A powder boronizing composition comprising: a. 0.5 to 4.5 wt % of a boron source selected from B.sub.4C, amorphous boron, calcium hexaboride, borax or mixtures thereof; b. 45.5 to 88.5 wt % of a diluent selected from SiC, alumina or mixtures thereof; c. 1.0 to 20.0 wt % of an activator selected from KBF.sub.4, ammonia chloride, cryolite or mixtures thereof; and d. 10.0 to 30.0 wt % of a sintering reduction agent selected from carbon black, graphite or mixtures thereof.

Cast alloys comprising 20 to 35 wt. % nickel; 25% to 42.5 wt. % chromium; 1.5 to 2.5 wt. % carbon; 0.5 to 2.0 wt. % manganese; 0.25 to 2.0 wt. % silicon; 0 to 1.5 wt. % aluminum; 0 to 0.5 wt. % titanium, niobium, tantalum combined, 0 to 1 wt. % copper, other residual elements up to 0.5 wt. %, and iron to bring the total percentage to 100 wt. %, are described. The cast alloys can be used to form components for mixers, turbines and pumps, such as impellers, diffusers, and spacers, or for fracking operations as seats or flow diverters, as well as other oil and gas or energy industry components. In some applications, the cast alloys are custom made for downhole electro submersible pump applications.

Cast alloys comprising 20 to 35 wt. % nickel; 25% to 42.5 wt. % chromium; 1.5 to 2.5 wt. % carbon; 0.5 to 2.0 wt. % manganese; 0.25 to 2.0 wt. % silicon; 0 to 1.5 wt. % aluminum; 0 to 0.5 wt. % titanium, niobium, tantalum combined, 0 to 1 wt. % copper, other residual elements up to 0.5 wt. %, and iron to bring the total percentage to 100 wt. %, are described. The cast alloys can be used to form components for mixers, turbines and pumps, such as impellers, diffusers, and spacers, or for fracking operations as seats or flow diverters, as well as other oil and gas or energy industry components. In some applications, the cast alloys are custom made for downhole electro submersible pump applications.

Apparatuses and methods of manufacturing of thermally formed composite structures, such as a projectile firing structure, are provided. One simplified exemplary method includes: determining material properties of a projectile firing structure comprising a rifled barrel including thermal conductivity, wear, and tensile strength; wrapping a plurality of thermally reactive layers onto a cylindrical press form structure, the cylindrical press form structure comprising a plurality of spiraled grooves and lands, the thermally reactive layers comprising metal or metal oxides that when heated produce thermal diffusion byproducts in a composite structure forming the rifled barrel having the plurality of material properties; disposing an enclosing structure around the thermally reactive layers wrapped around the cylindrical press form structure; and heating the plurality of thermally reactive layers at a temperature and time so that the plurality of thermally reactive layers thermally react via thermal diffusion forming the rifled barrel having the plurality of material properties.

Apparatuses and methods of manufacturing of thermally formed composite structures, such as a projectile firing structure, are provided. One simplified exemplary method includes: determining material properties of a projectile firing structure comprising a rifled barrel including thermal conductivity, wear, and tensile strength; wrapping a plurality of thermally reactive layers onto a cylindrical press form structure, the cylindrical press form structure comprising a plurality of spiraled grooves and lands, the thermally reactive layers comprising metal or metal oxides that when heated produce thermal diffusion byproducts in a composite structure forming the rifled barrel having the plurality of material properties; disposing an enclosing structure around the thermally reactive layers wrapped around the cylindrical press form structure; and heating the plurality of thermally reactive layers at a temperature and time so that the plurality of thermally reactive layers thermally react via thermal diffusion forming the rifled barrel having the plurality of material properties.

A hybrid method of surface hardening metallic components using a combination of chemical modification achieved through additive manufacturing and/or diffusion-based processing with transformation-based processing using a high energy density heat source. The hybrid process results in increased surface hardness and/or increased average case hardness and/or increased case depth compared to either treatment individually.

A manufacturing process is provided. During this process, material is solidified together within a chamber to form an object using an additive manufacturing device. At least a portion of the solidified material is conditioned within the chamber using a material conditioning device.

A gas turbine engine includes: a turbine section including a casing extending circumferentially about a plurality of turbine blades and having at least one seal member coated with an abradable coating. At least one turbine blade has sides and a tip and at least one seal member is located adjacent to the tip of the at least one turbine blade. The tip of the at least one turbine blade has a wear resistant layer and an abrasive coating disposed on the wear resistant layer. The wear resistant layer has a thickness less than or equal to 10 mils (254 micrometers) and includes metal boride compounds.

A gas turbine engine includes: a turbine section including a casing extending circumferentially about a plurality of turbine blades and having at least one seal member coated with an abradable coating. At least one turbine blade has sides and a tip and at least one seal member is located adjacent to the tip of the at least one turbine blade. The tip of the at least one turbine blade has a wear resistant layer and an abrasive coating disposed on the wear resistant layer. The wear resistant layer has a thickness less than or equal to 10 mils (254 micrometers) and includes metal boride compounds.

A gas turbine engine includes an engine static structure extending circumferentially about an engine centerline axis; a compressor section, a combustor section, and a turbine section within the engine static structure. At least one of the compressor section and the turbine section includes at least one airfoil and at least one seal member adjacent to the at least one airfoil. A tip of the at least one airfoil is metal having a wear resistant coating and the at least one seal member is coated with an abradable coating. The wear resistant coating is formed as a layer in a base metal surface of the airfoil, has a thickness less than or equal to 10 mils (254 micrometers) and includes metal boride compounds.