Abstract:
The present invention is directed to methods and apparatus (201) that use electrostatic and/or electromagnetic fields (203) to enhance the process of spray forming preforms or powders (8). The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas (24). 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 of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may generally comprise depositing a glass material onto at least a portion of a surface of a workpiece, and heating the glass material to form a surface coating on the workpiece that reduces heat loss from the workpiece. The present disclosure also is directed to an alloy workpieces processed according to methods described herein, and to articles of manufacture including or made from alloy workpieces made according to the methods.
Abstract:
Methods of refining the grain size of titanium and titanium alloys include thermally managed high strain rate multi-axis forging. A high strain rate adiabatically heats an internal region of the workpiece during forging, and a thermal management system is used to heat an external surface region to the workpiece forging temperature, while the internal region is allowed to cool to the workpiece forging temperature. A further method includes multiple upset and draw forging titanium or a titanium alloy using a strain rate less than is used in conventional open die forging of titanium and titanium alloys. Incremental workpiece rotation and draw forging causes severe plastic deformation and grain refinement in the titanium or titanium alloy forging.
Abstract:
The present invention relates to apparatus and method for melting and atomizing metals and metallic alloys to produce large diameter ingots. The apparatus and methods employ equipment and techniques that utilize electrons
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 (2) comprising a model wall and an electrically conductive member (8) disposed through the mold wall, contacting the slag (4) with a consumable electrode (6), 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 (4) through the electrically conductive member (8).
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 model 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:
Processes, systems, and apparatuses are disclosed for forming products from atomized metals and alloys. A stream of molten alloy and/or a series of droplets of molten alloy are produced. The molten alloy is atomized to produce electrically-charged particles of the molten alloy by impinging electrons on the stream of molten alloy and/or the series of droplets of molten alloy. The electrically-charged molten alloy particles are accelerated with at least one of an electrostatic field and an electromagnetic field. The accelerating molten alloy particles are cooled to a temperature that is less than a solidus temperature of the molten alloy particles so that the molten alloy particles solidify while accelerating. The solid alloy particles are impacted onto a substrate and the impacting particles deform and metallurgically bond to the substrate to produce a solid alloy preform.
Abstract:
A thermo-mechanical treatment process is disclosed. A nickel-base alloy workpiece is heated in a first heating step to a temperature greater than the M23C6 carbide solvus temperature of the nickel-base alloy. The nickel-base alloy workpiece is worked in a first working step to a reduction in area of 20% to 70%. The nickel-base alloy workpiece is at a temperature greater than the M23C6 carbide solvus temperature when the first working step begins. The nickel-base alloy workpiece is heated in a second working step to a temperature greater than 1700 F (926 C) and less than the M23C6 carbide solvus temperature of the nickel-base alloy. The nickel-base alloy workpiece is not permitted to cool to ambient temperature between completion of the first working step and the beginning of the second heating step. The nickel-base alloy workpiece is worked to a second reduction in area of 20% to 70%. The nickel-base alloy workpiece is at a temperature greater than 1700 F (926 C) and less than the M23C6 carbide solvus temperature of the nickel-base alloy when the second working step begins.
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:
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.