Abstract: A method of producing a nickel base alloy includes casting the alloy within a casting mold and subsequently annealing and overaging the ingot at at least 1200° F. (649° C.) for at least 10 hours. The ingot is electroslag remeelted at a melt rate of at least 8 lbs/min (3.63 kg/mm.), and the ESR ingot is then transferred to a heating furnace within 4 hours of complete solidification and is subjected to a novel post-ESR heat treatment. A suitable VAR electrode is provided form the ESR ingot, and the electrode is vacuum arc remelted at a melt rate of 8 to 11 lbs/minute (3.63 to 5.00 kg/minute) to provide a VAR ingot. The method allows premium quality VAR ingots having diameters greater than 30 inches (762 mm) to be prepared from Alloy 718 and other nickel base superalloys subject to significant segregation on casting.

Abstract: Method for removing a portion of the binder phase from the surface of a substrate that is composed of particles of at least a first phase joined together by the binder phase, and wherein the surface is etched by contacting it with a gas flow of an etchant gas and a second gas. The second gas is one or more gases that will not react with the substrate or the removed binder phase and will not alter the oxidation state of the substrate during etching.

Abstract: A process for providing a zirconium basic sulfate includes providing a zirconium oxychloride solution, and then dialyzing the solution against a liquid selected from water and an aqueous solution across at least one anion exchange membrane to provide a dialyzate and diffusate. The dialyzate includes at least 90 percent of the zirconium ions of the zirconium oxychloride chloride solution and has a total acidity that is lower than the original zirconium oxychloride solution. A precipitate including zirconium basic sulfate may be formed from at least a portion of the diffusate. The zirconium oxychloride solution may be provided, for example, by dissolving zirconium tetrachloride in one of water and a hydrochloric acid solution. A material including zirconium basic sulfate produced by the process of the invention also is disclosed.

Abstract: An austenitic stainless steel comprising, by weight, 17 to 23% chromium, 19 to 23% nickel, 1 to 6% molybdenum. The addition of molybdenum to the iron-base alloys of the invention increases their resistance to corrosion. The austenitic stainless steel may consisting essentially of, by weight, 17 to 23% chromium, 19 to 23% nickel, 1 to 6% molybdenum, 0 to 0.1% carbon, 0 to 1.5% manganese, 0 to 0.05% phosphorus, 0 to 0.02% sulfur, 0 to 1.0% silicon, 0.15 to 0.6% titanium, 0.15 to 0.6% aluminum, 0 to 0.75% copper, iron, and incidental impurities. Austenitic stainless steels according to the present invention exhibit enhanced resistance corrosion by salt at a broad temperature range up to at least 1500° F. Thus, the stainless steel of the present invention would find broad application as, for example, automotive components and, more particularly, as automotive exhaust system components and flexible connectors, as well as in other applications in which corrosion resistance is desired.

Abstract: A thread milling tool includes a proximal shank portion and a distal cutting portion. The cutting portion includes at least one thread milling tooth and at least one flute oriented helically, or spirally, about a rotational axis of the tool. The helix angle of the thread milling tool of at least 20°. The cutting portion may be configured to form internal or external threads in a workpiece as the cutting portion moves relative to the workpiece.

Abstract: A process for producing a steel includes subjecting at least a portion of a melt of the steel to electroslag remelting and, in a subsequent step, heating the steel to a temperature at least as great as the lowest temperature at which all carbides that can form in the remelted steel will dissolve and no greater than the nil ductility temperature of the of the remelted steel, and maintaining the temperature for a period of time sufficient to dissolve primary and clustered carbide particles in the remelted steel greater than 15 micrometers in length. A novel martensitic stainless steel also is disclosed including 0.65 to 0.70 carbon; 0 to 0.025 phosphorus; 0 to 0.020 sulfur; 0.20 to 0.50 silicon; at least one of greater than 0.0004 boron and greater than 0.03 nitrogen; 0.45 to 0.75 manganese; 12.7 to 13.7 chromium; and 0 to 0.50 nickel.

Abstract: A locking assembly and a process for electrode or ingot formation that include a stub, a locking member, and a support member. The locking member removably extends through the support member and at least a portion of the stub. Molten material is introduced over the support member and the stub to form the electrode. The electrode and integrated stub may be incorporated into an electrode assembly, including a yoke, a fastening member, a shoe, and a conducting tube.

Abstract: A cutting tool or drill insert with chip control geometry comprising a body including a portion securable in a holder and a forward portion. The forward portion defining at least one cutting edge extending from the central axis of the body to an edge of the body. A chip groove is defined by the surface of the body adjacent to the cutting edge. The chip groove incorporates chip control geometry as spaced apart elongate projections.

Abstract: A refining hearth. The refining hearth comprises an open vessel defining a first deep zone having a predetermined depth, a second deep zone having a predetermined depth, and a shallow zone intermediate the first deep zone and the second deep zone, wherein the shallow zone has a predetermined depth less that of the first deep zone and less than that of the second deep zone. A furnace for refining metal is also disclosed which employs a similarly constructed hearth. A method of refining metal is also disclosed. The method includes depositing molten metal in a first deep pool, passing the molten metal through a shallow pool having a depth less than the depth of the first deep pool, directing an energy source at the molten metal, and passing the molten metal into a second deep pool having a depth greater than the depth of the shallow pool.

Abstract: Method for removing a portion of the binder phase from the surface of a substrate that is composed of particles of at least a first phase joined together by the binder phase, and wherein the surface is etched by contacting it with a gas flow of an etchant gas and a second gas. The second gas is one or more gases that will not react with the substrate or the removed binder phase and will not alter the oxidation state of the substrate during etching.

Abstract: An electrochemical gas sensor including a sensor body having a cavity, an electrolyte in the cavity, an auxiliary electrode in contact with the electrolyte, a sensing electrode in contact with the electrolyte, and a blocking electrode in contact with the electrolyte. At least a portion of the blocking electrode is positioned intermediate the auxiliary electrode and the sensing electrode, and the blocking electrode reduces electroactive materials within the electrolyte. Also disclosed is a method for sensing a partial pressure of a target gas in a sample gas, the method including introducing the sample gas into a gas sensor, applying different potentials to the auxiliary electrode, sensing electrode and blocking electrode, reducing electroactive materials present in the electrolyte to prevent the electroactive materials from contacting the sensing electrode, and outputting an electrical signal from the gas sensor representative of the target gas partial pressure.

Abstract: A balancing mechanism for an engine that has a rotating crankshaft and reciprocating pistons such as those engines used in automobiles, aircrafts, boats, piston-driven compressors, piston-driven slider crank mechanisms, etc. The present balancing mechanism may comprise a first balance mass non-rotatably affixed to the crankshaft and a second balance mass rotatably supported on the crankshaft. A driver assembly is affixed to crankshaft to cause the second balance mass to rotate in a direction that is opposite to the direction in which the crank shaft is rotating. The driver assembly may include auxiliary gears configured to transport rotary power to auxiliary components.

Abstract: A flow sensor including a symmetrical sensor tube for carrying the fluid, first and second heaters symmetrically disposed at the sensor tube, and a first temperature sensor in thermal communication with the fluid. A flow meter including a flow sensor having a sensor tube, a first heater disposed at the sensor tube, a second heater disposed at the sensor tube, and a first temperature sensor in thermal communication with the fluid. The meter also includes a circuit for selectively applying power to the first and second heaters to maintain a temperature difference between a temperature of the first and second heaters and the temperature of the fluid, and for determining a difference in power supplied to the first and second heaters.