Abstract: There are provided processes for encapsulating a device 14 on a substrate 12 utilizing a flux material 18. The incorporation of the flux material 18 substantially reduces oxide formation and porosity in the cladding 24 that encapsulates the encapsulated device 14.

Abstract: A method of welding with low shrinkage stress, including forming an excavation (42, 70) in a surface (24, 76) of a substrate (24, 76) with a shallow geometry (D, W, A) limited to surfaces oriented within 45 degrees of the surface. Molten weld metal (46, 80) in the excavation solidifies with largely unopposed shrinkage vectors directed toward the substrate within 45 degrees of normal to the surface. The molten metal may be warmed along the sides of the excavation (42A, 42B) so it solidifies upward (56) from the bottom, rather than from the sides inward. A metal insert (78, 84) may be fitted into the excavation and welded along the interface between them using a process that minimizes mechanical restraint on the weld by accommodating weld shrinkage.

Abstract: A method for depositing clad material (24) onto a substrate (10) by melting a layer of powdered material (16) using an energy beam (20), and also applying vibratory mechanical energy (27, 29 and/or 31). The vibratory mechanical energy may be applied before, during or after the melting and solidification of the powdered material in order to preheat the powder, to distribute powder over a top surface (18) of the substrate, to control the formation of dendrites in the clad material as the melt pool (22) solidifies, to remove slag, and/or to perform stress relief. Simultaneous application of beam energy and vibratory mechanical energy facilitates the continuous deposition of the clad material, including directionally solidified material.

Abstract: A laser waveguide (22) with a tubular wall (24) that conducts laser energy (30) from a near end (23) to a far end (27) of the waveguide. A filler feed wire (36) slides through the hollow center of the waveguide. A laser emitter (40) delivers laser beam energy (30) to a first end of the waveguide within an acceptance angle A. The laser beam may be non-parallel to an axis (25) of the waveguide by at least 20 degrees to provide room for the laser emitter beside the feed wire. The near end of the waveguide may be flared (23C) to accept a laser beam at a greater angle from the axis. The beam exits the waveguide (32) with an annular energy distribution about the feed wire, and may be focused toward the feed wire by a lens (34) having an axial hole (37) for the wire.

Abstract: Method and apparatus (20) for forming a smooth metal surface (42) on a metal substrate (22). A melt pool (32) solidifying under a layer of molten electrolytic slag (34) on the metal substrate is subjected to a DC current (12) between a cathode (28) in contact with the molten slag and the substrate, thereby causing anodic leveling of the surface. The cathode may be buried in a layer of flux material (26) which is melted by a laser beam (30) traversing the substrate. A filler material (24) may be melted coincidently in an additive process. The flux material includes electrolytic, optically transmissive and viscosity reducing constituents.

Abstract: A method including: flowing a liquid carrier medium (12) having a supply (14) of metal particles (16) across a surface (20) of a substrate (10); directing an energy beam (30) through the flowing liquid carrier medium toward the surface; and heating at least some of the metal particles in the liquid carrier medium with the energy beam to form a metallic deposit (32) that is bonded to the substrate surface and that is covered by the liquid carrier medium.

Abstract: A filler feed wire (20) including both a laser conductive element (26) and a filler material (22) extending along a length of the wire. Laser energy (30) can be directed into a proximal end (32) of the laser conductive element for melting a distal end (34) of the feed wire to form a melt pool (24) for additive fabrication or repair. The laser conductive element may serve as a flux material. In this manner, laser energy is delivered precisely to the distal end of the feed wire, eliminating the need to separately coordinate laser beam motion with feed wire motion.

Abstract: A method for forming three-dimensional anchoring structures on a surface is provided. This method may result in a thermal barrier coating system exhibiting enhanced adherence for its constituent coatings. The method involves applying a first laser beam (20) through a first portion (7) of a multi-core fiber (4) to a surface (12) of a solid material (14) to form a liquefied bed (16) on the surface (12) of the solid material (14), then applying a pulse of laser energy (24) through a second portion (6) of the multi-core fiber (4) to a portion of the liquefied bed (16) to cause a disturbance, such as a splash (28) of liquefied material outside the liquefied bed (16). A three-dimensional anchoring structure (30) may thus be formed on the surface (12) upon solidification of the splash (28) of the liquefied material.

Abstract: A method, including: detecting in a nondestructive manner a marker (10, 12, 50, 70, 76, 78) that is fully submerged in a substrate (14) to obtain spatial information about the marker; detecting in a nondestructive manner the marker after a period of time to obtain a change in the spatial information; and using the change in the spatial information to determine a change in a dimension (30) of the substrate. The method may be used to measure creep in a gas turbine engine component.

Abstract: A method for forming a reinforced cladding on a superalloy substrate. The method includes forming a melt pool including a superalloy material and a plurality of discrete carbon reinforcing structures on the superalloy substrate via application of energy from an energy source. The method further includes cooling the melt pool to form a reinforced cladding including the superalloy material and the carbon reinforcing structures on the substrate.

Abstract: A method for forming a coating on a substrate is provided. To an assembly 10 including a substrate 12, a porous matrix 14 on the substrate 12, and an impregnating material 16 on or within the porous matrix 14, the method includes applying an amount of energy 18 from an energy source 20 effective to melt the impregnating material 16 and a portion of the substrate. In this way, the impregnating material 16 impregnates the porous matrix 14. The method further includes cooling the assembly 10 to provide a coating 26 comprising the porous matrix 14 integrated with the substrate 12.

Abstract: Refurbishment of hot gas path components of gas turbine engines can now be performed locally in lieu of the traditional use of a specialized fixed regional repair facility. A mobile manufacturing platform (10) is provided with the capability to inspect and to repair ceramic coated superalloy alloy components, including the ability to perform flux assisted laser processing (68) of powdered materials. The mobile platform may include a powder mixing capability (32) for custom on-site mixing of proprietary powder compositions from a standardized powder inventory (34). A communications element (36) conveys the proprietary powder compositions from a remote home office location (38). Superalloy components can now be repaired (62) or fabricated (80) on-site by qualified technicians rather than certified welders. The mobile platform may be self-powered by a vehicle hybrid power unit or a renewable energy source.

Abstract: A process for repair of a surface (32) of a substrate (30) including the application of an energy beam (40) and vibratory mechanical energy (42) to the surface in a region of a discontinuity (34) in order to form a renewed surface (48) on the substrate. A powdered flux material (36) may be disposed over the discontinuity and melted in order to trap and remove contaminants (28) into a layer of slag (46). The vibratory mechanical energy may be applied to dislodge contaminants within the discontinuity, to add friction heat to the discontinuity, to assist in the flotation of the slag, to remove solidified slag, and/or to provide stress relief of the renewed surface.

Abstract: A method for depositing clad material (24) onto a substrate (10) by melting a layer of powdered material (16) using an energy beam (20), and also applying vibratory mechanical energy (27, 29 and/or 31). The vibratory mechanical energy may be applied before, during or after the melting and solidification of the powdered material in order to preheat the powder, to distribute powder over a top surface (18) of the substrate, to control the formation of dendrites in the clad material as the melt pool (22) solidifies, to remove slag, and/or to perform stress relief. Simultaneous application of beam energy and vibratory mechanical energy facilitates the continuous deposition of the clad material, including directionally solidified material.

Abstract: A disclosed method includes the steps of generating at least one ultrasonic standing wave (6?) between at least one set of mutually-opposed ultrasonic transducers (20A, 20B), dispensing metal-containing particles (22, 24, 26) into a node (14) located within the ultrasonic standing wave such that the particles are trapped in the node, positioning a surface of a substrate (160) proximate to the node, melting the particles with an energy beam to form a melt pool (170) in contact with the surface, and allowing the melt pool to cool and solidify into a metal deposit (176) bound to the surface. Apparatuses for carrying out such methods are also disclosed.

Abstract: A method for forming a dispersion strengthened alloy. An alloy material (8) is melted with a heat source (28) to form a melt pool (30) in the presence of a flux material (26), and strengthening particles (36) are directed into the melt pool such that the particles are dispersed within the melt pool. Upon solidification, a dispersion strengthened alloy (44) is formed as a layer or weld joint bonded to an underlying substrate or as an object contained in a removal support.

Abstract: A layer of a powdered material (4) is heated with an energy beam (10) such that at least one gas-generating agent (8) reacts to form at least one gaseous substance (14) to produce a void-containing coating (16) adhered to the surface of a substrate (2). The powdered material may contain a metallic material, a ceramic material, or both, and may also contain at least one of a flux material (32) containing the gas-generating agent and an exothermic agent (64). The heating may occur using a laser beam and may induce a melting or sintering of the powdered material to produce the void-containing coating. A gas turbine engine component exhibiting improved thermal and mechanical properties may be formed to include the void-containing coating, which may take the form of a bond coating, a thermal barrier coating, or both.

Abstract: Method for forming an oxide dispersion strengthened alloy. An alloy material (24) is melted with an energy beam (28) to form a melt pool (30) in the presence of a flux material (26), and particles (36) of a metal oxide are directed into the melt pool such that the particles are dispersed within the melt pool. Upon solidification, an oxide dispersion strengthened alloy (44) is formed as a layer bonded to an underlying substrate (20) or as an object contained on a removable support.

Abstract: Superalloy components, such as steam and gas turbine blades or vanes, are cooled during welding fabrication or repair, so as to reduce likelihood of weld metal and weld heat affected zone cracking during weld solidification and during post weld heat treatment. More particularly the invention relates to cooling superalloy steam and gas turbine components, such as turbine blades or vanes during weld repair. A heat sink apparatus includes a heat sink having a first surface adapted for abutting orientation with a turbine component second surface; and a non-gaseous, conformable, heat conductive material adapted for conforming contact with both surfaces. The heat conductive material fills gaps between the heat sink and turbine component abutting surfaces, and facilitates enhanced conductive heat transfer, in order to minimize negative heat effects from welding. The apparatus may be incorporated in a cooling system that varies heat sink cooling capacity in response to sensed component temperature.

Abstract: A metal cladding process utilizing a feed material (66) formed as a hollow sheath (68) containing a powdered core (70) including powdered metal and powdered flux material. The powdered metal and flux may have overlapping mesh size ranges. The sheath may be an extrudable subset of elements of a desired superalloy cladding material, with the powdered metal and powdered flux materials complementing the sheath to form the desired superalloy material when melted. The powdered metal may include an excess of titanium to compensate for a reaction of titanium with oxygen or carbon dioxide in a shielding gas. Heat for melting may be provided by an energy beam (64) or by utilizing the feed material as an electrode in a cold metal arc welding torch (54).