Abstract: A method of producing a metallic powder material comprises supplying feed materials to a melting hearth, and melting the feed materials on the melting hearth with a first heat source to provide a molten material having a desired chemical composition. At least a portion of the molten material is passed from the melting hearth either directly or indirectly to an atomizing hearth, where it is heated using a second heat source. At least a portion of the molten material from the atomizing hearth is passed in a molten state to an atomizing apparatus, which forms a droplet spray from the molten material. At least a portion of the droplet spray is solidified to provide a metallic powder material.

Abstract: A method of processing a metal alloy includes heating to a temperature in a working temperature range from a recrystallization temperature of the metal alloy to a temperature less than an incipient melting temperature of the metal alloy, and working the alloy. At least a surface region is heated to a temperature in the working temperature range. The surface region is maintained within the working temperature range for a period of time to recrystallize the surface region of the metal alloy, and the alloy is cooled so as to minimize grain growth. In embodiments including superaustenitic and austenitic stainless steel alloys, process temperatures and times are selected to avoid precipitation of deleterious intermetallic sigma-phase. A hot worked superaustenitic stainless steel alloy having equiaxed grains throughout the alloy is also disclosed.

Abstract: Processes and methods related to processing and hot working alloy ingots are disclosed. A metallic material layer is deposited onto at least a region of a surface of an alloy ingot before hot working the alloy ingot. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.

Abstract: Processes and methods related to processing and hot working alloy ingots are disclosed. A metallic material layer is deposited onto at least a region of a surface of an alloy ingot before hot working the alloy ingot. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.

Abstract: A method of processing a workpiece to inhibit precipitation of intermetallic compounds includes at least one of thermomechanically processing and cooling a workpiece including an austenitic alloy. During the at least one of thermomechanically working and cooling the workpiece, the austenitic alloy is at temperatures in a temperature range spanning a temperature just less than a calculated sigma solvus temperature of the austenitic alloy down to a cooling temperature for a time no greater than a critical cooling time.

Abstract: A method of producing a metallic powder material comprises supplying feed materials to a melting hearth, and melting the feed materials on the melting hearth with a first heat source to provide a molten material having a desired chemical composition. At least a portion of the molten material is passed from the melting hearth either directly or indirectly to an atomizing hearth, where it is heated using a second heat source. At least a portion of the molten material from the atomizing hearth is passed in a molten state to an atomizing apparatus, which forms a droplet spray from the molten material. At least a portion of the droplet spray is solidified to provide a metallic powder material.

Abstract: Processes and methods related to processing and hot working alloy ingots are disclosed. A metallic material layer is deposited onto at least a region of a surface of an alloy ingot before hot working the alloy ingot. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.

Abstract: Methods of refining the grain size of titanium and titanium alloys include multiple upset and draw forging. Titanium and titanium alloy workpieces are heated to a workpiece forging temperature within a workpiece forging temperature range in the alpha+beta phase field. The workpiece may comprise a starting cross-sectional dimension. The workpiece is upset forged in the workpiece forging temperature range. After upsetting, the workpiece is multiple pass draw forged in the workpiece forging temperature range. Multiple pass draw forging may comprise incrementally rotating the workpiece in a rotational direction followed by draw forging the workpiece after each incremental rotation. Incrementally rotating and draw forging the workpiece is repeated until the workpiece comprises substantially the same starting cross-sectional dimension.

Abstract: A method of producing an article selected from a titanium article and a titanium alloy article comprises melting feed materials with a source of hydrogen to form a molten heat of titanium or a titanium alloy, and casting at least a portion of the molten heat to form a hydrogenated titanium or titanium alloy ingot. The hydrogenated ingot is deformed at an elevated temperature to form a worked article comprising a cross-sectional area smaller than a cross-sectional area of the hydrogenated ingot. The worked article is dehydrogenated to reduce a hydrogen content of the worked article. In certain non-limiting embodiments of the method, the dehydrogenated article comprises an average ?-phase particle size of less than 10 microns in the longest dimension.

Abstract: One embodiment of a method of refining alpha-phase grain size in an alpha-beta titanium alloy comprises working an alpha-beta titanium alloy at a first working temperature within a first temperature range in the alpha-beta phase field of the alpha-beta titanium alloy. The alloy is slow cooled from the first working temperature. On completion of working at and slow cooling from the first working temperature, the alloy comprises a primary globularized alpha-phase particle microstructure. The alloy is worked at a second working temperature within a second temperature range in the alpha-beta phase field. The second working temperature is lower than the first working temperature. The is worked at a third working temperature in a third temperature range in the alpha-beta phase field. The third working temperature is lower than the second working temperature. After working at the third working temperature, the titanium alloy comprises a desired refined alpha-phase grain size.

Abstract: An alloy is disclosed comprising up to 0.05 weight percent carbon, 27.0 to 31.0 weight percent chromium, up to 0.5 weight percent copper, 7.0 to 11.0 weight percent iron, up to 0.5 weight percent manganese, up to 0.015 weight percent sulfur, up to 0.5 weight percent silicon, at least 58 weight percent nickel, and incidental impurities, wherein the alloy exhibits an ASTM grain size of 3.0 to 9.0, exhibits a uniform grain size distribution, includes intergranular M23C6 carbide precipitates uniformly distributed on grain boundaries, and includes minimal or no intragranular M23C6 carbide precipitates. Articles of manufacture including the alloy also are described.

Abstract: A method of processing a non-magnetic alloy workpiece comprises heating the workpiece to a warm working temperature, open die press forging the workpiece to impart a desired strain in a central region of the workpiece, and radial forging the workpiece to impart a desired strain in a surface region of the workpiece. In a non-limiting embodiment, after the steps of open die press forging and radial forging, the strain imparted in the surface region is substantially equivalent to the strain imparted in the central region. In another non-limiting embodiment, the strain imparted in the central and surface regions are in a range from 0.3 inch/inch to 1 inch/inch, and there exists no more than a 0.5 inch/inch difference in strain of the central region compared with the strain of the surface region of the workpiece. An alloy forging processed according to methods described herein also is disclosed.

Abstract: An alloy is disclosed comprising up to 0.05 weight percent carbon, 27.0 to 31.0 weight percent chromium, up to 0.5 weight percent copper, 7.0 to 11.0 weight percent iron, up to 0.5 weight percent manganese, up to 0.015 weight percent sulfur, up to 0.5 weight percent silicon, at least 58 weight percent nickel, and incidental impurities, wherein the alloy exhibits an ASTM grain size of 3.0 to 9.0, exhibits a uniform grain size distribution, includes intergranular M23C6 carbide precipitates uniformly distributed on grain boundaries, and includes minimal or no intragranular M23C6 carbide precipitates. Articles of manufacture including the alloy also are described.

Abstract: An apparatus for casting metals by a nucleated casting technique to create a preform, the apparatus including a mold having a base and a side wall where the base can be moved relative to the side wall to withdraw the preform as it is being created. In various circumstances, portions of a droplet spray created by an atomizing nozzle, i.e., overspray, may accumulate on a top surface of the side wall and prevent or inhibit the preform from being moved relative to the side wall. The atomizing nozzle can be oriented such that the droplet spray passes over the top of the side wall to remelt and remove at least a portion of the overspray that has accumulated thereon. The mold can be rotated such that the overspray formed on a region of or on the entire perimeter of the top surface can pass through the droplet spray and can be removed from the side wall.

Abstract: Forge lubrication processes are disclosed. A solid lubricant sheet is placed between a workpiece and a die in a forging apparatus. Force is applied to the workpiece with the die to plastically deform the workpiece. The solid lubricant sheet decreases the shear factor for the forging system and reduces the incidence of die-locking.

Abstract: A forging die heating or preheating apparatus comprises a burner head comprising a plurality of flame ports. The burner head is oriented to compliment an orientation of at least a region of a forging surface of a forging die and is configured to receive and combust a supply of an oxidizing gas and a supply of a fuel and produce flames at the flame ports. The plurality of flame ports are configured to impinge the flames onto the forging surface of the forging die to substantially uniformly heat at least the region of the forging surface of the forging die.

Abstract: A method of producing an article selected from a titanium article and a titanium alloy article comprises melting feed materials with a source of hydrogen to form a molten heat of titanium or a titanium alloy, and casting at least a portion of the molten heat to form a hydrogenated titanium or titanium alloy ingot. The hydrogenated ingot is deformed at an elevated temperature to form a worked article comprising a cross-sectional area smaller than a cross-sectional area of the hydrogenated ingot. The worked article is dehydrogenated to reduce a hydrogen content of the worked article. In certain non-limiting embodiments of the method, the dehydrogenated article comprises an average ?-phase particle size of less than 10 microns in the longest dimension.

Abstract: A forging die heating or preheating apparatus comprises a burner head comprising a plurality of flame ports. The burner head is oriented to compliment an orientation of at least a region of a forging surface of a forging die and is configured to receive and combust a supply of an oxidizing gas and a supply of a fuel and produce flames at the flame ports. The plurality of flame ports are configured to impinge the flames onto the forging surface of the forging die to substantially uniformly heat at least the region of the forging surface of the forging die.

Abstract: A method of producing an article selected from a titanium article and a titanium alloy article comprises melting feed materials with a source of hydrogen to form a molten heat of titanium or a titanium alloy, and casting at least a portion of the molten heat to form a hydrogenated titanium or titanium alloy ingot. The hydrogenated ingot is deformed at an elevated temperature to form a worked article comprising a cross-sectional area smaller than a cross-sectional area of the hydrogenated ingot. The worked article is dehydrogenated to reduce a hydrogen content of the worked article. In certain non-limiting embodiments of the method, the dehydrogenated article comprises an average ?-phase particle size of less than 10 microns in the longest dimension.

Abstract: A method of processing a workpiece to inhibit precipitation of intermetallic compounds includes at least one of thermomechanically processing and cooling a workpiece including an austenitic alloy. During the at least one of thermomechanically working and cooling the workpiece, the austenitic alloy is at temperatures in a temperature range spanning a temperature just less than a calculated sigma solvus temperature of the austenitic alloy down to a cooling temperature for a time no greater than a critical cooling time.