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 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 of making an article includes forming a molten material by melting at least a portion of a mass of a metal and an alloy. The method further includes forming the article by solidifying at least a portion of the molten material within a mold, and contacting the article with plasma during formation of the article. A method for making an article also is disclosed wherein a molten material is formed by melting at least a portion of a mass of one of a metal and an alloy, the molten material is collected within a mold, and at least a portion of the molten material is magnetohydrodynamically stirred within the mold.

Abstract: The present disclosure relates to electroslag remelting methods and apparatus for producing metallic ingots, as well as to articles of manufacture made from materials processed according to the methods and/or using the apparatus. One such method includes disposing slag within a withdrawal mold comprising a mold wall and an electrically conductive member disposed through the mold wall, contacting the slag with a consumable electrode, and heating the slag by conducting an electrical current through the consumable electrode into the slag, thereby melting at least a portion of the consumable electrode in contact with the slag. At least a fraction of the melted portion of the consumable electrode is collected in the withdrawal mold to form the ingot. At least a portion of the electrical current is conducted form the slag through the electrically conductive member.

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 cobalt-nickel-chromium-molybdenum alloy useful in surgical implant applications includes, in weight percent based on total alloy weight, at least 20 cobalt, 33.0 to 37.0 nickel, 19.0 to 21.0 chromium, 9.0 to 10.5 molybdenum, and less than 30 ppm nitrogen. Embodiments of the alloy lack significant levels of titanium nitride and mixed carbonitride inclusions. The alloy may be cold drawn to thin-gauge wire without damage to the die as may be caused by hard particle inclusions in certain conventional alloy formulations.