Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: The present invention relates to a ceramic or metallic component including a first region having a first porosity ranging between 1 and 30%. The component includes a second region having a second porosity that is less than the first porosity. The component includes at least one graded transition between the first and second regions.

Abstract: Methods of forming an intermediate alloy and a Ni-base super alloy are disclosed along with the intermediate alloy and the Ni-base super alloy formed by the method. The method includes at least partially melting and solidifying a powder including about 5 to 15 wt. % of Co, 10 to 20 wt. % of Cr, 3 to 6 wt. % of Mo, 3 to 6 wt. % of W, 2 to 4 wt. % of Al, 4.2 to 4.7 wt. % of Ti, 0.01 to 0.05 wt. % of Zr, 0.015 to 0.060 wt. % of C, 0.001 to 0.030 wt. % of B and balance substantially Ni to form an intermediate alloy including a dendrite structure that includes columnar regions and intercolumnar regions and a primary dendrite arm spacing less than about 3 micrometers. The intermediate alloy is heat-treated to form the texture-free Ni-base super alloy.

Abstract: A bladed disk for a gas turbine engine is provided. The bladed disk includes a rotor disk, a plurality of rotor blades, and an interlocking transition zone. The rotor disk includes a plurality of fused layers of a first material formed via additive manufacturing and defines an outer rim. The plurality of rotor blades includes a plurality of fused layers of a second material formed via additive manufacturing. The interlocking transition zone includes a plurality of projections alternately extending from the outer rim of the rotor disk and the plurality of rotor blades, respectively, to undetachably couple the rotor disk and the plurality of rotor blades.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone comprising a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.

Abstract: A surface of an article is modified by first disposing a nickel-enriched region at the surface of a substrate, then enriching the nickel-enriched region with aluminum to form an aluminized region, and finally removing at least a portion of the aluminized region to form a processed surface of the substrate. Upon removal of this material, the roughness of the surface is reduced from a comparatively high initial roughness value to a comparatively low processed roughness value. In some embodiments, the processed roughness is less than about 95% of the initial roughness. Moreover, the sequence of steps described herein may be iterated one or more times to achieve further reduction in substrate surface roughness.

Abstract: An article, for example a turbomachinery article is presented. The article includes a weldable first component having a base portion and a flange portion. The flange portion is outwardly projecting normal to a surface of the base portion; and is joined with the base portion by a solid state joint. The base portion comprises a nanostructured ferritic alloy; and the flange portion comprises a steel substantially free of oxide nanofeatures. The first component is joined to a second component through the flange portion of the first component by a weld joint.

Abstract: A turbine component includes: a metallic wall having opposed interior and exterior surfaces, the wall configured for directing a combustion gas stream in a gas turbine engine; and a metallic negative CTE structure rigidly attached to one of the surfaces

Abstract: Rhenium-free nickel based alloys are provided. More particularly, the alloys comprise preferred levels and ratios of elements so as to achieve good high temperature strength of both gamma matrix phase and gamma prime precipitates, as well as good environmental resistance, without using rhenium. When cast and directionally solidified into single crystal form, the alloys exhibit creep and oxidation resistance substantially equivalent to or better than rhenium-bearing single-crystal alloys. Further, the alloys can be processed by directional solidification into articles in single crystal form or columnar structure comprising fine dendrite arm spacing, e.g., less than 400 ?m, if need be, so that further improvements in mechanical properties in the articles can be seen.

Abstract: A method for treating a powder, includes: dry mixing the powder with an effective amount of a treating additive to distribute a layer of the treating additive on a surface of a particle of the powder, a primary particle size of the treating additive being smaller than an average particle size of the powder. An associated treated powder is also described.

Abstract: A cobalt-nickel base alloy is disclosed. The alloy includes, in weight percent: greater than about 4 % of Al, about 10 to about 20 % of W, about 10 to about 40 % Ni, about 5 to 20 % Cr and the balance Co and incidental impurities. The alloy has a microstructure that is substantially free of a CoAl phase having a B2 crystal structure and configured to form a continuous, adherent aluminum oxide layer on an alloy surface upon exposure to a high-temperature oxidizing environment. A method of making an article of the alloy includes: selecting the alloy; forming an article from the alloy; solution-treating the alloy; and aging the alloy to form an alloy microstructure that is substantially free of a CoAl phase having a B2 crystal structure, wherein the alloy is configured to form a continuous, adherent aluminum oxide layer on an alloy surface upon exposure to a high-temperature oxidizing environment.

Abstract: Gamma titanium aluminide intermetallic compositions (gamma TiAl intermetallics) based on the TiAl (gamma) intermetallic compound. The gamma TiAl intermetallics contain chromium and niobium, as well as controlled amounts of carbon that achieve a desirable balance in room temperature mechanical properties and high temperature creep capabilities at temperatures approaching and possibly exceeding 1600° F. (about 870° C.).

Abstract: Methods for casting a metallic material to form a component are described. The component can be a superalloy-containing turbine part, for example. The general method includes the step of pouring the metallic material, in molten form, into an investment mold; and then rapidly immersing the entire investment mold into a bath that contains a low-melting liquid coolant metal, so as to achieve substantially uniform, multi-directional heat transfer out of the molten material. The molten material that solidifies to form the component is characterized by a fine-grained, equiaxed grain structure. Related embodiments include the use of two ingots that constitute the superalloy material. One ingot includes the oxygen-reactive elements, and is prepared by a vacuum-melting technique. The other ingot includes the remainder of the elements, and can be prepared by a number of techniques, such as air-melting processes.

Abstract: A cobalt-nickel alloy composition is described, containing about 20% to about 28% cobalt; about 37% to about 46% nickel; at least about 6% chromium; aluminum; and at least one refractory metal. The total weight of cobalt, aluminum, and refractory metal in the composition is less than about 50% of the total weight of the composition. Moreover, the alloy composition comprises both a (Co, Ni)-gamma phase and an L12-structured (gamma prime) phase. Various components made from the cobalt-nickel alloy composition are also described. Examples include high-temperature machinery and devices, e.g., components of gas turbine engines.

Abstract: A high-temperature, high-strength, oxidation-resistant cobalt-nickel base alloy is disclosed. The alloy includes, in weight percent: about 3.5 to about 4.9% of Al, about 12.2 to about 16.0% of W, about 24.5 to about 32.0% Ni, about 6.5% to about 10.0% Cr, about 5.9% to about 11.0% Ta, and the balance Co and incidental impurities. A method of making an article having high-temperature strength, cyclic oxidation resistance and corrosion resistance is disclosed. The method includes forming a high-temperature, high-strength, oxidation-resistant cobalt-nickel base alloy as described herein; forming an article from the alloy; solution-treating the alloy by a solution heat treatment; and aging the alloy by providing at least one aging heat treatment at an aging temperature that is less than the gamma-prime solvus temperature, wherein the alloy is configured to form a continuous, protective, adherent oxide layer on an alloy surface upon exposure to a high-temperature oxidizing environment.

Abstract: A cobalt-nickel base alloy is disclosed. The alloy includes, in weight percent: greater than about 4% of Al, about 10 to about 20% of W, about 10 to about 40% Ni, about 5 to 20% Cr and the balance Co and incidental impurities. The alloy has a microstructure that is substantially free of a CoAl phase having a B2 crystal structure and configured to form a continuous, adherent aluminum oxide layer on an alloy surface upon exposure to a high-temperature oxidizing environment. A method of making an article of the alloy includes: selecting the alloy; forming an article from the alloy; solution-treating the alloy; and aging the alloy to form an alloy microstructure that is substantially free of a CoAl phase having a B2 crystal structure, wherein the alloy is configured to form a continuous, adherent aluminum oxide layer on an alloy surface upon exposure to a high-temperature oxidizing environment.

Abstract: Casting molds suitable for directional solidification processes using a liquid cooling bath include a graded facecoat structure on a mold body. The graded facecoat structure includes an innermost layer and a delamination layer, wherein the delamination layer fractures upon cooling of the molten metal so as to separate the mold body from the innermost layer, which remains in contact with or in close proximity to the metal being cast. Also disclosed are directional solidification processes.