Abstract: Method for removing ceramic shell mold material from one or more castings in a relatively rapid manner wherein the casting and hot caustic solution spray nozzles are relatively moved to direct hot caustic solution under pressure at the castings to remove post-knock-out ceramic shell material thereon prior to further processing of the castings.

Abstract: A thermal barrier protected nickel based or cobalt based superalloy component for use in a gas turbine engine includes a thermal barrier coating system having a multi-layered structure. The first bondcoat layer of the thermal barrier coating system comprises a chemical vapor deposited, platinum modified diffusion aluminide layer on the superalloy component (substrate). The diffusion aluminide layer includes an inner diffusion zone proximate the substrate and an outer layer region comprising a platinum modified (platinum-bearing) intermediate phase of aluminum and at least one of nickel and cobalt depending on the superalloy composition. The intermediate phase is a non-ordered solid solution having a range of compositions and is free of other phase constituents.

Abstract: A method of predicting a grain condition in a directionally solidified casting, comprises generating thermal history data for a directional solidification casting process, determining a plurality of casting process variables that statistically influence a plurality of different grain conditions, identifying each grain condition by determining a function containing values of each selected variable, and categorizing the selected variables with respect to variance among and between the different grain conditions to determine a pattern between the selected variable and the grain conditions.

Abstract: A method of improving oxidation resistance of a platinum modified aluminide diffusion coating on a substrate involves electroplating the substrate with a platinum layer from an aqueous hydroxide based electroplating solution and aluminizing the substrate to grow the platinum modified aluminide diffusion coating on said layer. The electroplating solution preferably includes an alkali element and/or alkaline earth element that is incorporated in the platinum layer and in the aluminide diffusion coating formed thereon to significantly improve oxidation resistance of the coating.

Abstract: A nickel base superalloy composition consisting essentially of, in weight %, 9.3-10.0% Co, 6.4-6.8% Cr, 0.5-0.7% Mo, 6.2-6.6% W, 6.3-6.7% Ta, 5.45-5.75% Al, 0.8-1.2% Ti, 0.07-0.12% Hf, 2.8-3.2% Re, and balance essentially Ni wherein a carbon concentration of about 0.01 to about 0.08 weight % is provided for improving the cleanliness of a single crystal investment casting produced therefrom.

Abstract: A method of making a single crystal or columnar grain superalloy casting comprises casting a superalloy in a mold wherein at least one of the mold and optional core comprises an oxygen-bearing ceramic, directionally solidifying the superalloy to form a single crystal or columnar grain superalloy casting, and solution heat treating the superalloy casting. The heat treatment is conducted under an atmosphere including a carbon-bearing gas, such as a carbon monoxide and inert gas mixture, wherein the carbon-bearing gas is present in an effective amount to reduce loss of carbon from the casting during the heat treatment. The heat treatment can be conducted prior to removal of all of the mold and core, if present, such as, for example, when the cast mold is in the as-knocked out condition wherein residual mold and/or core material is present on the casting. Alternately, the heat treatment can be conducted after removal of the mold and core, if present.

Abstract: Creep resistant gamma titanium alumninide comprising titanium in the range of about 55 to about 71 weight % and aluminum in the range of 29 to about 35 weight % by virtue of including oxygen intentionally in the composition in an effective amount to significantly increase the high temperature creep resistance of the alloy. The composition can include greater than about 800 ppm up to about 1500 ppm oxygen to this end.

Abstract: Method and apparatus for removing ceramic shell mold material from one or more castings in a relatively rapid manner wherein the casting and hot caustic solution spray nozzles are relatively moved to direct hot caustic solution under pressure at the castings to remove post-knock-out ceramic shell material thereon prior to further processing of the castings.

Abstract: A method of removing ceramic material, such as for example a ceramic core, from a metallic cast or other component involves contacting the metallic cast component and a caustic ceramic leaching medium at elevated temperature for a time effective to substantially remove the ceramic material from the component and providing an oxygen getter in the caustic ceramic leaching medium in an amount effective to avoid deleterious surface corrosion of the component while the ceramic material is being removed therefrom.

Abstract: A method of improving the oxidation resistance of a platinum modified aluminide coating formed on a nickel base superalloy substrate, comprises providing a platinum layer on the substrate, heating the substrate in a coating retort to a temperature of at least about 1000.degree. C., forming external of the coating retort a high purity coating gas comprising hydrogen and aluminum trichloride, and introducing the coating gas into the coating retort to contact the heated substrate to form an outwardly grown, single phase [(Ni,Pt)]Al] platinum modified aluminide coating having reduced concentration of at least one of a substrate substitutional alloying element and a surface active tramp element selected from at least one of B, P, and S in said coating as compared to a platinum modified aluminide coating formed at a lower temperature.