Abstract: A repaired nickel-based superalloy substrate that has applied thereon a nickel-based polycrystalline repair alloy comprising 0.03-2.5 weight % hafnium, 0.003-0.32% boron, 0.02-0.16% yttrium and 0.007-0.35% zirconium. The present invention further provides a repaired single crystal alloy substrate that has applied thereon a repair alloy wherein the repair alloy's composition is similar to or the same as the single crystal alloy composition except that the repair alloy additionally comprises at least one grain boundary strengthener element and at least one element that enhances oxidation resistance.

Abstract: A hollow article is made by providing and diffusion bonding the opposing parts of an article made of an alpha-beta titanium alloy. Hydrogen is introduced into the surface of an internal cavity before, during, or after diffusion bonding. The article is heat treated with the hydrogen present, typically by solution treating and aging the hydrogen-containing bonded article. The result is the production of a microstructure at the internal surface of the cavity that is resistant to fatigue-crack initiation, while retaining a microstructure throughout the rest of the article that is resistant to fatigue-crack propagation. After heat treating, the hydrogen Is removed from the article, and any further heat treating and other operations are completed.

Abstract: A method of applying a stable intermetallic diffusion barrier layer to a metallic article is described. In many instances, protective coatings are incompatible with the material of the substrate to which they are applied. Such incompatibility is overcome in the invention through in situ formation of an intermediate stable diffusion barrier layer by sequential deposition and subsequent reaction of suitable metals to form a continuous intermetallic layer. A conventional overlay coating may then be applied to the intermetallic layer without risk to the underlying substrate. The invention also contemplates creation of unitary diffusion barriers from multi-layer deposits; deposition of plural diffusion barriers, and formation of complete protective systems comprising substrate, diffusion barrier(s) and overlay coating prior to heat treatment in situ.

Abstract: An improved method is described for restoring the mechanical properties to carbide-containing Co-based superalloy gas turbine components which have been exposed to high temperatures and pressures for extended periods of time. The method includes solution heat treating to 2250.degree.-2300.degree. F. for one to twelve hours to dissolve complex carbides, and aging at approximately 1965.degree.-1975.degree. F. for two to twenty four hours. The rejuvenated components exhibit excellent high temperature creep properties.

Abstract: A method of combining a beta titanium alloy with advanced carbon composites, the combination having a matched yield strength and modules of elasticity ratio. When the combination is adhesively bonded both parts will approach maximum yield strength and fail at a similar amount of total strain. The titanium and carbon composites are combined by first abrading the titanium to be bonded, coating the titanium with platinum, aging the titanium, spraying primer on the coated titanium, applying adhesive to the primer side of the titanium and then applying the carbon to the adhesive. This allows the carbon composite to bond securely to the titanium. This composite uses the best properties of each component, the combination having a better set of properties than either part.

Abstract: A process for making a cladding for a nuclear fuel rod is disclosed which includes the following steps. First, at least two layers of zirconium-based metals are spray deposited on a generally cylindrical substrate in a manner that provides a rough, cylindrically-shaped, porous billet. The zirconium-based metal for each layer is different from an adjacent layer and is selected to provide a desired combination of properties. Next, the substrate is removed from the spray deposited material, thereby providing an elongated tube hollow. The spray deposited material is then consolidated in a known manner to remove the porosity, densify the tube hollow to substantially full density, and reduce the cross-sectional dimension of the tube hollow to a desired size.

Abstract: A method of preparing a beta titanium-fiber reinforced composite laminate comprising the steps of, first, providing a beta titanium alloy having a first yield strength to modulus of elasticity ratio; then, heating the beta titanium alloy at a first preselected temperature for a first preselected time to produce a beta titanium alloy having a second yield strength to modulus of elasticity ratio; and then, adhering a fiber reinforced composite having a strength to modulus of elasticity ratio to the beta titanium alloy to produce a beta titanium-fiber reinforced composite laminate; wherein the first preselected temperature and the first preselected time are preselected such that the second yield strength to modulus of elasticity ratio of the beta titanium alloy is substantially similar to the strength to modulus of elasticity ratio of the fiber reinforced composite.

Abstract: A body compatible stent is formed of multiple filaments arranged in two sets of oppositely directed helical windings interwoven with one another in a braided configuration. Each of the filaments is a composite including a central core and a case surrounding the core. In the more preferred version, the core is formed of a radiopaque and relatively ductile material, e.g. tantalum or platinum. The outer case is formed of a relatively resilient material, e.g. a cobalt/chromium based alloy. Favorable mechanical characteristics of the stent are determined by the case, while the core enables in vivo imaging of the stent. The composite filaments are formed by a drawn filled tubing process in which the core is inserted into a tubular case of a diameter substantially more than the intended final filament diameter. The composite filament is cold-worked in several steps to reduce its diameter, and annealed between successive cold-working steps.

Abstract: A method of fabricating sheet metal parts comprising the steps of: stamping a pair of overlying metal sheets together to form a pair of stampings, heat treating the stampings, clamping the stampings together to correct distortion of the stampings during the heat treatment and welding the clamped stampings together to produce the part.

Abstract: A heat treatment and hot working method for producing a thin sheet of nickel base superalloy single crystals is described, wherein a single crystal preform of an alloy is first heat treated in vacuum at temperatures below the .gamma.' solvus temperature of the alloy in order to obtain an overaged .gamma.' microstructure in the preform, sized and surface ground in order to remove surface defects, and then preferably surrounded by plates and interlayers of refractory metal or alloy and parting agent coatings; the plates are then welded to form an enclosure and evacuated, preheated and soaked at 1093.degree. to 1150.degree. C. and rolled at roll speeds of about 0.12 to 0.25 rods in successive passes, at about 5 to 15% reduction per pass with reheating at the soaking temperature between successive passes, to a reduction in thickness of 50 to 75%; the plates are then removed and the preform is conditioned, repacked and successively rolled to preselected thickness.

Abstract: A hollow article is made by providing and diffusion bonding the opposing parts of an article made of an alpha-beta titanium alloy. Hydrogen is introduced into the surface of an internal cavity before, during, or after diffusion bonding. The article is heat treated with the hydrogen present, typically by solution treating and aging the hydrogen-containing bonded article. The result is the production of a microstructure at the internal surface of the cavity that is resistant to fatigue-crack initiation, while retaining a microstructure throughout the rest of the article that is resistant to fatigue-crack propagation. After heat treating, the hydrogen is removed from the article, and any further heat treating and other operations are completed.

Abstract: A method to produce high temperature oxidation resistant metal matrix composites by fiber diameter grading which comprises the steps of (a) laying up an alloy/fiber preform consisting of a plurality of alternating layers of metal alloy and fibers and (b) consolidating the preform under suitable conditions, wherein fibers of at least two diameters are employed and wherein the layers of fibers in the preform are graduated so that larger diameter fibers are located nearer what will become the exposed surface of the composite and smaller diameter fibers are located toward the interior of the composite.

Abstract: A method is provided for obtaining a uniform grain size on the order of about ASTM 5 or coarser in at least a portion of an article formed from a .gamma.' precipitation strengthened nickel-base superalloy. The method comprises forming an article by: providing a billet, preheating the billet above 2000.degree. F. for at least 0.5 hours, working at least a portion to near-net shape at working conditions including a first strain rate of less than about 0.01 per second and at a subsolvus temperature at or near the recrystallization temperature, supersolvus heating to form a grain size in the portion of at least 5 ASTM, and cooling to reprecipitate .gamma.' within the article. The method can be utilized to form a .gamma.' precipitation strengthened nickel-base superalloy article whose grain size varies uniformly between portions thereof, so as to yield a desirable microstructure and property gradient in the article in accordance with the in-service temperature and stress-state gradient experienced by the article.

Abstract: A metal surface is now described having enhanced adhesion of subsequently applied coatings. The substrate metal of the article, such as a valve metal as represented by titanium, is provided with a highly desirable surface characteristic for subsequent coating application. This can be initiated by selection of a metal of desirable metallurgy and heat history, including prior heat treatment to provide surface grain boundaries which may be most readily etched. In subsequent etching operation, the surface is made to exhibit well defined, three dimensional grains with deep grain boundaries. Subsequently applied coatings, by penetrating into the etched intergranular valleys, are desirably locked onto the metal substrate surface and provide enhanced lifetime even in rugged commercial environments.

Abstract: Disclosed is a method of manufacturing a surface treated metal member excellent in wear resistance, comprising the steps of: applying Ni--P electroplating on the surface of a metal base member and heat-treating the metal base member; and blasting, on the surface of the metal base member, fine particles having nearly spherical shapes and having an average particle size of 10-400 .mu.m.

Abstract: A process of preparing clad contact material comprises forming a contact belt-like member by bonding an Au or Au alloy tape to the surface of an Ag or Ag alloy tape, thermally treating that contact member for forming an Au diffusion layer, and cladding that contact member having the Au diffusion layer to a base belt-like member made of Cu or a Cu alloy. Since, according to the process, the thermal diffusion treatment is carried out before the contact belt-like member is set in the base belt-like member, the thermal diffusion treatment of the contact belt-like member can be performed in the most suitable conditions for obtaining an Au diffusion layer with excellent characteristics, and no dissolution may occur at the interface between the two belt-like members.

Abstract: The present invention is directed to a pre-weld overageing heat treatment for nickel-based superalloys, where the alloy is heated to solutionization temperature for a time sufficient to dissolve the gamma prime phase of the alloy microstructure, then slowly cooled with periods of intermittent heating, so that the gamma prime phase reprecipitates as coarse equiaxed particles, and the presence of fine sized gamma prime phase particles is substantially avoided. The present invention is also directed to a welding method wherein said pre-weld overageing treatment is used.

Abstract: A method of manufacturing golf club is to design the contour of a club head and a club shaft. Sheet metal forming for divided golf club head are formed by stretching the Titanium Alloy plate within the forming dies, then processed with stress relief. Assembly welding are processed in a vacuum chamber where inner-gas, argon, is filled therein to avoid any inpurity may occur on the product during manufacture. Temperatures for stress relief, solid solution and aging are controlled in various degree depending upon each different procedures in order to form a best quality in vacuum furnace where vacuum gauge is best under ten to the negative fourth power of TORR.

Abstract: A method including preparing an aluminum scrap containing a total of about 0.3 to 2.0 wt % of Fe and Si; melting and then adjusting the material composition so as to attain an Mg content of about 3 to 10 wt % or a composition further containing at least one of the elements Cu, Mn, Cr, Zr and Ti, each in the amount of 0.02 to 0.5 wt %; subjecting the material to casting, hot rolling, cold rolling and continuous annealing to obtain an aluminum alloy sheet having a tensile strength of about 31 kgf/mm.sup.2 or more; and applying a lubricant surface coating to impart a coefficient of friction of not more than about 0.11.

Abstract: A method of making twin roll cast clad material includes producing a composite material using a liner stock produced by drag casting techniques. The drag cast liner stock can be directly used in a twin roll continuous casting process without additional process steps such as heat treatment, surface cleaning and/or rolling. The drag cast liner stock can be applied to one or both of the surfaces of the twin roll cast material to produce a composite material that is useful in a cast form or can be adapted for reduction by rolling processes or the like. The twin roll cast cladding process can utilize aluminum alloy core and cladding materials to form a brazing sheet from the as-cast composite material.

Abstract: A method of making metal alloy articles having inclusions which are predetermined and controlled with respect to their size, shape, composition, crystal structure and location and orientation within the article is disclosed. In a preferred embodiment, the method of making is directed toward titanium alloy articles containing synthesized hard-alpha inclusions of titanium/nitrogen, titanium/oxygen and titanium/oxygen/nitrogen alloys.

Abstract: An intermediate layer (3) constituted essentially by one or more of the following metals: Ni, Cu, Ti, and Al is interposed between the insert (2) and the part (1) to be clad, e.g. a vane for a steam turbine. After the part and insert assembly has been calibrated in an isothermal matrix, it is inserted in an isostatic pressing oven and raised to a temperature that is lower than the melting temperature of the layer (3) but higher than the forging temperature of the part. This method makes it possible to retain the metallurgical properties of the part.

Abstract: Composite parts of Ni-Ti alloys joined to a different metal have a melt forged structure obtained through the reactive fusion of both metals, initiated by the fusion of at least one metal bordering on the joint interface and the application of pressure; a hot forged structure of Ni-Ti alloy obtained through softening the alloy at high temperature and applying pressure on the Ni-Ti alloy side of the joint; and a hot forged structure of the different metal obtained by softening the metal at high temperature and applying pressure on the different metal side of the joint.

Abstract: A process for producing a crack-free, laser nitride-hardened layer on a titanium substrate, the process including preheating the substrate, melting a small area of substrate with a laser, and shrouding the melted area with a gas mixture having a maximum critical amount of nitrogen not greater than 85%. A crack-free pump shaft so hardened to Rockwell 52 C is produced.

Abstract: A method of strengthening an aluminum casting by modifying qualities of a specified part thereof comprises the steps of forming a weld overlay on the specified part using powders made of heat resisting element and remelting the specified part, now overlaid with the layer of heat resisting alloy layer, using high density energy.

Abstract: Highly wear-resistant sliding bearings with good sliding properties are difficult to manufacture by electrochemical deposition of the sliding alloy, because the corresponding electrolyte solutions are unstable. Conventional sliding alloys are also too hard for a run-in period and wear too rapidly when used in accordance with specifications. The new sliding layer is simple to manufacture and has an extremely favorable run-in period. The soft constituent of the sliding layer is present in a concentration which decreases along a concentration gradient perpendicular to the effective surface of the sliding layer as the distance from the effective surface increases. The sliding layer is particularly suitable for use as a lead-tin-copper alloy in a multilayered bearing.

Abstract: A protective layer for a metal substrate is metallurgically bonded to the substrate and contains (as a percentage by mass) 35 to 50% chromium, up to 10% of which can be replaced by molybdenium, and at least iron, the proportion of iron being at least 25%. The minimum hardness is 800 HVO.1, obtained by a structure having a minimum content of 5% by volume as sigma phase. The sigma phase is obtained by heat-treatment of the coated substrate. The protective layer is particularly resistant to corrosion and also has good resistance to erosion and wear.

Abstract: A high strength, light weight "in-situ" Ti-Y composite is produced by deformation processing a cast body having Ti and Y phase components distributed therein. The composite comprises elongated, ribbon-shaped Ti and Y phase components aligned along an axis of the deformed body.

Abstract: Disclosed herein is a method of making a surface structure on a ceramic substrate capable of suppressing diffusion of Ni to an Au plating layer and of reducing the necessary thickness of the Au plating layer. A metallized layer (12), Ni layer (13) and Au layer (14) are formed in this order on a surface of a ceramic substrate (11). The substrate (11) is heated in a non-oxidizing atmosphere to cause an alloying reaction between the Ni layer (13) and the Au layer (14). Thereafter, an Au plating layer (16) is formed on the NiAu alloy layer (15). Since Ni in the NiAu alloy layer is not easily released, diffusion of Ni into the Au plating layer can be suppressed sufficiently. Therefore, the Au plating layer can be small in thickness, generally less than 1 micron.

Abstract: A method for fabricating a titanium aluminide composite structure consisting of a filamentary material selected from the group consisting of silicon carbide, silicon carbide-coated boron, boron carbide-coated boron, titanium boride-coated silicon carbide and silicon-coated silicon carbide, embedded in an alpha-2 titanium aluminide metal matrix, which comprises the steps of providing a beta-stabilized Ti.sub.3 Al foil containing a sacrificial quantity of beta stabilizer element in excess of the desired quantity of beta stabilizer, fabricating a preform consisting of alternating layers of foil and a plurality of at least one of the aforementioned filamentary materials, and applying heat and pressure to consolidate the preform. In another embodiment of the invention, the beta-stabilized Ti.sub.3 Al foil is coated on at least one side with a thin layer of sacrificial beta stabilizer.

Abstract: There is disclosed an engine valve of titanium alloy having a stem portion made of a cold-worked titanium alloy containing 2% to 4% by weight of aluminum, 1.5% to 3.5% by weight of vanadium and balance titanium. The engine valve suitable for use as an intake valve has a head portion made of a cast titanium alloy containing 2% to 7% by weight of aluminum, 3% to 20% by weight of vanadium and balance titanium. Moreover, an exhaust engine valve has a head portion made of a cast titanium alloy containing 5% to 10% by weight of aluminum and balance titanium.