Patent application number | Description | Published |
20080223174 | METHODS AND APPARATUS FOR SPRAY FORMING, ATOMIZATION AND HEAT TRANSFER - The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention. | 09-18-2008 |
20080237200 | Melting Furnace Including Wire-Discharge Ion Plasma Electron Emitter - An apparatus for melting an electrically conductive metallic material includes a vacuum chamber and a hearth disposed in the vacuum chamber. At least one wire-discharge ion plasma electron emitter is disposed in or adjacent the vacuum chamber and is positioned to direct a wide-area field of electrons into the vacuum chamber, wherein the wide-area electron field has sufficient energy to heat the electrically conductive metallic material to its melting temperature. The apparatus may further include at least one of a mold and an atomizing apparatus which is in communication with the vacuum chamber and is positioned to receive molten material from the hearth. | 10-02-2008 |
20090139682 | Casting Apparatus and Method - A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold. | 06-04-2009 |
20090272228 | Apparatus and Method for Clean, Rapidly Solidified Alloys - One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating 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. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed. | 11-05-2009 |
20100012629 | Ion Plasma Electron Emitters for a Melting Furnace - An apparatus for melting an electrically conductive metallic material comprises an auxiliary ion plasma electron emitter configured to produce a focused electron field including a cross-sectional profile having a first shape. The apparatus further comprises a steering system configured to direct the focused electron field to impinge the focused electron field on at least a portion of the electrically conductive metallic material to at least one of melt or heat any solidified portions of the electrically conductive metallic material, any solid condensate within the electrically conductive metallic material, and/or regions of a solidifying ingot. | 01-21-2010 |
20100258262 | METHOD AND APPARATUS FOR PRODUCING LARGE DIAMETER SUPERALLOY INGOTS - Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot. | 10-14-2010 |
20100276112 | Apparatus and Method for Clean, Rapidly Solidified Alloys - 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. | 11-04-2010 |
20100307216 | FORGING DIE HEATING APPARATUSES AND METHODS FOR USE - 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. | 12-09-2010 |
20100314068 | Casting Apparatus and Method - A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold. | 12-16-2010 |
20110195270 | SYSTEMS AND METHODS FOR PROCESSING ALLOY INGOTS - 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. | 08-11-2011 |
20110214833 | CASTING APPARATUS AND METHOD - A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold. | 09-08-2011 |
20110302978 | LUBRICATION PROCESSES FOR ENHANCED FORGEABILITY - 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. | 12-15-2011 |
20110302979 | LUBRICATION PROCESSES FOR ENHANCED FORGEABILITY - 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 friction factor for the forging system and reduces the incidence of die-locking. | 12-15-2011 |
20120060981 | Processing Routes for Titanium and Titanium Alloys - 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. | 03-15-2012 |
20120168110 | Casting Apparatus and Method - A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold. | 07-05-2012 |
20120183708 | HOT WORKABILITY OF METAL ALLOYS VIA SURFACE COATING - 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. | 07-19-2012 |
20120308428 | THERMO-MECHANICAL PROCESSING OF NICKEL-BASE ALLOYS - 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 M | 12-06-2012 |
20130040067 | PROCESSES, SYSTEMS, AND APPARATUS FOR FORMING PRODUCTS FROM ATOMIZED METALS AND ALLOYS - 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. | 02-14-2013 |
20130125604 | FORGING DIE HEATING APPARATUSES AND METHODS FOR USE - 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. | 05-23-2013 |
20130156628 | High Strength, Corrosion Resistant Austenitic Alloys - An austenitic alloy may generally comprise, in weight percentages based on total alloy weight: up to 0.2 carbon; up to 20 manganese; 0.1 to 1.0 silicon; 14.0 to 28.0 chromium; 15.0 to 38.0 nickel; 2.0 to 9.0 molybdenum; 0.1 to 3.0 copper; 0.08 to 0.9 nitrogen; 0.1 to 5.0 tungsten; 0.5 to 5.0 cobalt; up to 1.0 titanium; up to 0.05 boron; up to 0.05 phosphorous; up to 0.05 sulfur; iron; and incidental impurities. | 06-20-2013 |
20130279533 | MELTING FURNACE INCLUDING WIRE-DISCHARGE ION PLASMA ELECTRON EMITTER - An apparatus for melting an electrically conductive metallic material includes a vacuum chamber and a hearth disposed in the vacuum chamber. At least one wire-discharge ion plasma electron emitter is disposed in or adjacent the vacuum chamber and is positioned to direct a wide-area field of electrons into the vacuum chamber, wherein the wide-area electron field has sufficient energy to heat the electrically conductive metallic material to its melting temperature. The apparatus may further include at least one of a mold and an atomizing apparatus which is in communication with the vacuum chamber and is positioned to receive molten material from the hearth. | 10-24-2013 |
20140076471 | PROCESSING ROUTES FOR TITANIUM AND TITANIUM ALLOYS - 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. | 03-20-2014 |
20140116582 | THERMO-MECHANICAL PROCESSING OF NICKEL-BASE ALLOYS - 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 M | 05-01-2014 |
20140230605 | METHODS OF PROCESSING METALLIC MATERIALS - A method of processing a metallic material includes introducing an electrically conductive metallic material comprising at least one of a metal and a metallic alloy into a furnace chamber maintained at a low pressure relative to atmospheric pressure. A first electron field having a first area of coverage is generated using at least a first ion plasma electron emitter, and the material within the furnace chamber is subjected to the first electron field to heat the material to a temperature above a melting temperature of the material. A second electron field having a second area of coverage smaller than the first area of coverage is generated using a second ion plasma electron emitter. At least one of any solid condensate within the furnace chamber, any solidified portions of the electrically conductive metallic material, and regions of a solidifying ingot to the second electron field, is subjected to the second electron field, using a steering system. | 08-21-2014 |
20140238552 | METHODS FOR PROCESSING ALLOYS - 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. | 08-28-2014 |
20140255719 | THERMOMECHANICAL PROCESSING OF HIGH STRENGTH NON-MAGNETIC CORROSION RESISTANT MATERIAL - 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. | 09-11-2014 |
20140260478 | METHODS TO IMPROVE HOT WORKABILITY OF METAL ALLOYS - A method of processing an alloy workpiece to reduce thermal cracking may comprise spraying a metallic coating material onto at least a portion of a surface of the alloy workpiece to form a surface coating metallurgically bonded to the alloy workpiece. The surface coating may be more ductile than the alloy workpiece and reduces heat loss from the alloy workpiece. | 09-18-2014 |
20140261922 | THERMOMECHANICAL PROCESSING OF ALPHA-BETA TITANIUM ALLOYS - 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. | 09-18-2014 |
20140290321 | HOT WORKABILITY OF METAL ALLOYS VIA SURFACE COATING - 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. | 10-02-2014 |
20140374048 | PROCESSES, SYSTEMS, AND APPARATUS FOR FORMING PRODUCTS FROM ATOMIZED METALS AND ALLOYS - 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 is atomized to produce particles of the molten alloy. The 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. The solid alloy particles impact a collector and produce a solid alloy preform. | 12-25-2014 |