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 method for making an article comprising a multilayered structure comprising a series of magnetic layers is provided. The method includes providing a substrate and depositing a series of magnetic layers on the substrate and disposing insulating layers between successive magnetic layers. Each magnetic layer has a thickness of at least about 2 micrometers and magnetic material has an average grain size less than 200 nm.

Abstract: An amorphous magnetic alloy is presented. The alloy has the general formula: (Fe1-xCox)nMoaPbBcCdSie, wherein n is the atomic percent of iron and cobalt; x is the fraction of n; a, b, c, d and e are the atomic percent of molybdenum, phosphorous, boron, carbon and silicon respectively and n, x, a, b, c, d and e are defined by following relationship: 76?n?85; 0.05<x?0.50; 0?a?4; b?10; 0?c<d; and 0.1?e?2. Articles comprising the alloy and methods employing the alloy for making articles are also presented.

Abstract: Coatings suitable for use as protective oxide-forming coatings on Nb-based substrates exposed to high temperatures and oxidative environments. The coatings contain chromium and/or molybdenum, preferably contains silicon, and optionally contains niobium, titanium, hafnium, iron, rhenium, tantalum, and/or tungsten, which in combination form multiple intermetallic phases, which in combination form one or more intermetallic phases that promote the formation of a slow-growing oxide scale. Depending on the particular coating composition, the intermetallic phases maybe: a silicon-modified Cr2Nb Laves phase and optionally a chromium solid solution phase, a CrNbSi intermetallic phase, and/or an M3Si intermetallic phase where M is niobium, titanium, and/or chromium; or M5Si3, MSi2 and/or M3Si2 where M is molybdenum, niobium, titanium, chromium, hafnium, iron, rhenium, tantalum, and/or tungsten.

Abstract: A method of coating a substrate with cryo-milled, nano-grained particles includes forming a face-centered-cubic gamma matrix comprising nickel, cobalt, chromium, tungsten and molybdenum, adding a dispersion strengthening material to the gamma matrix to form a first mixture, cryo-milling the first mixture to form a second mixture to form a nano-grained structure, and cold spraying the second mixture onto a substrate to form a coating having a nano-grained structure.

Abstract: Coatings suitable for use as protective oxide-forming coatings on Nb-based substrates exposed to high temperatures and oxidative environments. The coatings contain chromium and/or molybdenum, preferably contains silicon, and optionally contains niobium, titanium, hafnium, iron, rhenium, tantalum, and/or tungsten, which in combination form multiple intermetallic phases, which in combination form one or more intermetallic phases that promote the formation of a slow-growing oxide scale. Depending on the particular coating composition, the intermetallic phases may be: a silicon-modified Cr2Nb Laves phase and optionally a chromium solid solution phase, a CrNbSi intermetallic phase, and/or an M3Si intermetallic phase where M is niobium, titanium, and/or chromium; or M5Si3, MSi2 and/or M3Si2 where M is molybdenum, niobium, titanium, chromium, hafnium, iron, rhenium, tantalum, and/or tungsten.

Abstract: The present invention provides a method for forming a refractory metal-intermetallic composite. The method includes providing a first powder comprising a refractory metal suitable for forming a metal phase; providing a second powder comprising a silicide precursor suitable for forming an intermetallic phase; blending the first powder and the second powder to form a powder blend; consolidating and mechanically deforming the powder blend at a first temperature; and reacting the powder blend at a second temperature to form the metal phase and the intermetallic phase of the refractory metal-intermetallic composite, wherein the second temperature is higher than the first temperature.

Abstract: An amorphous magnetic alloy is presented. The alloy has the general formula: (Fe1-xCox)nMoaPbBcCdSie, wherein n is the atomic percent of iron and cobalt; x is the fraction of n; a, b, c, d and e are the atomic percent of molybdenum, phosphorous, boron, carbon and silicon respectively and n, x, a, b, c, d and e are defined by following relationship: 76?n?85; 0.05<x?0.50; 0?a?4; b?10; 0?c<d; and 0.1?e?2. Articles comprising the alloy and methods employing the alloy for making articles are also presented.

Abstract: An article including a monolithic body including iron, cobalt, and nitrogen is provided. The monolithic body includes a matrix phase and a plurality of particles disposed within the matrix phase. The particles include a phase comprising nitrogen.

Abstract: Articles suitable for use in high temperature applications, such as turbomachinery components, and methods for making such articles, are provided. One embodiment is an article. The article comprises a material comprising a plurality of L12-structured gamma-prime phase precipitates distributed within a matrix phase at a concentration of at least 20% by volume, wherein the gamma-prime phase precipitates are less than 1 micrometer in size, and a plurality of A3-structured eta phase precipitates distributed within the matrix phase at a concentration in the range from about 1% to about 25% by volume. The solvus temperature of the eta phase is higher than the solvus temperature of the gamma-prime phase. Moreover, the material has a median grain size less than 10 micrometers. The method comprises providing a workpiece, the workpiece comprising at least about 40% nickel, from about 1.5% to about 8% titanium, and from about 1.5% to about 4.5% aluminum.

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: An article comprising a multilayered structure comprising a series of magnetic layers is provided. The magnetic layers comprise a magnetic material, and an insulating layer is disposed between successive magnetic layers. Each magnetic layer has a thickness of at least about 2 micrometers and magnetic material has an average grain size less than 200 nm. Also provided is a method for making the article.

Abstract: A coating suitable for use as protective oxide-forming coatings on Nb-based substrates, and particularly monolithic niobium-based alloys, exposed to high temperatures and oxidative environments. The coating contains aluminum, may further contain silicon, and optionally contains niobium, titanium, hafnium, and/or chromium, which in combination form one or more intermetallic phases that promote the formation of a slow-growing oxide scale. The intermetallic phases may be M(Al,Si)3, M5(Al,Si)3, and/or M3Si5Al2 where M is niobium, titanium, hafnium, and/or chromium.

Abstract: Coatings suitable for use as protective oxide-forming coatings on Nb-based substrates exposed to high temperatures and oxidative environments. The coatings contain chromium and/or molybdenum, preferably contains silicon, and optionally contains niobium, titanium, hafnium, iron, rhenium, tantalum, and/or tungsten, which in combination form multiple intermetallic phases, which in combination form one or more intermetallic phases that promote the formation of a slow-growing oxide scale. Depending on the particular coating composition, the intermetallic phases may be: a silicon-modified Cr2Nb Laves phase and optionally a chromium solid solution phase, a CrNbSi intermetallic phase, and/or an M3Si intermetallic phase where M is niobium, titanium, and/or chromium; or M5Si3, MSi2 and/or M3Si2 where M is molybdenum, niobium, titanium, chromium, hafnium, iron, rhenium, tantalum, and/or tungsten.

Abstract: A method for making an article comprising a multilayered structure comprising a series of magnetic layers is provided. The method includes providing a substrate and depositing a series of magnetic layers on the substrate and disposing insulating layers between successive magnetic layers. Each magnetic layer has a thickness of at least about 2 micrometers and magnetic material has an average grain size less than 200 nm.

Abstract: The present invention provides methods for manufacturing an article having a wetting-resistant surface. The method includes providing a substrate. The method further includes disposing a coating mixture on a surface of the substrate, wherein the coating mixture comprises a braze material and a texture-providing material. The method further includes heating the braze material to bond the texture-providing material to the surface of the substrate to form the article having the wetting-resistant surface.

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: 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 oxidation resistance better than or comparable to rhenium-bearing single-crystal alloys, and creep rupture life comparable to 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: 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 resistance substantially equivalent to 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 altering a dimension of an element made of an amorphous metallic material is provided. The method includes providing an anode comprising the amorphous metallic material, wherein the amorphous metallic material comprises at least two primary constituents, providing a cathode disposed in a spaced-apart relationship with the anode, providing an electrolyte in contact with the anode and the cathode, and applying an electrical potential between the anode and the cathode.