Abstract: Components and methods of processing such components from precipitation-strengthened alloys so that the components exhibit desirable grain sizes following a supersolvus heat treatment. The method includes consolidating a powder of the alloy to form a billet having an average grain size. The billet is then forged at a temperature below the solvus temperature to form a forging having an average grain size of not coarser than the grain size of the billet. The billet is then forged at a total strain of at least 5%, after which at least a portion of the forging is heat treated at a temperature below the solvus temperature to pin grains within the portion. The entire forging can then be heat treated at a temperature above the solvus temperature of the alloy without coarsening the grains in the portion.

Abstract: Components and methods of processing such components from precipitation-strengthened alloys so that the components exhibit desirable grain sizes following a supersolvus heat treatment. The method includes consolidating a powder of the alloy to form a billet having an average grain size. The billet is then forged at a temperature below the solvus temperature to form a forging having an average grain size of not coarser than the grain size of the billet. The billet is then forged at a total strain of at least 5%, after which at least a portion of the forging is heat treated at a temperature below the solvus temperature to pin grains within the portion. The entire forging can then be heat treated at a temperature above the solvus temperature of the alloy without coarsening the grains in the portion.

Abstract: Improved methods and containers for forming billets using hot isostatic pressing are provided. The methods and containers have features that control the deformations of the container during the high temperatures and pressures experienced in such processing so that the loss or removal of material from the resulting billet can be optimized.

Abstract: A powder metallurgical article and process are disclosed. The article is a repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a formed article including a first alloy and a material including a second alloy. The material is welded to the formed article to form the repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a substantially uniform grain structure.

Abstract: A formed article comprising a nanostructured ferritic alloy is provided. Advantageously, the article is not formed via extrusion, and thus, cost savings are provided. Methods are also provided for forming the article, and the articles so produced, exhibit sufficient continuous cycle fatigue crack growth resistance and hold time fatigue crack growth resistance to be utilized as turbomachinery components, and in particular, large, hot section components of a gas or steam turbine engines. In other embodiments, a turbomachinery component comprising an NFA is provided, and in some such embodiments, the turbomachinery component may be extruded.

Abstract: A method of separating a powder mixture is disclosed. A first magnetic field is applied to the powder mixture which may contains a non-magnetic metal powder and a contaminant powder. A field strength of the first magnetic field magnetizes the non-magnetic metal powder and leaves the contaminant powder non-magnetized. A second magnetic field is applied to the powder mixture to separate the magnetized metal powder from the non-magnetized contaminant powder.

Abstract: A powder metallurgical article and process are disclosed. The article is a repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a formed article including a first alloy and a material including a second alloy. The material is welded to the formed article to form the repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a substantially uniform grain structure.

Abstract: A method of separating a powder mixture is disclosed. A first magnetic field is applied to the powder mixture which may contains a non-magnetic metal powder and a contaminant powder. A field strength of the first magnetic field magnetizes the non-magnetic metal powder and leaves the contaminant powder non-magnetized. A second magnetic field is applied to the powder mixture to separate the magnetized metal powder from the non-magnetized contaminant powder.

Abstract: Components and methods of processing such components from precipitation-strengthened alloys so that the components exhibit desirable grain sizes following a supersolvus heat treatment. The method includes consolidating a powder of the alloy to form a billet having an average grain size. The billet is then forged at a temperature below the solvus temperature to form a forging having an average grain size of not coarser than the grain size of the billet. The billet is then forged at a total strain of at least 5%, after which at least a portion of the forging is heat treated at a temperature below the solvus temperature to pin grains within the portion. The entire forging can then be heat treated at a temperature above the solvus temperature of the alloy without coarsening the grains in the portion.

Abstract: An article includes a first section extending from an outer periphery to a predetermined surface located inward from the outer periphery. The first section comprises a nanostructured ferritic alloy. The article includes a second section extending from an inner periphery to the predetermined surface located outward from the inner periphery. The second section comprises at least one other alloy different from the nanostructured ferritic alloy.

Abstract: A alloy and a process of forming a alloy are disclosed. The alloy has a predetermined grain boundary morphology. The alloy includes by weight greater than about 0.06 percent carbon, up to about 0.0015 percent sulfur, less than about 16 percent chromium, between about 39 percent and about 44 percent nickel, between about 2.5 percent and about 3.3 percent niobium, between about 1.4 percent and about 2 percent titanium, up to about 0.5 percent aluminum, up to about 0.006 percent boron, up to about 0.3 percent copper, up to about 0.006 percent nitrogen, and greater than about 0.5 percent molybdenum.

Abstract: An improved container and method for forming billets using hot isostatic pressing is provided. The method and container allows for adjusting the volume of the container so as to obtain a billet of the desired shape based on selected powder charge for the container. In addition, the corner of the container can be adjusted to allow for elimination of edge effects and further shape control in the resulting billet.

Abstract: A formed article comprising a nanostructured ferritic alloy is provided. Advantageously, the article is not formed via extrusion, and thus, cost savings are provided. Methods are also provided for forming the article, and the articles so produced, exhibit sufficient continuous cycle fatigue crack growth resistance and hold time fatigue crack growth resistance to be utilized as turbomachinery components, and in particular, large, hot section components of a gas or steam turbine engines. In other embodiments, a turbomachinery component comprising an NFA is provided, and in some such embodiments, the turbomachinery component may be extruded.

Abstract: A method for forming an oxide-dispersion strengthened coating on a metal substrate is disclosed. The method generally includes comminuting MCrAlY alloy particles to form an oxygen-enriched powder, wherein at least about 25% by volume of the MCrAlY alloy particles within the oxygen-enriched powder have a particle size of less than about 5 ?m. Additionally, the method includes applying the oxygen-enriched powder to the metal substrate to form a coating and heating the oxygen-enriched powder to precipitate oxide dispersoids within the coating.

Abstract: Components and methods of processing such components from precipitation-strengthened alloys so that the components exhibit desirable grain sizes following a supersolvus heat treatment. The method includes consolidating a powder of the alloy to form a billet having an average grain size. The billet is then forged at a temperature below the solvus temperature to form a forging having an average grain size of not coarser than the grain size of the billet. The billet is then forged at a total strain of at least 5%, after which at least a portion of the forging is heat treated at a temperature below the solvus temperature to pin grains within the portion. The entire forging can then be heat treated at a temperature above the solvus temperature of the alloy without coarsening the grains in the portion.

Abstract: An improved method and container for forming billets using hot isostatic pressing is provided. The improved method and container have features that control the deformations of the container during the high temperatures and pressures experienced in such processing so as to provide a billet having a predetermined shape such as, for example, substantially parallel, convex, and/or concave sides. Conservations of the powder used for the billet and more efficient use of the container upon the resulting billet can be achieved.

Abstract: A method for forming an oxide-dispersion strengthened coating on a metal substrate is disclosed. The method generally includes comminuting MCrAlY alloy particles to form an oxygen-enriched powder, wherein at least about 25% by volume of the MCrAlY alloy particles within the oxygen-enriched powder have a particle size of less than about 5 ?m. Additionally, the method includes applying the oxygen-enriched powder to the metal substrate to form a coating and heating the oxygen-enriched powder to precipitate oxide dispersoids within the coating.

Abstract: A alloy and a process of forming a alloy are disclosed. The alloy has a predetermined grain boundary morphology. The alloy includes by weight greater than about 0.06 percent carbon, up to about 0.0015 percent sulfur, less than about 16 percent chromium, between about 39 percent and about 44 percent nickel, between about 2.5 percent and about 3.3 percent niobium, between about 1.4 percent and about 2 percent titanium, up to about 0.5 percent aluminum, up to about 0.006 percent boron, up to about 0.3 percent copper, up to about 0.006 percent nitrogen, and greater than about 0.5 percent molybdenum.

Abstract: A method for near net shape forging a titanium component includes heating a titanium billet to a temperature in the alpha-beta temperature range and extruding the titanium billet into a first die having a temperature approximately 500° F. below the temperature of the titanium billet. A system for near net shape forging a titanium component includes a titanium billet having a temperature in the alpha-beta temperature range and a punch in contact with the titanium billet. A first die proximate to the titanium billet for receiving the titanium billet has a temperature approximately 500° F. below the temperature of the titanium billet.

Abstract: A forging preform for a turbine rotor disk is disclosed. The preform includes a body of a superalloy material having a mass of about 5000 lbs or more, the superalloy material having a substantially homogeneous grain morphology and an ASTM average grain size of 10 or smaller. 5. A turbine rotor disk is also disclosed. The disk includes a substantially cylindrical disk of a superalloy material having a mass of about 5000 lbs or more, the superalloy material having a substantially homogeneous grain morphology and an ASTM average grain size of about 10 or smaller. A method of making a turbine rotor disk is also disclosed. The method includes providing a superalloy powder material and pressing the superalloy powder material to form a forging preform for a turbine rotor disk.