Abstract: A metallic article is produced by furnishing one or more nonmetallic precursor compound comprising the metallic base nickel, cobalt, iron, iron-nickel, or iron-nickel-cobalt, and at least one alloying element. The nonmetallic precursor compound(s) are chemically reduced to produce an initial metallic particle without melting the initial metallic particle. The initial metallic particle is thereafter melted and solidified to produce the metallic article. The melted-and-solidified metal may be used in the as-cast form, or it may be converted to billet and further worked to the final form.

Abstract: Methods for reducing carbon contamination when melting highly reactive alloys involving providing a graphite crucible having an interior, applying at least a first protective layer to the interior of the graphite crucible, placing a highly reactive alloy into the crucible having the first protective layer, and melting the highly reactive alloy to obtain a melted alloy having reduced carbon contamination.

Abstract: Molds 16 for casting molten materials using a directional solidification process and methods for forming a barrier layer between a liquid cooling medium 20 and a molten material of a casting process are provided. According to an embodiment, a mold 16 for casting a molten material comprises an inner surface at least partially coated with a metal oxide slurry 32 comprising metal oxide particles, wherein the metal oxide slurry 32 is capable of inhibiting a liquid cooling medium 20 from contacting a molten metal or metal alloy when the molten metal or metal alloy is disposed within an interior of the mold 16 and the mold 16 is disposed in the liquid cooling medium 20.

Abstract: Disclosed herein is a turbine component comprising a substrate; and a protective structure formed on the substrate, wherein the protective structure comprises an ?-? titanium alloy, a ?-titanium alloy or a near-? titanium alloy. Disclosed herein too is a process for providing a protective structure to a turbine component, comprising affixing a protective structure on a turbine component; wherein the protective structure comprises an ?-? titanium alloy, a near-? titanium alloy or a ?-titanium alloy.

Abstract: A martensitic steel metallic article (20) made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds is chemically reduced to produce a metallic martensitic steel, without melting the metallic martensitic steel. The metallic martensitic steel is consolidated to produce a consolidated metallic article (20), without melting the metallic martensitic steel and without melting the consolidated metallic article (20).

Abstract: A method and system for microstructural evaluation and degradation evaluation of an object are provided. The method comprises insonifying at least one subvolume of the object with ultrasonic energy at a fundamental frequency and acquiring receive energy from the object at the fundamental frequency and at least one harmonic frequency thereof. A nonlinearity parameter is determined using the receive energy. The nonlinearity parameter is then used to determine a grain size for the subvolume of the object and a variation of the grain size within the object. The nonlinearity parameter is also used to determine fatigue damage or a residual stress.

Abstract: Methods for making refractory crucibles capable of managing thermal stresses and suitable for melting highly reactive alloys, the method involving providing a crucible having at least a facecoat and a backing, heating at least one retaining ring, applying the at least one retaining ring about at least a portion of the backing of the crucible; and allowing the at least one retaining ring to cool and shrink-fit about the crucible.

Abstract: Refractory crucibles capable of managing thermal stress and suitable for melting highly reactive alloys having a facecoat, a backing, and at least one retaining ring applied about at least a portion of the backing of the crucible, the retaining ring comprising a composition selected from the group consisting of conductive materials, non-conductive materials, and combinations thereof.

Abstract: A titanium material production method for producing homogeneous fine grain titanium material in which the titanium material has a grain size in a range from about 5 ?m to about 20 ?m. The method comprises providing a titanium material blank; conducting a first heat treatment on the titanium material blank to heat the titanium material blank to a ?-range; quenching the titanium material blank from the ?-region to the ?+?-region; forging the titanium material blank; and conducting a second heat treatment on the titanium material blank. The titanium material production method subjects the titanium material blank to superplasticity conditions during part of the titanium material production method.

Abstract: Processes for directionally casting liquid metal to form an articles can include compressing a seal intermediate a mold chill plate and a mold assembly, wherein the seal circumscribes a shell mold in the mold assembly; filling the shell mold in the mold assembly with molten metal; immersing the mold assembly into a liquid metal cooling bath from a bottom portion to a top portion of the mold assembly; and transmitting heat from the mold assembly to the liquid metal cooling bath to solidify the molten metal from the bottom portion to the top portion of the mold assembly.

Abstract: A coating process and system suitable for use on components subjected to high temperatures. The coating system includes an overlay coating of predominantly B2 phase rhodium aluminide (RhAl) intermetallic compound containing about 25 to about 90 atomic percent rhodium, about 10 to about 60 atomic percent aluminum, optionally up to a combined total of about 25 atomic percent of one or more platinum group metals chosen from the group consisting of platinum, palladium, ruthenium, and iridium, and up to about 20 atomic percent of the base metal and alloying constituents of the substrate. The RhAl intermetallic coating may serve as an environmental coating, a diffusion barrier layer for an overlying environmental coating, or both, with or without an outer ceramic coating.

Abstract: Nb—Si based alloy articles comprising a Nb—Si based alloy upon which is disposed an environmentally-resistant coating are described. They include a coating comprising at least one phase selected from the group consisting of M(Al,Si)3, M5(Al,Si)3, and M3Si5Al2, wherein M is one or more of Nb, Ti, Hf, Cr. Such coating can improve the environmental (e.g., in oxidation-promoting environments) resistance of a Nb—Si based alloy and alloy articles. Methods for preparing these articles are described as well.

Abstract: Methods for making a reinforced refractory crucible for melting titanium alloys including providing a form, applying a facecoat to the form, the facecoat having at least one facecoat layer, applying a backing about the facecoat, the backing having at least one backing layer, applying at least one reinforcing element to at least a portion of the facecoat layer, the backing layer, or a combination thereof where the reinforcing element includes at least one composition selected from ceramic compositions, metallic compositions, and combinations thereof.

Abstract: Crucibles for melting titanium alloys having a facecoat including at least one facecoat layer containing an oxide selected from scandium oxide, yttrium oxide, hafnium oxide, a lanthanide series oxide, and combinations thereof, and a backing including at least one backing layer where the crucible has a backing to facecoat thickness ratio of from about 6.5:1 to about 20:1.

Abstract: Methods for making refractory crucibles for melting titanium alloys including providing a form, applying a facecoat to the form, and applying a backing to the facecoat where the facecoat has at least one facecoat layer including an oxide selected from the group consisting of scandium oxide, yttrium oxide, hafnium oxide, a lanthanide series oxide, and combinations thereof and where the backing to the facecoat has a thickness ratio of from about 6.5:1 to about 20:1.

Abstract: Reinforced crucibles for melting titanium alloys having a facecoat including at least one facecoat layer, a backing including at least one backing layer, and at least one reinforcing element applied to at least a portion of one or more of the facecoat layer, the backing layer, or a combination thereof where the reinforcing element includes at least one composition selected from ceramic compositions, metallic compositions, and combinations thereof.

Abstract: A method for preparing an article of a base metal alloyed with an alloying element includes the steps of preparing a compound mixture by the steps of providing a chemically reducible nonmetallic base-metal precursor compound of a base metal, providing a chemically reducible nonmetallic alloying-element precursor compound of an alloying element, and thereafter mixing the base-metal precursor compound and the alloying-element precursor compound to form a compound mixture. The compound mixture is thereafter reduced to a metallic alloy, without melting the metallic alloy. The step of preparing or the step of chemically reducing includes the step of adding an other additive constituent. The metallic alloy is thereafter consolidated to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.

Abstract: A method for preparing a metallic article made of metallic constituent elements includes furnishing a chemically reduced initial metallic material formed from chemically reducing a mixture of nonmetallic precursor compounds of the metallic constituent elements, without melting the initial metallic material, and consolidating the initial metallic material to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article.

Abstract: A mold assembly for a liquid metal cooled directional solidification furnace having a cooling chamber provided with liquid metal and a heating chamber includes a mold member having a main body portion that defines an interior mold cavity. The mold member is adapted to be positioned in the heating chamber. The mold assembly also includes a chill-plate formed from a material having a thermal diffusivity a 600° K greater than approximately 10 E-6 m2/s, inert to at least one of molten tin and molten aluminum and adapted to be at least partially immersed in the liquid metal. The chill-plate includes a main body portion having a first surface extending to a second surface through an intermediate portion. The chill-plate is adapted to establish a thermal gradient between the mold member and the heating chamber.

Abstract: A method for inspecting a part is provided. The method includes immersing the part in a couplant medium, delivering ultrasonic wave energy to at least one subvolume of the part using an ultrasonic transducer immersed in the couplant medium and receiving ultrasonic wave energy from the part at a fundamental frequency and at least one harmonic frequency using an ultrasonic receiver immersed in the couplant medium. The method also includes generating a nonlinear image corresponding to at least one material property variation of the part using the received ultrasonic energy and using the nonlinear image of the part to determine whether one or more material property anomalies are present in the part.