Abstract: A gas turbine engine fan blade includes an airfoil and dovetail having an integral aluminum core and a fatigue resistant reinforcing sheath.

Abstract: A method for manufacturing a composite material comprises the steps of furnishing a layer of a matrix material, forming a groove in the matrix-material layer using a laser to remove material from the layer of matrix material in the form of a groove, and placing a reinforcement into the groove. Preferably, the surface of the layer of matrix material is smoothed with a laser beam prior to formation of the groove. In most instances, more than one layer is desired, and the steps of furnishing, forming, and placing are repeated, using the same or different materials, to build up a multilayer composite material. Cylindrical, flat, or curved panel composite materials can be readily prepared, using metal, intermetallic, or ceramic materials for the matrix.

Abstract: A method for forming a ring structure having a high volume fraction of a filament reinforcement within a metal matrix is disclosed. The ring structure is formed by consolidating a set of nested rings each of which has a high volume fraction of the filamentary reinforcement therein. The nesting is done to provide a clearance between the rings of the nest of about 2 or 3 mils. The nested rings are enclosed within a HIPing can and the structure is HIPed at about 15 ksi and 1000.degree. C. for over an hour. A single superring structure results from the HIPing.

Abstract: Apparatus for producing a metal powder includes a cooled hearth structure in which a metallic alloy is melted and a heat source above the hearth positioned to heat the melt in the hearth. The cooling of the hearth causes a protective hearth skull to form between the melt and the hearth itself. The hearth is placed within an environmental control chamber. A supply structure provides a continuous supply of the metallic alloy to the hearth structure from the exterior of the chamber. A metal powder producer is positioned to receive molten metal from the hearth, and a continuous stream of the molten alloy from the hearth is transferred to the metal powder producer. The transfer is accomplished by tipping the hearth or by teeming through an opening in the bottom of the hearth. The hearth structure can utilize two individual hearths, controllably arranged so that molten metal is drawn from one hearth while the other is recharged.

Abstract: A method for forming a ring structure having a high volume fraction of a filament reinforcement within a metal matrix is disclosed. The ring structure is formed by consolidating a set of nested rings each of which has a high volume fraction of the filamentary reinforcement therein. The nesting is done to provide a clearance between the rings of the nest of about 2 or 3 mils. The nested rings are enclosed within a HIPing can and the structure is HIPed at about 15 ksi and 1000.degree. C. for over an hour. A single superring structure results from the HIPing.

Abstract: An improved method for making a metal powder employs improved apparatus comprising, in combination, a fluid-cooled hearth for receiving metallic material which defines an alloy and which is to be melted, a plasma heat source adapted to melt the metallic material, a powder metal producer, and means to introduce the molten metallic material from the hearth into the powder metal producer. The fluid-cooled walls of the hearth resolidify a portion of the molten metallic material to form a skull as a barrier between the hearth and additional molten alloy produced within the hearth. This method and apparatus restricts introduction of impurities into the molten alloy which is later introduced into the powder metal producer. In one form, a fluid-cooled pouring trough, as a stream control device, can be disposed between the hearth and the powder producer to receive molten metal from the hearth and to introduce it into the powder metal producer.

Abstract: A gas turbine, copper-based alloy part having a crystalline structure in which grain boundaries are elongated in the direction of principal stress applied to the part when in turbine service exhibits especially enhanced strength and fatigue resistance in such direction. The part is prepared in a process in which it is first cast to shape in a mold and then directionally solidified by substantially limiting the heat flow from the part to a direction parallel to the principal stress direction.