Abstract: Improved Ni, Fe and Co based superalloys having excellent oxidation resistance and weldability. The superalloys are obtained by at least partially replacing the Ni in conventional superalloys with Pd. The alloys may also contain strengtheners and modifiers such as Co, W, Mo, V, Ti, Re, Ta, Nb, C, B, Zr, Y, and Hf. The superalloy has good strength, improved weldability and excellent oxidation resistance suitable for use in many aerospace and power generation turbine applications. A preferred embodiment comprises (in wt %) 1-9% (Al+Ti), 0-0.01% B, 0-0.15% C, 0-25% Co, 5-30% Cr, 0-10% Fe, 0-0.009% (Hf+Y+Sc), 1-15% (Mo+W), 0-8% (Nb+Ta), 40-68% Ni, 4-32% Pd, 0-10% (Re+Rh), 0-5% V, and 0-0.015% Zr.

Abstract: An apparatus for smoothing and densifying or increasing the density of a coating on a workpiece includes a laser for generating a laser beam and a cylindrical lens for focusing the laser beam into a line of light on the coating surface. A manipulator is provided for moving one of the workpiece or the laser and the light line generated thereby relative to one another to cause the light line to scan across the coating to remove any rough portions and provide a smoother surface with a higher density depending upon the nature of the coating material. In one embodiment of the present invention, a mechanism is provided to oscillate the laser light line to homogenize adverse effects caused by any hot spots along the line.

Abstract: A welding apparatus operable with a high power CO.sub.2 laser beam having a laser beam wavelength-corresponding coating on an optical window mounted in the beam path deflecting the reflected workpiece image into a viewing channel allowing a real-time observation of the welding.

Abstract: An abrasive particle, for use in a manufacturing method in which the particle is exposed to a high energy beam, such as a laser, is provided with an abrasive core having an enclosing coating which protects the core from detrimental deterioration during exposure to the beam. In one form, the coating is multilayer.The particle is included on a surface of a member of a rotary seal for abrading an opposing surface.

Abstract: A laser plasma spray apparatus for depositing a feed material onto a substrate includes a nozzle having a plasma confinement chamber into which a laser beam is focused, the focal point being at a distance sufficiently far from the substrate that the substrate is not melted. Finely divided feed material in a carrier gas flow is fed axially into the confinement chamber along the direction of the laser beam and melted in the plasma formed in the interaction of the laser beam, the feed material, and the gas at the focal point. The melted feed material is then directed to deposit onto the substrate, while the plasma energy is largely confined within the apparatus by the confinement chamber and a constriction in the flow path upstream of the confinement chamber.

Abstract: A component is fabricated by depositing a succession of overlying beads of a material, the pattern and position of the beads being assigned the proper characteristics of the corresponding section of the desired component. Shape definition is accomplished by characterizing the component as a series of sections or slices having the thickness of the bead, and programming a computer-controlled deposition head to deposit a succession of beads with the respective patterns and positions. Deposition is preferably by precision laser welding. Complex shapes having properties comparable to properties of forged or cast material are readily prepared. The material used in successive beads may be varied, producing a component of graded composition to achieve particular properties in various regions.

Abstract: A feed material is melted by a focussed laser beam in a partially confined interaction volume, and ejected from the interaction volume in a direction different from the axis of the laser beam. The feed material, preferably in the form of a finely divided powder fluidized by a gas stream, is fed to the interaction volume in a direction transverse to the axis of the laser beam. Confinement of the molten feed material is preferably attained using balanced gas pressures that do not permit the molten feed material to flow in the direction parallel to the laser beam. The energy density of the laser beam is preferably sufficiently high to form a plasma within the interaction volume from gas and vaporized feed material atoms, so that the feed material is introduced into the plasma.