Abstract: A method of method of forming or repairing a superalloy article having a columnar or equiaxed or directionally solidified or amorphous or single crystal microstructure includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array corresponding to a pattern of a layer of the article onto a powder bed of the superalloy to form a melt pool; and controlling a temperature gradient and a solidification velocity of the melt pool to form the columnar or single crystal microstructure.

Abstract: A method to repair an opening in a metallic device including: mount the device on a positioner; while the device is mounted on the positioner, sense and record positions of a surface of an opening in the device using a probe operated by a manipulator; based on the recorded positions determine a centerline and diameter of the opening; orient a digital model of the opening with respect to the opening of the device based on the centerline and diameter of the opening, and apply an weld or cladding to the opening by a welding torch maneuvered automatically by the manipulator while the device is mounted to the positioner and based on the oriented digital model of the opening.

Abstract: A method of welding a wear layer onto a parent material, wherein a welding current is applied to a first wire electrode and to at least one second wire electrode. The first wire electrode and at least one second wire electrode are continuously fed to the parent material for producing a common weld pool. Metal powder and welding powder are fed to the weld pool. The wire electrodes are flux-cored wire electrodes, having a core and a covered electrode. The flux-cored wire electrodes have a higher alloy than a weld deposit analysis of the wear layer to be welded on the parent material. The covered electrode of the flux-cored wire electrodes includes an alloy, which has magnetization properties suitable for adhesion of the metal powder.

Abstract: A welding head is provided. The welding head includes a bracket and a plurality of blocks coupled to the bracket. Each of the plurality of blocks has a contact tip. The contact tips are adapted to receive an electrode. Further, at least one of the plurality of blocks is capable of variable positioning relative to the bracket.

Abstract: Electrodes for depositing hardfacing alloys containing boron, carbon, chromium, manganese, and silicon on the surface of metal components that are subjected to high thermal and mechanical stresses. The deposited hardfacing alloys have from about 2.5 to about 14.0 atomic weight percent boron and have a hardness on the Rockwell “C” scale of at least about 65 HRC in the first layer of the weld deposit.

Abstract: A submerged arc welding apparatus of the present invention includes: a flux receiver for receiving and holding flux in an area formed by itself and a workpiece inside thereof when abutting against the workpiece on the open side; a flux feeder for supplying flux to the flux receiver; a welding torch for supplying a welding wire toward the workpiece with the tip disposed in the area where the flux is held; and a moving mechanism for moving the flux receiver and the welding torch along the direction of a welding line of the workpiece with the flux receiver abutting against the workpiece. A submerged arc welding method of the present invention includes: performing welding by opposing the welding torch to the workpiece and by moving the welding torch along the direction of the welding line with flux held in an area formed between the workpiece and the welding torch.

Abstract: A method for depositing superalloy materials. A layer of powder (14) disposed over a superalloy substrate (12) is heated with an energy beam (16) to form a layer of superalloy cladding (10) and a layer of slag (18). The layer of powder includes flux material and alloy material, formed either as separate powders or as a hybrid particle powder. A layer of powdered flux material (22) may be placed over a layer of powdered metal (20), or the flux and metal powders may be mixed together (36). An extrudable filler material (44) such as nickel, nickel-chromium or nickel-chromium-cobalt wire or strip may be added to the melt pool to combine with the melted powder to give the superalloy cladding the composition of a desired superalloy material.

Abstract: A method of repairing service-induced surface cracks (92) in a superalloy component (90). A layer of powdered flux material (100) is applied over the cracks and is melted with a laser beam (98) to form a re-melted zone (104) of the superalloy material under a layer of slag (106). The slag cleanses the melt pool of contaminants that may have been trapped in the cracks, thereby eliminating the need for pre-melting fluoride ion cleaning. Optionally, alloy feed material may be applied with the powdered flux material to augment the volume of the melt or to modify the composition of the re-melted zone.

Abstract: A method and structure for welding an air-sensitive metal, such as titanium, in an ambient environment containing air. The method (10) includes forming a weld (12) through a weld-through coating (14) applied to the weld face(s) (28) and heat-affected zone (30) of one or more workpiece(s) (16) to be welded. The weld-through coating may contain a reactive material that comprises one or more halogenides of alkali metal, e.g., fluorides of barium, calcium, and strontium. The weld-through coating may be applied to the workpiece using a thermal-spray process, such as a plasma-spray process (32), prior to forming the weld. The weld-through coating may be applied to the workpiece(s) generally contemporaneously with the formation of the weld just ahead of the weld or may be applied at any time prior to forming the weld.