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1. (WO2019032364) HYBRID PRE-SINTERED PREFORM, GREEN PREFORM, AND PROCESS
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CLAIMS

What is claimed is:

1. A process comprising:

agitating at least one core of a core alloy together with a braze binder to form at least one coated core comprising the at least one core coated with a first layer of the braze binder;

agitating the at least one coated core together with a powder composition comprising a first metal powder of a first alloy and a second metal powder of a second alloy to form a green preform having a first powder composition layer of the first alloy and the second alloy; and

sintering the green preform to form at least one hybrid pre-sintered preform (PSP).

2. The process of claim 1, wherein the first alloy has a first melting point of at least about 2400 °F and the second alloy has a second melting point of below about 2350 °F.

3. The process of claim 1, wherein the braze binder is a braze binder gel.

4. The process of claim 1 further comprising agitating the green preform together with the braze binder to form a braze binder-coated green preform and agitating the braze binder-coated green preform together with the first metal powder and the second metal powder to form a powder-coated green preform, wherein the sintering is of the powder-coated green preform.

5. The process of claim 1, wherein the at least one core is spherical.

6. The process of claim 1, wherein the core alloy includes a composition, by weight, of between about 8% and about 10% molybdenum, between about 20.5%> and about 23%> chromium, between about 17%) and about 20%> iron, between about 0.2%> and about 1%> tungsten, between about 0.5%> and about 2.5%o cobalt, between about 0.05%> and about 0.15% carbon, up to about 1%> silicon, up to about 1%> manganese, up to about 0.01%> boron, up to about 0.04%> phosphorus, up to about 0.03 sulfur, incidental impurities, and a balance of nickel.

7. The process of claim 1, wherein the first alloy includes a composition, by weight, of between about 9.3%o and about 9.7%> tungsten, between about 9.0%> and about 9.5%> cobalt, between about 8.0%> and about 8.5%> chromium, between about 5.4%> and about 5.7%> aluminum, about 3.2%> tantalum, about 1.4%) hafnium, up to about 0.25%> silicon, up to about 0.1%> manganese, between about 0.06%> and about

0.09% carbon, incidental impurities, and a balance of nickel.

8. The process of claim 1, wherein the second alloy includes a composition, by weight, of about 14%) chromium, about 10%> cobalt, about 3.5% aluminum, about 2.5% tantalum, about 2.75% boron, about 0.05%) yttrium, incidental impurities, and a balance of nickel.

9. The process of claim 1, wherein the first metal powder and the second metal powder are present in the powder composition in a ratio, by weight, in the range of 90: 10 to 45:55.

10. The process of claim 1 further comprising brazing one of the at least one hybrid PSP in a passageway to seal the passageway.

11. The process of claim 10, wherein the passageway is a bucket ball chute of a gas turbine bucket.

12. The process of claim 1, wherein the agitating at least one core of a core alloy together with a braze binder occurs with the at least one core and the braze binder in a plastic container.

13. The process of claim 1, wherein the agitating at least one core of a core alloy together with a braze binder and the agitating the at least one coated core together with a powder composition comprising of a first metal powder of a first alloy and a second metal powder of a second alloy are performed by a three-dimensional shaker-mixer.

14. A green preform comprising:

a core of a core alloy;

a first layer of a braze binder coated on the core; and

a powder composition comprising a first metal powder of a first alloy and a second metal powder of a second alloy coated on the first layer, the first alloy having a first melting point of at least about 2400 °F and the second alloy having a second melting point of below about 2350 °F.

15. The green preform of claim 14 further comprising:

a second layer of the braze binder coated on the powder composition of the first metal powder and the second metal powder; and

the powder composition of the first metal powder of the first alloy and the second metal powder of the second alloy coated on the second layer.

16. A hybrid pre-sintered preform (PSP) comprising:

a core of a core alloy; and

a first layer sintered to the core, the first layer being a sintered powder composition

comprising a first alloy from a first metal powder and a second alloy from a second metal powder, the first alloy having a first melting point of at least about 2400 °F and the second alloy having a second melting point of below about 2350 °F.

17. The hybrid PSP of claim 16 further comprising a second layer sintered to the first layer, the second layer having the sintered powder composition of the first alloy and the second alloy.

18. The hybrid PSP of claim 16, wherein the core is spherical.

19. The hybrid PSP of claim 16, wherein:

the core alloy includes a composition, by weight, of between about 8% and about 10% molybdenum, between about 20.5% and about 23% chromium, between about 17% and about 20%) iron, between about 0.2% and about 1% tungsten, between about 0.5% and about 2.5% cobalt, between about 0.05% and about 0.15% carbon, up to about 1% silicon, up to about 1% manganese, up to about 0.01%) boron, up to about 0.04% phosphorus, up to about 0.03 sulfur, incidental impurities, and a balance of nickel;

the first alloy includes a composition, by weight, of between about 9.3% and about 9.7%o tungsten, between about 9.0% and about 9.5% cobalt, between about 8.0% and about 8.5% chromium, between about 5.4% and about 5.7% aluminum, about 3.2% tantalum, about 1.4% hafnium, up to about 0.25% silicon, up to about 0.1% manganese, between about 0.06% and about 0.09%) carbon, incidental impurities, and a balance of nickel; and

the second alloy includes a composition, by weight, of about 14% chromium, about 10%) cobalt, about 3.5% aluminum, about 2.5% tantalum, about 2.75% boron, about 0.05% yttrium, incidental impurities, and a balance of nickel.

20. The hybrid PSP of claim 16, wherein the first alloy and the second alloy are present in the sintered powder composition in a ratio, by weight, in the range of 90: 10 to 45:55.