Abstract: A method of fabricating a Ti-6Al-4V titanium alloy component including solution heat treating a forged Ti-6Al-4V titanium alloy component at a temperature within the alpha+beta two-phase field for the material of the component for a predetermined period of time, and subsequently cooling the component. The component is then age heat treated using an overaging process at a predetermined overaging temperature for a predetermined time, and the component is cooled to room temperature. The overaging temperature is selected to be a higher temperature than an aging heat treatment temperature for effecting a maximum yield strength in the component.

Abstract: A method of forming a thermocouple (12), including: depositing a first material on a component (10) to form a first leg (14); depositing a second material through a mask (30) to form a pattern (50) on the component (10), the pattern (50) forming a plurality of discrete second leg junction ends (20) and a continuous patch (52) of the second material comprising indiscrete lead ends of the second legs (16), each second leg junction end (20) spanning from a respective junction (18) with the first leg (14) to the continuous patch (52); and laser-ablating the continuous patch (52) to form discrete lead ends (22) of the second legs (16), each lead end (22) electrically connected to a respective junction end (20), thereby forming discrete second legs (16).

Abstract: An investment casting process wherein the wax pattern tool (42) is flexible to provide compliant support for an enclosed ceramic core (10) and to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. Positioning pins (106) may extend from the flexible tool to make compliant contact against the core during the wax injection step. The pins may cooperate with a pedestal (128) formed on the core to support the core along multiple axes during wax injection, thereby allowing a higher wax injection pressure without damage to the core.

Abstract: A method of forming a thermocouple (12), including: depositing a first material on a component (10) to form a first leg (14); depositing a second material through a mask (30) to form a pattern (50) on the component (10), the pattern (50) forming a plurality of discrete second leg junction ends (20) and a continuous patch (52) of the second material comprising indiscrete lead ends of the second legs (16), each second leg junction end (20) spanning from a respective junction (18) with the first leg (14) to the continuous patch (52); and laser-ablating the continuous patch (52) to form discrete lead ends (22) of the second legs (16), each lead end (22) electrically connected to a respective junction end (20), thereby forming discrete second legs (16).

Abstract: An investment casting process wherein the wax pattern tool (44) is flexible to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. The flexible tool may include a flexible insert (42) precisely indexed to a surrounding coffin mold (40), and thereby to an enclosed ceramic core (10). Positioning pins (106) may extend from the flexible tool to make compliant contact against the core prior to a wax injection step. The surface of the resulting wax pattern may contain an engineered topography (36) replicated through the flexible surface from a master tool (12). The flexible tool may encase thermally conductive or magnetic particles (92), or other active device (96) such as a sensor or vibrator which is operable during wax injection.

Abstract: A method of fabricating a Ti-6Al-4V titanium alloy component including solution heat treating a forged Ti-6Al-4V titanium alloy component at a temperature within the alpha+beta two-phase field for the material of the component for a predetermined period of time, and subsequently cooling the component. The component is then age heat treated using an overaging process at a predetermined overaging temperature for a predetermined time, and the component is cooled to room temperature. The overaging temperature is selected to be a higher temperature than an aging heat treatment temperature for effecting a maximum yield strength in the component.