Abstract: A method for preparing an article of a base metal alloyed with an alloying element includes the steps of preparing a compound mixture by the steps of providing a chemically reducible nonmetallic base-metal precursor compound of a base metal, providing a chemically reducible nonmetallic alloying-element precursor compound of an alloying element, and thereafter mixing the base-metal precursor compound and the alloying-element precursor compound to form a compound mixture. The compound mixture is thereafter reduced to a metallic alloy, without melting the metallic alloy. The step of preparing or the step of chemically reducing includes the step of adding an other additive constituent. The metallic alloy is thereafter consolidated to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.

Abstract: A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds contains more of a base-metal element, such as nickel, cobalt, iron, iron-nickel, and iron-nickel-cobalt than any other metallic element. The mixture of nonmetallic precursor compounds is chemically reduced to produce a metallic superalloy material, without melting the metallic superalloy material. The metallic superalloy material is consolidated to produce a consolidated metallic article, without melting the metallic superalloy material and without melting the consolidated metallic article.

Abstract: A metallic alloy made of metallic constituent elements is fabricated and utilized by first furnishing a mixture of nonmetallic precursor compounds of the metallic constituent elements, and thereafter chemically reducing the mixture of nonmetallic precursor compounds to produce a metallic alloy as a metallic alloy powder, without melting the metallic alloy. The metallic alloy powder is applied to a surface of a substrate article, preferably in a coating, joining, or deposition application.

Abstract: An article has a metallic matrix made of its constituent elements with a dispersoid distributed therein. The article is prepared by furnishing at least one nonmetallic matrix precursor compound. All of the nonmetallic matrix precursor compounds collectively include the constituent elements of the metallic matrix in their respective constituent-element proportions. A mixture of an initial metallic material and the dispersoid is produced. The matrix precursor compounds are chemically reduced to produce the initial metallic material, without melting the initial metallic material, and the dispersoid is distributed in the initial metallic material. The mixture of the initial metallic material and the dispersoid is consolidated to produce a consolidated article having the dispersoid distributed in the metallic matrix comprising the initial metallic material. The initial metallic material, the dispersoid, and the consolidated article are not melted during the consolidation.

Abstract: A metallic article is prepared by first furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively containing the constituent elements of the metallic article in their respective constituent-element proportions. The constituent elements together form a titanium-base alloy having a stable-oxide-forming additive element therein, such as magnesium, calcium, scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium, and mixtures thereof. The stable-oxide-forming additive element forms a stable oxide in a titanium-based alloy. At least one additive element is present at a level greater than its room-temperature solid solubility limit in the titanium-base alloy. The precursor compounds are chemically reduced to produce an alloy material, without melting the alloy material. The alloy material may be consolidated.

Abstract: An article made of a metallic material having its constituent elements is made by furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively include the constituent elements of the metallic material in their respective constituent-element proportions. The precursor compounds are chemically reduced to produce particles comprising the metallic material, without melting the precursor compounds and without melting the metallic material. The particles may be consolidated into a rod, which may be used as a welding rod in a welding operation. Alternatively, the nonmetallic precursor compounds may be consolidated prior to the chemical reduction.

Abstract: A method of preparing an article made of a metallic material having its constituent elements includes the steps of furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively include the constituent elements of the metallic material in their respective constituent-element proportions, and thereafter utilizing the nonmetallic precursor compound to produce a metallic injection molded brown article. The nonmetallic precursor compounds may be processed into the metallic material by first chemically reducing them to the metallic material, and then injection molding the metallic material, or first injection molding the nonmetallic precursor compounds and then chemically reducing them to the metallic material.

Abstract: A metallic alloy is prepared from a gaseous mixture of at least two non-oxide precursor compounds, wherein the non-oxide precursor compounds collectively comprise the metallic constituents. The mixture of the non-oxide precursor compounds is oxidized to form a solid mixed metallic oxide. The solid mixed metallic oxide is chemically reduced to produce the metallic alloy.

Abstract: A metallic alloy having at least two metallic constituents is produced by first furnishing at least two non-oxide compounds, wherein the non-oxide compounds collectively comprise each of the metallic constituents, and wherein each of the non-oxide compounds is soluble in a mutual solvent. The method further includes dissolving the non-oxide compounds in the mutual solvent to produce a solution containing the metallic constituents, thereafter heating the solution to remove the mutual solvent and oxidize the metallic constituents to produce a mixed metallic oxide, thereafter cooling the mixed metallic oxide to form a substantially homogeneous mixed metallic oxide solid mass, and thereafter chemically reducing the mixed metallic oxide solid mass to produce a metallic alloy. The metallic alloy may be consolidated or otherwise processed.

Abstract: An article of a base metal alloyed with an alloying element is prepared by mixing a chemically reducible nonmetallic base-metal precursor compound of a base metal and a chemically reducible nonmetallic alloying-element precursor compound of an alloying element to form a compound mixture. The alloying element is preferably thermophysically melt incompatible with the base metal. The method further includes chemically reducing the compound mixture to a metallic alloy, without melting the metallic alloy, and thereafter consolidating the metallic alloy to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.

Abstract: A method for fabricating an article of a titanium-base alloy, such as an alpha-beta titanium gas turbine fan or compressor disk, uses a starting ingot having a thickness of at least about 20 inches, and which is made of a titanium-base alloy having a temperature-composition phase diagram with a beta-phase field and an alpha-beta phase field. The method includes first forging the starting ingot in the beta-phase field to form an in-process billet, thereafter second forging the in-process billet in the alpha-beta phase field, thereafter heating the in-process billet into the beta-phase field to recrystallize the in-process billet, and thereafter third forging the in-process billet. The step of third forging includes forging the in-process billet from a first forging thickness of not less than about 15 inches to a second forging thickness of not more than about 13 inches, at a third-forging temperature of from about 1550° F. to about 1725° F.

Abstract: A method for heat treating titanium-alloy articles in a vacuum furnace includes a step of first determining, for a first set of titanium articles in a first vacuum furnace and for a first set of heat treatment conditions, a minimum surface area of the first set of titanium articles associated with an acceptable alpha case formation for the first set of titanium articles. There is a second determining, for a second set of titanium articles in a second vacuum furnace and for a second set of heat treatment conditions, of a minimum surface area of a second set of titanium articles associated with an acceptable alpha case formation for the second set of titanium articles, responsive to the value of the minimum surface area of the first set of titanium articles.

Abstract: An alpha-beta titanium alloy workpiece, preferably furnished in the form of a cast ingot, is processed by mechanically working in the beta phase field and in the alpha-beta phase field, and thereafter quenching from the beta phase field. The workpiece is thereafter mechanically worked at a first alpha-beta phase field temperature in the alpha-beta phase field and quenched from the first alpha-beta phase field temperature. The workpiece is thereafter mechanically worked at a second alpha-beta phase field temperature in the alpha-beta phase field, wherein the second alpha-beta phase field temperature is lower than the first alpha-beta phase field temperature, and optionally quenched from the second alpha-beta phase field temperature. The resulting microstructure is a distribution of globularized coarse alpha-phase particles and globularized fine alpha-phase particles in fine transformed beta grains.

Abstract: A metallic article is produced by furnishing one or more nonmetallic precursor compound comprising the metallic constituent element(s), and chemically reducing the nonmetallic precursor compound(s) to produce an initial metallic particle, preferably having a size of no greater than about 0.070 inch, without melting the initial metallic particle. The initial metallic particle is thereafter melted and solidified to produce the metallic article. By this approach, the incidence of chemical defects in the metal article is minimized. The melted-and-solidified metal may be used in the as-cast form, or it may be converted to billet and further worked to the final form.

Abstract: An article of a base metal alloyed with an alloying element is prepared by mixing a chemically reducible nonmetallic base-metal precursor compound of a base metal and a chemically reducible nonmetallic alloying-element precursor compound of an alloying element to form a compound mixture. The alloying element is preferably thermophysically melt incompatible with the base metal. The method further includes chemically reducing the compound mixture to a metallic alloy, without melting the metallic alloy, and thereafter consolidating the metallic alloy to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.

Abstract: A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds is chemically reduced to produce an initial metallic material, without melting the initial metallic material. The initial metallic material is consolidated to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article.