Abstract: In a method for manufacturing a turbine engine element such as a blade or vane, the element has an airfoil. The method includes: applying a load across an assembly of a first cast portion of the airfoil and a second cast portion of the airfoil; and applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion.

Abstract: A casting mold (260) comprises a shell (262) extending from a lower end (264) to an upper end (266) and having: an interior space (280) for casting metal; and an opening (268) for receiving metal to be cast. A plurality of thermocouples (900) are vertically-spaced from each other on the shell.

Abstract: A blade (60; 60-2) comprises an airfoil (61) and an attachment root (63). The blade has a tipward zone (80; 80-2; 80-2, 81) and a rootward zone (82; 82-2, 81; 82). The rootward zone has a single crystal structure. The tipward zone has a single crystal structure. The crystalline orientations of the rootward zone and tipward zone are at least 15° out of registry with each other.

Abstract: A casting method includes forming a seed. The seed has a first end and a second end and an inner diameter (ID) surface and an outer diameter (OD) surface. The seed second end is placed in contact or spaced facing relation with a chill plate. The first end is contacted with molten material. The molten material is cooled and solidified so that a crystalline structure of the seed propagates into the solidifying material. At least a portion of the seed contacted with the molten material has a solidus higher than a solidus of at least an initial pour portion of the molten material.

Abstract: A casting method includes: forming a seed, the seed having a first end and a second end, the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate; contacting the first end with molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness of the seed proximate the first end relative to a thickness of the seed proximate the second end.

Abstract: A casting method includes forming a seed. The seed has a first end and a second end. The forming includes bending a seed precursor. The seed second end is placed in contact or spaced facing relation a chill plate. The first end is contacted with molten material. The molten material is cooled and solidifies so that a crystalline structure of the seed propagates into the solidifying material.

Abstract: A method comprises: providing a spiral metallic workpiece having a cast structure associated with such spiral; and at least partially flattening the workpiece.

Abstract: The present disclosure relates to advanced materials, particularly single crystal grain structures including the formation of single crystal grain structures. Single crystal grain structures offer improved mechanical properties when used with individual components. Improving mechanical properties is favorable for components that are used in applications with high temperature, pressure, and stress. In these applications, mechanical failure is extremely undesirable. Individual components, such as seals, can be designed with a single crystal grain structure in a preferred direction. By selecting a preferred direction, and orienting the single crystal grain structure accordingly, the single crystal grain structure can improve the component's mechanical properties. Single crystal grain structure seals and the method of forming the seals, therefore, offer various improvements to individual components, specifically when the components are designed for high temperature, pressure, and stress applications.

Abstract: High modulus turbine shafts and high modulus cylindrical articles are described as are the process parameters for producing these shafts and cylindrical articles. The shafts/articles have a high Young's modulus as a result of having high modulus <111> crystal texture along the longitudinal axis of the shaft/article. The shafts are produced from directionally solidified seeded <111> single crystal cylinders that are axisymmetrically hot worked before a limited recrystallization process is carried out at a temperature below the recrystallization temperature of the alloy. The disclosed process produces an intense singular <111> texture and results in shaft or cylindrical article with a Young's modulus that is at least 40% greater than that of conventional nickel or iron alloys or conventional steels.

Abstract: An alloy has, by weight: nickel (Ni) as a largest constituent; 6.7% to 7.5% chromium; 1.8% to 2.3% molybdenum; 4.75% to 10.3% cobalt; 5.3% to 5.9% aluminum; 2.8% to 3.2% rhenium; 3.7% to 7.3% tungsten; and 6.0% to 9.0% tantalum.

Abstract: A process includes solution heat treating a nickel based superalloy with greater than about 40% by volume of gamma prime precipitate to dissolve the gamma prime precipitate in the nickel based superalloy; cooling the nickel based superalloy to about 85% of a solution temperature measured on an absolute scale to coarsen the gamma prime precipitate such that a precipitate structure is greater than about 0.7 micron size; and wrought processing the nickel based superalloy at a temperature below a recrystallization temperature of the nickel based superalloy. A material includes a nickel based superalloy with greater than about 40% by volume of gamma prime precipitate in which the precipitate structure is greater than about 0.7 micron size.

Abstract: Aspects are directed to a tribological and creep resistant system configured to operate at temperature in excess of 750° C., comprising: a piston seal that includes a nickel base alloy, where the nickel base alloy includes a Ni3(Al,X) type precipitated phase in an amount greater than 40% by volume. Aspects are directed to a system comprising: a piston seal that includes a cobalt-based alloy. Aspects are directed to a method comprising: heat treating an ingot of a nickel base alloy that includes coarsening a precipitated phase to facilitate forging or wrought forming the ingot, machining the ingot to include a substantially flat surface, and processing the ingot to generate a piston seal.

Abstract: An intermetallic matrix composite has an intermetallic matrix and a ceramic reinforcement. The intermetallic matrix comprises, in atomic percent: 28.0±2.0 Nb; 27.0±2.0 Mo; 27.0±2.0 Cr; 9.0 ±2.0 Si; 9.0 ±2.0 Al; and no more than 10.0 other alloying elements and impurities, if any.

Abstract: Shot sleeves for high temperature die casting include a low modulus single crystal nickel-based alloy having less than 1 ppm sulfur, a low modulus single crystal nickel-based alloy doped with a sulfur active element, a low modulus single crystal nickel-based alloy having a protective oxide coating, or a combination of two or more of the foregoing.

Abstract: A process for casting a single crystal axis-symmetric thick walled tube comprising forming a axisymmetric single crystal ring seed around a circular internal core, wherein the ring seed has an inner diameter and a taper on the inner diameter, and wherein the internal core has an outer diameter and a matching taper on the outer diameter, the matching taper matching the taper of the inner diameter of the ring seed, and the internal core being free to translate in a vertical direction relative to the ring seed; and heating the ring seed so as to expand the ring seed relative to the internal core, and allowing the circular internal core to translate relative to the ring seed in a direction of the force of gravity, thereby maintaining contact between the circular internal core and the ring seed.

Abstract: A method for manufacturing a blade, the method includes casting a nickel alloy blade precursor having an airfoil and a root. The airfoil and the root are solution heat treating differently from each other. After the solution heat treating, the root is wrought processed. After the wrought processing, an exterior of the root is machined.

Abstract: A gas turbine engine includes a rotor that has a rotor disk and a plurality of circumferentially-spaced blades. The rotor disk and the blades are co-rotatable about an axis. A case circumscribes the rotor. The rotor disk is tuned, with regard to centrifugal and thermal growth responsiveness, to the case for a given operational scenario of the gas turbine engine such that the rotor disk and case together provide a tuned clearance response. The operational scenario involves a series of engine events that include at least two of engine acceleration, engine deceleration, engine steady-state operation.

Abstract: A casting mold has a pour cone, a downsprue, and a part-forming cavity having a lower end and an upper end. The downsprue extends from the pour cone toward the part-forming cavity and has: a lower portion having a plurality of ports in communication with the part-forming cavity; and an upper portion telescoping relative to the lower portion and coupling the lower portion to the pour cone.

Abstract: A process includes solution heat treating a nickel based superalloy with greater than about 40% by volume of gamma prime precipitate to dissolve the gamma prime precipitate in the nickel based superalloy; cooling the nickel based superalloy to about 85% of a solution temperature measured on an absolute scale to coarsen the gamma prime precipitate such that a precipitate structure is greater than about 0.7 micron size; and wrought processing the nickel based superalloy at a temperature below a recrystallization temperature of the nickel based superalloy. A material includes a nickel based superalloy with greater than about 40% by volume of gamma prime precipitate in which the precipitate structure is greater than about 0.7 micron size.

Abstract: Aspects of the disclosure are directed to a seal configured to interface with at least a first component and a second component of a gas turbine engine. A method for forming the seal includes obtaining an ingot of a fine grained, or a coarse grained, or a columnar grained or a single crystal material from a precipitation hardened nickel base superalloy containing at least 40% by volume of the precipitate of the form Ni3(Al, X), where X is a metallic or refractory element, and processing the ingot to generate a sheet of the material, where the sheet has a thickness within a range of 0.010 inches and 0.050 inches inclusive.