Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.

Abstract: Embodiments of the present disclosure relate to nickel-base alloys and methods of direct aging nickel-base alloys. More specifically, certain embodiments of the present disclosure relate to methods of direct aging 718Plus® nickel-base alloy to impart improved mechanical properties, such as, but not limited to, tensile strength, yield strength, low cycle fatigue, fatigue crack growth, and creep and rupture life to the alloys. Other embodiments of the present disclosure relate to direct aged 718Plus® nickel-base alloy, and articles of manufacture made therefrom, having improved mechanical properties, such as, but not limited to, tensile strength, yield strength, low cycle fatigue, fatigue crack growth, and creep and rupture life.

Abstract: Embodiments of the present invention relate to nickel-base alloys, and in particular 718-type nickel-base alloys, having a desired microstructure that is predominantly strengthened by ??-phase precipitates and comprises an amount of at least one grain boundary precipitate. Other embodiments of the present invention relate to methods of heat treating nickel-base alloys, and in particular 718-type nickel-base alloys, to develop a desired microstructure that can impart thermally stable mechanical properties. Articles of manufacture using the nickel-base alloys and methods of heat treating nickel-base alloys according to embodiments of the present invention are also disclosed.

Abstract: Embodiments of the present invention provide methods of processing cobalt alloys including, in weight percent, from 26 to 30 chromium, from 5 to 7 molybdenum, and greater than 50 cobalt, the methods comprises cold working and aging the alloys such that after aging the cobalt alloys have a hardness of at least Rockwell C 50. Other embodiments provide methods of selectively cold working at least one portion of a cobalt alloy, and subsequently aging the alloy, such after aging, the selectively cold worked portions of the alloy have a higher hardness value then portions of the alloy that were not selectively cold worked. The present invention also discloses cobalt alloys, implants, and articles of manufacture made from cobalt alloys within the present invention.

Abstract: Embodiments of the present invention relate to nickel-base alloys, and in particular 718-type nickel-base alloys, having a desired microstructure that is predominantly strengthened by ??-phase precipitates and comprises an amount of at least one grain boundary precipitate. Other embodiments of the present invention relate to methods of heat treating nickel-base alloys, and in particular 718-type nickel-base alloys, to develop a desired microstructure that can impart thermally stable mechanical properties. Articles of manufacture using the nickel-base alloys and methods of heat treating nickel-base alloys according to embodiments of the present invention are also disclosed.

Abstract: A nickel-base alloy having favorable toughness and thermal fatigue resistance comprises, in weight percentages based on total alloy weight: 9 to 20 chromium; 25 to 35 iron; 1 to 3 molybdenum; 3.0 to 5.5 niobium; 0.2 to 2.0 aluminum; 0.3 to 3.0 titanium; less than 0.10 carbon; no more than 0.01 boron; nickel; and incidental impurities. Also disclosed are die casting dies, other tooling, and other articles of manufacture made from or comprising the nickel-base alloy.

Abstract: An apparatus for melting an electrically conductive metallic material includes a vacuum chamber and a hearth disposed in the vacuum chamber. At least one wire-discharge ion plasma electron emitter is disposed in or adjacent the vacuum chamber and is positioned to direct a wide-area field of electrons into the vacuum chamber, wherein the wide-area electron field has sufficient energy to heat the electrically conductive metallic material to its melting temperature. The apparatus may further include at least one of a mold and an atomizing apparatus which is in communication with the vacuum chamber and is positioned to receive molten material from the hearth.

Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.

Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.

Abstract: Embodiments of the present invention relate to nickel-base alloys, and in particular 718-type nickel-base alloys, having a desired microstructure that is predominantly strengthened by ??-phase precipitates and comprises an amount of at least one grain boundary precipitate. Other embodiments of the present invention relate to methods of heat treating nickel-base alloys, and in particular 718-type nickel-base alloys, to develop a desired microstructure that can impart thermally stable mechanical properties. Articles of manufacture using the nickel-base alloys and methods of heat treating nickel-base alloys according to embodiments of the present invention are also disclosed.

Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.

Abstract: Embodiments of the present invention provide methods of processing cobalt alloys including, in weight percent, from 26 to 30 chromium, from 5 to 7 molybdenum, and greater than 50 cobalt, the methods comprises cold working and aging the alloys such that after aging the cobalt alloys have a hardness of at least Rockwell C 50. Other embodiments provide methods of selectively cold working at least one portion of a cobalt alloy, and subsequently aging the alloy, such after aging, the selectively cold worked portions of the alloy have a higher hardness value then portions of the alloy that were not selectively cold worked. The present invention also discloses cobalt alloys, implants, and articles of manufacture made from cobalt alloys within the present invention.

Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.

Abstract: A nickel-based fine grained alloy consisting essentially of 40-55 wt % Ni, 14.5-21 wt % Cr, 2.5-5.5 wt % Nb+Ta, up to 3.3 wt % Mo, 0.65-2.00 wt % Ti, 0.10-0.8 wt % Al, up to 0.35 wt % Mn, up to 0.07 wt % C, up to 0.015 wt % S, up to 0.35 wt % Si, at least 0.016 wt % P, from 0.003 % to 0.030 wt % B, and the balance Fe and incidental impurities, has a high stress rupture life.

Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.

Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.

Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.

Abstract: A nickel-based fine grained alloy consisting essentially of 40-55 wt % Ni, 14.5-21 wt % Cr, 2.5-5.5 wt % Nb+Ta, up to 3.3 wt % Mo, 0.65-2.00 wt % Ti, 0.10-0.8 wt % Al, up to 0.35 wt % Mn, up to 0.07 wt % C, up to 0.015 wt % S, up to 0.35 wt % Si, at least 0.016 wt % P, from 0.003 % to 0.030 wt % B, and the balance Fe and incidental impurities, has a high stress rupture life.