Abstract: Examples described herein provide a method that includes receiving weld data about a weld. The method further includes analyzing, using a physics-based model, the weld data to predict a formation of a defect in the weld. The method further includes providing feedback to enable process optimization during a design stage or active control during welding to control a welding machine to correct for and eliminate the formation of the defect in the weld.

Abstract: The present disclosure provides advantageous probabilistic models and applications for component (e.g., titanium component) design optimization, and related methods of use. More particularly, the present disclosure provides advantageous probabilistic models, systems and applications for component design optimization and related methods of use, and where the probabilistic models, systems and applications can accurately predict the life/failure of components (e.g., titanium components) based on material microstructure statistics and/or product mission specifics and/or variations. Disclosed are probabilistic systems and methods for predicting dwell fatigue behavior of a component (e.g., titanium component). The present disclosure advantageously provides an analytical modeling framework that captures the various physics-based mechanisms for dwell fatigue damage accumulation, crack nucleation, crack propagation and fracture in components or materials (e.g., anisotropic components/materials).

Abstract: Disclosed herein is a suspension plasma spray process that comprises suspending metal oxide particles in a carrier fluid to produce a suspension. The suspension is ejected onto a substrate via a plasma flame. The particles are evaporated in the plasma flame to form a gaseous ceramic during their travel to the substrate. The gaseous ceramic is deposited on the substrate to form columnar grains.

Abstract: Aspects of the disclosure are directed to an analysis of a material of a component. A radiation source is activated to transmit radiation to the component. A beam pattern is obtained based on the component interfering with the radiation. The beam pattern is compared to a reference beam pattern. An anomaly is detected to exist in the material when the comparison indicates a deviation between the beam pattern and the reference beam pattern.

Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

Abstract: A heat exchanger includes an additively manufactured manifold. The manifold includes an inlet feed manifold and an outlet feed manifold, and a plurality of hypotubes fluidly coupled to the manifold. The hypotubes are round in cross-section, wherein each of the hypotubes has a diameter that has a first value between 0.03 inches and 0.3 inches, and wherein each of the hypotubes has a wall thickness that has a second value between 0.001 inches and 0.0.015 inches.

Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

Abstract: Aspects of the disclosure are directed to an analysis of a material of a component. A radiation source is activated to transmit radiation to the component. A beam pattern is obtained based on the component interfering with the radiation. The beam pattern is compared to a reference beam pattern. An anomaly is detected to exist in the material when the comparison indicates a deviation between the beam pattern and the reference beam pattern.

Abstract: An x-ray diffraction system includes an x-ray source having a first interchangeable x-ray generating component, a second interchangeable x-ray generating component, an actuator and a controller operatively connected to the actuator. The first and second interchangeable x-ray generating components are interchangeable with one another. The actuator is operatively connected to the first and second interchangeable x-ray generating components.

Abstract: Aspects of the disclosure are directed to an analysis of a material of a component. A radiation source is activated to transmit radiation to the component. A beam pattern is obtained based on the component interfering with the radiation. The beam pattern is compared to a reference beam pattern. An anomaly is detected to exist in the material when the comparison indicates a deviation between the beam pattern and the reference beam pattern.

Abstract: Aspects of the disclosure are directed to an analysis of a material of a component. A radiation source is activated to transmit radiation to the component. A beam pattern is obtained based on the component interfering with the radiation. The beam pattern is compared to a reference beam pattern. An anomaly is detected to exist in the material when the comparison indicates a deviation between the beam pattern and the reference beam pattern.

Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

Abstract: An x-ray diffraction system includes an x-ray source having a first interchangeable x-ray generating component, a second interchangeable x-ray generating component, an actuator and a controller operatively connected to the actuator. The first and second interchangeable x-ray generating components are interchangeable with one another. The actuator is operatively connected to the first and second interchangeable x-ray generating components. A method for non-destructive x-ray diffraction includes emitting a first x-ray beam from an x-ray source with a first x-ray generating component based on a first desired depth to measure a crystallographic signature of a sample at the first desired depth, interchanging the first x-ray generating component with a second x-ray generating component to form a modified x-ray source, and emitting a second x-ray beam from the modified x-ray source based on a second desired depth, to non-destructively measure a crystallographic signature of the sample at the second desired depth.

Abstract: A heat treatment technique may include heating an alloy component to a temperature above a transition temperature of the alloy or heating an alloy component to a temperature below the transition temperature of the alloy. The heat treatment technique further may include cooling a first portion of the alloy component at a first cooling rate, and cooling a second portion of the alloy component at a second cooling rate different than the first rate. The first cooling rate may result in formation of a plurality of first precipitate phase domains comprising a first average size in the first portion, and the second cooling rate may result in formation of a plurality of second precipitate phase domains comprising a second average size in the second portion. The average size of the first precipitate phase domains may be different than the average size of the second precipitate phase domains.

Abstract: A method (40) of improving the mechanical properties of a component, for example a gas turbine engine turbine disc, (24) comprises isothermally forging (42) a preform to produce a shaped preform with a predetermined shape at a first predetermined temperature, solution heat treating (44) the shaped preform, quenching (46) the shaped preform, forging (48) the shaped preform at a second predetermined temperature to impart a predetermined residual strain in the shaped preform, ageing (50) the shaped preform and finally machining (52) the shaped preform to a finished shape. The second predetermined temperature is less than the first predetermined temperature.

Abstract: A method of heat treating a superalloy component includes solution heat treating the component at a temperature below the gamma prime solvus temperature to produce a fine grain structure. Insulation is placed over a first area to form an insulated assembly that is placed in a furnace at a temperature below the solvus temperature and maintained at that temperature for a predetermined time to achieve a uniform temperature. The temperature is increased at a predetermined rate to a temperature above the solvus temperature to maintain a fine grain structure in a first region, produce a coarse grain structure in a second region and produce a transitional structure in a third region between the first and second regions. The insulated assembly is removed from the furnace when the second region has been above the solvus temperature for a predetermined time and/or the first region has reached a predetermined temperature.

Abstract: A method of heat treating a superalloy component includes solution heat treating the component at a temperature below the gamma prime solvus temperature to produce a fine grain structure. Insulation is placed over a first area to form an insulated assembly that is placed in a furnace at a temperature below the solvus temperature and maintained at that temperature for a predetermined time to achieve a uniform temperature. The temperature is increased at a predetermined rate to a temperature above the solvus temperature to maintain a fine grain structure in a first region, produce a coarse grain structure in a second region and produce a transitional structure in a third region between the first and second regions. The insulated assembly is removed from the furnace when the second region has been above the solvus temperature for a predetermined time and/or the first region has reached a predetermined temperature.

Abstract: A heat treatment technique may include heating an alloy component to a temperature above a transition temperature of the alloy or heating an alloy component to a temperature below the transition temperature of the alloy. The heat treatment technique further may include cooling a first portion of the alloy component at a first cooling rate, and cooling a second portion of the alloy component at a second cooling rate different than the first rate. The first cooling rate may result in formation of a plurality of first precipitate phase domains comprising a first average size in the first portion, and the second cooling rate may result in formation of a plurality of second precipitate phase domains comprising a second average size in the second portion. The average size of the first precipitate phase domains may be different than the average size of the second precipitate phase domains.

Abstract: A method of heat treating a superalloy component comprises solution heat treating the component at a temperature below the gamma prime solvus temperature to produce a fine grain structure in the component. Insulation is placed over a first area of the component to form an insulated assembly. The insulated assembly is placed in a furnace at a temperature below the solvus temperature and maintained at that temperature for a predetermined time to achieve a uniform temperature in the component. The temperature is increased at a predetermined rate to a temperature above the solvus temperature to maintain a fine grain structure in a first region, to produce a coarse grain structure in a second region and to produce a transitional structure in a third region between the first and second regions of the component.