Patent application number | Description | Published |
20080245445 | PROCESS FOR FORMING A CHROMIUM DIFFUSION PORTION AND ARTICLES MADE THEREFROM - In one embodiment, a method for forming an article with a diffusion portion comprises: forming a slurry comprising chromium and silicon, applying the slurry to the article, and heating the article to a sufficient temperature and for a sufficient period of time to diffuse chromium and silicon into the article and form a diffusion portion comprising silicon and a microstructure comprising α-chromium. In one embodiment, a gas turbine component comprises: a superalloy and a diffusion portion having a depth of less than or equal to 60 μm measured from the superalloy surface into the gas turbine component. The diffusion portion has a diffusion surface having a microstructure comprising greater than or equal to 40% by volume α-chromium. | 10-09-2008 |
20100034692 | NICKEL-BASE SUPERALLOY, UNIDIRECTIONAL-SOLIDIFICATION PROCESS THEREFOR, AND CASTINGS FORMED THEREFROM - An alloy composition and method by which the incidence of freckling can be reduced in castings produced with properties similar to the René N5 nickel-base superalloy. The casting has a unidirectional crystal structure and a composition consisting of, by weight, 6% to 8% chromium, 6% to 9% cobalt, 0% to 2% molybdenum, 4% to 6% tungsten, 6.4% to 6.9% tantalum, 0% to 2% titanium, 5% to 7% aluminum, 2.7% to 3.0% rhenium, 0.3% to 0.7% haffiium, 0.04% to 0.08% carbon, 0.002% to 0.006% boron, 0% to 0.075% yttrium, 0.002% to 0.004% zirconium, the balance being nickel and incidental impurities. | 02-11-2010 |
20100119871 | Machine components and methods of fabricating - A thermal barrier coating (TBC) system is provided. The system includes at least one thermal barrier coating (TBC) bond coat layer formed over a substrate surface region. The TBC bond coat layer includes at least one TBC bond coat material. The TBC bond coat material is a nickel-chromium-aluminum-yttrium (NiCrAlY) composition that also includes silicon (Si), hafnium (Hf) and less than 10 weight percent (wt %) cobalt (Co). The TBC system further includes at least one top coat layer formed over the TBC bond coat layer. | 05-13-2010 |
20100135847 | NICKEL-CONTAINING ALLOYS, METHOD OF MANUFACTURE THEREOF AND ARTICLES DERIVED THEREFROM - A nickel-containing alloy is disclosed. The alloy contains about 1.5 to about 4.5 weight percent aluminum; about 1.5 to about 4.5 weight percent titanium; about 0.8 to about 3 weight percent niobium; about 14 to about 28 weight percent chromium; up to about 0.2 weight percent zirconium; about 10 to about 23 weight percent cobalt; about 1 to about 3 weight percent tungsten; about 0.05 to about 0.2 weight percent carbon, about 0.002 to about 0.012 weight percent boron; and about 40 to about 70 weight percent nickel. The atomic ratio of aluminum to titanium is at least about 0.5. The alloy is also substantially free of tantalum. Related processes and articles are also disclosed. | 06-03-2010 |
20110062220 | SUPERALLOY COMPOSITION AND METHOD OF FORMING A TURBINE ENGINE COMPONENT - A nickel-base composition is disclosed that includes:
| 03-17-2011 |
20110318601 | PROCESS FOR FORMING A CHROMIUM DIFFUSION PORTION AND ARTICLES MADE THEREFROM - In one embodiment, a method for forming an article with a diffusion portion comprises: forming a slurry comprising chromium and silicon, applying the slurry to the article, and heating the article to a sufficient temperature and for a sufficient period of time to diffuse chromium and silicon into the article and form a diffusion portion comprising silicon and a microstructure comprising α-chromium. In one embodiment, a gas turbine component comprises: a superalloy and a diffusion portion having a depth of less than or equal to 60 μm measured from the superalloy surface into the gas turbine component. The diffusion portion has a diffusion surface having a microstructure comprising greater than or equal to 40% by volume α-chromium. | 12-29-2011 |
20120080158 | UNIDIRECTIONAL SOLIDIFICATION PROCESS AND APPARATUS THEREFOR - An apparatus and method for casting an alloy using a unidirectional casting technique. The apparatus includes a mold adapted to contain a molten quantity of an alloy, a primary heating zone adapted to heat the mold and the molten alloy therein to a temperature above the liquidus temperature of the alloy, a cooling zone adapted to cool the mold and molten alloy therein to a temperature below the solidus temperature of the alloy and thereby yield the unidirectionally-solidified casting, and an insulation zone between the primary heating zone and the cooling zone. The apparatus also has a secondary heating zone separated from the insulation zone by the primary heating zone. The secondary heating zone maintains the mold and the molten alloy therein at a temperature below the liquidus temperature of the alloy. The temperatures within the primary and secondary heating zones are individually set and controlled. | 04-05-2012 |
20120152483 | UNIDIRECTIONAL SOLIDIFICATION PROCESS AND APPARATUS AND SINGLE-CRYSTAL SEED THEREFOR - A single-crystal seed, apparatus and process for producing a casting having a single-crystal (SX) microstructure. The seed has a geometry that includes a vertex capable of destabilizing an oxide film that forms at the interface between the seed and a molten metal during the casting process, and thereby promotes a continuous single-crystal grain growth and reduces grain misorientation defects that can initiate from the seed/metal interface. | 06-21-2012 |
20120171070 | ALLOY - A alloy and a process of forming a alloy are disclosed. The alloy has a predetermined grain boundary morphology. The alloy includes by weight greater than about 0.06 percent carbon, up to about 0.0015 percent sulfur, less than about 16 percent chromium, between about 39 percent and about 44 percent nickel, between about 2.5 percent and about 3.3 percent niobium, between about 1.4 percent and about 2 percent titanium, up to about 0.5 percent aluminum, up to about 0.006 percent boron, up to about 0.3 percent copper, up to about 0.006 percent nitrogen, and greater than about 0.5 percent molybdenum. | 07-05-2012 |
20120214019 | COMPONENT AND A METHOD OF PROCESSING A COMPONENT - A component and a method of processing a component are disclosed. The method includes providing a base metal having a feature, removing the feature to form a processed region, applying a first layer to the processed region, and applying a second layer to the first layer. The base metal, the first layer, and the second layer each have predetermined thermal expansion coefficients, yield strengths, and elongations. The processed component includes the first layer applied to a processed region of the base metal and a second layer applied to the first layer. | 08-23-2012 |
20120267344 | WELDED COMPONENT, A WELDED GAS TURBINE COMPONENT, AND A PROCESS OF WELDING A COMPONENT - A welded component, a welded gas turbine component, and a process of welding a component are disclosed. The welded component includes a first alloy, a second alloy, and a weld positioned between the first alloy and the second alloy. The weld is formed by a first shim and a second shim being beam welded. | 10-25-2012 |
20120282086 | NICKEL-BASE ALLOY - The invention is a class of nickel-base alloys for gas turbine applications, comprising, by weight, about 13.7 to about 14.3 percent chromium, about 5.0 to about 10.0 percent cobalt, about 3.5 to about 5.2 percent tungsten, about 2.8 to about 5.2 percent titanium, about 2.8 to about 4.6 percent aluminum, about 0.0 to about 3.5 percent tantalum, about 1.0 to about 1.7 percent molybdenum, about 0.08 to about 0.13 percent carbon, about 0.005 to about 0.02 percent boron, about 0.0 to about 1.5 percent niobium, about 0.0 to about 2.5 percent hafnium, about 0.0 to about 0.04 percent zirconium, and the balance substantially nickel. The nickel-base alloys may be provided in the form of useful articles of manufacture, and which possess a unique combination of mechanical properties, microstructural stability, resistance to localized pitting and hot corrosion in high temperature corrosive environments, and high yields during the initial forming process as well as post-forming manufacturing and repair processes. | 11-08-2012 |
20130126056 | CAST NICKEL-IRON-BASE ALLOY COMPONENT AND PROCESS OF FORMING A CAST NICKEL-IRON-BASE ALLOY COMPONENT - A cast nickel-iron-base alloy component having by weight about 12.0% to about 16.5% Cr, about 1.0% to about 2.0% Al, about 2.0% to about 3.0% Ti, about 2.0% to about 3.0% W, about 3.0 to about 5.0% Mo, up to about 0.1% Nb, up to about 0.2% Mn, up to about 0.1% Si, about 0.05% to about 0.10% C, about 0.003 to about 0.010% B, about 35% to about 37% Fe, and balance essentially Ni and inevitable impurities. The nickel-iron-base alloy component has a creep rupture life greater than about 1000 hours at about 25 ksi to about 30 ksi at about 1400° F. A method for forming the cast nickel-iron-base alloy component is also disclosed. | 05-23-2013 |
20130206352 | UNIDIRECTIONAL SOLIDIFICATION PROCESS AND APPARATUS AND SINGLE-CRYSTAL SEED THEREFOR - A single-crystal seed, apparatus and process for producing a casting having a single-crystal (SX) microstructure. The seed has a geometry that includes a vertex capable of destabilizing an oxide film that forms at the interface between the seed and a molten metal during the casting process, and thereby promotes a continuous single-crystal grain growth and reduces grain misorientation defects that can initiate from the seed/metal interface. | 08-15-2013 |
20140037981 | CASTING METHODS AND MOLDED ARTICLES PRODUCED THEREFROM - A method comprising introducing a first casting material into a casting mold; applying directional solidification to the first casting material in the casting mold; introducing a second casting material into the casting mold, the second casting material having a different chemical composition than the first casting material; applying directional solidification to the second casting material in the casting mold; and forming a molded article, wherein the molded article comprises a first region | 02-06-2014 |
20140042128 | ELECTRIC DISCHARGE MACHINING PROCESS, ARTICLE FOR ELECTRIC DISCHARGE MACHINING, AND ELECTRIC DISCHARGE COOLANT - An electric discharge machining process, an article for electric discharge machining, and an electrically-conductive electric discharge machining coolant are disclosed. The electric discharge machining process includes electric discharge machining a target region of a component. The article includes a non-electrically-conductive layer, an electrically-conductive layer, and a target region on the non-electrically-conductive layer. The electrically-conductive electric discharge machining coolant includes a hydrocarbon liquid and carbon powder suspended within the hydrocarbon liquid. | 02-13-2014 |
20140120308 | REINFORCED ARTICLES AND METHODS OF MAKING THE SAME - An article comprising a substrate; a bond layer disposed on the substrate, the bond layer comprising one or more bonding segments and at least one reinforcing segment; at least one protective layer disposed on the bond layer; and at least one cooling hole extending through the substrate, the at least one reinforcing segment and the at least one protective layer, wherein the at least one reinforcing segment reduces cracking and/or delamination at the interface between the substrate and the bond layer, and methods of making the same. | 05-01-2014 |
20140199164 | NICKEL-BASED ALLOY AND TURBINE COMPONENT HAVING NICKEL-BASED ALLOY - A nickel-based alloy and a turbine component are disclosed. The alloy includes, by weight, between about 0.8% and about 1.3% hafnium, between about 5.7% and about 6.4% aluminum, between about 7.0% and about 10.0% cobalt, up to about 0.1% carbon, up to about 8.7% chromium, up to about 0.6% molybdenum, up to about 9.7% tungsten, up to about 0.9% titanium, up to about 0.02% boron, up to about 0.1% manganese, up to about 0.06% silicon, up to about 0.01% phosphorus, up to about 0.004% sulfur, up to about 0.02% zirconium, up to about 1.8% niobium, up to about 0.1% vanadium, up to about 0.1% copper, up to about 0.2% iron, up to about 0.003% magnesium, up to about 0.002% oxygen, up to about 0.002% nitrogen, and a balance nickel. The turbine component is a turbine bucket, a turbine nozzle, or any other suitable turbine component including the alloy. | 07-17-2014 |
20140205490 | NICKEL-BASED ALLOY AND TURBINE COMPONENT HAVING NICKEL-BASED ALLOY - A nickel-based alloy and a turbine component including a nickel-based alloy are disclosed. The nickel-based alloy includes, by weight, between about 8% and about 11% cobalt, up to about 3% niobium, up to about 3% titanium, up to about 2.3% aluminum, up to about 3% tungsten, up to about 25% chromium, up to about 0.1% carbon, up to about 0.01% boron, and a balance nickel, or the nickel-based alloy includes, by weight, between about 1% and about 3% niobium, between about 1% and about 3% titanium, between about 2.1% and about 2.5% aluminum, up to about 3% tungsten, up to about 11% cobalt, up to about 25% chromium, up to about 0.1% carbon, up to about 0.01% boron, and a balance nickel. The turbine component includes the nickel-based alloy. | 07-24-2014 |
20140314618 | CAST NICKEL-BASE ALLOYS INCLUDING IRON - A cast nickel-base superalloy that includes iron added substitutionally for nickel. The cast nickel base superalloy comprises, in weight percent about 1-6% iron, about 7.5-19.1% cobalt, about 7-22.5% chromium, about 1.2-6.2% aluminum, optionally up to about 5% titanium, optionally up to about 6.5% tantalum, optionally up to about 1% Nb, about 2-6% W, optionally up to about 3% Re, optionally up to about 4% Mo, about 0.05-0.18% C, optionally up to about 0.15% Hf, about 0.004-0.015 B, optionally up to about 0.1% Zr, and the balance Ni and incidental impurities. The superalloy is characterized by a □′ solvus temperature that is within 5% of the □′ solvus temperature of the superalloy that does not include 1-6% Fe and a mole fraction of □′ that is within 15% of the mole fraction of the superalloy that does not include 1-6% Fe. | 10-23-2014 |
20140342139 | CASTING METHOD, CAST ARTICLE AND CASTING SYSTEM - A casting method, cast article and casting system are disclosed. The casting method includes providing a base material in a mold, directing a fluid material into the mold, and solidifying the base material and the fluid material to form a cast article. The base material has a first density and first composition. The fluid material has a second density and a second composition. The first density differs from the second density, the first composition differs from the second composition, or the first density differs from the second density and the first composition differs from the second composition. The cast article includes a first material solidification from the base material, and a second material solidification from the fluid material. The casting system includes a mold for containing a base material and an input configuration, with flow control feature, for directing a fluid material into the mold containing the base material. | 11-20-2014 |