Powder metallurgical article

Abstract

A powder metallurgical article and process are disclosed. The article is a repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a formed article including a first alloy and a material including a second alloy. The material is welded to the formed article to form the repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a substantially uniform grain structure.

What is claimed is: 
     
         1 . A repaired or enlarged powder metallurgical article, comprising:
 a formed article comprising a first alloy;   a material comprising a second alloy;   wherein the material is welded to the formed article, and   wherein the repaired or enlarged powder metallurgical article includes a substantially uniform grain structure between the formed article and the material.   
     
     
         2 . The repaired or enlarged article of  claim 1 , wherein the formed article is formed of a consolidated powder metal. 
     
     
         3 . The repaired or enlarged article of  claim 1 , wherein the material welded to the formed article is a powdered metal. 
     
     
         4 . The repaired or enlarged article of  claim 1 , wherein the material welded to the formed article is a second formed article. 
     
     
         5 . The repaired or enlarged article of  claim 1 , further comprising a weld deposit formed by the material. 
     
     
         6 . The repaired or enlarged article of  claim 1 , wherein the first alloy and second alloy are nickel-based alloys. 
     
     
         7 . The repaired or enlarged article of  claim 1 , wherein the formed article and the material include Nickel at 55.0-59.0%, Chromium at 19.0-22.5%, Molybdenum at 7.0-9.5%, Niobium at 2.75-4.0%, Titanium at 1.0-1.7%, Aluminum at 0.35 max %, at Carbon 0.03 max %, Manganese at 0.35 max %, Silicon at 0.20 max %, Phosphorus at 0.015 max %, Sulfur at 0.010 max %, and an Iron balance. 
     
     
         8 . The repaired or enlarged article of  claim 1 , wherein the first alloy is a field-run alloy. 
     
     
         9 . The repaired or enlarged article of  claim 1 , wherein the formed article includes an undesirable feature. 
     
     
         10 . The repaired or enlarged article of  claim 9 , wherein the undesirable feature is selected from the group consisting of a crack, oxidation, corrosion, a defect, and combinations thereof 
     
     
         11 . The repaired or enlarged article of  claim 10 , wherein the second material forms a repair on the undesirable feature. 
     
     
         12 . The repaired or enlarged article of  claim 1 , wherein the second material forms a weld deposit on the article. 
     
     
         13 . The repaired or enlarged article of  claim 1 , wherein the second material is a brazed or fusion arc welded alloy. 
     
     
         14 . A repaired or enlarged powder metallurgical article, comprising:
 a formed article comprising a first nickel-based alloy, the first nickel-based alloy being a consolidated powder metal;   a material comprising a second nickel-based alloy;   wherein the material is welded to the formed article, and   wherein the repaired or enlarged powder metallurgical article includes a substantially uniform grain structure between the formed article and the material.   
     
     
         15 . The repaired or enlarged article of  claim 14 , wherein the formed article and the material include Nickel at 55.0-59.0%, Chromium at 19.0-22.5%, Molybdenum at 7.0-9.5%, Niobium at 2.75-4.0%, Titanium at 1.0-1.7%, Aluminum at 0.35 max %, at Carbon 0.03 max %, Manganese at 0.35 max %, Silicon at 0.20 max Phosphorus at 0.015 max %, Sulfur at 0.010 max %, and an Iron balance. 
     
     
         16 . The repaired or enlarged article of  claim 1 , wherein the first alloy is a field-run alloy. 
     
     
         17 . The repaired or enlarged article of  claim 14 , wherein the formed article includes an undesirable feature. 
     
     
         18 . The repaired or enlarged article of  claim 17 , wherein the undesirable feature is selected from the group consisting of a crack, oxidation, corrosion, a defect, and combinations thereof 
     
     
         19 . The repaired or enlarged article of  claim 18 , wherein the second material forms a repair on the undesirable feature. 
     
     
         20 . The repaired or enlarged article of  claim 14 , wherein the second material is a brazed or fusion arc welded alloy.