remelt Evaluation [0082] The dhiwe different mixtures considered in this Example-A, MarMS00 /B (Examples-04,-05, of FIG. 1) \were subjected to typical solution heat tet eyele afer the braze was completed in order to determine ifthe braze alloy ‘would ikely be affected ifthe component so brazed were later stibjected to a normal repair process. The melt percentage was aleulated by comparing the alloy hejht following sol tion heat treatment tothe alloy height following the braze: process but belore the solution heat treatment, For SO/S0 (MarMS00./3) more than 100% remelt was observed. The alloy returned (0 is liquid state and ran olf the workpiece resulting in a depression below the level of the original sur face. For 60/40 (MaeMS09A/B), approximately 50% alloy Iheight Toss was observed, Por 70/30 (MarMS09.AVB), approximately 30% alloy eight oss was observed. A photo- ‘micrograph of taese results s provided in PIG. 12 A-IV(v): Post Brave Weld Evaluation [0083] No weld evaluation was performed on these braze samples dv to the failure ofthe remelt tests A-IV(o): Mechanical Testing [084] No mechanical testing was performed on these samples du to the failure ofthe remelt ests. Example B (€M247/B RB Mixtures 0085] “CM247/BRB™ denotes 2 mixture of CM247 and [BRB materials having the compositions substantially” as aiven in Eqs. 3 and 4 respectively. [0086] Additional beaze tests were performed combining braze and diffasion eycles performed to the same times and ‘temperatures used forthe base material heat treat eyele. The tests consisted of one braze eyele, one surface preparation method, with wo base alloys mixed using three different levels of two diferent bmze alloys. Example Bel ‘Surface Preparation [0087] ‘The braze surfaces were prepared using a mechani- cal cleaning method with carbide blend tools to create a simulated erack approximately 0.050" in wid by appeoxi- ‘mately 0.050" in depth. No vacuum cleaning furnace eycle ‘was performed after the mechanical cleaning operation. One blade was cleaned using. fluoride ion cleaning (FIC) furnace ‘with HF gas to prepare the surface forbrize. FIGS. 14,18, 16 show typical blades at various tages inthe surface prepare ‘ion processUS 2015/0125282 AI Example B-IL Alloy Application [0088] Three different mixtures of two base and braze alloys were prepared and tested: (MarM-S09A base/MarM- 098 braze) and (CM247/BRB), [0089] The MagM-509A (°SO9A") base was mixed with “MaeMS008 ("50918") braze ally ia the ratios (bY weight) (6040, 70/30, 820 (5094/5098). These mixtures were then ‘combines! wih liquid binder in an amount of 10%4-15% by volume o form a paste 10090] |The CM247 base was mixed with BRB braze allay in the ratios CM247/BRB (by weight) 60/0, 70/30, 80/20. These mixtures were then combined with liquid binder in an amount of 10%-15% by volume to fon a paste. Thus, six pastes were prepared and test [0091] Each paste was worked into plastic caneidge with regulated compressed air behind a piston to force the paste through an application noedle that was used o work the paste ino the eracksas required. Stop olf] an he appli ws roid to the base material around the braze to assure that the allay ‘docs not run outside the intended repair one. [0092] FIG. 17 shows typical blades following the step of alloy application Example BIL raze Cycle 10093] The braze eyele used was chosen fo have the same times and temperatures standard solution eat treat eyele, as given in FIG. 18. Example BV Results 10098} Results from 20 tests are reported herein, identified fs Example B-14 to Example B-39 in FIG. 13. BV): Post Braze Visual Evaluation 10095] A visual inspection was performed following dhe ‘combined brize and diffusion furnace eycle of FIG. 18. The results for MarMS09A/B (Examples B-29, B-30, B31) are showin as flows 10096] FIG. 19 is a photomicrograph of results obtained with the 60/40 alloy mixture. This mixture appears hot with ‘excessive run of the alloy fom the braze area [0097] FIG. 20 isa photomicrograph of results obtained with the 70/30 alloy mixture. This mixture has an excellent smooth appearaice with good continuous How at the edges. 10098] FIG. 21 is a photomicrograph of results obtained ‘withthe 80/20 alloy mixture. This mixture has slight slug~ ish appearance bt appears to be acceptable with some con- Teast atthe braze edges. 10099] ‘Theresutsof the visual inspoction for CM247/BRB (Examples B-14, B-15, B-16) are shown as follows: [0100] FIG. 22 i a photomicrograph of results obtained ‘with the 60140 alloy mixture. This misture appears very hot With excessive un ofthe ally from the braze rca [0101] FIG. 23 is a photomicrograph of results obtained ‘with the 70/30 alloy mixture. This mixture hasa good smooth appearance at the exlges with some alloy Hw fs the re May 7, 2015 [0102] FIG. 24 is a photomicrograph of results obtained ‘with the 80/30 alloy mixture. This mixture has a smooth appearance at the braze ees with a slight sluggish appear- ‘ance, but probably an acceptable eppearance, BAIV(i): Metallographic Evaluation [0103] Metallographic evaluation was performed at SOx for ow, interlace quality, porosity and other defects. The results or MarMS09A/B (Examples 8.29, B-30, B31) areshownas follows: [0104) FIG. 25 is a photomicrograph of results obtained ‘with the 60/40 braze mixture. The photomicrograph appar- enlly shows good flow into the base material providing @ Smooth transition from the baz alloy. The iterlace appears to be acceptable but with a hint of Being hot. Prosity was Similar to the casting material and below about 1%% of the ‘measured volume of the repair are. [0108] FIG. 26 is a photomicrograph of results obtained ‘with the 7030 braze mixture. The photomicrograph shows excellent flow into the hase material, providing a smoqth transition from the edges. The interface is excellent. The porosity is simlarto the casting material and below about 1% ofthe measured volumeo the repaired area The right edge of the braze was apparently missed and not filled during the application ofthe alloy [0106] FIG. 27 is a photomicrograph of results obtained ‘with the 80/20 braze alloy mixture. The photomicrograph shoves slugaish flow ino the base material witha sharp con- trast from the regions at the edges. The actual interlace is apparently acceptable but the porosity was beyond typically Aaccepiable limits with severe voiding from lack of flow: [0107]. The results for CM24775RB (Examples B-14, B-15, B-16) ae shown as follows: [0108] FIG. 28 is a photomicrograph of results obtained ‘with the 60/40 braze mixture. The photomicrograph appar- ently shows good flow into the base material providing & Smooth transition ftom the braze repair area. The interface Appears to he acceptable but with a in of being ho, Porosity the casting material nd below about 1% aft volume ofthe repair area [0109] FIG. 29 is a photomicrograph of results obtained ‘with the 7030 braze mixture. The photomicrograph shows excellent flow into the hase material, providing a smoath ‘ransition from the braze repair area. The interface is excel- lent. The porosity is similar to the costing material and below about 19% ofthe measured volume of the repair area [0110] FIG. 30 is a photomicrograph of results obtained ‘with the 80/20 braze alloy mixture. The photomicrograph shoves slugash flow into the base material witha sharp con- ‘rast at the edges. The actual interface is apparently accept able bu the porosity was beyond typically acceptable imits ith severe voiding from Isek of fow. Example B-IV Gi) Remelt Evaluation [0111] Three different mixtures of MarMSO9/A/B were subjected to solution heat treat cycle (2270deg. after the inital braze was completed to determine ifthe braze would be affected during & future normal repair process. The remit pereentage was calculated by comparing the bead height fl- Towing the solution heat treat eyele with the post braze alloy bead height.US 2015/0125282 AI [0112] 60/40 Remelt Bvaluation: 100% ofthe alloy height Joss was observed (Total Remel). [0113] 70/30 Remelt Evaluation: An alley height loss of approximately 10% of was observed [0114] 80/20 Remelt Evaluation: No alloy height loss was observed, [0115] It is important to note that this remelt evaluation shows marked improvement over the remelt discussed ia Example A-1V ii) for the 7030 and 80120 compesitions. [0116] » Weattibute this othe use of generally higher braze temperature and times for these Examples-B in comparison the braze temperature and times used in Example-A. Prom FIG. 18 we see that Example-B components were held at 2270 deg. P. (212 deg. F.) for 240-285 mia, while in Example- ‘A the components were held at 220 dog, F, (210 deg. F.) for M0 min. and at 2050 deg, F.(+10deg.F)for270 min. (FIG. 8) Ths, we conclude tht the different time-temperature proto~ col as.an important elfect on the properties of braze joints for '509A/509B braze compositions and that ratios of 509A/S09B less than about 7030 sre contraindicated, [0117] Three different mixtures of CM247/ARB were sub- ‘oa solution beat teat eyele (2270 deg. F.) after the ‘nial raze was completed to determine ifthe braze wotld be affected during a future normal repair process. The remit Percentage was calculated by comparing the bead height fl- Jowing the solution heat treat eyele with the post braze alloy bead height. 10118} 60/40 Remelt Evaluation: 100% ofthe alloy height Joss was observed (Total Remel). 10119] "70/30 Remelt Evaltation: An alley height loss of approximately 10% of was observe. 10120] 80/20 Remelt Evaluation: No alloy height loss was observed, 10121] In summary, 60/40 shows ood flowsbility, deposi tion and mechanical properties, but lacks good remeltchar- ‘acteristics when compared to 70°30 or 80/20. It appears ‘advantageous to use the 70/30 mixture if the braze compost tion isto be applied and if itis to be subjected to any re- heating above ubout 2270 deg, Example BIVGv) Post Braze Weld Evaluation 10122] An evaluation was dane on CM247/BRB (Example 13.24) to observe the eflect of a post hme weld repair using 1IN625 filler material. Thetestwas completedafera post weld solution eycle. However, no age heat teat was performed No ‘racks were observed a the interlace or surrounding ares, ‘and the welder performing the work reported that this weld seemed to be similar to that of @ weld af the base alloy, See FIG. 31 10123] "Aa evaluation was done on MarMSOSIA/B. (Ex- ample B-39) to observe the effect ofa post braze weld repait using IN62S filler material. The test was completed after @ Post weld solution eyele. However, no age heat treat was Performed, No cracks were observed at the interface oF st Founding areas, andthe welder performing the work reported that this weld seemed he similar that ofa weld ofthe base alloy. Seo FIG. 32. Therefore, the 70/30 mixture is considered to be advantageous on the basis ofthe following tests andor ‘observations: [0124] Flowabitity abit to fill the gaps and cracks) [12s] Remett [126] Reweld May 7, 2015 0127] Hardness [0128] Tensile Tests [0129] Mechanical Tess Example B-IV(si) Mechanical Testing [0130] | Mechanical resting was done to compare the hard- ‘ess, tensile strength, yield andelongation ofthe wo lloysof ‘Various mixtures against the base material and the base mate- rial with IN62S weld repairs. The tests were carried out by ‘Metcut Researeh, Inc. of Cincinnati, Ohio avording to the procedures given in FIG. 33. Six samples of each type were tested and the average of those six are reported in FIG. 33 ‘including the Base Material (Specimen 45) and the base ‘material with IN62S weld repairs (Specimen 46). ‘CONCLUSIONS, ‘Surface Preparation [0131] Mechanical cleaning provided an excellent braze surface an interface between braze and the base allo. The ‘mechanieal-vacvum cleaning process used in Example pro- vided an equal interface, however no better than the mechani- cal cleaning process alone, No apparent benefits resulted from using the extra furnace eycle. Examples B were per- ormed after mechanical preparation of the surface using a carbide buro remove the top layerof material, Themecha cal test samples were also prepared using this same method ‘which further indicates the aceptbilty ofthe process. The FICeleaning process did providea better visual wetting ofthe alloy and apparently avery slightly improved interface ‘observed during the lab examination, However, all meclani- ‘al tests performed showed a consistent loss of tensile strengtl oF about 496.5%. Braze Alloy Selection and Application [0132] | TheCM247 base alloy mixed with BRR braze mate- ial consistently provided the best test results observed herein. Tae CM247 and MarMS09.A base alloy powders pro- vided substantially equal results with reyard 0 visual flow and interfice quality. However, when mixed with equal ‘amounts of braze alloy the CM247 typically was slighty ‘more free owing. The CM247 alloy typically provided 13% 15% better tensile strength values than the MarMS09 alloy of the same mixture with higher and more consistent strain ate ‘through 2.0% yild values, Both M247 and MaeMS09 braze provid substantially equal visual ests when welded with IN625 filler material However, iis generally better practice tostriveto have the chemical composition of the repair area as lose othe original base materials possible (tht i, higher base alloy content inthe mixtures). [0133] The 70:30 mixture ofthe CM247 base powder with the BRB braze alloy provided better results with regard 10 porosity, crack fill post braze solution eyele remelt and ten- Sile strength Its also observed that the braze elongation with the CM247 base alloy was typically superioeto the MarMS09 alloy. However the elongation numbers typically decreased {rom the 60/40 mixture up tothe 70/30 misture 0134} ‘Theremitewaluation with the 70/30 mixture seemed tobe acceptable with regard to future epair eyeles with only 4 slight hint (10% height loss) of the alloy tuming ligt {during subsequent solution eyeles,US 2015/0125282 AI Braze Cycle 10135] All braze cycles performed with the lower braze cycle temperature 2200 deg. F.) experienced complete rem tet failures even when higher base materia alloy was ‘added t9 the mixture. The higher braze eyele temperature used inthe second (B) tests provided improved results in the remit evaluations [0136] The axvantage t the higher temperature braze ‘eycle, which in effect i equal to the standard solution heat twoateyelvof the base materia, isthat the opportunity to braze before of afler weld repais is always preseat without the addition of heat treat eyeles which add cost to the Te process nd may have some unknown elfet to the base mate- Fial properties. 10137] Although varions embodiments that incorporate the teachings of the present invention have been shown and ‘described in detail herein, those skilled in the at can readily ‘devise many other varied embodiments tht still incorporate these teachings. The invention isnot limited in its application to the exemplary embodiment details of construction and the arrangement of components set forth in the description oF ‘ustrated in the drawings. The invention is eapable of other ‘embodiments and of being practiced or of being carried out in various ways. Also itis to be understood tha the phraseology and terminology used herein i forthe purpose of description fd should not be regarded as limiting. The use of “inchud- ing;”*comprising.” or “having” nd variations thereof herein js meant to encompass the items listed thereafter and equiva- Jents thereof as well 3s additional items. ‘What s claimed is 1. A material fr the braze repair ofa nickel-base superal- Joy turbine component comprising aCM247/BRB mixtureof ‘M247 base alloy in the range from approximately 60% t0 70% by weight snd the balance comprises BRB braze alloy 2A material asin claim 1, wheroin the nickel-base super- alloy curbine component comprises CM247. A material as inclaim 1, wherein the Ni-base superallay ‘component i a turbine vane or blade 40 material as in claim 1, wherein the CM247/BRB. mixture comprises bout 80% of CM247 hase alloy by Weight tnd the balance comprises the BRB braze alloy wherein the ‘components brazed with the material are not subjected 10 ‘temperatures exceeding about 2270 deg. F. during thebrazing process 8. A material asin claim 4, wheroin te nickel-base super- alloy (urbine component comprises CM247. 6. material as in claim 4, wherein the Ni-base superalloy ‘component i a turbine vane oF blade 77.A method for brzing a Nicbase superallay component ‘comprising: placing the Ni-base superalloy component to be brazed and ‘the brazing material into a brazing furnace, properly ‘configured to perform the desired brazing process upon heating: and increasing the amace temperature to within about 25 deg F.of 1800 deg. Fata rateof approximately 28 deg, F. per smite; and May 7, 2015 exucing the pressure within the furnace to less than about 10.008 Torr and hold for stabilization; and ‘increasing the famace temperature to within about 12 deg. of 270 deg Fata rate no greater than about 10 dea. per min. and hold at this temperature for about 240%0 255 minutes for combined braze and diffesion cycle time while maintaining the pressure no greater than about 0.005 Torr and ‘vacuum cooling the furnace temperatureto within about 25 ‘dog. F-of 1975 de. Fin a time no more than about 3 ‘minutes; and ‘pid cooling to room temperature by back purging with inert gas; and wherein the breving material comprises a CM247/BRB mixture of CM247 base alloy inthe range from approxi imately 60% 10 70% by weight and the balance com- prises BRB braze alloy. 8. The method of claim 7, wherein the nickel-base super- alloy turbine componeat comprises CM247. 9. The method of elaim 7, wherein the Ni-base superalloy ‘component isa turbine vane or blade 10, The method of claim 7, futher comprising re-epsiring the superalloy component by postbraze welding und desig- ‘ating the superalloy component as suitable for continued 11, Themethod of claim 10, wherein thenickel-base super- alloy turbine component comprises CM247. 12. The method of elaim 10, wherein the Ni-base superal- Joy component is turbine vane or blade 13, The method of elim 7, further comprising post-braze fat treatment ofthe superalloy component and designating the superalloy component us suitable for continued service 14. The method of claim 13, wherein thenickel-basesuper- alloy turbine componeat comprises CM247. 18, The method of claim 13, wherein the Ni-base superal- Joy component is turbine vane or blade 16, Anaricle of manufacture comprising a Ni-base super alloy component wherein the Ni-base superalloy component has a portion thereof repaired by brazing with a brazing smateeal, wherein the brazing material comprises mixture of (CM247 base alloy in the range from about 60% to about 70% by weight and the balance comprising » BRB braze alloy. 17. An article of manufacture asin claim 16, wherein the rickel-hase superalloy turbine component comprises cna7, 18, An anicle of manufcture asin claim 16, wherein the [Nicbase superalloy component is turbine vane or blade. 19, An article of manufocture as in claim 16, wherein the [Nichase superalloy component has a portion thersaf re-e- ng and is suitable for continued 20, An article of manufatare as in claim 16, wherein the [Nichase superalloy component is post-beaze heat rested and js suitable for continoed service