Abstract: Novel materials and methods for repairing/reclassifying superalloy components are described herein. These materials are non-traditional blends of materials having a much higher base material content than traditional repair/reclassification materials. In embodiments used to repair/reclassify nickel-based components, these materials may comprise about 5-18.9 weight percent of a low melting point alloy and about 81.1-95 weight percent of a base material. In embodiments used to repair/reclassify cobalt-based components, these materials may comprise about 15-30 weight percent of a low melting point alloy and about 70-85 weight percent of a base material. These materials can be used to repair surface defects and/or build up worn or eroded areas of a component to meet precise dimensional and metallurgical requirements. These materials create robust repaired components having a dense, isothermally solidified structure having minimal borides and a high re-melt temperature.

Abstract: A method of restoring dimensions to an article includes the steps of providing an article having a section requiring dimensional restoration, providing a preform having first and second layers made from different materials, and joining the preform to the article.

Abstract: Putty-like gap-filling compounds for insulation that can be utilized at temperatures from about ?420° F. (?250° C.) up to about 500° F. (260° C.) are described herein. Embodiments of these compounds contain about 25-50 volume percent base material, about 50-75 volume percent microspheres, and about 0.1-0.3 volume percent catalyst. Embodiments of these compounds contain about 70-80 weight percent base material, about 20-30 weight percent microspheres, and about 0.1-0.5 weight percent catalyst.

Abstract: Systems and methods for repairing Thermo-Span® gas turbine engine components are described herein. Embodiments of these methods minimize post-weld residual stresses in a weld repaired Thermo-Span® component by solution heat treating the component by heating the component to about 2000° F.±25° F., holding the component at about 2000° F.±25° F. for about one hour; and cooling the component to below about 700° F. at a rate equivalent to cooling in air; and precipitation heat treating the component by heating the component to about 1325° F.±25° F., holding the component at about 1325° F.±25° F. for about 8 hours, cooling the component to about 1150° F.±25° F. at a maximum rate of about 100° F./hour, holding the component at about 1150° F.±25° F. for about 8 hours, and cooling the component at a predetermined cooling rate. Dimensions of the fully-machined and weld repaired component are maintained during solution heat treating and precipitation heat treating via custom designed furnace tools.

Abstract: Systems and methods for determining the velocity of ultrasonic surface skimming longitudinal waves on various materials are described herein. In embodiments, a surface skimming longitudinal wave is generated at a first location on a material, at least a portion of that wave is detected at a second location on the material, the time-of-flight of that wave between the first and second locations is determined, and then the velocity of that wave is determined. One or more crystallographic orientations of the material may then be determined based upon that velocity.

Abstract: A cleaning preparation method, comprising: providing a part with an internal cavity, an opening, and foreign material within the cavity; and creating an additional opening in the part adjacent the foreign material. A cleaning method, comprising: providing a part with an internal cavity and an opening; creating an additional opening in the part; and flushing the cavity with a fluid. The additional opening acts as an exit or entrance for the fluid. A repair method, comprising: providing a part with an internal cavity, an opening and foreign material within the cavity; creating an additional opening in the part; and removing the foreign material through the additional opening. A part, comprising: an exterior surface; an internal cavity; an opening through the surface to the cavity; and a repaired section of the surface, which was an additional opening that provided a temporary exit or entrance to the cavity for foreign material removal.

Abstract: The present invention deals with the catalytic hydrogenation of fluid used to cool and dielectrically insulate an x-ray generating device within an x-ray system. According to the present invention, a method and apparatus are provided for hydrogenating fluid that has been exposed to x-rays to reduce the amount of H2 gas, free hydrogen atoms and unsaturated molecules in the fluid. The method comprises exposing the fluid within the x-ray system to a catalytically effective amount of catalyst. The catalyst operates in temperatures in the range of about 10-300° C. and pressures in the range of about 0.1-30 atmospheres. The catalyst may comprise a solid, non-soluble catalyst, a soluble catalyst, or a combination of both. A suitable solid, non-soluble catalyst comprises Group VIII elements and their compounds. Group VIII elements comprise iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium and platinum.

Abstract: An article for controlling flow of a fluid medium in a fluid path comprises a brush seal carrier and at least one brush seal coil disposed within the brush seal carrier. The brush seal coil is arranged in predetermined array and comprises a continuous helical member. In addition, a brush seal, for controlling the flow of the fluid medium in the fluid path, comprises a plurality of fibers secured to the brush seal coil.

Abstract: A CHTS reactor plate has wells that can be individually heated. The reactor plate includes a substrate with an array of reaction wells and a ferromagnetic material included with the substrate. A CHTS method provides a reactor plate having a substrate with an array of reaction wells and a ferromagnetic material responsive to the application of an electric field included with the substrate. The electric field is energized to control temperature in the proximity of at least one of the reaction wells. Another method comprises providing a reactor plate comprising an array of reaction wells and depositing a ferromagnetic object within at least one of the wells. The object is responsive to the application of an electric field. An electric field is then energized to control temperature in the reaction well.

Abstract: A welding method that enables the joining of at least two dissimilar, metallic alloys to form a weld that is free of cracks is disclosed. The method incorporates a pure (99.00% minimum by weight) nickel fill-wire, integrally assembled into the joint between the two alloyed metals to be joined. The alloys joined by this method are an iron-based, low expansivity, gamma-prime strengthened superalloy (i.e., Incoloy®) and a high carbon, powder metallurgical tool steel high in refractory metal alloying agents (i.e., CPM REX 20). Welding of the joint results in the formation of a nickel rich region within the weld, thus “inoculating” the weld against cracks. The weld joint formed by the method of the present invention can be used in the fabrication of a rotating anode bearing shaft assembly for use in an x-ray generating device.

Abstract: A process management system for at least one of monitoring and controlling operation of a machine comprises at least one sensor assembly capable of being disposed on the machine for at least one of sensing, monitoring, and transmitting machine process variables of the machine, the at least one sensor assembly is capable of transmitting signals concerning the machine process variables; at least one machine operator control unit that is capable of receiving signals transmitted from the at least one sensor assembly, the at least one machine operator control unit being capable of generating information concerning machine process variables; at least one process management system control unit that is capable of being connected to the at least one machine operator control unit; at least one communications link that interconnects the at least one sensor assembly on the machine, the at least one machine operator control unit, and the at least one process management system control unit, each communications link capable