Multiple materials and microstructures in cast alloys

Abstract

Cast components are provided that include a first section comprising a first metal material and having first grains with a first average grain size and a second section comprising a second metal material and having second grains with a second average grain size.

What is claimed is: 
     
         1 . A cast component comprising:
 a first section comprising a first metal material and having first grains with a first average grain size; and   a second section comprising a second metal material and having second grains with a second average grain size, wherein the first metal material has a different composition than the second metal material, and wherein the first average grain size is greater than the second average grain size.   
     
     
         2 . The cast component of  claim 1 , wherein the first grains have an average first aspect ratio that is greater than an average second aspect ratio of the second grains. 
     
     
         3 . The cast component of  claim 2 , wherein the first average grain size has an aspect ratio of 2 or greater. 
     
     
         4 . The cast component of  claim 2 , wherein the first average grain size has an aspect ratio of 3 or greater. 
     
     
         5 . The cast component of  claim 2 , wherein the second average grain size has an aspect ratio of 2 or less. 
     
     
         6 . The cast component of  claim 2 , wherein the second average grain size has an aspect ratio of 0.5 to 2. 
     
     
         7 . The cast component of  claim 1 , further comprising:
 a third section having third grains with a third average grain size, wherein the third section forms a transition zone between the first section and the second section.   
     
     
         8 . The cast component of  claim 7 , wherein the third average grain size is less than the first average grain size, and wherein the third average grain size is greater than the second average grain size. 
     
     
         9 . The cast component of  claim 7 , wherein the first grains have an average first aspect ratio that is greater than an average second aspect ratio of the second grains, and wherein the third grains have an average third aspect ratio that is less than the average first aspect ratio of the first grains, and further wherein the average third aspect ratio of the third grains is greater than the average second aspect ratio of the second grains. 
     
     
         10 . The cast component of  claim 7 , wherein the transition zone has a compositional gradient within the cast component spanning from the first metal material of the first section to the second metal material of the second section. 
     
     
         11 . The cast component of  claim 1 , wherein the first metal material has a different composition than the second metal material. 
     
     
         12 . The cast component of  claim 1 , wherein the first section defines internal passages therein. 
     
     
         13 . The cast component of  claim 1 , wherein the cast component is a bladed disk comprising a plurality of airfoils extending radially outward from an internal disk, wherein the plurality of airfoils comprises the first section, and wherein the internal disk comprises the second section. 
     
     
         14 . The cast component of  claim 13 , wherein the plurality of airfoils define internal cavities therein. 
     
     
         15 . The cast component of  claim 1 , wherein the first metal material comprises a nickel-based superalloy. 
     
     
         16 . A cast component comprising:
 a first section comprising a first metal material in a single crystal; and   a second section comprising a second metal material and having grains with an average grain size, wherein the first metal material has a different composition than the second metal material.   
     
     
         17 . The cast component of  claim 16 , wherein the cast component is a bladed disk comprising a plurality of airfoils extending radially outward from an internal disk, wherein the plurality of airfoils comprises the first section, and wherein the internal disk comprises the second section. 
     
     
         18 . The cast component of  claim 17 , wherein the first section defines internal passages therein. 
     
     
         19 . The cast component of  claim 16 , wherein the first metal material comprises a nickel-based superalloy. 
     
     
         20 . The cast component of  claim 16 , further comprising:
 a transition area comprises an average transition grain size that is greater than the average grain size within the second section.