Abstract: A shaped rotor wheel, a turbo machine including the rotor wheel, and a method for producing the same are disclosed. In an embodiment, a rotor wheel is provided which includes at least one disk member and at least one spacer member, and is a capable of carrying and axially spacing one or more stages of blades. Also disclosed is a method for producing such a rotor wheel using metal powders as a starting material, and processing the metal powder using powder metallurgy techniques.

Abstract: A forging preform for a turbine rotor disk is disclosed. The preform includes a body of a superalloy material having a mass of about 5000 lbs or more, the superalloy material having a substantially homogeneous grain morphology and an ASTM average grain size of 10 or smaller. 5. A turbine rotor disk is also disclosed. The disk includes a substantially cylindrical disk of a superalloy material having a mass of about 5000 lbs or more, the superalloy material having a substantially homogeneous grain morphology and an ASTM average grain size of about 10 or smaller. A method of making a turbine rotor disk is also disclosed. The method includes providing a superalloy powder material and pressing the superalloy powder material to form a forging preform for a turbine rotor disk.

Abstract: A shaped rotor wheel, a turbo machine including the rotor wheel, and a method for producing the same are disclosed. In an embodiment, a rotor wheel is provided which includes at least one disk member and at least one spacer member, and is a capable of carrying and axially spacing one or more stages of blades. Also disclosed is a method for producing such a rotor wheel using metal powders as a starting material, and processing the metal powder using powder metallurgy techniques.

Abstract: A cast article of a ductile iron wherein the ductile iron includes carbon from about 2.8 to 3.7 w/o, silicon from about 3.0 to 3.5 w/o, molybdenum from 0.8 to 1.5 w/o, magnesium from about 0.025 to 0.60 w/o, sulfur less than 0.01 w/o and nickel from about 0.0 to 1.3 w/o, the remaining content being iron is provided. The cast article is suitable for a gas turbine casing. A method of manufacturing a cast article is also provided.

Abstract: A forging die and process suitable for producing large forgings, including turbine disks and other rotating components of power-generating gas turbine engines, using billets formed by powder metallurgy. The forging die includes a backplate, and segments arranged in a radial pattern about a region on a surface of the backplate. Each segment has a backside facing the backplate and an interface surface facing away from the backplate, with the interface surface being adapted to engage the billet during forging. The segments are physically coupled to the surface of the backplate in a manner that enables radial movement of the segments relative to the backplate.

Abstract: A forging die and process suitable for producing large forgings, including turbine disks and other rotating components of power-generating gas turbine engines, using billets formed by powder metallurgy. The forging die includes a backplate, and segments arranged in a radial pattern about a region on a surface of the backplate. Each segment has a backside facing the backplate and an interface surface facing away from the backplate, with the interface surface being adapted to engage the billet during forging. The segments are physically coupled to the surface of the backplate in a manner that enables radial movement of the segments relative to the backplate.

Abstract: Methods for repairing nickel based alloy articles such as gas turbine rotors generally includes a removing a damaged portion of the articles and laser cladding a high temperature nickel based alloy powder thereto to form a solid layer. The process can be repeated until a desired thickness is obtained. Optionally, a peening process subsequent to laser cladding can be implemented to introduce compressive stress to the solid layer formed by laser cladding.

Abstract: A method and a HIP can structure for hot isostatically pressed (HIP) production of flat sheet metal matrix composites having a dimension greater than about 4.times.5 inches. The HIP can is constructed so that most of the expensive components are reusable for further processing of other composites. The side walls of the HIP can have reduced thickness relative to the top and bottom walls and the can has a reinforced centerpiece between the two composites used in the example. Molybdenum foils are utilized to separate the composites from the stiffening structure so that when the HIP can is opened by breaking the weld at one of its wings, the components of the can and the composites come apart so that the most expensive structural members of the HIP can be reused.