Abstract: The specification relates to a high gamma prim nickel based superalloy, its use and a method of manufacturing of turbine engine components by welding, 3D additive manufacturing, casting and hot forming, and the superalloy comprises by wt %: from 9.0 to 10.5% Cr, from 16 to 22% Co, from 1.0 to 1.4% Mo, from 5.0 to 5.8% W, from 2.0 to 6.0% Ta, from 1.0 to 4.0% Nb provided that total content of Ta and Nb remains with a range from 3.0 to 7.0%, from 3.0 to 6.5% Al, from 0.2 to 1.5% Hf, from 0.01 to 0.2% C, from 0 to 1.0% Ge, from 0 to 1.0 wt. % Si, from 0 to 0.2 wt. % Y, from 0 to 0.015 wt. % B, from 1.5 to 3.5 wt. % Re, and nickel with impurities to balance.

Abstract: A system and method for controlling the position of a filler wire and/or a laser head, or other heating head, in a welding system. The distal end of the filler wire is gradually moved, e.g., upward, until electrical continuity with the weld pool is lost; the filler wire is then moved back into contact with the weld pool. The heating head may be stationary relative to the weld pool, or it may move, with the distal end of the filler wire, relative to the weld pool.

Abstract: The invention is related to a high gamma prim nickel based superalloy, its use and a method of manufacturing of turbine engine components by welding, 3D additive manufacturing, casting and hot forming, and the superalloy comprises 9.0-10.5 wt. % Cr, 20-22 wt. % Co, 1.0-1.4 wt. % Mo, 5.0-5.8 wt. % W, 2.0-6.0 wt. % Ta, 3.0-6.5 wt. % Al, 0.2-0.5 wt. % Hf, 0.01-0.16 wt. % C, 1.5-3.5 wt. % Re, 0-1.0 Ge wt. %, 0-0.2 wt. % Y, 0-1 wt. % Si, 0-0.015 wt. % B and nickel with impurities to balance.

Abstract: An arc welder with current and voltage control. The welder includes a current control loop for sensing and controlling the arc current. In an operating state, a voltage control loop senses an average arc voltage and controls it to be equal to a setpoint, by sending a current control signal to the current control loop, the current control signal being a constant frequency, variable duty cycle square wave. When starting a weld, the welder operates for an initial time interval in an arc-starting state, in which a constant frequency, constant duty cycle square wave is sent to the current control loop as a current control signal. In some embodiments the weld head position is controlled based on a ratio of the average arc voltage to the average arc current, and the frequency of the current control signal is adjusted to be synchronized with droplet detachment from the feed wire.

Abstract: The present invention is a composite welding wire for fusion welding of components manufactured of superalloys. The composite weld wire includes a surface layer applied to the core wire in a green condition and bonded to the core wire. The surface layer includes alloying elements selected from among B and Si, the total bulk content of B and Si representing 0.5 to 4.0 wt. % of the composite welding wire. The boron and silicon alloying elements reduce the melting temperature and increase the solidification range of the weld pool, minimizing the incidence of weld cracking compared to welding without the coating. The green condition surface layer is comprised of more than 80 wt. % of the bulk content of the composite welding wire selected from the combination of B and Si.

Abstract: A ductile boron bearing nickel based welding material which includes boron within the range of 0.4-0.6 wt. % B, carbon from a trace amount to 0.04 wt. % C, 17-23 wt. % Cr, 0.35-10 wt. % Mo, 0.1-4.15 wt. % Nb with nickel or iron and impurities to balance for manufacturing of welding and brazing wires, powders and foils used in the repair of various articles made of nickel, cobalt and iron based alloys.

Abstract: Welding material for welding of superalloys comprising boron with the range of 0.3-0.8 wt. % B, 0.2-0.8 wt. % C, 17-23 wt. % Cr, 0.35-10 wt. % Mo, 0.1-4.15 wt. % Nb with nickel or iron and impurities to balance for weld repair of engine components manufactured of precipitation hardening superalloys with high content of gamma prime phase at an ambient temperature.

Abstract: Method of repairing and manufacturing of turbine engine components includes application of a transition layer by fusion welding with dissimilar nickel based filler material, preferably comprising from about 0.05 wt. % to about 1.2 wt. % B and other alloying elements, followed by a diffusion and primary aging heat treatment and application of the top oxidation resistance layer using dissimilar nickel based filler materials comprised 3-6 wt. % Al, 0.5-6 wt. % Si, 12-25 wt. % Cr and other alloying elements that enhance strength and oxidation resistance followed by a secondary aging heat treatment and machining of the repaired area to restore geometry of turbine engine components. The inventions also relates to a turbine engine components repaired and manufactured by the method.

Abstract: A precipitation strengthened nickel based welding material that comprises 5-15 wt. % Co, 5-25 wt. % Cr, 1-6 wt. % Al, 0.05-0.2 wt. % C, 0.015-0.4 wt. % B, 1-3 wt. % Si, chemical elements selected from among tungsten and molybdenum from about 1 to 20 wt. %, chemical elements selected from among titanium, zirconium, hafnium, tantalum and rhenium from about 1 to 18 wt. % and nickel with impurities to balance, wherein the boron content is inversely proportional to silicon content and decreases from about 0.3 wt. % to about 0.015 wt. % when silicon content increases from about 1 wt. % to about 3 wt. % produces sound high strength and high oxidation resistance crack free welds on precipitation strengthened superalloys and single crystal materials.

Abstract: A precipitation strengthened nickel based welding material that comprises 5-15 wt. % Co, 5-25 wt. % Cr, 1-6 wt. % Al, 0.05-0.2 wt. % C, 0.015-0.4 wt. % B, 1-3 wt. % Si, chemical elements selected from among tungsten and molybdenum from about 1 to 20 wt. %, chemical elements selected from among titanium, zirconium, hafnium, tantalum and rhenium from about 1 to 18 wt. % and nickel with impurities to balance, wherein the boron content is inversely proportional to silicon content and decreases from about 0.3 wt. % to about 0.015 wt. % when silicon content increases from about 1 wt. % to about 3 wt. % produces sound high strength and high oxidation resistance crack free welds on precipitation strengthened superalloys and single crystal materials.

Abstract: The present concept is a method of substantially crack-free cladding, fusion welding and additive manufacturing of superalloys. The method involves the application of a high temperature pre-alloyed filler powder that includes melting point depressants, to a superalloy base material. The base material and pre-alloyed filler powder are heated to a temperature that will fully melt the pre-alloyed filler powder and also melt a surface layer of the base material, thereby forming a weld pool. Upon solidification and cooling of the weld pool, there is coalescence between a weld bead and the base material thereby forming the weld bead which is substantially crack-free. The high temperature pre-alloyed filler powder consists in wt % of the following chemical elements: Co 9-15%; Al 3-6.5%; C 0.1-0.2%; Ti, Zr and Hf with a total content from 1 to 8.5%; Ta and Nb with a total content from 0.5 to 8.5%; W and Mo with a total content from 7 to 20%; Cr and Re with a total content from 6.5 to 18.

Abstract: A method for manufacturing an abrasive coating on a gas turbine component, especially on a gas turbine rotor blade tip, comprising at least the following steps: a) providing a gas turbine component, especially a gas turbine rotor blade; b) providing a high temperature melting alloy powder; c) providing abrasive particles; d) providing a low temperature melting alloy powder; e) blending at least said high temperature melting alloy powder and said abrasive particles to provide a mixture; f) applying said low temperature melting alloy powder and said mixture to an area of said gas turbine component, especially to a tip of said turbine rotor blade; g) locally heating said area of said gas turbine component to a temperature above the melting point of said low temperature melting alloy powder but below the melting point of said high temperature melting alloy powder is provided.

Abstract: A ductile boron bearing nickel based welding material which includes boron within the range of 0.4-0.6 wt. % B, carbon from a trace amount to 0.04 wt. % C, 17-23 wt. % Cr, 0.35-10 wt. % Mo, 0.1-4.15 wt. % Nb with nickel or iron and impurities to balance for manufacturing of welding and brazing wires, powders and foils used in the repair of various articles made of nickel, cobalt and iron based alloys.

Abstract: A precipitation strengthened nickel based welding material that comprises 5-15 wt. % Co, 5-25 wt. % Cr, 1-6 wt. % Al, 0.05-0.2 wt. % C, 0.015-0.4 wt. % B, 1-3 wt. % Si, chemical elements selected from among tungsten and molybdenum from about 1 to 20 wt. %, chemical elements selected from among titanium, zirconium, hafnium, tantalum and rhenium from about 1 to 18 wt. % and nickel with impurities to balance, wherein the boron content is inversely proportional to silicon content and decreases from about 0.3 wt. % to about 0.015 wt. % when silicon content increases from about 1 wt. % to about 3 wt. % produces sound high strength and high oxidation resistance crack free welds on precipitation strengthened superalloys and single crystal materials.

Abstract: The present invention is a composite welding wire for fusion welding of components manufactured of superalloys. The composite weld wire includes an inner core wire and a surface layer applied and bonded to the inner core wire. The surface layer includes alloying elements selected from among B and Si with a total bulk content of B and Si in the composite welding wire of 0.1 to 10 wt. %. Preferably the total bulk content of B is less than 4 wt. % and the surface layer comprises from 5 to 95 wt. % of the alloying elements selected from among B and Si.

Abstract: Welding material for welding of superalloys comprising boron with the range of 0.3-0.8 wt. % B, 0.2-0.8 wt. % C, 17-23 wt. % Cr, 0.35-10 wt. % Mo, 0.1-4.15 wt. % Nb with nickel or iron and impurities to balance for weld repair of engine components manufactured of precipitation hardening superalloys with high content of gamma prime phase at an ambient temperature.

Abstract: The present concept is a method of cladding and fusion welding of superalloys and includes the steps of firstly application of a composite filler powder that consists of 5-50% by weight brazing powder which includes melting point depressants, and 50-95% by weight high temperature welding powder, to a superalloy base material. Secondly there is simultaneous heating of the base material and the composite filler powder by a welding heat source that is movable relative to the base material. There is heating to a temperature that will fully melt the brazing powder and at least partially melt the high temperature welding powder and also melt a surface layer of the base material, thereby forming a weld pool. Thirdly upon solidification and cooling of the weld pool, there is coalescence between the weld bead and the base material.

Abstract: A method for manufacturing an abrasive coating on a gas turbine component, especially on a gas turbine rotor blade tip, comprising at least the following steps: a) providing a gas turbine component, especially a gas turbine rotor blade; b) providing a high temperature melting alloy powder; c) providing abrasive particles; d) providing a low temperature melting alloy powder; e) blending at least said high temperature melting alloy powder and said abrasive particles to provide a mixture; f) applying said low temperature melting alloy powder and said mixture to an area of said gas turbine component, especially to a tip of said turbine rotor blade; g) locally heating said area of said gas turbine component to a temperature above the melting point of said low temperature melting alloy powder but below the melting point of said high temperature melting alloy powder is provided.

Abstract: This invention relates to a composition for repairing metallic articles which in its initial state is in the form of an adhesive, self-supporting putty, capable of being molded including 5–15% by weight of a sacrificial binder containing at least one acrylic resin and volatile solvent. The invention also relates to a kit for the composition and methods for repair.

Abstract: A process of coating a refractory turbine part with a protective coating which is ultimately diffusion bonded to the part. A slurry coating material is prepared from a mixture of a silicon alkyd paint and suspended particles of an aluminum or aluminum alloy powder. Parts may be dipped in the slurry and subsequently be heat treated in selected atmospheres and temperatures to diffuse the coating into the surface of the part.