Abstract: A cast nickel-base superalloy that includes iron added substitutionally for nickel. The cast nickel-base superalloy comprises, in weight percent about 1-6% iron, about 7.5-19.1% cobalt, about 7-22.5% chromium, about 1.2-6.2% aluminum, optionally up to about 5% titanium, optionally up to about 6.5% tantalum, optionally up to about 1% Nb, about 2-6% W, optionally up to about 3% Re, optionally up to about 4% Mo, about 0.05-0.18% C, optionally up to about 0.15% Hf, about 0.004-0.015 B, optionally up to about 0.1% Zr, and the balance Ni and incidental impurities. The superalloy is characterized by a ?? solvus temperature that is within 5% of the ?? solvus temperature of the superalloy that does not include 1-6% Fe and a mole fraction of ?? that is within 15% of the mole fraction of the superalloy that does not include 1-6% Fe.

Abstract: A cast nickel-base superalloy that includes iron added substitutionally for nickel. The cast nickel-base superalloy comprises, in weight percent about 1-6% iron, about 7.5-19.1% cobalt, about 7-22.5% chromium, about 1.2-6.2% aluminum, optionally up to about 5% titanium, optionally up to about 6.5% tantalum, optionally up to about 1% Nb, about 2-6% W, optionally up to about 3% Re, optionally up to about 4% Mo, about 0.05-0.18% C, optionally up to about 0.15% Hf, about 0.004-0.015 B, optionally up to about 0.1% Zr, and the balance Ni and incidental impurities. The superalloy is characterized by a ?? solvus temperature that is within 5% of the ?? solvus temperature of the superalloy that does not include 1-6% Fe and a mole fraction of ?? that is within 15% of the mole fraction of the superalloy that does not include 1-6% Fe.

Abstract: A cast nickel-base superalloy that includes iron added substitutionally for nickel. The cast nickel base superalloy comprises, in weight percent about 1-6% iron, about 7.5-19.1% cobalt, about 7-22.5% chromium, about 1.2-6.2% aluminum, optionally up to about 5% titanium, optionally up to about 6.5% tantalum, optionally up to about 1% Nb, about 2-6% W, optionally up to about 3% Re, optionally up to about 4% Mo, about 0.05-0.18% C, optionally up to about 0.15% Hf, about 0.004-0.015 B, optionally up to about 0.1% Zr, and the balance Ni and incidental impurities. The superalloy is characterized by a ?? solvus temperature that is within 5% of the ?? solvus temperature of the superalloy that does not include 1-6% Fe and a mole fraction of ?? that is within 15% of the mole fraction of the superalloy that does not include 1-6% Fe.

Abstract: Molded articles and methods for forming molded articles are provided. For example, a molded article comprises a first region formed by a first casting material and a second region formed by mixing a molten or liquid portion of the first casting material and a second casting material. The first casting material is a molten, liquid, or fluid metal alloy, and the second casting material is a molten or fluid metal alloy. The first casting material has a different chemical composition than the second casting material. The first region and the second region are cast as one integral casting using directional solidification, and the first region and the second region have different microstructure patterns. The molded article has a lower concentration of impurities than were present in the first and second casting materials, and an interface between the first region and the second region is devoid of an oxidation layer.

Abstract: A casting method, cast article and casting system are disclosed. The casting method includes providing a base material in a mold, directing a fluid material into the mold, and solidifying the base material and the fluid material to form a cast article. The base material has a first density and first composition. The fluid material has a second density and a second composition. The first density differs from the second density, the first composition differs from the second composition, or the first density differs from the second density and the first composition differs from the second composition. The cast article includes a first material solidification from the base material, and a second material solidification from the fluid material. The casting system includes a mold for containing a base material and an input configuration, with flow control feature, for directing a fluid material into the mold containing the base material.

Abstract: A nickel alloy for direct metal laser melting is disclosed. The alloy comprising includes a powder that contains about 1.6 to about 2.8 weight percent aluminum, about 2.2 to about 2.4 weight percent titanium, about 1.25 to about 2.05 weight percent niobium, about 22.2 to about 22.8 weight percent chromium, about 8.5 to about 19.5 weight percent cobalt, about 1.8 to about 2.2 weight percent tungsten, about 0.001 to about 0.05 weight percent carbon, about 0.002 to about 0.015 weight percent boron, and about 40 to about 70 weight percent nickel. Related processes and articles are also disclosed.

Abstract: Embodiments of the present disclosure provide turbine buckets, turbomachinery, and related methods for identifying bucket deformation. A turbine bucket according to embodiments of the present disclosure can include an airfoil extending radially from a base, relative to a rotor axis of a turbomachine; and a magnetized material coupled to the airfoil proximal to a radially outer end thereof. To identify bucket deformation, a magnetic sensor can measure a magnetic field strength of the magnetized material, and a computing device in communication with the magnetic sensor can identify the turbine bucket as being one of deformed and non-deformed based on the magnetic field strength of the magnetized material.

Abstract: A method comprising introducing a first casting material into a casting mold; applying directional solidification to the first casting material in the casting mold; introducing a second casting material into the casting mold, the second casting material having a different chemical composition than the first casting material; applying directional solidification to the second casting material in the casting mold; and forming a molded article, wherein the molded article comprises a first region

Abstract: An article and a method for forming the article are disclosed. The article comprising a composition, wherein the composition comprises, by weight percent, about 20.0% to about 22.0% chromium (Cr), about 18.0% to about 20.0% cobalt (Co), about 1.0% to about 2.0% tungsten (W), about 3.0% to about 6.0% niobium (Nb), about 0.5% to about 1.5% titanium (Ti), about 2.0% to about 3.0% aluminum (Al), about 0.5% to about 1.5% molybdenum (Mo), about 0.03% to about 0.18% carbon (C), up to about 0.15% tantalum (Ta), up to about 0.20% hafnium (Hf), up to about 0.20% iron (Fe),balance nickel (Ni) and incidental impurities. The amount of Al is present according to the following formula: Al??(0.5*Ti)+3.75 The composition is weldable, has a microstructure comprising between about 35 vol % and 45 vol % gamma prime (??) and is substantially devoid of Eta and reduced content of TCP phases at elevated working temperatures. A method of making an article and a method of operating a gas turbine are also disclosed.

Abstract: A method comprising introducing a first casting material into a casting mold; applying directional solidification to the first casting material in the casting mold; introducing a second casting material into the casting mold, the second casting material having a different chemical composition than the first casting material; applying directional solidification to the second casting material in the casting mold; and forming a molded article, wherein the molded article comprises a first region.

Abstract: Modified turbine components include an original turbine component comprising an outer wail enclosing an internal cavity, wherein the outer wall has an original portion removed therefrom to expose the internal cavity, and, an internally cooled supplemental element joined to the outer wall that replaces the original portion removed from the outer wall and re-encloses the internal cavity. The internally cooled supplemental element comprises one or more cooling channels that circulate air from the internal cavity through at least a portion of the internally cooled supplemental element.

Abstract: An article and a method for forming the article are disclosed. The article comprising a composition, wherein the composition comprises, by weight percent, about 13.7% to about 14.3% chromium (Cr), about 9.0% to about 10.0% cobalt (Co), about 3.5% to about 3.9% aluminum (Al), about 3.4% to about 3.8% titanium (Ti), about 4.0% to about 4.4% tungsten (W), about 1.4% to about 1.7% molybdenum (Mo), about 1.55% to about 1.75% niobium (Nb), about 0.08% to about 0.12% carbon (C), about 0.005% to about 0.040% zirconium (Zr), about 0.010% to about 0.014% boron (B), and balance nickel (Ni) and incidental impurities. The composition is substantially free of tantalum (Ta) and includes a microstructure substantially devoid of Eta phase.

Abstract: A composite ceramic core that, in combination with a shell mold, is suitable for use in a casting process to produce metal alloy components. The core and casting process make use of a highly leachable interior layer in combination with an exterior layer that is less reactive than the interior layer in the presence of common alloying elements. The interior layer contains at least one hollow channel that allows a point of entry for a leaching solution, as well as exit for gaseous byproducts generated during the casting process.

Abstract: A nickel alloy for direct metal laser melting is disclosed. The alloy comprising includes a powder that contains about 1.6 to about 2.8 weight percent aluminum, about 2.2 to about 2.4 weight percent titanium, about 1.25 to about 2.05 weight percent niobium, about 22.2 to about 22.8 weight percent chromium, about 8.5 to about 19.5 weight percent cobalt, about 1.8 to about 2.2 weight percent tungsten, about 0.07 to about 0.1 weight percent carbon, about 0.002 to about 0.015 weight percent boron, and about 40 to about 70 weight percent nickel. Related processes and articles are also disclosed.

Abstract: An article comprising a substrate; a bond layer disposed on the substrate, the bond layer comprising one or more bonding segments and at least one reinforcing segment; at least one protective layer disposed on the bond layer; and at least one cooling hole extending through the substrate, the at least one reinforcing segment and the at least one protective layer, wherein the at least one reinforcing segment reduces cracking and/or delamination at the interface between the substrate and the bond layer, and methods of making the same.

Abstract: In one embodiment, a method for forming an article with a diffusion portion comprises: forming a slurry comprising chromium and silicon, applying the slurry to the article, and heating the article to a sufficient temperature and for a sufficient period of time to diffuse chromium and silicon into the article and form a diffusion portion comprising silicon and a microstructure comprising ?-chromium. In one embodiment, a gas turbine component comprises: a superalloy and a diffusion portion having a depth of less than or equal to 60 ?m measured from the superalloy surface into the gas turbine component. The diffusion portion has a diffusion surface having a microstructure comprising greater than or equal to 40% by volume ?-chromium.

Abstract: A method of forming an article can comprise heating a metal to form a molten metal having a metal temperature; heating a mold to a mold temperature greater than or equal to the metal temperature; introducing the molten metal to the mold; cooling a first portion of the molten metal while maintaining a second portion of the molten metal at the metal temperature, wherein the first portion has a first side and a second side, wherein the second side is opposite the first side and adjacent to the second portion, and wherein the cooling comprises progressively cooling the first portion from the first side to the second side such that a solidification interface progresses from the first side to the second side; and cooling the remainder of the molten metal from multiple directions after the first portion is cooled to less than or equal to a crystallization temperature.

Abstract: A single-crystal seed, apparatus and process for producing a casting having a single-crystal (SX) microstructure. The seed has a geometry that includes a vertex capable of destabilizing an oxide film that forms at the interface between the seed and a molten metal during the casting process, and thereby promotes a continuous single-crystal grain growth and reduces grain misorientation defects that can initiate from the seed/metal interface.

Abstract: An article and a method for forming the article are disclosed. The article comprising a composition, wherein the composition comprises, by weight percent, about 13.7% to about 14.3% chromium (Cr), about 9.0% to about 10.0% cobalt (Co), about 3.5% to about 3.9% aluminum (Al), about 3.4% to about 3.8% titanium (Ti), about 4.0% to about 4.4% tungsten (W), about 1.4% to about 1.7% molybdenum (Mo), about 1.55% to about 1.75% niobium (Nb), about 0.08% to about 0.12% carbon (C), about 0.005% to about 0.040% zirconium (Zr), about 0.010% to about 0.014% boron (B), and balance nickel (Ni) and incidental impurities. The composition is substantially free of tantalum (Ta) and includes a microstructure substantially devoid of Eta phase.

Abstract: An article and a method for forming the article are disclosed. The article includes an equiaxed grain structure and a composition. The composition includes, by weight percent, about 6.0% to about 9.0% aluminum, up to about 0.5% titanium, about 2.5% to about 4.5% tantalum, about 10.0% to about 12.5% chromium, about 5.0% to about 10.0% cobalt, about 0.30% to about 0.80% molybdenum, about 2.0% to about 5.0% tungsten, up to about 1.0% silicon, about 0.35% to about 0.60% hafnium, about 0.005% to about 0.010% boron, about 0.06% to about 0.10% carbon, up to about 0.02% zirconium, up to about 0.1% lanthanum, up to about 0.03% yttrium, and balance nickel and incidental impurities. Rhenium, if present, is a trace element. The method for forming the article includes providing the composition having up to about 0.01% rhenium and forming the article.