Abstract: Methods for depositing wear resistant NiW plating systems on metallic components are provided. In various embodiments, the method includes the step or process of preparing a NiW plating bath containing a particle suspension. The NiW plating bath is prepared by introducing wear resistant particles into the NiW plating path and adding at least one charged surfactant. The first type of wear resistant particles and the first charged surfactant may be contacted when introduced into the NiW plating bath or prior to introduction into the NiW plating bath. The at least one charged surfactant binds with the wear resistant particles to form a particle-surfactant complex. The wear resistant NiW plating system is then electrodeposited onto a surface of a component at least partially submerged in the NiW plating bath. The resulting wear resistant NiW plating system comprised of a NiW matrix in which the wear resistant particles are embedded.

Abstract: Embodiments of a method for producing powder mixtures having uniform dispersion of ceramic particles within larger superalloy particles are provided, as are embodiments of superalloy powder mixtures. In one embodiment, the method includes producing an initial powder mixture comprising ceramic particles mixed with superalloy mother particles having an average diameter larger than the average diameter of the ceramic particles. The initial powder mixture is formed into a consumable solid body. At least a portion of the consumable solid body is gradually melted, while the consumable solid body is rotated at a rate of speed sufficient to cast-off a uniformly dispersed powder mixture in which the ceramic particles are embedded within the superalloy mother particles.

Abstract: Methods for depositing wear resistant NiW plating systems on metallic components are provided. In various embodiments, the method includes the step or process of preparing a NiW plating bath containing a particle suspension. The NiW plating bath is prepared by introducing wear resistant particles into the NiW plating path and adding at least one charged surfactant. The first type of wear resistant particles and the first charged surfactant may be contacted when introduced into the NiW plating bath or prior to introduction into the NiW plating bath. The at least one charged surfactant binds with the wear resistant particles to form a particle-surfactant complex. The wear resistant NiW plating system is then electrodeposited onto a surface of a component at least partially submerged in the NiW plating bath. The resulting wear resistant NiW plating system comprised of a NiW matrix in which the wear resistant particles are embedded.

Abstract: Embodiments of a method for producing powder mixtures having uniform dispersion of ceramic particles within larger superalloy particles are provided, as are embodiments of superalloy powder mixtures. In one embodiment, the method includes producing an initial powder mixture comprising ceramic particles mixed with superalloy mother particles having an average diameter larger than the average diameter of the ceramic particles. The initial powder mixture is formed into a consumable solid body. At least a portion of the consumable solid body is gradually melted, while the consumable solid body is rotated at a rate of speed sufficient to cast-off a uniformly dispersed powder mixture in which the ceramic particles are embedded within the superalloy mother particles.

Abstract: High temperature rolling element bearings and methods for manufacturing high temperature bearing components, such as bearing races or rings, are provided. In one embodiment, the method includes obtaining a powder mixture containing a superalloy powder admixed with hard wear particles, such as carbide particles. The powder mixture is consolidated utilizing a spark plasma sintering process during which the powder mixture is compressed into a sintered blank, while an electrical current is conducted through the powder mixture to heat the powder mixture to a sintering temperature. The sintered blank is then machined to impart the bearing component with its final shape. Precipitate hardening may also be performed, if desired. The spark plasma sintering process is controlled to limit the temperature and duration of the powder consolidation process thereby imparting the resulting bearing component with an enhanced hot hardness and other desirable properties at highly elevated operating temperatures.

Abstract: High temperature rolling element bearings and methods for manufacturing high temperature bearing components, such as bearing races or rings, are provided. In one embodiment, the method includes obtaining a powder mixture containing a superalloy powder admixed with hard wear particles, such as carbide particles. The powder mixture is consolidated utilizing a spark plasma sintering process during which the powder mixture is compressed into a sintered blank, while an electrical current is conducted through the powder mixture to heat the powder mixture to a sintering temperature. The sintered blank is then machined to impart the bearing component with its final shape. Precipitate hardening may also be performed, if desired. The spark plasma sintering process is controlled to limit the temperature and duration of the powder consolidation process thereby imparting the resulting bearing component with an enhanced hot hardness and other desirable properties at highly elevated operating temperatures.

Abstract: Embodiments of a method for producing powder mixtures having uniform dispersion of ceramic particles within larger superalloy particles are provided, as are embodiments of superalloy powder mixtures. In one embodiment, the method includes producing an initial powder mixture comprising ceramic particles mixed with superalloy mother particles having an average diameter larger than the average diameter of the ceramic particles. The initial powder mixture is formed into a consumable solid body. At least a portion of the consumable solid body is gradually melted, while the consumable solid body is rotated at a rate of speed sufficient to cast-off a uniformly dispersed powder mixture in which the ceramic particles are embedded within the superalloy mother particles.

Abstract: A method for manufacturing a valve assembly includes the steps of: providing one or more nickel-based superalloy components of the valve assembly, wherein the one or more components are designed to be subjected to operating environments including temperatures of about 760° C., +/?about 30° C.; aluminizing the one or more components using an aluminizing process, wherein the aluminizing process causes inter-diffusion between the nickel-based superalloy and aluminum as well as forms an aluminum-rich surface layer on the one or more components, thereby forming one or more aluminized components; and subjecting the one or more aluminized components to a plasma electrolytic oxidation process to convert the aluminum rich surface layer into a hard, wear-resistant, and oxidation-resistant aluminum oxide coating layer, wherein the hardness, wear-resistance, and oxidation-resistance of the aluminum oxide coating layer is maintained in the operating environments including temperatures of about 760° C., +/?about 30° C.

Abstract: Embodiments of a method for producing powder mixtures having uniform dispersion of ceramic particles within larger superalloy particles are provided, as are embodiments of superalloy powder mixtures. In one embodiment, the method includes producing an initial powder mixture comprising ceramic particles mixed with superalloy mother particles having an average diameter larger than the average diameter of the ceramic particles. The initial powder mixture is formed into a consumable solid body. At least a portion of the consumable solid body is gradually melted, while the consumable solid body is rotated at a rate of speed sufficient to cast-off a uniformly dispersed powder mixture in which the ceramic particles are embedded within the superalloy mother particles.

Abstract: Embodiments of a method for producing powder mixtures having uniform dispersion of ceramic particles within larger superalloy particles are provided, as are embodiments of superalloy powder mixtures. In one embodiment, the method includes producing an initial powder mixture comprising ceramic particles mixed with superalloy mother particles having an average diameter larger than the average diameter of the ceramic particles. The initial powder mixture is formed into a consumable solid body. At least a portion of the consumable solid body is gradually melted, while the consumable solid body is rotated at a rate of speed sufficient to cast-off a uniformly dispersed powder mixture in which the ceramic particles are embedded within the superalloy mother particles.

Abstract: Embodiments of a lightweight, high temperature airborne valve are provided. In one embodiment, the airborne vale includes a valve element and a flowbody. The flowbody is formed at least partially from a titanium aluminide alloy and has a flow passage therethrough in which the valve element is movably mounted. Embodiments of a method for producing such a lightweight, high temperature airborne valve are also provided. In one embodiment, the method includes the steps of forming a lightweight flowbody at least partially from a titanium aluminide alloy, hot isostatically pressing the lightweight flowbody, and machining the lightweight flowbody to desired dimensions.

Abstract: Methods and apparatus are provided for retaining a hinge shaft of a check valve with a bushing. The check valve includes a valve body defining a flow passage therethrough; a hinge shaft; a bushing coupled to the valve body and welded to the hinge shaft; and a closure element pivotally mounted on the hinge shaft for opening and closing the flow passage.

Abstract: Embodiments of a lightweight, high temperature airborne valve are provided. In one embodiment, the airborne vale includes a valve element and a flowbody. The flowbody is formed at least partially from a titanium aluminide alloy and has a flow passage therethrough in which the valve element is movably mounted. Embodiments of a method for producing such a lightweight, high temperature airborne valve are also provided. In one embodiment, the method includes the steps of forming a lightweight flowbody at least partially from a titanium aluminide alloy, hot isostatically pressing the lightweight flowbody, and machining the lightweight flowbody to desired dimensions.

Abstract: A method of forming a wear-resistant coating on a surface of a substrate includes the step of depositing a material comprising a rhenium-based composition onto the substrate surface using a handheld laser deposition device. A soluble interlayer may be formed on the surface of the substrate prior to the laser deposition step, and a heat treatment may be performed after the laser deposition step.

Abstract: Methods of manufacturing a noise attenuator are provided. In an embodiment, by way of example only, the method includes shaping a plate to have a three-dimensional contour, and forming a plurality of openings through the shaped plate with an abrasive fluid jet to thereby form the bleed valve noise attenuator. In another embodiment, a bleed valve assembly is provided. By way of example only, the assembly includes a plate having a three-dimensional contour including a rim section surrounding a dome section and a plurality of openings formed in at least one of the rim section and the dome section, the plate comprising a material having no recast material thereon.

Abstract: Methods and apparatus are provided for retaining a hinge shaft of a check valve with a bushing. The check valve includes a valve body defining a flow passage therethrough; a hinge shaft; a bushing coupled to the valve body and welded to the hinge shaft; and a closure element pivotally mounted on the hinge shaft for opening and closing the flow passage.

Abstract: A method is provided for manufacturing a magnetic steel component. An electroless nickel plating is formed on a substrate that includes magnetic steel. A thermal cycle is thereafter performed at a temperature that is sufficiently high to sinter the electroless nickel plating and thereby form a densified plating on the substrate. According to one embodiment, the thermal cycle includes a solid state diffusion sintering process wherein the substrate and the densified plating are heated to a temperature of at least about 1300° F. (about 704° C.) but.below the melting temperature of the electroless nickel plating. According to another embodiment, the thermal cycle includes a transient liquid phase sintering process wherein the substrate and the densified plating are heated at least to the melting temperature of the electroless plating.

Abstract: There is provided a method for repair of a regulator valve. The present invention provides a method for repairing a regulator valve. The method provides a machining of a housing so as to incorporate an oversize poppet. A poppet is provided that matches the resized housing. Further the poppet is shaped so as to provide an increased efficiency in the regulation of the air flow through the valve. Additionally the poppet is selected of a material that provides an increased wear life over the original material.