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.

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 is prepared by furnishing a plurality of powder particle substrates made of a substrate metal, providing a nonmetallic precursor of a metallic coating material, wherein the metallic coating material comprises an alloying element that is thermophysically melt incompatible with the substrate metal, contacting the powder particle substrates with the nonmetallic precursor, chemically reducing the nonmetallic precursor to form coated powder particles comprising the powder particle substrates having a surface-enriched layer of the metallic coating material thereon without melting the powder particle substrates, and processing the coated powder particles to form the article, without melting the powder particle substrates.

Abstract: A metallic component is by at least one peripheral edge. The component includes at least one elongated treated zone having a length substantially greater than its width. This treated zone is spaced away from and disposed generally parallel to the peripheral edge of the component and the entire thickness of the component within the treated zone is in a state of residual compressive stress. Crack growth from the edge due to fatigue or damage is resisted.

Abstract: A metallic component, which may be an airfoil, includes at least one treated patch, wherein the entire thickness of the component within the treated patch is in a state of residual compressive stress. A surface-treated area overlaps at least a boundary between the treated patch and the remainder of the component. The surface of the component within the surface-treated area is in a state of residual compressive stress, so as to resist crack initiation at the boundary between the treated patch and the remainder of the component. A method is also provided for making such a component.

Abstract: An article includes a microscale composite material having a matrix with more titanium than any other element, and a dispersion of titanium boride particles in the matrix. At least about 50 volume percent of the titanium boride particles have a maximum dimension of less than about 2 micrometers.

Abstract: An article made of constituent elements is prepared by furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively contain the constituent elements. The constituent elements include a titanium-base metallic composition, boron present at a level greater than its room-temperature solid solubility limit, and, optionally, a stable-oxide-forming additive element present at a level greater than its room-temperature solid solubility limit. The precursor compounds are chemically reduced to produce a material comprising a titanium-base metallic composition having titanium boride particles therein, without melting the titanium-base metallic composition. The titanium-base metallic composition having the titanium boride particles therein is consolidated without melting.

Abstract: A method for preparing a metallic article made of metallic constituent elements includes furnishing a mixture of nonmetallic precursor compounds of the metallic constituent elements. The method further includes chemically reducing the mixture of nonmetallic precursor compounds to produce an initial metallic material, without melting the initial metallic material, and consolidating the initial metallic material to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article.

Abstract: A titanium-alloy article is produced by providing a workpiece of an alpha-beta titanium alloy having a beta-transus temperature, and thereafter mechanically working the workpiece at a mechanical-working temperature above the beta-transus temperature. The mechanically worked workpiece is solution heat treated at a solution-heat-treatment temperature of from about 175° F. below the beta-transus temperature to about 25° F. below the beta-transus temperature, quenched, overage heat treated at an overage-heat-treatment temperature of from about 400° F. below the beta-transus temperature to about 275° F. below the beta-transus temperature, and cooled from the overage-heat-treatment temperature.

Abstract: An elongated rod assembly is made by preparing a plurality of rods. Each rod is prepared by the steps of furnishing at least one nonmetallic precursor compound, thereafter chemically reducing the precursor compounds to produce the metallic material, and thereafter consolidating the metallic material to form the rod, wherein the rod has a rod length equal to the assembly length. The rods are bundled together to form a bundled rod assembly. The rod assembly may be used as a consumable feedstock in a melting-and-casting operation.

Abstract: A metallic article is produced by furnishing one or more nonmetallic precursor compound comprising the metallic base nickel, cobalt, iron, iron-nickel, or iron-nickel-cobalt, and at least one alloying element. The nonmetallic precursor compound(s) are chemically reduced to produce an initial metallic particle without melting the initial metallic particle. The initial metallic particle is thereafter melted and solidified to produce the metallic article. 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 iron base metal base metal alloyed with an alloying element is prepared by mixing a chemically reducible nonmetallic base-metal precursor compound of the iron 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 iron 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 martensitic-composition consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.

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 electroslag-cold hearth (ESCH) system for refining or producing a desired metal or metal alloy is described. The system includes at least one cold hearth vessel capable of holding a pool of molten liquid metal and an overlying slag layer, and an ingot mold laterally off-set from the cold hearth. A source of raw material, e.g., a feed electrode, is positioned above the cold hearth, and fed into the molten slag in a refining operation. A flow-over dam separates the ingot mold from the cold hearth, preventing the flow of inclusions and other foreign bodies into the ingot mold. In some instances, a non-consumable electrode provides additional thermal energy to the slag. In the production operation, the metal source can be a salt from which the desired metal can be electrochemically extracted. Related methods for refining or producing metals such as titanium alloys are also described.

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 base metal is nickel, cobalt, iron, iron-nickel, or iron-nickel-cobalt. One or more of the alloying elements are thermophysically melt incompatible with the base metal. The method further includes chemically reducing the compound mixture to a metallic superalloy, without melting the metallic superalloy, and thereafter consolidating the metallic superalloy to produce a consolidated metallic article, without melting the metallic superalloy and without melting the consolidated metallic article.