Methods and compositions are provided for improving metal dusting corrosion, abrasion resistance and/or erosion resistance for various materials, preferably for applications relating to high-temperature reactors, including dense fluidized bed reactor components. In particular, cermets comprising (a) at least one ceramic phase selected from the group consisting of metal carbides, metal nitrides, metal borides, metal oxides, metal carbonitrides, and mixtures of thereof and (b) at least one metal alloy binder phase are provided. Ceramic phase materials include chromium carbide (Cr.sub.23C.sub.6). Metal alloy binder phase materials include β-NiAl intermetallic alloys and Ni.sub.3Sn.sub.2 intermetallic alloys, as well as alloys that contain α-Cr and/or γ′-Ni.sub.3Al hard phases. Preferably, bimetallic materials are provided when the cermet compositions are applied using a laser, e.g., a laser cladding method such as high power direct diode (HPDD) laser, or by plasma-based methods such as plasma transfer arc (PTA) welding and powder plasma welding (PPW).

A blade has an attachment root and an airfoil, the airfoil having a proximal end and a distal end. The blade has a compositional variation along the airfoil.

An alloy contains the following elements, the proportions being indicated as percentage by weight of the alloy (limit values included): Cr 20 to 35%, Fe 0 to 6%, W 3 to 8%, Nb 0.5 to 3%, Ti 0 to 1%, C 0.4 to 1%, Co 0 to 3%, Si 0.1 to 1.5%, Mn 0.1 to 1%, the remainder consisting of nickel and unavoidable impurities.

An alloy contains the following elements, the proportions being indicated as percentage by weight of the alloy (limit values included): Cr 20 to 35%, Fe 0 to 6%, W 3 to 8%, Nb 0.5 to 3%, Ti 0 to 1%, C 0.4 to 1%, Co 0 to 3%, Si 0.1 to 1.5%, Mn 0.1 to 1%, the remainder consisting of nickel and unavoidable impurities.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

The present invention provides an alloy, an alloy powder, an alloy member, and a composite member which are excellent in corrosion resistance and wear resistance, have crack resistance, and are suitable for an additive manufacturing method and the like. An alloy and an alloy powder include, by mass %, Cr: 18 to 22%, Mo: 18 to 28%, Ta: 1.5 to 57%, C: 1.0 to 2.5%, Nb: 0 to 42%, Ti: 0 to 15%, V: 0 to 27%, Zr: 0 to 29%, and a remainder consisting of Ni and unavoidable impurities, where a molar ratio of (Ta+0.7Nb+Ti+0.6V+Zr)/C=0.5 to 1.5 is satisfied. An alloy member is an additively manufactured product or a cast having such a solidification structure, and the solidification structure is a dendrite-like crystal structure having a metal phase having a face-centered cubic structure and carbides.

The present invention provides an alloy, an alloy powder, an alloy member, and a composite member which are excellent in corrosion resistance and wear resistance, have crack resistance, and are suitable for an additive manufacturing method and the like. An alloy and an alloy powder include, by mass %, Cr: 18 to 22%, Mo: 18 to 28%, Ta: 1.5 to 57%, C: 1.0 to 2.5%, Nb: 0 to 42%, Ti: 0 to 15%, V: 0 to 27%, Zr: 0 to 29%, and a remainder consisting of Ni and unavoidable impurities, where a molar ratio of (Ta+0.7Nb+Ti+0.6V+Zr)/C=0.5 to 1.5 is satisfied. An alloy member is an additively manufactured product or a cast having such a solidification structure, and the solidification structure is a dendrite-like crystal structure having a metal phase having a face-centered cubic structure and carbides.

A coating-substrate combination includes: a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content; 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.

A coating-substrate combination includes: a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content; 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.

Provided are a Ni-based heat resistant superalloy for aircraft engine cases excellent in high-temperature characteristic such as tensile characteristics and low-cycle fatigue characteristics in a high-temperature range and also excellent in workability, and an aircraft engine case formed of the same. The Ni-based heat resistant superalloy has composition containing, by mass, Co: 4.0 to 11.0%, Cr: 12.0 to 17.0%, Al: 2.0 to 4.0%, Ti: 2.0 to 4.0%, Al+Ti: 4.6 to 6.7%, Mo: more than 5.5 to 10.0%, W: more than 0 to 4.0%, B: 0.001 to 0.040%, C: 0.02 to 0.06%, Zr: 0 to 0.05%, Mg: 0 to 0.005%, P: 0 to 0.01%, Nb: 0 to 1.0%, Ta: 0 to 1.0%, and Fe: 0 to 2.0%, and the balance of Ni with inevitable impurities, and is suitable for aircraft engine cases.