Abstract: Simple or complex cross-sectional configuration metal components of an article are bonded together through a forged joint with application of localized high frequency induction heating combined with high energy rate impacting of the metal components together. An improved induction heating and impacting apparatus is provided, including an induction heating element the shape of which varies with substantial variations in the cross-sectional area of each component to provide substantially uniform heating.

Abstract: Complete coating or localized repair and replacement of a diffusion aluminide coating applied to the surface of an article is attained through use of a powdered Fe-Al alloy as a source of aluminum. In another aspect, more accurate control of a coating method, such as for aluminide diffusion coating, is achieved when a source powder is provided in a layer, such as a tape, preferably by combining the powder with a binder which decomposes substantially without residue upon heating.

Abstract: A metallic article is provided with improved resistance to high temperature environmental conditions through the inclusion of about 0.1-10 weight percent Hf in an article surface, such as through coating. A method for providing such a coating includes application of the Hf alone or in combination with other surface protective means. Application of Hf can occur before, during or after use of such protective means.

Abstract: A fabricated article, including a portion of non-uniform sectional thickness, is provided through an improved method employing a plurality of cooperating, particularly shaped and sized sheet metal members or member portions which, in an article including a cavity, generally define selected inner and outer surfaces of the article. Also employed is at least one particularly shaped and sized insert member to provide increased sectional thickness in a selected portion. The sheet metal members or member portions and the insert member are assembled at bonding surfaces so that the sheet metal members or member portions retain the insert between them. Thereafter, the assembly is fabricated into the article by solid state diffusion bonding at the bonding surfaces.

Abstract: A plurality of cooperating members of an article are heat bonded at interface surfaces through use of a bonding material at such surfaces and fluid pressure, such as through a resilient, single- or multi-compartment closed member, applied through a flexible heating blanket. Heat is applied at least partially through the heating blanket and preferably through the blanket and through a backing member, such as a mold, which carries heating means.

Abstract: A silicone resin base fire retardant system having a temperature capability at least to about 450.degree.F (230.degree.C) combines intumescent characteristics with a crusting and charring capability through use of a combination of an oxide of iron and a phosphate of potassium for crusting, along with a charring material such as tripentaerythritol and a blowing agent, such as melamine, in a silicone resin base to allow for adequate expansion.

Abstract: A friction welded metallic article such as a fluid directing element for turbomachinery apparatus has a cast airfoil and a wrought base joined by friction welding. One such article having a hollow interior portion is made from a hollow or cored casting and a wrought base member. There is provided a metal airfoil casting having a hollow interior portion and an enlarged foot including an interface portion. Also provided is a wrought metal base portion including an interface portion. Interface surfaces of the interface portions are placed in spaced apart opposed relationship and then the airfoil casting and the wrought base member are friction welded at their interface portions.

Abstract: An alloy based on Fe, Co or Ni, and including Al, is provided with improved environmental resistance through the inclusion in the composition of the combination of 0.1-10 weight percent Hf and 0.5-20 wt. % of an element selected from Pt, Rh and Pd. The combination is particularly useful in providing an article coated with such alloy.

Abstract: A seal member is provided with an improved combination of oxidation resistance, fluid erosion resistance, reduced thermal conductivity and low flow stress at elevated temperatures through a plurality of metallurgically bonded metal alloy powder particles in the size range substantially of about +140 to about -270 ASTM (U.S. Standard Sieve) the metal particles being metallographically distinguishable and consisting essentially of, by weight, 15 - 35% Cr, about 8 to 20% Al, up to 5% of elements selected from Y, Hf and the rare earth elements, with the balance selected from Fe, Co and Ni, the member having a density in the range of about 65 - 90% of theoretical density.

Abstract: An article is provided with improved resistance to hot corrosion through a coating on a metal surface based on an element selected from Fe, Co and Ni, the coating comprising a filled matrix bonded by interdiffusion with the substrate. The matrix is applied by impinging on the substrate metal surface a plurality of heated metallic particles, such as by plasma spraying. The coating includes a filler metal of aluminum and preferably an alloy of aluminum and at least one other element, for example Cr, deposited on and interdiffused with the matrix, such as through a halide vapor deposition process employing a mixture of aluminum powder and other powders. As a result of application of the filler metal, there is provided from the matrix a coating layer of an alloy including an average of about 8-20 weight percent aluminum, the application process resulting in substantial recrystallization of the matrix.

Abstract: An article is provided with improved resistance to hot corrosion through a coating on a metal surface based on an element selected from Fe, Co and Ni, the coating comprising a filled matrix bonded by interdiffusion with the substrate. The matrix is applied by impinging on the substrate metal surface a plurality of heated metallic particles, such as by plasma spraying. The coating includes a filler metal of aluminum and preferably an alloy of aluminum and at least one other element, for example Cr, deposited on and interdiffused with the matrix, such as through a halide vapor deposition process employing a mixture of aluminum powder and other powders. As a result of application of the filler metal, there is provided from the matrix a coating layer of an alloy including an average of about 8 - 20 weight percent aluminum, the application process resulting in substantial recrystallization of the matrix.

Abstract: An article is provided with improved resistance to hot corrosion through a coating on a metal surface based on an element selected from Fe, Co and Ni, the coating comprising a filled matrix bonded by interdiffusion with the substrate. The matrix is applied by impinging on the substrate metal surface a plurality of heated metallic particles, such as by plasma spraying. The coating includes a filler metal of aluminum and preferably an alloy of aluminum and at least one other element, for example Cr, deposited on and interdiffused with the matrix, such as through a halide vapor deposition process employing a mixture of aluminum powder and other powders. As a result of application of the filler metal, there is provided from the matrix a coating layer of an alloy including an average of about 8 - 20 weight percent aluminum, the application process resulting in substantial recrystallization of the matrix.

Abstract: A metallic article is provided with improved resistance to high temperature environmental conditions through the inclusion of about 0.1-10 weight percent Hf in an article surface, such as through coating. A method for providing such a coating includes application of the Hf alone or in combination with other surface protective means. Application of Hf can occur before, during or after use of such protective means.

Abstract: An inlet duct for use with gas turbine engines or the like is provided with an axially upstream projecting deflector means to reduce noise propagation emanating within said duct. The deflector member has an essentially double arcuate contour of the lip in the axial direction which improves noise attenuation and inlet total pressure recovery. The contour is provided with at least one point of curvature inflection.

Abstract: Variable geometry guide vanes are provided in a variable pitch turbofan assembly. A method is disclosed for reducing aerodynamically induced stresses in the variable pitch fan blades as the blades are changed between the forward and reverse pitch modes. The guide vane geometry is scheduled to change in a manner to control the flow into and out of the fan blades in order to establish a favorable aerodynamic environment during the transition between the forward and the reverse pitch modes.

Abstract: An improved gas turbine engine exhaust nozzle diverter valve is provided to selectively direct the flow of motive fluid through one of two nozzle exhaust ports and to provide improved sealing to prevent the flow of fluid through the second nozzle exhaust port. Linkage and actuator means are provided to retract a blocker door having a deformable seal attached thereto from a first seated position over the second nozzle exhaust port, and to then rotate the blocker door to a position over the first nozzle exhaust port. The method of retracting the blocker door prior to rotating it eliminates sliding friction and minimizes the potential of damage to the seal between the blocker door and the nozzle exhaust port.

Abstract: A composite metallic preform tape for use as laminae in the manufacture of metallic composite articles is made from a pair of metallic foils and high strength, high modulus filaments aligned between the foils. One form of the method involves first coating either the foil inner surfaces or the filament outer surfaces, or both, with a thin, non-metallic adhesive bonding material which will decompose leaving substantially no residue upon heating at a temperature below that at which the foil and filaments will melt, and preferably below that at which they will bond together. The foil and the aligned filaments are themselves aligned and, in a continuous form of the method, are moved at substantially the same rate and in the same direction so that the coated surface is between the foil and filaments.