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Spray Forming of Nickel Superalloys

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Metal Sprays and Spray Deposition

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Abstract

Superalloy parts are conventionally manufactured using either cast, cast & wrought, or powder metallurgy processing. When cast, superalloys are usually precision-cast to final shape using the lost wax investment casting process. In the cast & wrought process, an ingot is cast and remelted, then converted into a forging billet via thermomechanical processing. In the powder metallurgy process, a billet is prepared by gas atomizing liquid metal to form powder that is consolidated into a fully dense solid. Spray forming offers a high-production-rate alternative that bypasses many of the steps associated with both cast & wrought and powder metallurgy processes.

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Acknowledgements

The Clean Metal Spray Forming project was partially funded by the Defense Advanced Research Projects Agency (DARPA) under Cooperative Agreement F33615-96-2-2565. The Clean Metal Nucleated Casting Project was partially sponsored by the U.S. National Institute of Standards and Technology (NIST) under the Advanced Technology Program (No. 70NANB1H3042). The authors gratefully acknowledge their technical and financial support. Further technical contributions from several individuals, particularly Lawrence A. Jackman, are gratefully acknowledged.

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Authors and Affiliations

  1. GE Global Research, Additive Manufacturing Laboratory, One Research Circle, Niskayuna, NY, 12309, USA

    William T. Carter

  2. ATI Specialty Materials, Monroe, NC, 28110, USA

    Ramesh S. Minisandram

  3. Newyork, USA

    Robin M. Forbes Jones (Retired)

Authors
  1. William T. Carter
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  2. Robin M. Forbes Jones
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  3. Ramesh S. Minisandram
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Correspondence to William T. Carter .

Editor information

Editors and Affiliations

  1. Advanced Materials and Processing Lab, University of Alberta, Edmonton, Alberta, Canada

    Hani Henein

  2. Foundation Institute of Materials Science, University of Bremen, Bremen, Germany

    Volker Uhlenwinkel

  3. Foundation Institute of Materials Science, University of Bremen, Bremen, Germany

    Udo Fritsching

Trademark Identification

Trademark Identification

13.1.1 CRS Holdings: A Subsidiary of Carpenter Technology Corporation

Thermospan

13.1.2 General Electric Corporation

René 41, René 77, René 80, René 88, René 95

13.1.3 Haynes Alloys International

Haynes 242

13.1.4 Howmet Corporation

Spraycast-X

13.1.5 Martin Metals Corporation

MAR-M-002, MAR-M247

13.1.6 Special Metals Corporation: A Wholly Owned Subsidiary of Precision Castparts Corp.

Inconel 100, Inconel 617, Inconel 625, Inconel 707, Inconel 713C, Inconel 718, Inconel 783, Inconel 939, Nimonic 115, Udimet 720

13.1.7 United Technologies Corporation

Waspaloy

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Carter, W.T., Forbes Jones, R.M., Minisandram, R.S. (2017). Spray Forming of Nickel Superalloys. In: Henein, H., Uhlenwinkel, V., Fritsching, U. (eds) Metal Sprays and Spray Deposition. Springer, Cham. https://doi.org/10.1007/978-3-319-52689-8_13

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