Abstract: A nickel-based alloy and a turbine component are disclosed. The alloy includes, by weight, between about 0.8% and about 1.3% hafnium, between about 5.7% and about 6.4% aluminum, between about 7.0% and about 10.0% cobalt, up to about 0.1% carbon, up to about 8.7% chromium, up to about 0.6% molybdenum, up to about 9.7% tungsten, up to about 0.9% titanium, up to about 0.02% boron, up to about 0.1% manganese, up to about 0.06% silicon, up to about 0.01% phosphorus, up to about 0.004% sulfur, up to about 0.02% zirconium, up to about 1.8% niobium, up to about 0.1% vanadium, up to about 0.1% copper, up to about 0.2% iron, up to about 0.003% magnesium, up to about 0.002% oxygen, up to about 0.002% nitrogen, and a balance nickel. The turbine component is a turbine bucket, a turbine nozzle, or any other suitable turbine component including the alloy.

Abstract: An electric discharge machining process, an article for electric discharge machining, and an electrically-conductive electric discharge machining coolant are disclosed. The electric discharge machining process includes electric discharge machining a target region of a component. The article includes a non-electrically-conductive layer, an electrically-conductive layer, and a target region on the non-electrically-conductive layer. The electrically-conductive electric discharge machining coolant includes a hydrocarbon liquid and carbon powder suspended within the hydrocarbon liquid.

Abstract: A heat transfer component and heat transfer process are disclosed. The heat transfer component includes thermally-responsive features positioned along a surface of the heat transfer component. The thermally-responsive features deploy from or retract toward the surface in response to a predetermined temperature change. The deploying from or the retracting toward of the thermally-responsive features increases or decreases a rate of heat transfer between a flow along the surface and the surface. The heat transfer process includes providing a heat transfer component having thermally-responsive features positioned along a surface of the heat transfer component; and increasing or decreasing a heat transfer rate between the surface and a flow by deploying the thermally-responsive features from or the retracting the thermally-responsive features toward the surface in response to a predetermined temperature change.

Abstract: A metallic seal assembly, a turbine component, and a method of regulating flow in turbo-machinery are disclosed. The metallic seal assembly includes a sealing structure having thermally-responsive features. The thermally-responsive features deploy from or retract toward a surface of the sealing structure in response to a predetermined temperature change. The turbine component includes the metallic seal assembly. The method of regulating flow in turbo-machinery includes providing the metallic seal assembly and raising or retracting the thermally-responsive features in response to the predetermined temperature change.

Abstract: A thermally-controlled component and thermal control process are disclosed. The thermally-controlled component includes thermally-responsive features. The thermally-responsive features are configured to modify a flow path to control temperature variation of the thermally-controlled component. The thermally-responsive features deploy from or retract toward a surface of the thermally-controlled component in response to a predetermined temperature change. The thermal control process includes modifying the flow path in the thermally-controlled component to control temperature variation of the thermally-controlled component and/or cooling a region of the thermally-controlled component through the thermally-responsive features deploying from or retracting toward a surface of the thermally-controlled component.

Abstract: A turbine bucket that includes a pressure side, a suction side opposite the pressure side, and a rib extending between the pressure side and the suction side. A tip cap is attached to the pressure side and the suction side and covers the rib. The tip cap includes a precipitation hardened material and a passage aligned with the rib. A method for assembling a turbine bucket having a pressure side and a suction side and a rib extending between the pressure side and suction side. The method includes receiving a tip cap made from a precipitation hardened material and having a passage in the tip cap. The method further includes locating the rib visually through the passage and aligning the passage with the rib. The method also includes welding the tip cap to the turbine bucket and to the rib.

Abstract: A system and method for laser beam welding at least two adjacent superalloy components involves substantially simultaneous formation of a base weld with a first filler metal placed between the components and cap weld with second filler metal formed over the base weld. A shim is inserted between the components, which may optionally be formed with a groove along the joint surface. A filler wire is fed to a location over the given surface or within the optional groove. Two lasers or a laser and coupled beam splitter supply first and second laser beams that are applied at focal points separated by a predetermined distance (e.g., 0.05-1.5 cm). The first laser beam is used to form a base weld with the first filler metal between the components, and the second laser beam is used to form a cap weld with the second filler metal on top of the base weld.

Abstract: A turbine bucket that includes a pressure side, a suction side opposite the pressure side, and a rib extending between the pressure side and the suction side. A tip cap is attached to the pressure side and the suction side and covers the rib. The tip cap includes a precipitation hardened material and a passage aligned with the rib. A method for assembling a turbine bucket having a pressure side and a suction side and a rib extending between the pressure side and suction side. The method includes receiving a tip cap made from a precipitation hardened material and having a passage in the tip cap. The method further includes locating the rib visually through the passage and aligning the passage with the rib. The method also includes welding the tip cap to the turbine bucket and to the rib.

Abstract: A nickel-base composition is disclosed that includes: about 15 to about 20 wt % Co; about 10 to about 19 wt % Cr; about 2.5 to about 3.4 wt % Al; less than about 0.5 wt % Ta; less than about 1.0 wt % Mo; less than about 0.06 wt % Zr; less than about 0.04 wt % B; about 1.1 to about 1.5 wt % Nb; about 3.0 to about 3.9 wt % Ti; about 3 to about 5 wt. % W; about 0.03 to about 0.07 wt. % C; and balance Ni; wherein aluminum, titanium, niobium, and tantalum are present within the alloy in a combined amount of 9 to 14 atomic percent.

Abstract: A system and method for laser beam welding at least two adjacent superalloy components involves substantially simultaneous formation of a base weld with a first filler metal placed between the components and cap weld with second filler metal formed over the base weld. A shim is inserted between the components, which may optionally be formed with a groove along the joint surface. A filler wire is fed to a location over the given surface or within the optional groove. Two lasers or a laser and coupled beam splitter supply first and second laser beams that are applied at focal points separated by a predetermined distance (e.g., 0.05-1.5 cm). The first laser beam is used to form a base weld with the first filler metal between the components, and the second laser beam is used to form a cap weld with the second filler metal on top of the base weld.

Abstract: A process for repairing a damaged portion of a thermal barrier coating on a turbine engine component includes sintering a mixture comprising particles of a bond coat and particles of a brazing alloy to form a composite preform; depositing a thermal barrier coating on the composite preform; contacting the composite preform with the deposited thermal barrier coating with an uncoated surface of the damaged portion of the turbine engine component; and heating the composite preform with the deposited thermal barrier coating to a temperature effective to form a brazed joint between the composite preform and the uncoated surface of the damaged portion of the turbine engine component.

Abstract: Disclosed is a method for welding an article, the method including the steps of placing the article in an enclosure with walls that enclose the article on all sides, the enclosure having a heating device associated therewith, the heating device configured and sized to uniformly heat the article over at least a substantial entirety of the article, establishing a nonreactive atmosphere in the enclosure, operating the heating device to uniformly heat the article in the enclosure to a welding temperature over at least the substantial entirety of the article, and welding the article in the enclosure while maintaining the welding temperature over at least the substantial entirety of the article.

Abstract: A weld repair method uses a gas tungsten or plasma arc welding torch and matching filler. An amperage supplied to the torch and a travel speed of the torch are controlled to produce a weld bead having a mushroom shape. The weld bead is ground from all sides to remove at least one half of a thickness of the weld bead, and another weld bead is formed. The technique produces crack free welds with directionally solidified weld metal that is similar to that of the base material and hence has comparable mechanical properties.

Abstract: Disclosed is a projection welding method including providing a first metal substrate, a second metal substrate, and a projection material of separate construction from the first metal substrate and the second metal substrate, disposing the metal projection material between the first metal substrate and the second metal substrate, applying a current and pressure to at least one of the first metal substrate and the second metal substrate, melting the metal projection material via the application of the current and pressure, creating a weld between the first metal substrate and the second metal substrate via the melting, and fixedly associating the first metal substrate and the second metal substrate via the weld.

Abstract: A process for repairing a metal component includes sintering a mixture comprising particles of a coating composition and particles of a brazing alloy to form a composite preform; disposing the composite preform on an uncoated surface of the metal component; and heating the preform to a temperature effective to form a brazed joint between the composite preform and the metal component.