General Electric Company

Ganjiang Feng

Srikanth Chandrudu Kottilingam

Yan Cui

Dechao Lin

David Vincent Bucci

Jon Conrad Schaeffer

Canan Uslu Hardwicke

Michael Douglas Arnett

Melvin Robert Jackson

Gary Michael Itzel

Brian Lee Tollison

Shyh-Chin Huang

Shan Liu

Daniel Anthony Nowak

Kathleen Blanche Morey

Ariel Caesar-Prepena Jacala

Dennis William Cavanaugh

David Andrew Helmick

Doyle Clyde Lewis

David Edward Schick

Jason Robert Parolini

George Albert Goller

Raymond Joseph Stonitsch

John Thomas Murphy

Matthew Joseph Laylock

Cem Murat Eminoglu

John Herbert Wood

Warren Martin Miglietti

Andrew John Elliott

Paul S Dimascio

Cyril Gerard Beck

Mark Roger Brown

Stephen Joseph Balsone

Kenneth Burrell Potter

Jian Zheng

Gregory Keith Bouse

Gitahi Charles Mukira

Hariharan Sundaram

Lyle B Spiegel

Matthew Laylock

Sundar Amancherla

Srikanth Chandrudu Kottilingham

Mark R Brown

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 &#x3b3;' solvus temperature that is within 5% of the &#x3b3;&#x2032; solvus temperature of the superalloy that does not include 1-6% Fe and a mole fraction of &#x3b3;&#x2032; that is within 15% of the mole fraction of the superalloy that does not include 1-6% Fe.

Cast nickel-base superalloy 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 &#x3b3;' solvus temperature that is within 5% of the &#x3b3;&#x2032; solvus temperature of the superalloy that does not include 1-6% Fe and a mole fraction of &#x3b3;&#x2032; that is within 15% of the mole fraction of the superalloy that does not include 1-6% Fe.

Cast nickel-base alloys including iron

Molded articles and methods for forming molded articles are provided. For example, a molded article comprises a first region formed by a first casting material and a second region formed by mixing a molten or liquid portion of the first casting material and a second casting material. The first casting material is a molten, liquid, or fluid metal alloy, and the second casting material is a molten or fluid metal alloy. The first casting material has a different chemical composition than the second casting material. The first region and the second region are cast as one integral casting using directional solidification, and the first region and the second region have different microstructure patterns. The molded article has a lower concentration of impurities than were present in the first and second casting materials, and an interface between the first region and the second region is devoid of an oxidation layer.

Casting methods and molded articles produced therefrom

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.

Casting method, cast article and casting system

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.

Molded articles

Modified turbine components include an original turbine component comprising an outer wail enclosing an internal cavity, wherein the outer wall has an original portion removed therefrom to expose the internal cavity, and, an internally cooled supplemental element joined to the outer wall that replaces the original portion removed from the outer wall and re-encloses the internal cavity. The internally cooled supplemental element comprises one or more cooling channels that circulate air from the internal cavity through at least a portion of the internally cooled supplemental element.

Modified turbine components with internally cooled supplemental elements and methods for making the same

An article and a method for forming the article are disclosed. The article comprising a composition, wherein the composition comprises, by weight percent, about 13.7% to about 14.3% chromium (Cr), about 9.0% to about 10.0% cobalt (Co), about 3.5% to about 3.9% aluminum (Al), about 3.4% to about 3.8% titanium (Ti), about 4.0% to about 4.4% tungsten (W), about 1.4% to about 1.7% molybdenum (Mo), about 1.55% to about 1.75% niobium (Nb), about 0.08% to about 0.12% carbon (C), about 0.005% to about 0.040% zirconium (Zr), about 0.010% to about 0.014% boron (B), and balance nickel (Ni) and incidental impurities. The composition is substantially free of tantalum (Ta) and includes a microstructure substantially devoid of Eta phase.

Article and method for forming an article

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.

Reinforced articles and methods of making the same

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 &#x3b1;-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 &#x3bc;m 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 &#x3b1;-chromium.

Process for forming a chromium diffusion portion and articles made therefrom

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.

Unidirectional solidification process and apparatus and single-crystal seed therefor

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.

Welded component, a welded gas turbine component, and a process of welding 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.

Component and a method of processing a component

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.

Alloy

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.

Unidirectional solidification process and apparatus therefor

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Greenville, SC, United States of America

Ganjiang Feng