Abstract: A method of protecting a hole in a component during a coating process is disclosed. The method includes: placing a plug in the hole, the plug including a water insoluble core and a water soluble layer surrounding at least a portion of an outer surface of the metal core. A coating is applied over the plug and at least a portion of the component. The component is immersed in water to dissolve the water soluble layer, allowing removal of the water insoluble core. Removal of the coating from over the hole and the water insoluble core from within the hole may follow.

Abstract: Manufactured articles, and methods of manufacturing enhanced wear protected components and articles. More particularly, wear protected components and articles, such as combustor components of turbine engines, and even more particularly enhanced wear protected micromixer tubes and assemblies thereof with one or more micromixer plates, the micromixer tubes having wear protection for enhanced performance and reduced wear related failure. Methods including surface treatment to enhance wear, including vacuum braze application of coatings to enhance surface hardness for wear benefits.

Abstract: An alloy includes a matrix that includes an amount of high-melting-temperature superalloy between about 30% and 95% by weight and an amount of low-melting-temperature superalloy between about 0% and 70% by weight. The alloy also includes an amount of a ceramic reinforcement material between about 2% and 50% by volume, dispersed in the matrix.

Abstract: A method for counteracting tensile stress in an article is disclosed, including heating the article and applying compressive stress to the article along a compressive stress vector, the compressive stress vector including a compressive stress vector component opposite in direction to a tensile stress vector of a thermally-induced tensile stress of the article. The compressive stress is applied by thermally-induced autogenous pressure by a fixture contacting the article. A fixture for counteracting tensile stress is disclosed, including a first compression member and a second compression member, and a position lock connecting the first compression member to the second compression member and reversibly fixing the first compression member relative to the second compression member. The first compression member and the second compression member include compressive surfaces having mating conformations for surfaces of an article. The position lock includes a material composition.

Abstract: A polyhedral-sealed article is disclosed including an article having a surface and a polyhedral seal layer disposed on the surface. The polyhedral seal layer includes a polyhedral structure having a plurality of polyhedral units. The polyhedral seal layer further includes at least one of a composition including an HTW composition, a heterogeneous pattern of the polyhedral structure, an orientation of the polyhedral structure extending from the surface at non-orthogonal angle, and at least one polyhedral unit conformation other than a hexagonal prism. A method for forming the polyhedral-sealed article is disclosed including forming a polyhedral seal layer by binder jet additive manufacturing and disposing the polyhedral seal layer on a surface of an article.

Abstract: A joining process and a joined article are disclosed. The joining process includes positioning an article having a base material, and friction joining a pre-sintered preform to the base material. The pre-sintered preform forms a feature on the article. The joined article includes a feature joined to a base material by friction joining of a pre-sintered preform.

Abstract: A system for sealing an internal passage of a component includes a closure element positioned within the internal passage, and a joint material coupling the closure element to at least one passage wall that defines the internal passage. The system also includes a flexible braze element positioned proximate the closure element, the joint material, and the at least one passage wall.

Abstract: A hybrid article is disclosed including a coating disposed on and circumscribing the lateral surface of a core having a core material. The coating includes about 35% to about 95% of a first metallic material having a first melting point, and about 5% to about 65% of a second metallic material having a second melting point lower than the first melting point. The coating is sinter-bonded to the core. A method for forming the hybrid article is disclosed including disposing the core in a die, introducing a slurry having the metallic materials into a gap between the lateral surface and the die, and sintering the slurry, forming the coating. A method for closing an aperture of an article is disclosed including inserting the hybrid article into the aperture, and brazing the hybrid article to the article, welding the aperture with the hybrid article serving as weld filler, or both.

Abstract: A clad article is disclosed including an article and a cladding layer. The article includes a surface layer, at least one cavity disposed within the article below the surface layer, and at least one microcrack disposed in the surface layer. The surface layer includes an HTW alloy. The cladding layer is disposed on a surface of the surface layer, and is formed from a PSP brazed to the article. The cladding layer is disposed over the at least one microcrack. A method for forming the clad article is disclosed including disposing the PSP on the article and brazing the PSP to the article. Brazing the PSP to the article forms the cladding layer disposed on the article over the at least one microcrack.

Abstract: An article and method of forming an article are provided. The article includes a side wall at least partially defining an inner region and an outer region of the article, the side wall having a first end and a second end, an end wall formed proximal to the first end of the side wall, the end wall defining a tip portion of the article, and a cooling channel formed in the side wall, within the tip portion. The method of forming an article includes positioning a first sheet of material having a channel formed therein over a first end of a body, positioning at least one additional sheet of material over the first sheet of material, and securing the first sheet of material and the at least one additional sheet of material to the body to form a tip portion including a cooling channel formed therein.

Abstract: A process includes placing a powder composition of a first metal powder of a first alloy and a second metal powder of a second alloy in a ceramic die and sintering the powder composition in the ceramic die to form a sintered rod in the ceramic die. The process also includes removing the sintered rod from the ceramic die and slicing the sintered rod into a plurality of pre-sintered preforms.

Abstract: A process includes agitating at least one core of a core alloy together with a braze binder to form at least one coated core comprising the at least one core coated with a first layer of the braze binder. The process also includes agitating the at least one coated core together with a powder composition comprising a first metal powder of a first alloy and a second metal powder of a second alloy to form a green preform having a first powder composition layer of the first alloy and the second alloy. The process further includes sintering the green preform to form at least one hybrid pre-sintered preform. A green preform includes a core, a first layer of a braze binder coated on the core, and a powder composition coated on the first layer. A hybrid pre-sintered preform includes a core and a first layer sintered to the core.

Abstract: A method of welding a component and a treated component are provided. The method comprises an initial heat-treating of the component comprising a substrate. The method further comprises removing a portion of the substrate to form a treatment region comprising an exposed surface. The method further comprises buttering the exposed surface with a first filler additive to form a weld metal adjacent to the fusion line comprising an easy-to-weld alloy. The method further comprises welding the component with the easy-to-weld alloy and a second filler additive. The first filler additive comprises a sufficient amount of each of Co, Cr, Mo, Fe, Al, Ti, Mn, C and Ni to form the easy-to-weld alloy, when welded with the hard-to-weld base alloy.

Abstract: A method of welding a superalloy component includes the following sequential steps. A welding step for welding a cavity using a filler metal in an inert atmosphere, where the cavity is located in the component. A covering step for covering the filler metal and a portion of the component with a weld filler layer in the inert atmosphere. The weld filler layer has a greater ductility than material comprising the component and/or material comprising the filler metal. A second covering step for covering the weld filler layer with a braze material, and subsequently performing a brazing operation. A heat treating step heat treats the component.

Abstract: A method of fabricating a component includes preparing at least a portion of a surface of the component and forming a pre-sintered preform hybrid hardface mixture comprising combining a predetermined portion of at least one hardfacing material with a predetermined portion of at least one brazing material. The method further includes forming a pre-sintered preform using additive manufacturing, the pre-sintered preform having a near-net shape and forming a sintered preform. The method further includes positioning the sintered preform on the component and fixedly coupling the sintered preform to at least a portion of the component via brazing.

Abstract: A thermally dissipative article and a method of forming a thermally dissipative article are disclosed. The thermally dissipative article includes a component, a porous material formed in a layer on the component. The method of forming a thermally dissipative article includes providing a metal powder mixture and a soluble particulate mixture which forms a porous coating upon sintering and immersion in a solvent to remove the soluble particulate.

Abstract: A method of forming a passive strain indicator on a preexisting component includes directly depositing a plurality of fiducial markers on a portion of the outer surface of the preexisting component, the fiducial markers including a material that is compatible with the material of the outer surface. A method of evaluating a component includes initially scanning a plurality of fiducial markers on a portion of an outer surface of the component, subjecting the component to at least one duty cycle, subsequently scanning the plurality of fiducial markers after the at least one duty cycle, measuring a displacement of the plurality of fiducial markers by comparing the subsequent scan to the initial scan, and determining a remaining usable life of the component by looking up in a database a predetermined value of the remaining usable life of the component corresponding to the measured displacement of the plurality of fiducial markers.

Abstract: A method of making a pre-sintered preform, including forming a pre-sintered preform by a binder jet additive manufacturing technique. The binder jet additive manufacturing technique includes depositing a first powder layer including a first powder and a second powder followed by depositing a first binder at a pre-determined location of the first powder layer. The binder jet additive manufacturing technique also includes depositing a second powder layer over at least a portion of the first powder layer followed by depositing a second binder at a pre-determined location of the second powder layer. At least a portion of the first binder and at least a portion of the second binder is cured forming a green part. The green part is then densified to form a pre-sintered preform near net shape component.

Abstract: A clad article is disclosed including an article and a cladding layer. The article includes a surface layer, at least one cavity disposed within the article below the surface layer, and at least one microcrack disposed in the surface layer. The surface layer includes an HTW alloy. The cladding layer is disposed on a surface of the surface layer, and is formed from a PSP brazed to the article. The cladding layer is disposed over the at least one microcrack. A method for forming the clad article is disclosed including disposing the PSP on the article and brazing the PSP to the article. Brazing the PSP to the article forms the cladding layer disposed on the article over the at least one microcrack.

Abstract: A method for counteracting tensile stress in an article is disclosed, including heating the article and applying compressive stress to the article along a compressive stress vector, the compressive stress vector including a compressive stress vector component opposite in direction to a tensile stress vector of a thermally-induced tensile stress of the article. The compressive stress is applied by thermally-induced autogenous pressure by a fixture contacting the article. A fixture for counteracting tensile stress is disclosed, including a first compression member and a second compression member, and a position lock connecting the first compression member to the second compression member and reversibly fixing the first compression member relative to the second compression member. The first compression member and the second compression member include compressive surfaces having mating conformations for surfaces of an article. The position lock includes a material composition.