Abstract: A process for rejuvenating a turbine disk having a plurality of slots includes the steps of determining a depth of a damaged layer containing M23C6 carbide dissolution; and removing the damaged layer from the slots in accordance with the determined depth.

Abstract: A method of estimating an unknown solvus for a phase of a given alloy includes providing empirical data of a plurality of alloys from an alloy class, the empirical data at least including chemical compositions, heating rates, cooling rates and alloy solvus temperatures of the plurality of alloys, providing an alloy chemical composition, a selected heating rate and a selected cooling rate of another alloy from the alloy class that has an unknown solvus temperature, estimating the unknown solvus temperature based upon the empirical data to provide an estimated solvus temperature of the alloy, and establishing a solution heat treatment temperature corresponding to the estimated solvus temperature at which to treat a component that includes the alloy.

Abstract: A nickel alloying process includes providing a metal powder containing substantially unalloyed nickel for high inherent thermal conductivity, forming a nickel alloy from the metal powder with addition of additives to form a uniform fine thermo-dynamically stable incoherent precipitate dispersion like carbides, oxides or nitrides, apply mechanical or thermo-chemical reactions to form or maintain a uniform fine dispersion of the incoherent precipitates, removing air and absorbed water from the nickel alloy, and hot extruding the nickel alloy to substantially full density and prescribed dispersion strengthened condition. A net result is a dispersion strengthened high thermal conductivity nickel alloy.

Abstract: A process for rejuvenating a turbine disk having a plurality of slots includes the steps of determining a depth of a damaged layer containing M23C6 carbide dissolution; and removing the damaged layer from the slots in accordance with the determined depth.

Abstract: A method for adjusting properties of components made of an alloy includes providing historical data for one or more properties of components made of an alloy and produced at different times. The components are solution heat treated at a pre-established solution heat treatment condition. A trending change in the one or more properties is then identified and test specimens made of the alloy are provided. The test specimens are divided into a plurality of groups and solution heat treated at different conditions. The test specimens are then mechanically tested to provide empirical data. The empirical data is compared to performance criteria and a solution heat treatment condition is identified over which the empirical data meets the performance criteria. The pre-established solution heat treatment condition is then adjusted for future ones of the plurality of components according to the identified solution heat treatment condition.

Abstract: A seal assembly for a solid oxide fuel cell stack, includes at least two fuel cell stack components having opposed surfaces and a seal member disposed between the surfaces, wherein the seal member is a compliant seal member that is mechanically compliant in both in-plane and out-of-plane directions relative to the surfaces. The seal member is advantageously formed of one or more substantially continuous fibers. Further, preferred materials for the seal member are provided which advantageously allow for a desired level of impermeability while preventing contamination of the fuel cell stack.

Abstract: A castable high temperature aluminum alloy is cast by controlled solidification that combines composition design and solidification rate control to synergistically enhance the performance and versatility of the castable aluminum alloy for a wide range of elevated temperature applications. In one example, the aluminum alloy contains by weight approximately 1.0-20.0% of rare earth elements that contribute to the elevated temperature strength by forming a dispersion of insoluble particles via a eutectic microstructure. The aluminum alloy also includes approximately 0.1 to 15% by weight of minor alloy elements. Controlled solidification improves microstructural uniformity and refinement and provides the optimum structure and properties for the specific casting condition. The molten aluminum alloy is poured into an investment casing shell and lowered into a quenchant at a controlled rate.

Abstract: High toughness, high strength alloys are thermochemically processed by performing concurrent bulk alloy heat treatment and surface engineering processing. The concurrent steps can include high temperature solutionizing together with carburizing and tempering together with nitriding.

Abstract: A surface processing method and power transmission component includes transforming a surface region of a metal alloy into a hardened surface region at a temperature that is less than a heat treating temperature of the metal alloy. The metal alloy includes about 11.1 wt % Ni, about 13.4 wt % Co, about 3.0 wt % Cr, about 0.2 wt % C, and about 1.2 wt % Mo which reacts with the C to form a metal carbide precipitate of the form M2C. The surface processing temperature, vacuum pressure, precursor gas flow and ratio, and time of processing are controlled to provide a desirable hardened surface region having a gradual transition in nitrogen concentration.

Abstract: A durable Pd-based alloy is used for a H2-selective membrane in a hydrogen generator, as in the fuel processor of a fuel cell plant. The Pd-based alloy includes Cu as a binary element, and further includes “X”, where “X” comprises at least one metal from group “M” that is BCC and acts to stabilize the ? BCC phase for stability during operating temperatures. The metal from group “M” is selected from the group consisting of Fe, Cr, Nb, Ta, V, Mo, and W, with Nb and Ta being most preferred. “X” may further comprise at least one metal from a group “N” that is non-BCC, preferably FCC, that enhances other properties of the membrane, such as ductility. The metal from group “N” is selected from the group consisting of Ag, Au, Re, Ru, Rh, Y, Ce, Ni, Ir, Pt, Co, La and In. The at. % of Pd in the binary Pd—Cu alloy ranges from about 35 at. % to about 55 at. %, and the at. % of “X” in the higher order alloy, based on said binary alloy, is in the range of about 1 at. % to about 15 at. %.

Abstract: A castable high temperature aluminum alloy is cast by controlled solidification that combines composition design and solidification rate control to synergistically enhance the performance and versatility of the castable aluminum alloy for a wide range of elevated temperature applications. In one example, the aluminum alloy contains by weight approximately 1.0-20.0% of rare earth elements that contribute to the elevated temperature strength by forming a dispersion of insoluble particles via a eutectic microstructure. The aluminum alloy also includes approximately 0.1 to 15% by weight of minor alloy elements. Controlled solidification improves microstructural uniformity and refinement and provides the optimum structure and properties for the specific casting condition. The molten aluminum alloy is poured into an investment casing shell and lowered into a quenchant at a controlled rate.

Abstract: A castable high temperature aluminum alloy is cast by controlled solidification that combines composition design and solidification rate control to synergistically enhance the performance and versatility of the castable aluminum alloy for a wide range of elevated temperature applications. In one example, the aluminum alloy contains by weight approximately 1.0-20.0% of rare earth elements that contribute to the elevated temperature strength by forming a dispersion of insoluble particles via a eutectic microstructure. The aluminum alloy also includes approximately 0.1 to 15% by weight of minor alloy elements. Controlled solidification improves microstructural uniformity and refinement and provides the optimum structure and properties for the specific casting condition. The molten aluminum alloy is poured into an investment casing shell and lowered into a quenchant at a controlled rate.

Abstract: Components, such as gears and other power transmission components, are formed by near-net-forging a high strength, high toughness ferrous metal alloy, surface processing metal alloy to form a hardened surface region (28), and coating the surface region with a lubricious coating (84) as shown in FIG. 9.

Abstract: High toughness, high strength alloys are thermochemically processed by performing concurrent bulk alloy heat treatment and surface engineering processing. The concurrent steps can include high temperature solutionizing together with carburizing and tempering together with nitriding.

Abstract: A fuel cell stack includes a plurality of fuel cells each having an anode layer, an electrolyte layer, and a cathode layer, the fuel cells each having a first effective thermal expansion coefficient; a plurality of bipolar plates positioned between adjacent fuel cells having an anode interconnect, a separator plate, and a cathode interconnect, the bipolar plates being positioned between adjacent fuel cells, wherein the anode interconnect is in electrical communication with the anode layer of one adjacent fuel cell, wherein the cathode interconnect is in electrical communication with the cathode layer of another adjacent fuel cell, and wherein at least one interconnect of the cathode interconnect and the anode interconnect has a second thermal expansion coefficient and is adapted to reduce strain between the at least one interconnect and an adjacent fuel cell due to differences between the first and second thermal expansion coefficients over repeated thermal cycles.

Abstract: A nickel base super alloy composition wherein the ratio of molybdenum to tungsten or to the sum of tungsten and rhenium, Mo W ? ? ? o ? ? ? r , Mo W + Re Is in the range of about 0.25 to about 0.5 weight percent.

Abstract: An interconnect for a solid oxide fuel cell includes a compliant superstructure having a first portion defining a separator plate contact zone and a second portion defining an electrode contact zone, wherein the super structure is porous. In one embodiment, the superstructure is defined by a plurality of compliant substructures provided in a first direction and a plurality of compliant substructures provided in second direction to define a woven structure.

Abstract: A seal assembly for a solid oxide fuel cell stack, includes at least two fuel cell stack components having opposed surfaces and a seal member disposed between the surfaces, wherein the seal member is a compliant seal member that is mechanically compliant in both in-plane and out-of-plane directions relative to the surfaces. The seal member is advantageously formed of one or more substantially continuous fibers. Further, preferred materials for the seal member are provided which advantageously allow for a desired level of impermeability while preventing contamination of the fuel cell stack.

Abstract: A fuel cell stack includes a plurality of fuel cells each having an anode layer, an electrolyte layer, and a cathode layer, the fuel cells each having a first effective thermal expansion coefficient; a plurality of bipolar plates positioned between adjacent fuel cells having an anode interconnect, a separator plate, and a cathode interconnect, the bipolar plates being positioned between adjacent fuel cells, wherein the anode interconnect is in electrical communication with the anode layer of one adjacent fuel cell, wherein the cathode interconnect is in electrical communication with the cathode layer of another adjacent fuel cell, and wherein at least one interconnect of the cathode interconnect and the anode interconnect has a second thermal expansion coefficient and is adapted to reduce strain between the at least one interconnect and an adjacent fuel cell due to differences between the first and second thermal expansion coefficients over repeated thermal cycles.

Abstract: A nickel base super alloy composition wherein the ratio of molybdenum to tungsten or to the sum of tungsten and rhenium, 1 M ⁢   ⁢ o W ⁢   ⁢ o ⁢   ⁢ r , M ⁢   ⁢ o W + R ⁢   ⁢ e