Abstract: A method of forming a component from a gamma prime precipitation-strengthened nickel-base superalloy. The method entails formulating the superalloy to have a sufficiently high carbon content and forging the superalloy at sufficiently high local strain rates so that, following a supersolvus heat treatment, the component is characterized by a fine and substantially uniform grain size distribution, preferably finer than ASTM 7 and more preferably in a range of about ASTM 8 to 10.

Abstract: A steel article is fabricated by providing an iron-base alloy having less than about 0.5 weight percent aluminum, melting the alloy to form a melt, adding calcium to the melt, thereafter adding aluminum to the melt to increase the aluminum content of the melt to more than about 0.5 weight percent aluminum, and casting the melt to form a casting. Other calcium additions may be made simultaneously with the adding of aluminum, and after the adding of aluminum but before casting the melt. The calcium additions deoxidize the melt to minimize the formation of clustered aluminum-oxygen-based inclusions.

Abstract: An article made of a nickel-base superalloy strengthened by the presence of a gamma-prime phase is prepared by solution heat treating the nickel-base superalloy at a solutionizing temperature above a gamma-prime solvus temperature of the nickel-base superalloy, thereafter first quenching the nickel-base superalloy in a first molten salt bath maintained at a temperature of from the gamma-prime solvus temperature to about 100° F. below the gamma-prime solvus temperature, thereafter second quenching the nickel-base superalloy in a second molten salt bath maintained at a temperature below an aging temperature of the nickel-base superalloy, and thereafter precipitation heat treating the nickel-base superalloy at the aging temperature to precipitate an aged microstructure having gamma prime phase in a nickel-base matrix.

Abstract: A forging blank of a forging nickel-base superalloy is forged in a forging press having forging dies made of a die nickel-base superalloy. The forging is accomplished by heating the forging blank to a forging-blank starting temperature of from about 1850° F. to about 1950° F., heating the forging dies to a forging-die starting temperature of from about 1500° F. to about 1750° F., placing the forging blank into the forging press and between the forging dies, and forging the forging blank at the forging-blank starting temperature using the forging dies at the forging-die starting temperature, to produce a forging.

Abstract: A superalloy made of a forging nickel-base superalloy such as Rene™ 88DT or ME3 is forged in a forging press having forging dies made of a die nickel-base superalloy. The forging is accomplished by heating to a forging temperature of from about 1700° F. to about 1850° F., and forging at that forging temperature and at a nominal strain rate. The die nickel-base superalloy is selected to have a creep strength of not less than a flow stress of the forging nickel-base superalloy at the forging temperature and strain rate.

Abstract: A superalloy made of a forging nickel-base superalloy such as Rene™ 88DT or ME3 is forged in a forging press having forging dies made of a die nickel-base superalloy. The forging is accomplished by heating to a forging temperature of from about 1700° F. to about 1850° F., and forging at that forging temperature and at a nominal strain rate. The die nickel-base superalloy is selected to have a creep strength of not less than a flow stress of the forging nickel-base superalloy at the forging temperature and strain rate.

Abstract: A steel article is fabricated by providing an iron-base alloy having less than about 0.5 weight percent aluminum, melting the alloy to form a melt, adding calcium to the melt, thereafter adding aluminum to the melt to increase the aluminum content of the melt to more than about 0.5 weight percent aluminum, and casting the melt to form a casting. Other calcium additions may be made simultaneously with the adding of aluminum, and after the adding of aluminum but before casting the melt. The calcium additions deoxidize the melt to minimize the formation of clustered aluminum-oxygen-based inclusions.

Abstract: A forging blank of a forging nickel-base superalloy is forged in a forging press having forging dies made of a die nickel-base superalloy. The forging is accomplished by heating the forging blank to a forging-blank starting temperature of from about 1850° F. to about 1950° F., heating the forging dies to a forging-die starting temperature of from about 1500° F. to about 1750° F., placing the forging blank into the forging press and between the forging dies, and forging the forging blank at the forging-blank starting temperature using the forging dies at the forging-die starting temperature, to produce a forging.

Abstract: A steel article is fabricated by providing an iron-base alloy having less than about 0.5 weight percent aluminum, melting the alloy to form a melt, adding calcium to the melt, thereafter adding aluminum to the melt to increase the aluminum content of the melt to more than about 0.5 weight percent aluminum, and casting the melt to form a casting. Other calcium additions may be made simultaneously with the adding of aluminum, and after the adding of aluminum but before casting the melt. The calcium additions deoxidize the melt to minimize the formation of clustered aluminum-oxygen-based inclusions.

Abstract: A steel article is fabricated by providing an iron-base alloy having less than about 0.5 weight percent aluminum, melting the alloy to form a melt, adding calcium to the melt, thereafter adding aluminum to the melt to increase the aluminum content of the melt to more than about 0.5 weight percent aluminum, and casting the melt to form a casting. Other calcium additions may be made simultaneously with the adding of aluminum, and after the adding of aluminum but before casting the melt. The calcium additions deoxidize the melt to minimize the formation of clustered aluminum-oxygen-based inclusions.

Abstract: A method for forming nickel base superalloy articles of manufacture by a combination of hot die forging, isothermal forging and heat treatment below and above the solvus.