Abstract: A multi-layer article (1) disclosed herein contains a metallic substrate (2), a protective layer (6), and an adhesive bonding layer (14) including an oxygen-containing compound that bonds the adhesive bonding layer to the metallic substrate, the protective layer, or both. A method for forming the multi-layer article includes the steps of heating a protective bonding composition (20) to form a molten material (24) in contact with a metal-containing surface (2), allowing the molten material to cool and solidify into the adhesion bonding layer (14) affixed to the metal-containing surface, depositing a ceramic material (26) onto the adhesive bonding layer, and heating the ceramic material to form the protective layer (6) affixed to the adhesive bonding layer.

Abstract: A method of progressing a melt front (55) around a curved progression path (20) via a pattern (LP) of transverse laser scan lines (S1-S8) of differing lengths. Multiple area bands (B1-B8) conceptually divide a width of the curved path. The multiple transverse scan lines distribute the laser power among the bands with a predetermined uniformity that provides relatively consistent power density across the melt front. The scan lines may extend from a less curved side (24) of the curved path, through a band (B4 or B8) of largest area, toward a more curved side (22) of the path. At least one of the scan lines (S1, S8) may cross all bands. Other scan lines are shorter and extend by varying distances into the inner bands (B1-B3 or B1-B7), normalizing the power density across the bands.

Abstract: A method, including: providing a layer of powder material (106) on a substrate (12) having protruding rib material (26); and traversing an energy beam (100) across the layer of powder material to form a cladding layer (10) around and bonded to the protruding rib material, wherein the cladding layer defines a layer of an airfoil skin (94).

Abstract: A method, including: providing a layer of powder material (156) on a substrate (130); and traversing an energy beam (15) across the layer of powder material to form a cladding layer (10), wherein the cladding layer forms a layer of an airfoil. The traversing step includes: starting a first path (40) and a second path (44) of traversal of the energy beam from a common initiation point (48); forming a portion (60) of a first side wall (18) of the cladding layer and a first rib section (24) by traversing the energy beam along the first path and concurrently forming a portion (62) of a second side wall (16) of the cladding layer by traversing the energy beam along the second path; and creating not more than one initiation point (72, 96, 118) for each rib section (24, 26, 28) in the cladding layer.

Abstract: A tungsten submerged arc welding process wherein a non-consumable electrode (18) provides an arc (16) under a protective bed of flux powder (26), thereby eliminating the need for an inert cover gas supply. The arc melts a feed material in the form of alloy powder (22) or filler wire (40) along with a surface of a substrate (12) to form a layer of cladding material (10, 32) covered by a layer of slag (20, 44). The flux and slag function to shape the deposit, to control cooling, to scavenge contaminants and to shield the deposit from reaction with air, thereby facilitating the deposit of previously unweldable superalloy materials.

Abstract: A method for depositing superalloy materials. A layer of powder (14) disposed over a superalloy substrate (12) is heated with an energy beam (16) to form a layer of superalloy cladding (10) and a layer of slag (18). The layer of powder includes flux material and alloy material, formed either as separate powders or as a hybrid particle powder. A layer of powdered flux material (22) may be placed over a layer of powdered metal (20), or the flux and metal powders may be mixed together (36). An extrudable filler material (44) such as nickel, nickel-chromium or nickel-chromium-cobalt wire or strip may be added to the melt pool to combine with the melted powder to give the superalloy cladding the composition of a desired superalloy material.

Abstract: A method of repairing service-induced surface cracks (92) in a superalloy component (90). A layer of powdered flux material (100) is applied over the cracks and is melted with a laser beam (98) to form a re-melted zone (104) of the superalloy material under a layer of slag (106). The slag cleanses the melt pool of contaminants that may have been trapped in the cracks, thereby eliminating the need for pre-melting fluoride ion cleaning. Optionally, alloy feed material may be applied with the powdered flux material to augment the volume of the melt or to modify the composition of the re-melted zone.

Abstract: Methods are disclosed for melting a cored feed material (31) using a low heat input process. The feed material may be a sheath (34) consisting essentially of pure nickel, nickel-chromium, or nickel-chromium-cobalt, containing a powdered core material (36) having a powdered alloy material (42) and powdered flux material (38) which, when melted, form a desired superalloy material. Flux materials for use with the methods are disclosed. The process may be a cold metal transfer process wherein the feed material is oscillated at greater than 130 oscillations per second.

Abstract: A tungsten submerged arc welding process wherein a non-consumable electrode (18) provides an arc (16) under a protective bed of flux powder (26), thereby eliminating the need for an inert cover gas supply. The arc melts a feed material in the form of alloy powder (22) or filler wire (40) along with a surface of a substrate (12) to form a layer of cladding material (10, 32) covered by a layer of slag (20, 44). The flux and slag function to shape the deposit, to control cooling, to scavenge contaminants and to shield the deposit from reaction with air, thereby facilitating the deposit of previously unweldable superalloy materials.

Abstract: A method for forming a reinforced cladding (10) on a superalloy substrate (12) The method includes forming a melt pool (22) including a superalloy material (16) and a plurality of discrete carbon reinforcing structures (18) on the superalloy substrate (12) via application of energy from an energy source (20) The method further includes cooling the melt pool (22) to form a reinforced cladding (10) comprising the superalloy material (16) and the carbon reinforcing structures (18) on the substrate (12).

Abstract: The loss of aluminum content during the laser (20) deposition of superalloy powders (16) is accommodated by melting pure aluminum foil (14) with the superalloy powder to increase a concentration of aluminum in the melt pool (24) so that the resulting layer of deposited material (26) has a desired elemental composition Foils, screens or strips of any material may be melted with powders to achieve any desired cladding composition, including a graded composition across a thickness of a clad layer (50).

Abstract: A laser microcladding process utilizing powdered flux material (93b). A jet (92) of propellant gas containing powdered alloy material (93a) and the powdered flux material are directed toward a substrate (94). The powdered materials are melted by a laser beam (96) to form a weld pool (98) which separates into a layer of slag (100) covering a layer of clad alloy material (102). The flux material deoxidizes the weld pool and protects the layer of clad alloy material as it cools, thereby allowing the propellant gas to be nitrogen or air rather than an inert gas. In one embodiment, the substrate and alloy materials are superalloys with compositions beyond the traditional zone of weldability.

Abstract: Laser pre-processing to stabilize high-temperature coatings and surfaces. One method involves melting a surface of a metal substrate (2) with an energy beam (22) to form a melt pool (24), allowing the melt pool to cool and solidify into a melt-processed alloy layer (28) bonded to the metal substrate, and coating the melt-processed alloy layer with a protective alloy layer (4) to form a coated substrate. A flux composition (18) may also be deposited onto the surface of the metal substrate, such that the melt processing also forms a slag layer (30) at least partially covering the melt-processed alloy layer. A protective material (34) containing a carbon source may also be deposited onto the surface of the metal substrate, such that the melt processing forms a carbon-enriched melt-processed alloy layer (36) having a higher proportion of carbon than the metal substrate.

Abstract: Laser processing of reactive metals. One repair process involves laser melting a titanium alloy filler material (4) in the presence of a flux composition (8) to form a titanium alloy cladding (14) bonded to a surface of a titanium-containing component (2). A laser beam (10) may be applied to a flux composition (8) covering a powdered filler material (4) such that the laser beam simultaneously melts the flux composition and the powdered filler material to form a melt pool (12) which solidifies into a resulting alloy layer (14) covered by a slag layer (16). A laser beam (20) may heat a flux composition (8) such that an amount of energy applied to the flux composition is controlled so that a molten slag blanket (24) heats and melts a powdered filler material (4) by thermal conduction in the presence of a shielding gas (26).

Abstract: A coating arrangement (16), including: a layer (18) of bond coat material (20); and a light-transmissive thermal barrier coating (TBC) mesh (28) having a TBC material (24) and secured in position relative to the layer of bond coat material. The coating arrangement may be positioned over a superalloy substrate material (12) and melted with a laser beam (62) to metallurgically bond the thermal barrier coating onto the substrate.

Abstract: Superalloy components, such as service-degraded turbine blades and vanes, are clad by laser beam welding. The welding/cladding path, including cladding application profile, is determined by prior, preferably real time, non-contact 3D dimensional scanning of the component and comparison of the acquired dimensional scan data with specification dimensional data for the component. A welding path for cladding the scanned component to conform its dimensions to the specification dimensional data is determined. The laser welding apparatus, preferably in cooperation with a cladding filler material distribution apparatus, executes the welding path to apply the desired cladding profile. In some embodiments a post-weld non-contact 3D dimensional scan of the welded component is performed and the post-weld scan dimensional data are compared with the specification dimensional data.

Abstract: An additive manufacturing process (110) wherein a powder (116) including a superalloy material and flux is selectively melted in layers with a laser beam (124) to form a superalloy component (126). The flux performs a cleaning function to react with contaminants to float them to the surface of the melt to form a slag. The flux also provides a shielding function, thereby eliminating the need for an inert cover gas. The powder may be a mixture of alloy and flux particles, or it may be formed of composite alloy/flux particles.

Abstract: An additive manufacturing apparatus (10) including: a container (12) configured to bound a bed of powdered metal material; a fluidization arrangement (18) configured to fluidize the bed of powered material; an articulation mechanism (40) disposed within the container and configured to support and to rotate a component (38) about at least one horizontal axis; and an energy beam (34) configured to selectively scan portions (36) of a surface of the bed of powdered metal material to melt or sinter the selectively scanned portions onto the component.

Abstract: A method of removing a coating (14) from a substrate (12) by applying both vibratory mechanical energy (16, 20) and an energy beam (32) to the coating. Localized combination of thermally and mechanically induced stressed in the coating result in the formation of cracks (34) in the coating.

Abstract: Metallic components, including superalloy components such as turbine vanes and blades, are joined or repaired by electric resistance with a high electrical resistivity brazing alloy composition. In some embodiments the brazing alloy comprises filler metal selected from the group consisting of nickel, iron, and cobalt base alloy and elements selected from the group consisting of phosphorous (P), boron (B), silicon (Si), germanium (Ge), sulfur (S), selenium (Se), carbon (C), tellurium (Te) and manganese (Mn). In performing the method of the present invention a high electrical resistivity brazing alloy composition is introduced within a substrate defect or interposed between two substrates that are to be joined. An electric current is passed through the brazing alloy until the alloy melts and bonds to the adjoining substrate. High resistivity of the brazing alloy concentrates heat generated by the current flow in the brazing alloy rather than in the substrate.