Abstract: Processes for producing titanium aluminide SPF/DB components, particularly structural panels, are provided. In one embodiment, the process comprises providing rapidly solidified titanium aluminide alloy sheetstock, providing a plurality of rapidly solidified titanium aluminide alloy ribbons or strips, forming the ribbons into waveform structures, assembling a plurality of these waveform structures to produce a honeycomb core, positioning this core between face sheets, and bonding the core to the face sheets. In another embodiment, the process comprises providing rapidly solidified titanium aluminide alloy sheetstock, superplastically forming at least one piece of sheetstock into a shaped piece having spaced apart, parallel bonding regions, positioning this shaped piece between two face sheets, and bonding the shaped piece to each face sheet.

Abstract: A method for improving the microstructure of wrought titanium alloy material which comprises the steps of hydrogenating the material at a temperature near or above the titanium-hydrogen eutectoid of 815.degree. C. (about 780.degree. to 1020.degree. C.) to a hydrogen level of about 0.50 to 1.50 weight percent, cooling the thus-hydrogenated material to room temperature, heating the thus-cooled, hydrogenated material to a temperature of about 650.degree. to 750.degree. C., applying a vacuum to dehydrogenate the material and cooling the dehydrogenated material to room temperature at a controlled rate.

Abstract: System and method for producing metal or alloy powder are described which comprises a housing defining a cylindrical chamber having an inlet and an outlet and a plurality of passageways in the form of fluid nozzles defined through the housing wall along axes oriented at preselected angle to the chamber wall, the passageways being operatively connected to a pressurized source of fluid so that fluid is injected into the chamber as fluid jets of preselected flow rate and is swirled in controllable helical fashion generally toward the chamber outlet, and a molten source of metal or alloy operatively connected through a molten metal nozzle and atomization die to the inlet of the chamber for directing molten particles into contact with the fluid jets for solidification and cooling along downward helical paths within the chamber. A plurality of concentric annular bins may be disposed near the outlet of the chamber for collecting powder formed within the chamber.

Abstract: A method to produce titanium alloy articles having high creep resistance which comprises the steps of:(a) providing a titanium alloy material containing at least one dispersoid forming alloy addition:(b) hydrogenating the alloy material to a level of about 0.1 to 4.0 weight percent hydrogen;(c) introducing the resulting hydrogenated material into a mold;(d) hot compacting the alloy material in the mold to produce a substantially fully dense article;(e) beta heat treating the compacted article; and,(f) dehydrogenating the article.Following heat treatment, the microstructure in the article will be lenticular transformed beta which is highly creep resistant, while size of the dispersoid will be approximately the same as before the heat treatment, due to the relatively low beta treatment temperature.

Abstract: A method for producing an integral titanium alloy article having at least two regions, each region having a distinct microstructure is provided. The method comprises heat treating one or more selected region(s) of the article at a temperature greater than the beta-transus temperature of the region(s), while simultaneously heat treating the remaining region(s) of the article at a temperature below the beta-transus temperature of the remaining region(s).

Abstract: A method for improving the microstructure of prealloyed titanium alloy compacted articles which comprises the steps of hydrogenating the article at a temperature of about 780.degree. to 1020.degree. C. to a hydrogen level of about 0.50 to 1.50 weight percent, cooling the thus-hydrogenated article to room temperature at a controlled rate, heating the thus-cooled, hydrogenated article to a temperature of about 650.degree. to 750.degree. C. and applying a vacuum to dehydrogenate the article.

Abstract: A method for producing an integral titanium alloy article having at least o regions, each region having a distinct microstructure, which comprises the steps of(a) providing a suitable mold for the article;(b) introducing a first titanium alloy into a first portion of the mold;(c) introducing a second titanium alloy in powder form into a second portion of the mold; and(d) hot compacting the first and second alloys in the mold to produce a substantially fully dense article.The second alloy may be the hydrided version of the first alloy, or may have a different overall composition from the first alloy, or may be hydrided and have a different overall composition from the first alloy.

Abstract: A method for improving the microstructure of consolidated titanium alloy metal matrix composites which comprises the steps of(a) heating the composite to a temperature in the range of 800.degree. to 2000.degree. F., the temperature being below the temperature at which interfacial reactions occur between the metal matrix and the fiber, and diffusing hydrogen into the composite to achieve a hydrogen level of about 0.50 to 1.50 weight percent;(b) altering the temperature of the composite to a transformation temperature at or near the temperature of transformation of (HCP) alpha in the hydrogenated composite to (BCC) beta;(c) cooling the composite to room temperature;(d) heating the thus-cooled composite to a temperature below the transformation temperature, and diffusing hydrogen out from the composite; and(e) cooling the composite to room temperature.

Abstract: A method for improving the microstructure of cast titanium alloy articles which comprises the steps of hydrogenating the cast article at a temperature near or above the titanium-hydrogen eutectoid of 815.degree. C. (of about 780.degree. to 1020.degree. C.) to a hydrogen level of about 0.50 to 1.50 weight percent, cooling the thus-hydrogenated article to room temperature at a controlled rate, heating the thus-cooled, hydrogenated article to a temperature of about 650.degree. to 750.degree. C., applying a vacuum to dehydrogenate the article, and cooling the thus-dehydrogenated article at a controlled rate.

Abstract: A method for fabricating an improved titanium alloy composite consisting of at least one high strength/high stiffness filament or fiber embedded in an alpha-beta titanium alloy matrix which comprises the steps of providing a rapidly-solidified foil made of a rich metastable beta titanium alloy, fabricating a preform consisting of alternating layers of the rapidly-solidified foil and the filamentary material, and applying heat and pressure to consolidate the preform, wherein consolidation is carried out at a temperature below the beta-transus temperature of the alloy.

Abstract: A method for producing an integral titanium alloy article having at least two regions, each region having a distinct microstructure is provided. The method comprises heat treating one or more selected region(s) of the article at a temperature greater than the beta-transus temperature of the region(s), while simultaneously heat treating the remaining region(s) of the article at a temperature below the beta-transus temperature of the remaining region(s).

Abstract: A method for improving the microstructure of blended elemental titanium alloy compacted articles which comprises the steps of hydrogenating the article at a temperature of about 780.degree. to 1020.degree. C. to a hydrogen level of about 0.50 to 1.50 weight percent, cooling the thus-hydrogenated article to room temperature at a controlled rate, heating the thus-cooled, hydrogenated article to a temperature of about 650.degree. to 750.degree. C. and applying a vacuum to dehydrogenate the article, and cooling the thus-dehydrogenated article to room temperature at a controlled rate.

Abstract: A method for fabricating an improved titanium alloy composite consisting of at least one high strength/high stiffness filament or fiber embedded in an alpha-beta titanium alloy matrix which comprises the steps of providing a rapidly-solidified foil made of a lean metastable beta titanium alloy, fabricating a preform consisting of alternating layers of the rapidly-solidified foil and the filamentary material, and applying heat and pressure to consolidate the preform, wherein consolidation is carried out at a temperature below the beta-transus temperature of the alloy.

Abstract: System and method for producing metal or alloy powder are described which mprises a housing defining a cylindrical chamber having an inlet and an outlet and a plurality of passageways in the form of fluid nozzles defined through the housing wall along axes oriented at preselected angle to the chamber wall, the passageways being operatively connected to a pressurized source of fluid so that fluid is injected into the chamber as fluid jets of preselected flow rate and is swirled in controllable helical fashion generally toward the chamber outlet, and a molten source of metal or alloy operatively connected through a molten metal nozzle and atomization die to the inlet of the chamber for directing molten particles into contact with the fluid jets for solidification and cooling along downward helical paths within the chamber. A plurality of concentric annular bins may be disposed near the outlet of the chamber for collecting powder formed within the chamber.

Abstract: System and method for producing metal or alloy powder are described comprising an electromagnetic levitating coil having an outlet for supporting a molten source of the metal or alloy and controllably discharging a molten stream thereof, an electromagnetic confining coil disposed at the outlet of the levitating coil and surrounding the molten stream for controlling the diameter of the molten stream, and either an atomization die and associated pressurized fluid source for disintergrating the confined molten stream into molten droplets for subsequent cooling to powder, or a controllable electromagnetic coil surrounding the confined molten stream for generating a downwardly and radially outwardly directed electromagnetic force interacting with the molten stream to form the droplets.

Abstract: A method for fabricating an improved titanium alloy composite consisting of at least one high strength/high stiffness filament or fiber embedded in a titanium-aluminum base alloy matrix which comprises the steps of providing a rapidly-solidified foil made of the titanium-aluminum base alloy, fabricating a preform consisting of alternating layers of the rapidly-solidified foil and the filamentary material, and applying heat and pressure to consolidate the preform, wherein consolidation is carried out at a temperature below the beta-transus temperature of the alloy.

Abstract: A method for fabricating an improved titanium alloy composite consisting of at least one high strength/high stiffness filament or fiber embedded in an alpha-beta titanium alloy matrix which comprises the steps of providing a rapidly-solidified foil made of an alpha-beta titanium alloy, fabricating a preform consisting of alternating layers of the rapidly-solidified foil and the filamentary material, and applying heat and pressure to consolidate the preform, wherein consolidation is carried out at a temperature below the beta-transus temperature of the alloy.

Abstract: A process for producing titanium alloy articles by Hot Isostatic Pressing of a rapidly-solidified titanium alloy powder is provided wherein such pressing is carried out at a pressure greater than 30 ksi, and a temperature of about 60 to 80 percent of the beta-transus temperature of the alloy, in degrees C. Hot Isostatic Pressing under these conditions allows retention of the fine microstructure of the rapidly-solidified powder. The compacted article may be subjected to heat treatment to alter its microstructure.

Abstract: The microstructure of forged titanium alloy components is improved by beta-transus heat treating the components, hydrogenating the components at an elevated temperature, cooling the thus-hydrogenated components to room temperature, dehydrogenating the components at an elevated temperature and cooling the dehydrogenated components to room temperature.

Abstract: The microstructure of titanium alloy powder compacts is refined and improved by a method which comprises beta solution heat treating the compact, hydrogenating and then dehydrogenating the compact.