Abstract: A method of processing a bimetallic part includes depositing an intermediary material having a metal powder onto a tooling surface of a cavity of a tool, transforming the intermediary material into a metal layer having a first composition on the tooling surface, and forming a metal core having a second, different composition in the cavity such that the metal layer bonds to the metal core to form a bimetallic part.

Abstract: A method of processing a superalloy powder includes mechanically alloying nitrogen with superalloy powder particles having at least one nitride-forming element such that each superalloy powder particle includes a microstructure having nitrogen dispersed throughout the microstructure. The powder may then be formed into an article having nitride regions dispersed throughout.

Abstract: A method of treating a porous work piece includes infiltrating a liquid metallic alloy into surface porosity of a work piece and isothermally solidifying the liquid metallic alloy to at least partially fill the surface porosity.

Abstract: There is provided cryogenic milled nanophase copper alloys and methods of making the alloys. The alloys are fine grained having grains in the size range from about 2 to about 100 nanometers, and greater. The nanophase alloys possess desirable physical properties stemming from the fine grain size, such as potentially high strength. Some embodiments of the cryogenic milled copper alloys may also be tailored for ductility, toughness, fracture resistance, corrosion resistance, fatigue resistance and other physical properties by balancing the alloy composition. In addition, embodiments of the alloys generally do not require extensive or expensive post-cryogenic milling processing.

Abstract: There is provided cryogenic milled copper alloys and methods of making the alloys. The alloys are fine grained and possess desirable physical properties stemming from the fine grain size. Embodiments include desirable physical properties, such as potentially high strength. Some embodiments of the cryogenic milled copper alloys may also be tailored for ductility, toughness, fracture resistance, corrosion resistance, fatigue resistance and other physical properties by balancing the alloy composition. In addition, embodiments of the alloys generally do not require extensive or expensive post-cryogenic milling processing.

Abstract: Disclosed is a method of manufacturing an airfoil. The method includes establishing an Argon (Ar)-free environment, providing a bed within the Argon free environment, providing a set of data instructions for manufacturing the airfoil, and providing a powdered Nickel (Ni)-based alloy on the bed. In one example, the powdered Nickel (Ni)-based alloy consists essentially of about 4.8 wt. % Iron (Fe), about 21 wt. % Chromium (Cr), about 8.6 wt. % Molybdenum (Mo), about 0.07 wt. % Titanium (Ti), about 0.40% Aluminum (Al), about 5.01 wt. % Niobium (Nb), about 0.03 wt. % Carbon (C), about 0.14 wt. % Silicon (Si), and a balance Nickel (Ni). The method further includes fusing the powdered Nickel (Ni)-based alloy with an electron beam with reference to the data instructions to form the airfoil.

Abstract: A method of processing a brazed article includes forming a braze joint with an aluminum component comprising a nano-grained aluminum alloy.

Abstract: A method of treating a porous work piece includes infiltrating a liquid metallic alloy into surface porosity of a work piece and isothermally solidifying the liquid metallic alloy to at least partially fill the surface porosity.

Abstract: A method of fabricating a rolling bladder propellant tank assembly includes providing a pair of half-domes comprising a nanophase metallic material and a bladder formed of a ductile metallic material. A bladder support ring extends from at least one of the pair of half-domes. The pair of half-domes are positioned together to form a cavity therein with a portion of the bladder trapped between the pair of half-domes adjacent to the bladder support ring, wherein the bladder is positioned within the cavity. A seal is formed between the pair of half-domes and the bladder by friction stir welding. A friction stir welding pin used to form the seal is aligned with the bladder support ring during the friction stir welding operation.

Abstract: An aluminum or aluminum-alloy material sheet comprised of an aluminum material having an ultra-fine, submicron grain structure. The strength and physical properties of the aluminum or aluminum-alloy material sheet are improved over previous aluminum and aluminum-alloy material sheets because the aluminum is produced by cryomilling the aluminum or aluminum-alloy materials into a metal powder with ultra-fine, submicron grain structure. The powder is consolidated and rolled into the form of a sheet.

Abstract: A method of processing a bimetallic part includes depositing an intermediary material having a metal powder onto a tooling surface of a cavity of a tool, transforming the intermediary material into a metal layer having a first composition on the tooling surface, and forming a metal core having a second, different composition in the cavity such that the metal layer bonds to the metal core to form a bimetallic part.

Abstract: There is provided cryogenic milled nanophase copper alloys and methods of making the alloys. The alloys are fine grained having grains in the size range from about 2 to about 100 nanometers, and greater. The nanophase alloys possess desirable physical properties stemming from the fine grain size, such as potentially high strength. Some embodiments of the cryogenic milled copper alloys may also be tailored for ductility, toughness, fracture resistance, corrosion resistance, fatigue resistance and other physical properties by balancing the alloy composition. In addition, embodiments of the alloys generally do not require extensive or expensive post-cryogenic milling processing.

Abstract: A method of producing high strength nanophase metal alloy powder by cryomilling metal powder under conditions which cause the formation of intrinsic nitrides, and of producing high strength metal articles by subjecting the nitrided cryomilled powder to thermo-mechanical processing. The intrinsic nitrides present within the alloy significantly reduce grain growth during thermo-mechanical processing, resulting in formed metal products of high strength and improved ductility.

Abstract: A method of processing a superalloy powder includes mechanically alloying nitrogen with superalloy powder particles having at least one nitride-forming element such that each superalloy powder particle includes a microstructure having nitrogen dispersed throughout the microstructure. The powder may then be formed into an article having nitride regions dispersed throughout.

Abstract: A rhenium alloy is provided having from about 50 atomic % to 99 atomic % rhenium and a refractory compound particulates that are present in the alloy in an amount up to about 10 atomic %. The refractory compound comprises a nano-scale dispersion that is incorporated into the conventional rhenium structure. The nano-scale dispersion acts as grain boundary pins that result in a relatively fine grained, equiaxed structure that improves the mechanical properties of the alloy and helps to minimize the growth of large grains during operations at high temperatures. As a result, the amount of the rhenium used in high temperature applications may be reduced without sacrificing its high temperature and mechanical properties. Cryomilling in the presence of nitrogen may be used to prepare the rhenium alloy having a stable fine grain structure at high temperatures.

Abstract: A method of fabricating a rolling bladder propellant tank assembly includes providing a pair of half-domes comprising a nanophase metallic material and a bladder formed of a ductile metallic material. A bladder support ring extends from at least one of the pair of half-domes. The pair of half-domes are positioned together to form a cavity therein with a portion of the bladder trapped between the pair of half-domes adjacent to the bladder support ring, wherein the bladder is positioned within the cavity. A seal is formed between the pair of half-domes and the bladder by friction stir welding. A friction stir welding pin used to form the seal is aligned with the bladder support ring during the friction stir welding operation.

Abstract: A method of processing a brazed article includes forming a braze joint with an aluminum component comprising a nano-grained aluminum alloy.

Abstract: Methods and powder blends are provided for fabricating a metal part. One method includes the first steps of spreading a layer of a powder blend on a platform, the powder blend including a titanium base metal or alloy, and an alloying metal having a lower melting temperature than that of the base metal or alloy. Next, an energy beam is directed onto selected areas of the powder blend layer to thereby melt the alloying metal. Then, the alloying metal is re-solidified by withdrawing the energy beam from the powder blend layer. Then, a preform part is built up by iteratively performing the spreading, melting, and re-solidifying steps on additional adjacently formed layers. A metal liquid phase sintering process is performed at a temperature sufficient to melt the alloying metal but not the base metal or alloy.

Abstract: High strength aluminum alloy rivets are provided in which the aluminum alloys exhibit high strength at atmospheric temperatures and maintain high strength and ductility at extremely low temperatures. The rivets are produced from an alloy which is made by blending about 89 atomic % to 99 atomic % aluminum, 1 atomic % to 11 atomic % of a secondary metal selected from the group consisting of magnesium, lithium, silicon, titanium, zirconium, and combinations thereof, and up to about 10 atomic % of a tertiary metal selected from the group consisting of Be, Ca, Sr, Ba, Ra, Sc, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, W, and combinations thereof. The alloy is produced by nanostructure material synthesis, such as cryomilling, in the absence of extrinsically added refractory dispersoids. The synthesized alloy is then consolidated and formed into a solid or blind rivet. Grain size within the rivet is less than 0.

Abstract: A method of producing high strength nanophase metal alloy powder by cryomilling metal powder under conditions which cause the formation of intrinsic nitrides, and of producing high strength metal articles by subjecting the nitrided cryomilled powder to thermo-mechanical processing. The intrinsic nitrides present within the alloy significantly reduce grain growth during thermo-mechanical processing, resulting in formed metal products of high strength and improved ductility.