Abstract: A cutting insert for milling operations, such as, face milling, slot milling, plunge milling, and ramping operations. The cutting insert exhibits a combination of favorable cutting edge strength, and unique cutting edge geometry, thus, allowing milling operations at relatively high feed rates. The cutting insert includes at least four cutting edges, wherein at least one of the cutting edges is a convex cutting edge. Certain embodiments of square cutting inserts will have four convex cutting edges which may be connected by nose corners. The convex cutting edge may comprise at least one of a circular arc, a portion of an ellipse, a portion of a parabola, a multi-segment spline curve, a straight line, or combinations of these. Wherein the convex cutting edge comprises a circular arc, the circular arc may have a radius greater than or equal to two times a radius of the largest circle that may be inscribed on the top surface.

Abstract: Embodiments of the present invention relate to nickel-base alloys, and in particular 718-type nickel-base alloys, having a desired microstructure that is predominantly strengthened by ??-phase precipitates and comprises an amount of at least one grain boundary precipitate. Other embodiments of the present invention relate to methods of heat treating nickel-base alloys, and in particular 718-type nickel-base alloys, to develop a desired microstructure that can impart thermally stable mechanical properties. Articles of manufacture using the nickel-base alloys and methods of heat treating nickel-base alloys according to embodiments of the present invention are also disclosed.

Abstract: Methods of coating cutting tool inserts including a hard substrate and a plurality of coatings are disclosed. In one embodiment, the method comprises applying a first coating of at least 2 microns to at least a portion of the hard substrate and applying a second coating. The first coating can comprise at least one of a metal carbide, a metal nitride, and a metal carbonitride of at least one metal selected from zirconium and hafnium. The second coating can comprise at least one of a metal carbide, a metal boride, a metal nitride, and a metal oxide of a metal selected from groups IIIA, IVB, VB, and VIB of the periodic table. Optionally, third and fourth coatings are also applied to the cutting tool inserts.

Abstract: A method is provided to optimize separation of zirconium from hafnium by extraction of a feed mix including (Zr+Hf)OCl2 with a thiocyanate-containing organic phase. The method includes maintaining the TA/MO2 ratio in a range from greater than about 2.55 to about 3.5.

Abstract: A nickel-base alloy includes, in weight percent, up to about 0.10 percent carbon; about 12 up to about 20 percent chromium; up to about 4 percent molybdenum; up to about 6 percent tungsten, wherein the sum of molybdenum and tungsten is at least about 2 percent and not more than about 8 percent; about 5 up to about 12 percent cobalt; up to about 14 percent iron; about 4 percent up to about 8 percent niobium; about 0.6 percent up to about 2.6 percent aluminum; about 0.4 percent up to about 1.4 percent titanium; about 0.003 percent up to about 0.03 percent phosphorous; about 0.003 percent up to about 0.015 percent boron; nickel; and incidental impurities. The sum of atomic percent aluminum and atomic percent titanium is from about 2 to about 6 percent, the ratio of atomic percent aluminum to atomic percent titanium is at least about 1.5, and the atomic percent of aluminum plus titanium divided by the atomic percent of niobium equals about 0.8 to about 1.3.

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 remelted at a melt rate of at least 8 lbs/min. (3.63 kg/min.), 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: A method of enhancing the corrosion resistance of an austenitic steel includes removing material from at least a portion of a surface of the steel such that corrosion initiation sites are eliminated or are reduced in number relative to the number resulting from processing in a conventional manner. Material may be removed from the portion by any suitable method, including, for example, grit blasting, grinding and/or acid pickling under conditions more aggressive than those used in conventional processing of the same steel.

Abstract: A fluid separation assembly having a fluid permeable membrane and a wire mesh membrane adjacent the fluid permeable membrane, wherein the wire mesh membrane supports the fluid permeable membrane and is coated with an intermetallic diffusion barrier. The barrier may be a thin film containing at least one of a nitride, oxide, boride, silicide, carbide and aluminide. Several fluid separation assemblies can be used in a module to separate hydrogen from a gas mixture containing hydrogen.

Abstract: A fluid separation assembly having a fluid permeable membrane and a wire mesh membrane adjacent the fluid permeable membrane, wherein the wire mesh membrane supports the fluid permeable membrane and is coated with an intermetallic diffusion barrier. The barrier may be a thin film containing at least one of a nitride, oxide, boride, silicide, carbide and aluminide. Several fluid separation assemblies can be used in a module to separate hydrogen from a gas mixture containing hydrogen.

Abstract: A method for producing a stainless steel with improved corrosion resistance includes homogenizing at least a portion of an article of a stainless steel including chromium, nickel, and molybdenum and having a PREN of at least 50, as calculated by the equation: PREN=Cr+(3.3×Mo)+(30×N), where Cr is weight percent chromium, Mo is weight percent molybdenum, and N is weight percent nitrogen in the steel. In one form of the method, at least a portion of the article is remelted to homogenize the portion. In another form of the method, the article is annealed under conditions sufficient to homogenize at least a surface region of the article. The method of the invention enhances corrosion resistance of the stainless steel as reflected by the steel's critical crevice corrosion temperature.

Abstract: A duplex stainless steel including, in weight percent, up to 0.06 percent carbon, 15 up to less than 25 percent chromium, greater than 3 up to 6 percent nickel, up to 3.75 percent manganese, 0.14 up to 0.35 percent nitrogen, up to 2 percent silicon, greater than 1.4 up to less than 2.5 percent molybdenum, up to less than 0.5 percent copper, up to less than 0.2 percent cobalt, up to 0.05 percent phosphorous, up to 0.005 percent sulfur, and 0.001 up to 0.0035 percent boron, with the remainder being iron and incidental impurities is disclosed. The duplex stainless steel may be included in an article of manufacture, such as a strip, bar, plate, sheet, casting, tubing or piping. A method for making such a duplex stainless steel is also disclosed.

Abstract: A composite rotary tool includes at least first and second regions comprising first and second materials, respectively. The first and second regions are autogenously bonded and differ with respect to at least one characteristic such as, for example, modulus of elasticity, hardness, wear resistance, fracture toughness, tensile strength, corrosion resistance, coefficient of thermal expansion, or coefficient of thermal conductivity. A method for producing the composite rotary tool includes placing a first metallurgical powder into a first region of a void of a mold, and placing a second metallurgical powder into a second region of the void. The first metallurgical powder differs from the second metallurgical powder, and at least a portion of the first metallurgical is brought into contact with the second metallurgical powder. The mold is compressed to consolidate the first and second metallurgical powders to form a compact, and the compact subsequently is sintered.

Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.

Abstract: An apparatus and associated method for manipulating an electrode comprising a stub, an electrode, and a yoke. The stub is affixed to and protrudes from the electrode, and has a first opening. The yoke is sized to receive at least a portion of the stub, and has a second opening positioned for alignment with the first opening of the stub and receipt of a locking member extending through the first opening and the second opening. The apparatus may include a current conducting tube. The elongated yoke may extend around at least a portion of the stub to be removably pinned thereto. The current conducting tube may extend around the elongated yoke to be in electrical contact with the stub.

Abstract: A cutting tool insert comprises a hard metal substrate having at least two wear-resistant coatings including an exterior ceramic coating and a coating under the ceramic coating being a metal carbonitride having a nitrogen to carbon atomic ratio between 0.7 and 0.95 which causes the metal carbonitride to form projections into the ceramic coating improving adherence and crater resistance of the ceramic coating. Also disclosed is a cutting tool insert including a hard substrate and at least first and second coatings on at least a portion of said substrate. The first coating is of at least about 2 microns, is in contact with the substrate, and includes at least one of a metal carbide, a metal nitride, and a metal carbonitride of a metal selected from the group consisting of zirconium and hafnium. The second coating may include at least one of a metal carbide, a metal nitride, and a metal oxide of a metal selected from groups IIIA, IVB, VB, and VIB of the periodic table.

Abstract: A fluid separation assembly having a fluid permeable membrane and a wire mesh membrane adjacent the fluid permeable membrane, wherein the wire mesh membrane supports the fluid permeable membrane and is coated with an intermetallic diffusion barrier. The barrier may be a thin film containing at least one of a nitride, oxide, boride, silicide, carbide and aluminide. Several fluid separation assemblies can be used in a module to separate hydrogen from a gas mixture containing hydrogen.

Abstract: An apparatus for tuning the weight distribution in a vehicle, typically a high performance automobile, is provided. The apparatus includes a weight tray having an internal passage, a screw element, typically a threaded bolt, that extends into an end of the internal passage, a retainer at the same end of the passage, defining a hole through which the screw is rotatably retained, a primary weight is disposed within the passage and having a bore into which the screw extends and a nut or a threaded portion (i.e., a tapped portion) disposed within the bore that operatively engages the threads of the screw. Additional weights may be attached to the primary weight to increase the weight in the weight tray. The primary and additional weights may further include interlocking portions that are suitably configured to interlock with a corresponding interlocking portion on another weight. One or more of the weights may be assembled from two weight segments to facilitate assembly of the apparatus with minimal tools.

Abstract: A valve is disclosed. The valve has a housing that defines a central area and has at least two flow ports therethrough. A cover is provided that has a flapper assembly pivotally attached thereto. The cover is removably attachable to the housing in a plurality of orientations to selectively orient the flapper assembly adjacent any one of the ports such that fluid is permitted to flow into the central area of the housing through the adjacent port. The flapper assembly prevents the fluid from flowing back out of the central area through the adjacent port. The cover may have a transparent portion to permit the flapper assembly to be viewed and inspected during operation. A double seal arrangement is also disclosed.

Abstract: Apparatus and methods for limiting interaction of electron beams produced by adjacent electron bean guns mounted within a vacuum chamber of a furnace. The apparatus may include one or more barriers that are suspended within the vacuum chamber between adjacent electron beam guns. The methods may include suspending one or more vertically extending barriers with the vacuum chamber between adjacent electron beam guns.

Abstract: A heater includes a housing having an angled top, a fan having a discharge disposed parallel to the angled top of the housing, and a baffle for laminarizing airflow through the heater. The heater may also create airflow through a cover, across a housing, a heat sensitive component, and/or a raceway, and into a housing inlet. The heater may include a manifold having at least one coupling member that slidingly engages and disengages a burner. Methods for propelling combustion air through a heater, laminarizing combustion airflow in a heater, improving the efficiency of a heater, and converting a heater to make it compatible with a different fuel are also disclosed.