Abstract: A method for preparing an improved article including a nickel-based superalloy is presented. The method includes heat-treating a workpiece including a nickel-based superalloy at a temperature above the gamma-prime solvus temperature of the nickel-based superalloy and cooling the heat-treated workpiece with a cooling rate less than 50 degrees Fahrenheit/minute from the temperature above the gamma-prime solvus temperature of the nickel-based superalloy so as to obtain a cooled workpiece. The cooled workpiece includes a coprecipitate of a gamma-prime phase and a gamma-double-prime phase, wherein the gamma-prime phase of the coprecipitate has an average particle size less than 250 nanometers. An article having a minimum dimension greater than 6 inches is also presented. The article includes a material having a coprecipitate of a gamma-prime phase and a gamma-double-prime phase, wherein the gamma-prime phase of the coprecipitate has an average particle size less than 250 nanometers.

Abstract: An article includes a substrate comprising a precipitate-strengthened alloy and a coating disposed over the substrate. The alloy comprises a) a population of gamma-prime precipitates, the population having a multimodal size distribution with at least one mode corresponding to a size of less than about 100 nanometers; or b) a population of gamma-double-prime precipitates having a median size less than about 300 nanometers. The coating comprises at least two elements, and further comprises a plurality of prior particles. At least a portion of the coating is substantially free of rapid solidification artifacts. Methods for fabricating the article and for processing powder useful for fabricating the article are also provided.

Abstract: An article treatment method includes providing an article including a substrate composed of a substrate material having an undesirable substrate feature. The undesirable substrate feature may include a recess, and a portion of the substrate containing the undesirable substrate feature may be removed to form a recess in a surface of the substrate. A feedstock mixture including a filler material and a liquid carrier is introduced into an HVAF apparatus having a combustion gas stream with a temperature greater than the melting point of the filler material. The filler material is applied to the recess by expelling the filler material while maintained at a temperature less than the melting point of the filler material by the liquid carrier. The filler material and an area of the substrate bordering the recess are heat treated, forming a treated portion.

Abstract: Coatings for substrates, such as superalloy substrates, are provided. The coating can include: 15 wt % to 45 wt % cobalt; 20 wt % to 40 wt % chromium; 2 wt % to 15 wt % aluminum; 0.1 wt % to 1 wt % yttrium; and nickel. The coatings may include nickel, cobalt, chromium and aluminum, and other optional additives to improve oxidation and corrosion resistance of the substrate without significant debit to its mechanical properties.

Abstract: A method for estimating an operating temperature of component in turbo machinery includes providing body detachably affixed to component, operating machinery, stopping operation of machinery, and removing body. The method includes obtaining concentration profile by determining final concentration of at least one species in first material and in second material, and determining a transient concentration of at least one species between first material and second material. The method includes determining an operating temperature by correlating concentration profile to corresponding operating temperature for system. A system including body is also provided. Body includes at least one species, a first material having a starting first concentration of the species, a second material arranged to permit migration of the species from first material to second material. Species migrates from first material to second material during operation of turbo machinery allowing body to estimate temperature during operation.

Abstract: A method of sealing a ceramic component to a metal component for a metal halide battery is provided. The method involves the steps of coating a portion of the ceramic component with a metallic coating, and then bonding the coated ceramic component to the metal component. The metallic coating includes a reactive metal. A sealing structure formed by using such a method is also presented.

Abstract: A device includes a substrate (308) and a metallic layer (336) formed over the substrate (308) with a deposition process for which the metallic layer (336) is characterizable as having a pre-determinable as-deposited defect density. As a result of a fabrication process, the defect density of the metallic layer (336) is reduced relative to the pre-determinable as-deposited defect density of the same layer (336) or another layer having like composition and which is formed under like deposition conditions. In a related method, a substrate (308) is provided and a removable layer (330) is formed over the substrate (308). A metallic layer (336) is formed over the removable layer (330) and is patterned and etched to define a structure over the removable layer (330). The removable layer (330) is removed, and the metallic layer (336) is heated for a time beyond that necessary for bonding of a hermetic sealing cap (340) thereover.

Abstract: A method for estimating an operating temperature of component in turbo machinery includes providing body detachably affixed to component, operating machinery, stopping operation of machinery, and removing body. The method includes obtaining concentration profile by determining final concentration of at least one species in first material and in second material, and determining a transient concentration of at least one species between first material and second material. The method includes determining an operating temperature by correlating concentration profile to corresponding operating temperature for system. A system including body is also provided. Body includes at least one species, a first material having a starting first concentration of the species, a second material arranged to permit migration of the species from first material to second material. Species migrates from first material to second material during operation of turbo machinery allowing body to estimate temperature during operation.

Abstract: A method of sealing a ceramic component to a metal component for a metal halide battery is provided. The method involves the steps of coating a portion of the ceramic component with a metallic coating, and then bonding the coated ceramic component to the metal component. The metallic coating includes a reactive metal. A sealing structure formed by using such a method is also presented.

Abstract: A device includes a substrate (308) and a metallic layer (336) formed over the substrate (308) with a deposition process for which the metallic layer (336) is characterizable as having a pre-determinable as-deposited defect density. As a result of a fabrication process, the defect density of the metallic layer (336) is reduced relative to the pre-determinable as-deposited defect density of the same layer (336) or another layer having like composition and which is formed under like deposition conditions. In a related method, a substrate (308) is provided and a removable layer (330) is formed over the substrate (308). A metallic layer (336) is formed over the removable layer (330) and is patterned and etched to define a structure over the removable layer (330). The removable layer (330) is removed, and the metallic layer (336) is heated for a time beyond that necessary for bonding of a hermetic sealing cap (340) thereover.