Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

A thin-walled metal part, and a method to fabricate such a part out of various alloys. A plurality of layers are formed, each of the layers being formed on a polymer template or on a previously formed layer. A homogenizing heat treatment is used to cause chemical elements in the layers to interdiffuse, to form a single continuous layer with a substantially uniform alloy composition.

A thin-walled metal part, and a method to fabricate such a part out of various alloys. A plurality of layers are formed, each of the layers being formed on a polymer template or on a previously formed layer. A homogenizing heat treatment is used to cause chemical elements in the layers to interdiffuse, to form a single continuous layer with a substantially uniform alloy composition.

A nickel-chromium-aluminum alloy includes (in mass %) 12 to 30% chromium, 1.8 to 4.0% aluminum, 0.1 to 7.0% iron, 0.001 to 0.50% silicon, 0.001 to 2.0% manganese, 0.00 to 1.00% titanium, 0.00 to 1.10% niobium, 0.00 to 0.5% copper, 0.00 to 5.00% cobalt, in each case 0.0002 to 0.05% magnesium and/or calcium, 0.001 to 0.12% carbon, 0.001 to 0.050% nitrogen, 0.001 to 0.030% phosphorus, 0.0001 to 0.020% oxygen, max. 0.010% sulfur, max. 2.0% molybdenum, max. 2.0% tungsten, and a remainder of nickel with a minimum content of ≥50% and the usual process-related impurities for use in solar power towers, using chloride and/or carbonate salt melts as a heat transfer medium, wherein in order to ensure a good processability, the following condition must be met: Fv≥0.9 with Fv=4.88050−0.095546*Fe−0.0178784*Cr−0.992452*AI−1.51498*Ti−0.506893*Nb+0.0426004*AI*Fe, where Fe, Cr, AI, Ti, and Nb are the concentration of the respective elements in mass %.

A seal member includes a γ′ precipitation-hardening alloy, in which the γ′ precipitation-hardening alloy has a component composition of, in mass %: Ni: from 40 to 62%; Cr: from 13 to 20%; Ti: from 1.5 to 2.8%; Al: from 1.0 to 2.0% (provided that Ti/Al: 2.0 or less); Nb: 2.0% or less; Ta: 2.0% or less (provided that Nb+Ta: from 0.2 to 2.0%); B: from 0.001 to 0.010%; W: 3.0% or less; and Mo: 2.0% or less (provided that Mo+(1/2)W: from 1.0 to 2.5%), and optionally, C: 0.08% or less; Si: 1.0% or less; Mn: 1.0% or less; P: 0.02% or less; and S: 0.01% or less, with the balance being Fe and inevitable impurities, and in which the seal member has a hardness of 250 Hv or more, and includes a cold-rolled microstructure obtained by a cold rolling.

The disclosure provides for a layered metal with resistance to hydrogen induced cracking and method of production thereof, comprising a core metal alloy and a skin metal alloy. The core metal alloy comprises twinned boundaries. The core metal alloy has undergone plastic deformation and a heat treatment. The core metal alloy comprises nickel and cobalt. The skin metal alloy is disposed on the core metal alloy, wherein the skin metal alloy comprises an entropy greater than the core metal alloy. The core metal alloy comprises a greater density of twinned boundaries than the skin metal alloy. The skin metal alloy comprises a stacking fault energy of at least about 50 mJ/m.sup.2, and the skin metal alloy comprises iron, aluminum, and boron.

The disclosure provides for a layered metal with resistance to hydrogen induced cracking and method of production thereof, comprising a core metal alloy and a skin metal alloy. The core metal alloy comprises twinned boundaries. The core metal alloy has undergone plastic deformation and a heat treatment. The core metal alloy comprises nickel and cobalt. The skin metal alloy is disposed on the core metal alloy, wherein the skin metal alloy comprises an entropy greater than the core metal alloy. The core metal alloy comprises a greater density of twinned boundaries than the skin metal alloy. The skin metal alloy comprises a stacking fault energy of at least about 50 mJ/m.sup.2, and the skin metal alloy comprises iron, aluminum, and boron.

A process for producing an amorphous ductile brazing foil is provided. According to one example embodiment, the method includes providing a molten mass, and rapidly solidifying the molten mass on a moving cooling surface with a cooling speed of more than approximately 10.sup.5° C./sec to produce an amorphous ductile brazing foil. A process for joining two or more parts is also provided. The process includes inserting a brazing foil between two or more parts to be joined, wherein the parts to be joined have a higher melting temperature than that the brazing foil to form a solder joint and the brazing foil comprises an amorphous, ductile Ni-based brazing foil; heating the solder joint to a temperature above the liquidus temperature of the brazing foil to form a heated solder joint; and cooling the heated solder joint, thereby forming a brazed joint between the parts to be joined.

A process for producing an amorphous ductile brazing foil is provided. According to one example embodiment, the method includes providing a molten mass, and rapidly solidifying the molten mass on a moving cooling surface with a cooling speed of more than approximately 10.sup.5° C./sec to produce an amorphous ductile brazing foil. A process for joining two or more parts is also provided. The process includes inserting a brazing foil between two or more parts to be joined, wherein the parts to be joined have a higher melting temperature than that the brazing foil to form a solder joint and the brazing foil comprises an amorphous, ductile Ni-based brazing foil; heating the solder joint to a temperature above the liquidus temperature of the brazing foil to form a heated solder joint; and cooling the heated solder joint, thereby forming a brazed joint between the parts to be joined.

Heat treatment of an Alloy 282 which has been subjected to an initial solution annealing followed by cooling can be heat treated by heating the Alloy 282 to a temperature between 954° C. and 1010° C. until the gamma prime (γ′) phase is sufficiently dissolved, and cooling the Alloy 282 to a temperature a sufficiently low temperature, and at a sufficiently high cooling rate, to suppress gamma prime precipitation. A component such as a turbine exhaust case and a gas turbine engine made of said alloy can be heat treated in the above manner.