Abstract: A process for filling openings, including blind holes, through-holes, and cavities, in high temperature components. The process entails forming a powder mixture by mixing particles of at least a base alloy and a second alloy that contains a sufficient amount of a melting point depressant to have a lower melting temperature than the base alloy. The powder mixture is combined with a binder and compacted to form a compacted preform, which is then heated to remove the binder and form a rigid sintered preform. The sintered preform is produced, or optionally is further shaped, to have a cross-sectional shape and dimensions to achieve a clearance of up to 200 micrometers with the opening, after which the preform is placed in the opening and diffusion bonded within the opening to form a brazement comprising the particles of the base alloy dispersed in a matrix formed by the second alloy.

Abstract: A process for filling openings, including blind holes, through-holes, and cavities, in high temperature components. The process entails forming a powder mixture by mixing particles of at least a base alloy and a second alloy that contains a sufficient amount of a melting point depressant to have a lower melting temperature than the base alloy. The powder mixture is combined with a binder and compacted to form a compacted preform, which is then heated to remove the binder and form a rigid sintered preform. The sintered preform is produced, or optionally is further shaped, to have a cross-sectional shape and dimensions to achieve a clearance of up to 200 micrometers with the opening, after which the preform is placed in the opening and diffusion bonded within the opening to form a brazement comprising the particles of the base alloy dispersed in a matrix formed by the second alloy.

Abstract: A nickel-based braze composition is described, containing nickel, palladium, and restricted amounts of boron and silicon. The composition can also contain tantalum, titanium, and zirconium, as well as aluminum, chromium, and cobalt. A method for joining two metal components, using the braze composition, is also described. The braze composition can also be used to fill cracks or other cavities in a component, e.g., a gas turbine part formed from a nickel-based superalloy. Articles of manufacture which contain the braze composition are also described.

Abstract: A nickel-based braze composition is described, containing nickel, palladium, and restricted amounts of boron and silicon. The composition can also contain tantalum, titanium, and zirconium, as well as aluminum, chromium, and cobalt. A method for joining two metal components, using the braze composition, is also described. The braze composition can also be used to fill cracks or other cavities in a component, e.g., a gas turbine part formed from a nickel-based superalloy. Articles of manufacture which contain the braze composition are also described.

Abstract: An alloy and a gas turbine engine component comprising an alloy are presented, with the alloy comprising: palladium, in an amount ranging from about 1 atomic percent to about 41 atomic percent; platinum, in an amount that is dependent upon the amount of palladium, such that a. for the amount of palladium ranging from about 1 atomic percent to about 14 atomic percent, the platinum is present up to about an amount defined by the formula (40+X) atomic percent, wherein X is the amount in atomic percent of the palladium, and b. for the amount of palladium ranging from about 15 atomic percent up to about 41 atomic percent, the platinum is present in an amount up to about 54 atomic percent; and the balance comprising rhodium, wherein the rhodium is present in an amount of at least 24 atomic percent; wherein the alloy comprises a microstructure that is essentially free of L12-structured phase at a temperature greater than about 1000° C.

Abstract: Methods for repairing and manufacturing a gas turbine blade, and the gas turbine blade repaired and manufactured with such methods are presented with, for example, the repair method comprising providing a gas turbine blade, the blade comprising a blade tip and a blade body; removing at least one portion of the blade tip; providing at least one freestanding tip insert; and disposing the at least one tip insert onto the gas turbine blade body such that the at least one tip insert replaces the at least one removed portion of the blade tip.

Abstract: A composition of matter is about 1 to about 3 percent rhenium, from about 6 to about 9 percent aluminum, from 0 to about 0.5 percent titanium, from about 4 to about 6 percent tantalum, from about 12.5 to about 15 percent chromium, from about 3 to about 10 percent cobalt, from about 2 to about 5 percent tungsten, from 0 to about 0.2 percent hafnium, from 0 to about 1 percent silicon, from 0 to about 0.25 percent molybdenum, from 0 to about 0.25 percent niobium, balance nickel and minor elements. The composition is preferably made into a substantially single crystal article, such as a component of a gas turbine engine.

Abstract: A composition of matter is about 1 to about 3 percent rhenium, from about 6 to about 9 percent aluminum, from 0 to about 0.5 percent titanium, from about 4 to about 6 percent tantalum, from about 12.5 to about 15 percent chromium, from about 3 to about 10 percent cobalt, from about 2 to about 5 percent tungsten, from 0 to about 0.2 percent hafnium, from 0 to about 1 percent silicon, from 0 to about 0.25 percent molybdenum, from 0 to about 0.25 percent niobium, balance nickel and minor elements. The composition is preferably made into a substantially single crystal article, such as a component of a gas turbine engine.

Abstract: An alloy and a gas turbine engine component comprising an alloy are presented, with the alloy comprising from about three atomic percent to about nine atomic percent of at least one precipitation-strengthening metal selected from the group consisting of zirconium, niobium, tantalum, titanium, hafnium, and mixtures thereof; from about one atomic percent to about five atomic percent ruthenium; and the balance rhodium; the alloy further comprising a face-centered-cubic phase and an L12—structured phase.

Abstract: A gas turbine airfoil and methods for manufacturing and repair of an airfoil, the airfoil comprising a wall, the wall defining the perimeter of the airfoil and comprising a leading edge section and a trailing edge section, wherein a majority of the surface area of the wall comprises a first material, the first material having an oxidation resistance and a melting temperature, and at least one portion of the wall comprises a second material, the second material having an oxidation resistance that is greater than the oxidation resistance of the first material and a melting temperature that is at least about 83 degrees Celsius (about 150 degrees Fahrenheit) greater than the melting temperature of the first material, the at least one portion of the wall located in at least one section of the wall selected from the group consisting of the leading edge section and the trailing edge section.

Abstract: An alloy comprising rhodium, aluminum, and chromium, wherein a microstructure of the alloy comprises a face-centered-cubic phase and a B2-structured phase and is essentially free of an L12-structured phase at temperatures greater than about 1000° C., and a gas turbine engine component comprising the alloy.

Abstract: A superalloy weld composition includes: up to about 5.1 wt % Co; about 7.2 to about 9.5 wt % Cr; about 7.4 to about 8.4 wt % Al; about 4.3 to about 5.6 wt % Ta; about 0.1 to about 0.5 wt % Si; about 0.1 to about 0.5 wt % Hf; up to about 0.05 wt % C; up to about 0.05 wt % B; about 0 to about 2.2 Re; about 2.7 to about 4.4 wt % W; and balance Ni and typical impurities.

Abstract: Methods for repairing and manufacturing a gas turbine blade, and the gas turbine blade repaired and manufactured with such methods are presented with, for example, the repair method comprising providing a gas turbine blade, the blade comprising a blade tip and a blade body; removing at least one portion of the blade tip; providing at least one freestanding tip insert; and disposing the at least one tip insert onto the gas turbine blade body such that the at least one tip insert replaces the at least one removed portion of the blade tip.

Abstract: An alloy comprising rhodium, aluminum, and chromium, wherein a microstructure of the alloy comprises a face-centered-cubic phase and a B2-structured phase and is essentially free of an L12-structured phase at temperatures greater than about 1000° C., and a gas turbine engine component comprising the alloy.

Abstract: An alloy and repair material comprising the alloy, articles comprising the alloy and repair material, and methods for repairing articles including provision of the alloy as repair material are described, with the alloy comprising ruthenium, nickel, aluminum, and chromium, wherein a microstructure of the alloy is essentially free of an L12-structured phase at temperatures greater than about 1000° C. and comprises an A3-structured phase and up to about 40 volume percent of a B2-structured phase.

Abstract: An alloy and a gas turbine engine component comprising an alloy are presented, with the alloy comprising from about three atomic percent to about nine atomic percent of at least one precipitation-strengthening metal selected from the group consisting of zirconium, niobium, tantalum, titanium, hafnium, and mixtures thereof; from about one atomic percent to about five atomic percent ruthenium; and the balance rhodium; the alloy further comprising a face-centered-cubic phase and an L12-structured phase.

Abstract: A gas turbine airfoil and methods for manufacturing and repair of an airfoil, the airfoil comprising a wall, the wall defining the perimeter of the airfoil and comprising a leading edge section and a trailing edge section, wherein a majority of the surface area of the wall comprises a first material, the first material having an oxidation resistance and a melting temperature, and at least one portion of the wall comprises a second material, the second material having an oxidation resistance that is greater than the oxidation resistance of the first material and a melting temperature that is at least about 83 degrees Celsius (about 150 degrees Fahrenheit) greater than the melting temperature of the first material, the at least one portion of the wall located in at least one section of the wall selected from the group consisting of the leading edge section and the trailing edge section.

Abstract: A superalloy weld composition, includes: about 2 to about 5 wt % Co; about 5 to about 15 wt % Cr; about 7 to about 10 wt % Al; about 4 to about 6 wt % Ta; about 0.5 to about 1.5 wt % Si; about 0.1 to about 0.5 wt % Hf; up to about 0.05 wt % C; up to about 0.05 wt % B; about 1.0 to about 2.0 Re; about 3 to about 4.5 wt % W; and balance Ni.

Abstract: A process for the manufacture of repair material. The repair material is ductile and readily mechanically deformed and can be used in the repair of turbine components. The process comprises providing a directionally solidified material, cold-swaging the directionally solidified material, and heat treating the cold-swaged material into the repair material. The repair material, after the steps of cold-swaging and heat treatment, comprises a microstructure that is essentially free from cracks, for repairing the turbine component. The invention also sets forth methods for repair of articles, such as turbine components, using the repair material, and a turbine component repaired using the repair material.

Abstract: A process for the manufacture of repair material. The repair material is ductile and readily mechanically deformed and can be used in the repair of turbine components. The process comprises providing a directionally solidified material, cold-swaging the directionally solidified material, and heat treating the cold-swaged material into the repair material. The repair material, after the steps of cold-swaging and heat treatment, comprises a microstructure that is essentially free from cracks, for repairing the turbine component. The invention also sets forth methods for repair of articles, such as turbine components, using the repair material, and a turbine component repaired using the repair material.