公开(公告)号：US20120251840A1

公开(公告)日：2012-10-04

申请号：US13075339

申请日：2011-03-30

申请人： Michael Patrick Maly ,  Thomas Joseph Kelly

发明人： Michael Patrick Maly ,  Thomas Joseph Kelly

IPC分类号： C22C19/05 ,  B32B15/01 ,  B23K31/02

CPC分类号： C22C19/056 ,  C22C19/057 ,  Y10T428/12944

摘要： Nickel-base alloys suitable for use as a weld material to weld high-temperature components (10), such as turbine blades and vanes of gas turbine engines. The nickel-base alloys consist essentially of, by weight, 5 to 10 percent chromium, 3 to 14 percent cobalt, up to 4 percent molybdenum, 3 to 7 percent tungsten, 5 to 9 percent tantalum, 5 to 8 percent aluminum, 0.1 to 2 percent hafnium, 0.005 to 0.03 percent boron, up to 0.15 percent carbon, the balance being nickel and incidental impurities and/or residual elements. Welds (12) formed with the alloys are capable of exhibiting desirable levels of strength and oxidation resistance, while containing little if any rhenium.

摘要翻译： 适合用作焊接材料以焊接高温部件（10）的镍基合金，例如燃气涡轮发动机的涡轮叶片和叶片。 镍基合金基本上由重量百分比为5至10％的铬，3至14％的钴，至多4％的钼，3至7％的钨，5至9％的钽，5至8％的铝，0.1至 2％的铪，0.005至0.03％的硼，至多0.15％的碳，余量为镍和附带的杂质和/或残余元素。 由合金形成的焊接（12）能够表现出期望的强度和抗氧化性，同时含有很少的铼。

公开(公告)号：US08206645B2

公开(公告)日：2012-06-26

申请号：US13207891

申请日：2011-08-11

申请人： Thomas Joseph Kelly

发明人： Thomas Joseph Kelly

IPC分类号： B23K35/22 ,  B23K35/00

CPC分类号： B23K35/40 ,  B22F3/225 ,  B22F2998/00 ,  B22F2998/10 ,  B23K35/3033 ,  B23K35/304 ,  B23K35/3086 ,  B23K35/325 ,  B22F1/0003 ,  B22F3/1021 ,  B22F3/15

摘要： A method for preparing a filler-metal weld rod of a filler-metal composition includes the steps of centerless grinding the filler metal weld rod of a forced mixture of a mass of titanium aluminide intermetallic alloy powder that was used to form the weld rod, and hot isostatic pressing the filler-metal weld rod at a temperature greater than 2150° F., at a pressure between about 15,000 pounds per square inch and about 25,000 pounds per square inch and for a time of about 1 to 5 hours, thereby increasing the relative density to between about 98% and about 99%.

摘要翻译： 制备填料 - 金属组合物的填料 - 金属焊条的方法包括以下步骤：对用于形成焊条的钛铝化物金属间合金粉末的强制混合物的填充金属焊条进行无心磨削;以及 在大于2150°F的温度下，以约15,000磅/平方英寸和约25,000磅/平方英寸之间的压力和约1至5小时的时间将热等静压压入填料金属焊条，从而增加 约98％至约99％之间的相对密度。

公开(公告)号：US07413620B2

公开(公告)日：2008-08-19

申请号：US10301767

申请日：2002-11-20

申请人： Thomas Joseph Kelly

发明人： Thomas Joseph Kelly

IPC分类号： C22F1/18

CPC分类号： C22F1/183 ,  B23K15/0006 ,  B23K33/00

摘要： A method is provided for welding two gamma titanium aluminide articles together. The method includes preheating the two articles to a welding temperature of from about 1700° F. to about 2100° F., thereafter electron beam welding the two articles together at the welding temperature and in a welding vacuum to form a welded structure, and thereafter annealing the welded structure at an annealing temperature of from about 1800° F. to about 2200° F., to form a joined structure.

摘要翻译： 提供了将两个γ钛化铝制品焊接在一起的方法。 该方法包括将两个物品预热至约1700°F至约2100°F的焊接温度，然后在焊接温度和焊接真空下将两个物体电子束焊接在一起，形成焊接结构，之后 在约1800°F至约2200°F的退火温度下退火焊接结构，以形成接合结构。

公开(公告)号：US20080160208A1

公开(公告)日：2008-07-03

申请号：US11647975

申请日：2006-12-29

申请人： Michael Patrick Maly ,  William Thomas Carter ,  Thomas Joseph Kelly ,  Mark David Veliz

发明人： Michael Patrick Maly ,  William Thomas Carter ,  Thomas Joseph Kelly ,  Mark David Veliz

IPC分类号： B05D1/36

CPC分类号： C23C14/16 ,  B23P6/007 ,  C23C14/325 ,  F01D5/005 ,  F01D5/288 ,  F05D2230/31

摘要： A system for restoring or regenerating an article, such as turbine blade or vane for a gas turbine engine, includes a first cathode and a second cathode operably disposed in a deposition chamber. The first cathode includes a first deposition material substantially similar in composition to the material of a residual substrate. The second cathode includes a second deposition material able to form an environmental coating on a restored/regenerated component. The first and second cathodes may be sequentially operated without interrupting the vacuum conditions in the deposition chamber. A method for restoring or regenerating an article includes utilizing the first cathode to deposit a layer of first deposition material onto the residual substrate and subsequently applying the environmental coating utilizing a common deposition chamber, and without interrupting the vacuum conditions between depositions.

摘要翻译： 用于恢复或再生制品（例如用于燃气涡轮发动机的涡轮机叶片或叶片）的系统包括可操作地设置在沉积室中的第一阴极和第二阴极。 第一阴极包括与残留基底的材料基本相似的第一沉积材料。 第二阴极包括能够在恢复/再生的部件上形成环境涂层的第二沉积材料。 可以顺序地操作第一和第二阴极而不中断沉积室中的真空条件。 一种用于恢复或再生制品的方法包括利用第一阴极将一层第一沉积材料沉积在残余基底上，随后使用公共沉积室施加环境涂层，并且不中断沉积之间的真空条件。

公开(公告)号：US06750430B2

公开(公告)日：2004-06-15

申请号：US10280393

申请日：2002-10-25

申请人： Thomas Joseph Kelly

发明人： Thomas Joseph Kelly

IPC分类号： B23K3534

CPC分类号： B23K35/3033 ,  B21C37/042 ,  B23K35/0266 ,  B23K35/406

摘要： An article is made by preparing an elongated preform having a net metallic composition, and including a tubular sheath made of a sheath nickel-base alloy, and a core disposed within the tubular sheath and including consolidated powder particles made of a core nickel-base alloy. The net metallic composition is preferably a nickel-base superalloy, and most preferably a high-gamma-prime nickel-base superalloy. The preform is wire drawn to a final maximum transverse size that is less than the initial maximum transverse size, to produce a drawn article. The drawn article may be used as a weld filler material.

摘要翻译： 通过制备具有净金属组合​​物的细长预制件制成制品，并且包括由护套镍基合金制成的管状护套和设置在管状护套内的芯，并且包括由芯镍基合金制成的固结粉末颗粒 。 净金属组合​​物优选为镍基超级合金，最优选为高γ值镍基超级合金。 预成型件被拉丝至小于初始最大横向尺寸的最终最大横向尺寸，以产生拉制制品。 拉伸制品可用作焊接填料。

公开(公告)号：US06596963B2

公开(公告)日：2003-07-22

申请号：US09944710

申请日：2001-08-31

申请人： Thomas Joseph Kelly

发明人： Thomas Joseph Kelly

IPC分类号： B23K2620

CPC分类号： B23K35/40 ,  B23K35/3033 ,  B23K35/325

摘要： A method for welding an article includes producing welding filler metal by the steps of furnishing a powder of a welding-filler-metal composition, preferably a titanium aluminide or a nickel-base superalloy, providing a continuous casting mold having a welding-filler-metal diameter, and melting the powder into a top of the continuous casting mold, while withdrawing a continuous length of the welding filler metal from a bottom of the continuous casting mold. The melting is preferably accomplished using a laser to achieve a concentrated heating zone. The welding filler metal is used to weld an article, by applying an overlay layer or by joining articles together.

摘要翻译： 一种用于焊接物品的方法包括通过提供焊接 - 填充金属组合物，优选钛铝化物或镍基超合金的粉末的步骤来生产焊接填料金属，提供具有焊接 - 填充金属的连续铸造模具 并且将粉末熔化成连续铸造模具的顶部，同时从连续铸模的底部排出连续长度的焊接填充金属。 熔化优选使用激光来实现浓缩加热区。 焊接填充金属用于焊接物品，通过施加覆盖层或通过将物品连接在一起。

公开(公告)号：US20080160213A1

公开(公告)日：2008-07-03

申请号：US11648493

申请日：2006-12-29

申请人： Michael Patrick Maly ,  William Thomas Carter ,  Thomas Joseph Kelly ,  Mark David Veliz

发明人： Michael Patrick Maly ,  William Thomas Carter ,  Thomas Joseph Kelly ,  Mark David Veliz

IPC分类号： B01J19/08

CPC分类号： F01D5/005 ,  B23P6/007 ,  C23C4/06 ,  C23C4/185 ,  C23C14/16 ,  C23C14/5806 ,  C23C14/5893 ,  C23C28/02 ,  F05D2230/80

摘要： A method for restoring or regenerating an article, particularly a component for use in a gas turbine engine, includes providing a residual substrate comprised of a first material, evaluating a wall thickness of the residual substrate, and depositing a layer of a second material overlying at least a portion of the residual substrate. The second material is substantially similar in composition to the first material. The layer is deposited by vapor phase deposition, ion plasma deposition, cathodic arc deposition, sputtering, and combinations thereof. An environmental coating is deposited onto the component by vapor phase deposition, cathodic arc deposition, and combinations thereof. The method may include a heat treatment at temperatures between about 1500° F. to about 2300° F. (about 816° C. to about 1260° C.) for between about 2 to about 24 hours. The method may include a surface treatment such as grit blast polishing. Following use of the restored/regenerated component, the repair process may be repeated. At least a non-structural portion of the deposited layer may be removed during a subsequent repair. A load-bearing portion of the deposited layer, if present, may be retained on the residual substrate during a subsequent repair.

摘要翻译： 用于恢复或再生制品，特别是用于燃气涡轮发动机中的部件的方法包括提供由第一材料构成的残留基材，评价残留基材的壁厚，以及沉积覆盖在其上的第二材料层 残留基材的至少一部分。 第二种材料的组成与第一种材料基本相似。 该层通过气相沉积，离子等离子体沉积，阴极电弧沉积，溅射及其组合沉积。 通过气相沉积，阴极电弧沉积及其组合将环境涂层沉积到部件上。 该方法可以包括在约1500°F至约2300°F（约816℃至约1260℃）之间的温度下进行约2至约24小时的热处理。 该方法可以包括诸如喷砂抛光的表面处理。 在使用还原/再生组分之后，可以重复修复过程。 沉积层的至少非结构部分可以在随后的修复期间被去除。 沉积层的承载部分（如果存在）可以在随后的修复期间保留在残留的基底上。

公开(公告)号：US07387763B2

公开(公告)日：2008-06-17

申请号：US11207922

申请日：2005-08-19

申请人： Thomas Joseph Kelly

发明人： Thomas Joseph Kelly

IPC分类号： C21D1/00

CPC分类号： B22F3/227 ,  B22F3/225 ,  B22F5/006 ,  B22F2003/248 ,  B22F2998/00 ,  B22F2998/10 ,  B23K35/3033 ,  B23K35/304 ,  B23K35/3086 ,  B23K35/325 ,  B23K35/40 ,  C21D1/00 ,  C21D9/46 ,  C22C19/05 ,  C22C21/00 ,  B22F1/0059 ,  B22F3/1021 ,  B22F3/15 ,  C22C1/0491 ,  B22F1/0085 ,  B22F1/0074 ,  B22F3/24

摘要： A sheet is prepared by mixing a mass of metallic powders with a temporary thermoplastic binder to form an injection-moldable mixture, thereafter injection molding the injection-moldable mixture to form a sheet precursor. The sheet precursor is consolidated to a relative density of substantially 100 percent to form the sheet, and thereafter heat treated. The final sheet is preferably a nickel-base superalloy having more than about 30 volume percent of gamma prime phase, or an intermetallic such as a titanium aluminide.

摘要翻译： 通过将大量金属粉末与临时热塑性粘合剂混合以形成可注射模塑的混合物制备片材，然后注塑成型可注塑混合物以形成片材前体。 将片材前体固结成基本上100％的相对密度以形成片材，然后进行热处理。 最终的片材优选是具有大于约30体积％的γ'相的镍基超级合金，或金属间化合物如铝化钛。

公开(公告)号：US07282681B2

公开(公告)日：2007-10-16

申请号：US10908293

申请日：2005-05-05

申请人： Thomas Joseph Kelly

发明人： Thomas Joseph Kelly

IPC分类号： H05B6/64 ,  B64C1/00

CPC分类号： F01D5/20 ,  B22F7/06 ,  B23P6/005 ,  B23P6/007 ,  B23P15/02 ,  B23P15/04 ,  F01D5/005 ,  F05D2230/22 ,  Y10T29/49318 ,  Y10T29/49336 ,  Y10T29/49737 ,  Y10T29/49742

摘要： A method of producing a metallic component includes: providing a body made of a first alloy; providing a preform comprising a metallic powder made of a second alloy and formed in the shape of an extension of the body; and heating the preform with microwave energy to sinter the metallic powder together and to bond the preform to the body. The method may be used to make new components as well as to repair or modify existing components.

摘要翻译： 一种制造金属部件的方法包括：提供由第一合金制成的主体; 提供包括由第二合金制成并形成为本体延伸部的形状的金属粉末的预制件; 并用微波能量加热预制件，将金属粉末烧结在一起，并将预成型件粘合到机体上。 该方法可用于制作新组件以及修复或修改现有组件。

公开(公告)号：US06489584B1

公开(公告)日：2002-12-03

申请号：US09850895

申请日：2001-05-08

申请人： Thomas Joseph Kelly

发明人： Thomas Joseph Kelly

IPC分类号： B23K1000

CPC分类号： B23P6/007 ,  B23K10/027

摘要： A near-surface defect in a nickel-base superalloy article having a nil-ductility range is weld repaired with a low-power, directional, spatially confined heat source. During the weld repair procedure, the body of the article is maintained at room temperature. Simultaneously, the surface of the article is locally melted in the region of the near-surface defect using the heat source to form a melted region, and thereafter the melted region is allowed to solidify. The heat source produces a shallow weld pool that allows the near-surface defect to be floated to the surface in the case of an inclusion, or welded closed in the case of a surface crack or near-surface void.

摘要翻译： 具有无延展性范围的镍基超级合金制品中的近表面缺陷是用低功率，定向的，空间狭窄的热源进行焊接修复。 在焊接修复过程中，制品的主体保持在室温。 同时，使用热源在物体的近表面缺陷的区域局部熔化制品的表面以形成熔融区域，然后使熔融区域固化。 热源产生一个浅的熔池，允许近场表面的缺陷在夹杂物的情况下漂浮到表面，或者在表面裂纹或近表面空隙的情况下被焊接封闭。