Abstract: A nanocomposite comprising a plurality of nanoparticles dispersed in a molybdenum-based matrix, and an x-ray tube component formed from such a nanocomposite. The nanocomposite contains volume fraction of nanoparticle dispersoids in a range from about 2 volume percent to about 20 volume percent. A method of making such molybdenum-based nanocomposites is also disclosed.

Abstract: A nanocomposite comprising a plurality of nanoparticles dispersed in a molybdenum-based matrix, and an x-ray tube component formed from such a nanocomposite. The nanocomposite contains volume fraction of nanoparticle dispersoids in a range from about 2 volume percent to about 20 volume percent. A method of making such molybdenum-based nanocomposites is also disclosed.

Abstract: A nanocomposite comprising a plurality of nanoparticles dispersed in a molybdenum-based matrix, and an x-ray tube component formed from such a nanocomposite. The nanocomposite contains volume fraction of nanoparticle dispersoids in a range from about 2 volume percent to about 20 volume percent. A method of making such molybdenum-based nanocomposites is also disclosed.

Abstract: A method and apparatus for casting a near-net-shape article from a high temperature material, such as a refractory metal intermetallic composite material. The apparatus includes: a means for forming a molten material comprising at least one of a metal and an alloy; a means for pouring the molten material; a mold assembly comprising a solid shell having a face coat interposed between the solid shell and molten material; and a heater assembly for maintaining the solid shell at a temperature. The molten material solidifies within the solid shell to form a near-net shape of the article. The near-net shape article may be a turbine assembly component, such as, but not limited to, a vane or airfoil.

Abstract: A method and apparatus for casting a near-net-shape article from a high temperature material, such as a refractory metal intermetallic composite material. The apparatus includes: a means for forming a molten material comprising at least one of a metal and an alloy; a means for pouring the molten material; a mold assembly comprising a solid shell having a face coat interposed between the solid shell and molten material; and a heater assembly for maintaining the solid shell at a temperature. The molten material solidifies within the solid shell to form a near-net shape of the article. The near-net shape article may be a turbine assembly component, such as, but not limited to, a vane or airfoil.

Abstract: Methods for repairing and manufacturing a gas turbine airfoil, and the airfoil repaired and manufactured with such methods are presented with, for example, the repair method comprising providing an airfoil having specified nominal dimensions, the airfoil comprising a first material, the first material having a creep life and a fatigue life, the airfoil further comprising a leading edge section and a trailing edge section; removing at least one portion of at least one section of the airfoil to create at least one deficit of material for the airfoil relative to the specified nominal dimensions, the at least one section selected from the group consisting of the leading edge section and the trailing edge section; providing at least one insert comprising a second material, the second material having a creep life that is at least substantially equal to the creep life of the first material, and a fatigue life that is at least substantially equal to the fatigue life of the first material; and disposing the at least o

Abstract: An article of manufacture forms a tool for determining cleaning parameters of an oxide removal process. The article comprises a block of material upon which an oxide can be formed and a simulated defect structure disposed in the block of material. The article is capable of determining oxide removal parameters of an oxide removal process by disposing an oxidized standard in a reactor, conducting an oxide removal process to remove oxide from the standard, and evaluating the standard and simulated defect structure for remaining oxide and other oxide removal parameters.

Abstract: Methods for repairing and manufacturing a gas turbine airfoil, and the airfoil repaired and manufactured with such methods are presented with, for example, the repair method comprising providing an airfoil having specified nominal dimensions, the airfoil comprising a first material, the first material having a creep life and a fatigue life, the airfoil further comprising a leading edge section and a trailing edge section; removing at least one portion of at least one section of the airfoil to create at least one deficit of material for the airfoil relative to the specified nominal dimensions, the at least one section selected from the group consisting of the leading edge section and the trailing edge section; providing at least one insert comprising a second material, the second material having a creep life that is at least substantially equal to the creep life of the first material, and a fatigue life that is at least substantially equal to the fatigue life of the first material; and disposing the at least o

Abstract: An article of manufacture forms a tool for determining cleaning parameters of an oxide removal process. The article comprises a block of material upon which an oxide can be formed and a simulated defect structure disposed in the block of material. The article is capable of determining oxide removal parameters of an oxide removal process by disposing an oxidized standard in a reactor, conducting an oxide removal process to remove oxide from the standard, and evaluating the standard and simulated defect structure for remaining oxide and other oxide removal parameters.

Abstract: A method of repairing cracks, imperfections, and the like in a cast article. A frusto-conical aperture is created in the article in the location of the crack or imperfection. A mating tapered plug is prepared such that the tapered plug can fit into the aperture so that the sloped side walls of the tapered plug evenly and unilaterally rest on frusto-conical sides of the aperture. The tapered plug is disposed into the aperture, and bonding material is applied between the surfaces of the tapered plug and the aperture, before or after insertion of the tapered plug into the aperture. The article is thereafter heated such that the bonding material joins the surfaces of the tapered plug and the aperture. The outer end of the tapered plug thereafter is polished so that such outer end is approximately level with the article's outer side in a refinement of the invention, the plug member may be pushed into the aperture such that a controlled interference fit is produced.

Abstract: In a method and apparatus for the electroslag refining of metal, the method includes providing a refining vessel to contain an electroslag refining layer floating on a layer of molten refined metal. The refining vessel representing an upper part of a cooled mould comprises a plurality of superimposed sleeves which are electrically insulated from one another. The top sleeve, being the refining vessel, is substantially a non-consumable electrode and has a current lead electrically insulated from the sleeve. The molten electroslag layer is heated by a refining current which is passed from a power source through the mould and slag layer to the metal pool. An unrefined metal is lowered into the vessel into contact with the molten electroslag layer such that its surface is melted and overheated at the point of contact with the slag such that droplets of the metal are formed and these droplets pass down through the slag and are collected in a pool of molten refined metal beneath the slag.

Abstract: A method of forming an internal channel within an article, such as a cooling channel in an air-cooled blade, vane, shroud, combustor or duct of a gas turbine engine. The method generally entails forming a substrate to have a groove recessed in its surface. A sacrificial material is then deposited in the groove to form a filler that can be preferentially removed from the groove. A permanent layer is then deposited on the surface of the substrate and over the filler, after which the filler is removed from the groove to yield the desired channel in the substrate beneath the permanent layer.

Abstract: A system for controlling the flow rate of the stream from an electroslag refining apparatus is taught. The system includes the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth.

Abstract: A method of repairing cracks, imperfections, and the like in a cast article. A frusto-conical aperture is created in the article in the location of the crack or imperfection. A mating tapered plug is prepared such that the tapered plug can fit into the aperture so that the sloped side walls of the tapered plug evenly and unilaterally rest on frusto-conical sides of the aperture. The tapered plug is disposed into the aperture, and bonding material is applied between the surfaces of the tapered plug and the aperture, before or after insertion of the tapered plug into the aperture. The article is thereafter heated such that the bonding material joins the surfaces of the tapered plug and the aperture. The outer end of the tapered plug thereafter is polished so that such outer end is approximately level with the article's outer side in a refinement of the invention, the plug member may be pushed into the aperture such that a controlled interference fit is produced.

Abstract: Systems for controlling the superheat of the stream of molten metal from an electroslag refining apparatus is taught. The systems include the introduction of unrefined metal into an electroslag refining process apparatus in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout or exit orifice is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth.

Abstract: A method for forming an exterior surface of a high-temperature component, such as a blade or vane of a gas turbine engine. The method entails forming a shell by a powder metallurgy technique that yields an airfoil whose composition can be readily tailored for the particular service conditions of the component. The method generally entails providing a pair of inner and outer mold members that form a cavity therebetween. One or more powders and any desired reinforcement material are then placed in the cavity and then consolidated at an elevated temperature and pressure in a non-oxidizing atmosphere. Thereafter, at least the outer mold member is removed to expose the consolidated powder structure. By appropriately shaping the mold members to tailor the shape of the cavity, the consolidated powder structure has the desired shape for the exterior shell of a component, such that subsequent processing of the component does not require substantially altering the configuration of the exterior shell.

Abstract: A method for forming an exterior surface of a high-temperature component, such as a blade or vane of a gas turbine engine. The method entails forming a shell by a powder metallurgy technique that yields an airfoil whose composition can be readily tailored for the particular service conditions of the component. The method generally entails providing a pair of inner and outer mold members that form a cavity therebetween. One or more powders and any desired reinforcement material are then placed in the cavity and then consolidated at an elevated temperature and pressure in a non-oxidizing atmosphere. Thereafter, at least the outer mold member is removed to expose the consolidated powder structure. By appropriately shaping the mold members to tailor the shape of the cavity, the consolidated powder structure has the desired shape for the exterior shell of a component, such that subsequent processing of the component does not require substantially altering the configuration of the exterior shell.

Abstract: A system and method of electroslag refining of metal is taught. The system and method includes the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The dimensions of the cold finger apparatus pour spout are controlled by positioning a retaining means around the outer surface of the pour spout thereby controlling the flow rate of molten metal through the cold finger apparatus.

Abstract: A melt guide is provided for enclosing a bottom of an electroslag refining crucible containing a melt of electroslag refined metal. A base plate is sized to have a perimeter to engage the crucible bottom for attachment thereto. The base plate includes an upper surface for defining with the crucible a reservoir for receiving the melt, and a lower surface spaced therebelow. A central drain extends through the base plate for draining by gravity the melt from the reservoir. A plurality of circumferentially spaced apart slots extend radially outwardly from the drain toward the base plate perimeter and extend vertically through the base plate. Induction heating coils are mounted below the base plate lower surface for heating the melt through the slots. The base plate may take various forms including a flat plate, with or without a cooperating and removable insert.

Abstract: Methods for controlling the superheat of the stream of molten metal from an electroslag refining apparatus is taught. The methods include the introduction of unrefined metal into an electroslag refining process apparatus in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout or exit orifice is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth.