Patent ID: 8021604

Claim:
A method for preparing a filler-metal weld rod of a filler-metal composition, comprising the steps of: providing a mass of titanium aluminide intermetallic alloy powder, wherein the mass of titanium aluminide intermetallic alloy powder has the filler-metal composition and further providing nonmetallic particles mixed with the mass of titanium aluminide intermetallic alloy powder; mixing the mass of titanium aluminide intermetallic alloy powder with a temporary thermoplastic binder to form a mixture; thereafter forcing the mixture through a nozzle at a temperature above the thermoplastic temperature of the thermoplastic binder to form a rod; thereafter removing excess thermoplastic binder from an external surface of the rod using a nonaqueous solvent; and thereafter sintering the rod to form the filler-metal weld rod having a relative density of not greater than 90 percent, wherein the temporary thermoplastic binder is removed in the step of sintering; and thereafter hot isostatic pressing the filler-metal weld rod at a temperature greater than 2150° F., at a pressure between about 15,000 pounds per square inch and about 25,000 pounds per square inch and for a time of about 1 to 5 hours, thereby increasing the relative density to between about 98% and about 99%; and thereafter centerless grinding the filler-metal weld rod.