Method for producing a metallic article having a graded composition, without melting

Abstract

A method for preparing a metallic article made of metallic constituent elements includes furnishing a chemically reduced initial metallic material formed from chemically reducing a mixture of nonmetallic precursor compounds of the metallic constituent elements, without melting the initial metallic material, and consolidating the initial metallic material to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article. A net macroscopic composition of the consolidated metallic article varies spatially according to a pre-selected pattern

1 . A method for preparing a metallic article made of metallic constituent elements, comprising the steps of
 furnishing a chemically reduced initial metallic material formed from chemically reducing a mixture of nonmetallic precursor compounds of the metallic constituent elements, without melting the initial metallic material; and   consolidating the initial metallic material to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article, wherein a net macroscopic composition of the consolidated metallic article varies spatially in the metal matrix of the metallic article according to a preselected pattern.   
   
   
       2 . The method of  claim 1 , wherein the initial metallic material includes more base metal than any other metallic element, wherein the base metal is selected from the group consisting of titanium, aluminum, nickel, and cobalt. 
   
   
       3 . The method of  claim 1 , wherein the initial metallic material includes a base metal, and an alloying element, wherein the alloying element is thermophysically melt incompatible with the base metal. 
   
   
       4 . The method of  claim 1 , wherein the initial metallic material includes an unreduced dispersoid therein. 
   
   
       5 . The method of  claim 1 , wherein the nonmetallic precursor compounds have been arranged in a spatially varying pattern. 
   
   
       6 . The method of  claim 1 , wherein the initial metallic material has been solid-phase reduced. 
   
   
       7 . The method of  claim 1 , wherein the initial metallic material has been vapor-phase reduced. 
   
   
       8 . The method of  claim 1 , wherein the step of consolidating includes the step of
 consolidating the initial metallic material without the use of a binder.   
   
   
       9 . The method of  claim 1 , further including a step, after the step of furnishing and before the step of consolidating, of
 arranging the initial metallic material in a spatially varying pattern.   
   
   
       10 . The method of  claim 1 , wherein the method includes the step of
 preparing the consolidated metallic article comprising a gas turbine engine disk starting shape.   
   
   
       11 . The method of  claim 1 , including an additional step, prior to the step of consolidating, of
 producing a mixture of a metallic material and an other additive constituent.   
   
   
       12 . The method of  claim 1 , including an additional step, after the step of consolidating, of
 forming the consolidated metallic article.   
   
   
       13 . The method of  claim 1 , including an additional step, after the step of consolidating, of
 heat treating the consolidated metallic article.   
   
   
       14 . A method for preparing a metallic article made of metallic constituent elements, comprising the steps of
 furnishing a chemically reduced initial metallic material formed from chemically reducing a mixture of nonmetallic precursor compounds of the metallic constituent elements, without melting the initial metallic material, wherein the initial metallic material has more titanium or aluminum or nickel or cobalt or iron or iron-nickel or iron-nickel-cobalt than another other element; and   consolidating the initial metallic material to produce a consolidated metallic article in the form of a gas turbine engine disk starting shape, without melting the initial metallic material and without melting the consolidated metallic article, wherein a net macroscopic composition of the consolidated metallic article varies spatially in the metal matrix of the metallic article according to a preselected pattern.   
   
   
       15 . The method of  claim 14 , wherein the initial metallic material includes more base metal than any other metallic element, wherein the base metal is selected from the group consisting of titanium, aluminum, nickel, and cobalt. 
   
   
       16 . The method of  claim 14 , wherein the initial metallic material includes more base metal than any other metallic element, wherein the base metal is selected from the group consisting of iron, iron-nickel, and iron-nickel-cobalt. 
   
   
       17 . The method of  claim 14 , wherein the initial metallic material includes a base metal, and an alloying element, wherein the alloying element is thermophysically melt incompatible with the base metal. 
   
   
       18 . The method of  claim 14 , wherein the initial metallic material has been solid-phase reduced. 
   
   
       19 . The method of  claim 14 , wherein the initial metallic material has been vapor-phase reduced. 
   
   
       20 . The method of  claim 14 , wherein the step of consolidating includes the step of
 consolidating the initial metallic material without the use of a binder.   
   
   
       21 . The method of  claim 14 , further including a step, after the step of furnishing and before the step of consolidating, of
 arranging the initial metallic material in a spatially varying pattern.   
   
   
       22 . The method of  claim 14 , including an additional step, prior to the step of consolidating, of
 producing a mixture of a metallic material and an other additive constituent.   
   
   
       23 . The method of  claim 14 , wherein the step of furnishing the mixture includes the step of
 furnishing the mixture comprising more base metal than any other metallic element, wherein the base metal is selected from the group consisting of iron, iron-nickel, and iron-nickel-cobalt.