Abstract: A fiber carrier provides an effective coupling means between a cleaved facing surface of an optical fiber and a light port in a mounting surface of an integrated optical device. Both the fiber carrier and the integrated optical device have an anisotropic thermal expansion property along the same known optic axis and both are substantially similar in magnitude to each other. The fiber carrier is positioned with the integrated optical device so that both the carrier optic axis is parallel to the device optic axis and so that an auxiliary surface of the carrier is parallel to the device mounting surface. The optical fiber is then bonded to the fiber carrier so that the plane of the optical fiber cleaved facing surface lies in the plane of the carrier auxiliary surface. The carrier auxiliary surface is finally bonded to the device mounting surface so that the optical fiber cleaved facing surface is placed in registration with the light port in the device mounting surface.

Abstract: A method for pigtailing an optical fiber to a lithium niobate integrated optical device (I/O chip) is shown and described wherein the bonding between the I/O chip and the optical fiber is a metallic bond. The lithium niobate may be attached to a metallic substrate which is welded to a metallic fiber optic carrier which is in turn welded to a metallized optical fiber. The fiber optic carrier may also be made of non-metallic materials which are given a metallic coating prior to attachment to the I/O chip by means of a metallic bond such as welding.

Abstract: Fabrication methods are described for producing an integrally bladed rotor wherein single crystal blade portions are securely metallurgically bonded to a polycrystalline disk. The polycrystalline disk is fabricated with protruding portions in the location where the blades are to be bonded. The blades are fabricated with a root portion having a cavity adapted to mate with the disk protrusions. The blade and disk are assembled and forced. Localized heating causes localized softening metal flow in the disk protrusion. Bonding occurs as a result of this combination of softening and force.

Abstract: A thermal barrier coating system for the protection of nickel and cobalt base superalloys at elevated temperature comprises 7% yttria partially stabilized zirconia plasma sprayed in air on a plasma sprayed NiCoCrAlY bond coat which has been plasma sprayed in air.

Abstract: A process is described for producing forged ring articles from high strength, high temperature materials such as superalloys and titanium alloys. The material to be forged is conditioned and placed into a condition of low strength and high ductility. This starting material is then back extruded to produce a cup. The cup can be sliced into rings in which can thereafter be final forged to a particular contour.

Abstract: Processing of Ti-6246 for improved mechanical properties including fracture toughness and low cycle fatigue. The process includes beta forging, sub beta transus solutionizing, controlled cooling and precipitation treating.

Abstract: A silver base electrical contact material is described which contains a dispersion of particles consisting of cadmium oxide and nickel. The nickel particles are surrounded by a continuous adherent coating of nickel oxide which eliminates the detrimental reaction which would otherwise occur between nickel and cadmium oxide. The invention contact materials have improved lives and are fabricated by any one of several different powder metallurgy techniques.

Abstract: Heat treatments are described for improving the fatigue properties of superalloy articles, without adversely affecting other mechanical properties. The entire heat treatment process is performed below the gamma prime solvus temperature so that significant grain growth does not occur. The heat treatment cycle causes the formation of gamma prime particles in a controlled manner and morphology, first at the grain boundaries and then within the grains. The resultant microstructure possesses the benefits of a fine grain structure (improved resistance to fatigue crack initiation) and fine gamma prime particle size (improved resistance to crack growth).

Abstract: Methods for cleaning in-process wire are developed. In one embodiment a moving string loops around the wire and advances to present a clean surface to remove dirt from the surface of the moving wire.

Abstract: An improved ternary alloy catalyst for fuel cells containing platinum and gallium. The method of fabricating the catalyst in a high surface area supportive form is also described. The resultant fuel cell catalyst displays a substantial resistance to sintering during operation combined with a resistance to a chemical dissolution during operation. These enhancements permit improved long-term operation of fuel cells.

Abstract: A process for forging hollow elongated articles from superalloys and titanium alloys. The process employs preconditioned material which has low strength and high ductility. The process is performed in a forging press and has an initial step which converts a preform into a intermediate shape by press motion which produces radial outward workpiece flow. Press punch geometry is then changed and the operation continues with radial inward flow about a mandrel.

Abstract: A superalloy composition and single crystal articles of the composition are described. The broad range is 3-12% Cr, 0-3% Mo, 3-10% W, 0-5% Re, 6-12% Ta, 4-7% Al, 0-15% Co, 0-0.045% C, 0-0.02% B, 0-0.1% Zr, 0-0.8% Hf, 0-2% Nb, 0-1% V, 0-0.7% Ti, 0-10% (Ru+Rh+Pd+Os+Ir+Pt), balance essentially Ni. An equation is presented to select the most useful specific compositions from within this range. An exemplary preferred composition is 5.0% Cr, 10.0% Co, 2.0% Mo, 6.0% W, 3.1% Re, 5.6% Al, 9.0% Ta, 0.1% Hf, balance essentially Ni.

Abstract: Methods of repairing defects in superalloy articles are described. Defective areas are cleaned and prepared to expose clean substrate surfaces. A layer of superalloy powder material containing a melt depressant (boron) is applied. A layer of superalloy material essentially free from boron is then applied. The dual coated article is heated to a temperature at which the boron containing layer melts, but the boron-free layer does not. The boron diffuses into the substrate raising the melting point of the molten material until solidification results. The unmelted surface layer is subsequently removed leaving behind a repaired article free from surface defects.

Abstract: High modulus turbine shafts are described as are the process parameters for producing these shafts. The shafts have a high modulus as a result of having high modulus <111> crystal texture in the axial direction. The shafts are produced from a nickel base material consisting largely of the compound Ni.sub.3 Si. Hot axisymmetric deformation followed by cold axisymmetric deformation produces an intense singular <111> texture and results in shaft material whose Young's modulus is at least 25% greater than that of the steel materials used in the prior art.

Abstract: The bonding of materials by the transient liquid phase process is improved through the use of multiple boronized interlayer foils. By providing the interlayer in the form of multiple foils a reservoir of liquid material is formed during the bonding process which eliminates the previously encountered porosity. The use of multiple foils is especially appropriate when bonding fine grained materials.

Abstract: Disclosed is a gas turbine disk made from powder metal, wherein the bore has improved fatigue life compared to conventional articles because the bore is formed from a fine fraction of powder separated from a lot of conventional powder metal suitable for hot isostatic compaction. The outer and rim portions of the disk, which are less prone to fatigue failure, are made from the remainder of the lot but nonetheless have no more limited performance from that resulting when a unitary unseparated powder lot is used. Improved bore fatigue properties result because the coarse fatigue failure-causing nonmetallic inclusions are biased into the outer portions of the disk where they do not have adverse effect.

Abstract: Heat treatments are described which improve subsequent HIP treatment results of superalloy articles. The heat treatments substantially eliminate certain low melting phases which otherwise would cause problems relating to gas entrapment during a HIP process. The articles are heated to a temperature near but below the intended HIP temperature for a period of time sufficient to reduce the low melting phase.

Abstract: Quench cracking of nickel base superalloy articles is avoided by plating the articles with a layer of nickel or similar metal prior to heat treatment.

Abstract: Ablative material is adhered to the surface of an article, such as the combustor of a ramjet, by a folded extensible member attached to the surface. Thus, when an ablative material such as a filled silicone rubber expands during use, the retaining member will extend with it to a void shearing separation, but at the same time will retain it against the surface. In a combustor a rib will run helically along the length of the interior of the combustor. When gases are swirling within the combustor, the pattern of the helix will be opposite to the pattern of the swirl.

Abstract: Aluminum alloy compositions and related fabrication techniques are described. Articles made of the composition by the process contain a novel dispersed strengthening phase based on iron and refractory metals. Rapid solidification techniques are used to assure a fine distribution of this phase. Articles made according to the invention have mechanical properties significantly in excess of those of conventional aluminum alloys.