Abstract: An article of aluminum base-metal alloyed with an alloying element is prepared by mixing a chemically reducible nonmetallic base-metal precursor compound of the aluminum base-metal and a chemically reducible nonmetallic alloying-element precursor compound of an alloying element to form a precursor compound mixture. The alloying element may be, but is not necessarily, thermophysically melt incompatible with the aluminum base metal. The method further includes chemically reducing the precursor compound mixture to a metallic alloy, without melting the metallic alloy, and thereafter consolidating the metallic alloy to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.

Abstract: An article has a metallic matrix made of its constituent elements with a dispersoid distributed therein. The article is prepared by furnishing at least one nonmetallic matrix precursor compound. All of the nonmetallic matrix precursor compounds collectively include the constituent elements of the metallic matrix in their respective constituent-element proportions. A mixture of an initial metallic material and the dispersoid is produced. The matrix precursor compounds are chemically reduced to produce the initial metallic material, without melting the initial metallic material, and the dispersoid is distributed in the initial metallic material. The mixture of the initial metallic material and the dispersoid is consolidated to produce a consolidated article having the dispersoid distributed in the metallic matrix comprising the initial metallic material. The initial metallic material, the dispersoid, and the consolidated article are not melted during the consolidation.

Abstract: A process for positioning at least one defect in a billet being forged into an article is described. The size and location of the billet is first determined, using a non-destructive test such as ultrasonic inspection. The movement of the defect under selected forging conditions is then predicted, using a finite element analysis model. The billet can then be positioned and forged under conditions which cause the defect to move to a non-critical area of the article. In this manner, a billet which might otherwise be discarded or set aside can often be retained for a useful purpose. Related articles are also described.

Abstract: An airfoil for an internal combustion engine, such as a gas turbine, formed by use of a preform. The airfoil includes: an outer surface forming the foil shape; and a plurality of craze-free cooling passages extending through the airfoil. In the preferred embodiment, a root on the airfoil joins the airfoil to the hub of a gas turbine vane assembly. Also, in the preferred embodiment, the gas turbine vane assembly is adapted to receive replaceable airfoils.

Abstract: An article of aluminum base-metal alloyed with an alloying element is prepared by mixing a chemically reducible nonmetallic base-metal precursor compound of the aluminum base-metal and a chemically reducible nonmetallic alloying-element precursor compound of an alloying element to form a precursor compound mixture. The alloying element may be, but is not necessarily, thermophysically melt incompatible with the aluminum base metal. The method further includes chemically reducing the precursor compound mixture to a metallic alloy, without melting the metallic alloy, and thereafter consolidating the metallic alloy to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.

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 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 metallic article 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 contains more of a base-metal element, such as nickel, cobalt, iron, iron-nickel, and iron-nickel-cobalt than any other metallic element. The mixture of nonmetallic precursor compounds is chemically reduced to produce a metallic superalloy material, without melting the metallic superalloy material. The metallic superalloy material is consolidated to produce a consolidated metallic article, without melting the metallic superalloy material and without melting the consolidated metallic article.

Abstract: An article has a metallic matrix made of its constituent elements with a dispersoid distributed therein. The article is prepared by furnishing at least one nonmetallic matrix precursor compound. All of the nonmetallic matrix precursor compounds collectively include the constituent elements of the metallic matrix in their respective constituent-element proportions. A mixture of an initial metallic material and the dispersoid is produced. The matrix precursor compounds are chemically reduced to produce the initial metallic material, without melting the initial metallic material, and the dispersoid is distributed in the initial metallic material. The mixture of the initial metallic material and the dispersoid is consolidated to produce a consolidated article having the dispersoid distributed in the metallic matrix comprising the initial metallic material. The initial metallic material, the dispersoid, and the consolidated article are not melted during the consolidation.

Abstract: A method to apply a material layer, comprises selecting a first material with a first melting temperature and a second material composition having a second melting temperature at least 40° C. lower than the first melting temperature; forming a suspension comprising the first material and second material composition in a carrier medium; depositing the suspension onto a surface to form a layer; and controllably heating the layer to a temperature at least 20° C. above the melting temperature of the second material composition but no higher than 20° C. below the melting temperature of the first material, to dissolve at least some of the first material in melted second material composition. A composition of matter, comprises a first material with a first melting temperature and a second material composition having a second melting temperature at least 40° C. lower than the first melting temperature and a carrier medium.

Abstract: A metallic article is prepared by first furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively containing the constituent elements of the metallic article in their respective constituent-element proportions. The constituent elements together form a titanium-base alloy having a stable-oxide-forming additive element therein, such as magnesium, calcium, scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium, and mixtures thereof. The stable-oxide-forming additive element forms a stable oxide in a titanium-based alloy. At least one additive element is present at a level greater than its room-temperature solid solubility limit in the titanium-base alloy. The precursor compounds are chemically reduced to produce an alloy material, without melting the alloy material. The alloy material may be consolidated.

Abstract: A gas turbine engine comprises (A) a turbine including a nozzle and shroud assembly supported within the engine; the nozzle and shroud assembly including an inner annular ring member, an outer annular ring structure and a plurality of airfoils being positioned between the inner and outer ring structure, wherein at least one of the airfoils of the plurality comprises; (i) a substrate comprising a first electrically conducting material; and (ii) a wire of dissimilar electrically conducting material extending a measured distance in intimate contact with the substrate at a reference point and electrically insulated to a measuring point.

Abstract: A solid oxide fuel cell comprises at least one hollow manifold, an anode, an electrolyte, and a cathode. The at least one hollow manifold comprises a wall that defines a chamber therein. A plurality of openings extending through, such that the plurality of openings are in flow communication with the chamber. The anode is formed on an exterior surface of the wall. The electrolyte is deposited on the anode, and the cathode is deposited on the electrolyte.

Abstract: A process for positioning at least one defect in a billet being forged into an article is described. The size and location of the billet is first determined, using a non-destructive test such as ultrasonic inspection. The movement of the defect under selected forging conditions is then predicted, using a finite element analysis model. The billet can then be positioned and forged under conditions which cause the defect to move to a non-critical area of the article. In this manner, a billet which might otherwise be discarded or set aside can often be retained for a useful purpose. Related articles are also described.

Abstract: A titanium article for an ultrasonic inspection is provided in which the titanium article can be ultrasonic inspected for determining its acceptability in for microstructurally sensitive applications. The ultrasonic inspection method comprises providing a titanium article, directing ultrasonic energy of ultrasonic inspection to the titanium article; scattering reflected energy in the titanium article; determining an amount of noise generated by the ultrasonic inspection of the titanium article; and characterizing the titanium article as acceptable if the amount of noise as a function of ultrasonic frequency or wavelength is characteristic of predominantly Rayleigh scattering and the magnitude of the noise is less than a pre-determined noise level. The titanium article comprises an uniform-fine grain microstructure. The uniform-fine grain microstructure generates predominantly Rayleigh scattering when undergoing ultrasonic inspection. The invention also sets forth a method of forming a titanium article.

Abstract: A method of repairing cracks, imperfections, and the like in a cast article of superalloy composition having a directionally oriented microstructure and growth axis. An aperture, usually frustois created in the article in the location of the crack or imperfection. A plug, having a second directionally oriented microstructure having a directional microstructure with a growth axis and a superalloy composition substantially identical to the article superalloy composition, is created. Such plug further possesses an inner end, an outer end, and a surface therebetween. The plug is inserted into the aperture whereby the plug growth axis is oriented in alignment with the article growth axis. Bonding material is applied between the surfaces of the plug and the aperture, before or after insertion of the plug into the aperture. The article is thereafter heated such that the bonding material joins the surface of the plug and the aperture.

Abstract: A ceramic casting shell mold having a pre-selected shape comprises alternate, repeating layers of a ceramic coating material and a ceramic stucco, defining a total thickness of the shell mold; and a ceramic-based reinforcing sheet disposed in the alternate, repeating layers of coating material and stucco at an intermediate thickness. The ceramic-based reinforcing sheet comprises a one-piece monolithic, integral body, which comprises a pattern of holes that enhance bonding between the ceramic-based reinforcing sheet and adjacent ones of the alternate, repeating layers of ceramic coating material. The ceramic-based reinforcing sheet conforms to the shape of the mold and providing structural reinforcement to the mold.

Abstract: An ultrasonic inspection method for inspecting titanium material is provided. The ultrasonic inspection method is capable of detecting critical flaws in the titanium material that may limit titanium material applications.

Abstract: A method for inspecting a titanium-based alloy that comprises alpha phase grains to detect flaws in the titanium-based alloy, the titanium-based alloy comprises an alpha phase that is provided by thermomechanically processing the alloy to provide a microstructure which comprises the alpha phase that defines an average grain size and a crystallographic orientation of the grains of the alpha phase that is highly randomized. The method comprises ultrasonically inspecting the titanium-based alloy using an ultrasonic beam, the ultrasonic beam comprising a cross-sectional area that is less than the average grain size of the alpha phase in the titanium-based alloy; and determining flaws based on the step of ultrasonic inspecting.

Abstract: An ultrasonic inspection method for determining acceptability of material for microstructurally sensitive applications comprises providing a material, directing ultrasonic energy of ultrasonic inspection to the material; scattering reflected energy in the material; determining an amount of noise generated by the ultrasonic inspection; and characterizing the material as acceptable if the amount of noise corresponds to a pre-determined noise level. The invention also sets forth a system for implementing the method, as embodied by the invention.