Abstract: A method of functionalizing a diamond crystal comprises hydrogenating a diamond crystal, chlorinating the hydrogenated diamond crystal; and exposing the chlorinated diamond crystal to a metal precursor. The exposing step deposits a layer of metal on surfaces of the diamond crystals. The diamond crystal formed by the method possesses surface sites that form a strong bond with the layer of metal to prevent separation thereat, and the layer of metal form strong bonds to a matrix material, for example one of a vitreous and metallic matrix. The functionalized diamond crystal can be used in abrasive products.

Abstract: A bond coat and method of forming a bond coat for a thermal barrier coating system are set forth. The bond coat is a roughened bond coat and comprises a layer possessing an uneven, undulated, and irregular surface. The layer is formed of a metal powder mixture disposed on a substrate, such as a turbine component, by high velocity oxygen fuel spraying. The metal powder mixture comprises at least one of a first powder having a first melting point and a second powder having a second melting point that is higher than the first melting point. The bond coat's uneven, undulated, and irregular surface enhances prevention of de-bonding of elements in a thermal barrier coating system.

Abstract: A die clamp assembly for an extruder comprises at least one passage through which product being extruded flows. The die clamp assembly is attached to an extruder and comprises at least one adapter plate that is connectable to the extruder. The die clamp assembly also comprises at least one adapter plate passage that communicates with the passage of the extruder; at least one die body comprising at least one die body passage that communicates with the adapter plate passage; and at least one die plate that comprises at least one die plate passage that communicates with the die body passage and at least one opening so product can be extruded from the at least one opening. A clamp collar assembly connects corresponding peripheral surfaces of the adapter plate to the die body, and comprises a closed position that connects the adapter plate to the die body and an open position that permits separation of the adapter plate and the die body.

Abstract: A current limiting device comprises at least two electrodes; an electrically conductive composite material between the electrodes; interfaces between the electrodes the said composite material; and an inhomogeneous resistance distribution structure at the interfaces. During a high current event, adiabatic resistive heating at the interfaces causes rapid thermal expansion and vaporization and at least a partial physical separation at the interfaces; so the resistance of the current limiting device increases. The composite material comprises at least one polymeric matrix material and at least one electrically conductive material, and the polymeric matrix material comprises at least one epoxy and at least one silicone.

Abstract: A cold hearth for an electroslag refining crucible includes a floor above which a melt pools. The floor includes a drain for draining the melt by gravity. A plug is deployed inside the drain to block discharge of the melt therethrough, and an actuator is attached to the plug for withdrawing the plug from the drain to permit drainage of the melt upon startup.

Abstract: A method and spray forming system for effectively spraying the inner diameters of intricate objects and makes inner diameter spray forming practical for articles that have various and complicated inner geometries. The spray forming system can include at least one of a rotating mandrel and preform, and atomizer, which is fed with liquid metal, to form a spray. The atomizer is positioned with respect to inner walls of at least one of the rotating mandrel and preform to accurately and fully spray form an inner diameter of an article, even if the article has complicated and irregular inner surfaces.

Abstract: The present invention is directed towards a system that makes high quality gypsum from a dry flue gas desulfurization process which utilizes a low temperature regeneration of the carbon adsorbent in the flue gas process. The high quality gypsum is easily filterable with large crystal size and has high purity with few contaminants, such as calcium sulfite and heavy metals. This invention is also directed towards a system that regenerates the carbon used in dry flue gas desulfurization at a temperature below 120.degree. C. and the recycling of sodium hydroxide to form a sodium sulfite reducing solution for carbon adsorbent regeneration.

Abstract: A lamp assembly comprises a incandescent lamp capable of generating light. The incandescent lamp comprises a incandescent lamp tube and at least one filament. The assembly also comprises a shroud separate from the incandescent lamp and mounted in communication with the lamp tube on an exterior of the incandescent lamp tube. The shroud also comprises a coating disposed on the reflecting section of the shroud for reflecting energy having predetermined wavelengths emitted by the incandescent lamp. The shroud comprises a reflecting section disposed about the incandescent lamp tube, where the geometry of the shroud generally conforms to the geometry of the at least one filament of the lamp, to reflect energy having predetermined wavelengths back substantially toward the incandescent lamp and focusing the reflected energy generally at the at least one filament of the incandescent lamp so as to increase the output from the assembly.

Abstract: Cathode filaments are recrystallized to a microstructure that maintains ductility for proper alignment and electron emission capability. The method comprises controlled heating of a cathode filament from an ambient temperature T.sub.amb to its recrystallization temperature T.sub.recryst ; controlled holding of the cathode filament at the temperature T.sub.recryst ; and controlled cooling of the cathode filament from the temperature T.sub.recryst to the ambient temperature T.sub.amb. The cathode filament is usable in an x-ray tube and can be formed of a tungsten-rhenium material.

Abstract: A method combining isothermal and high retained strain forging is described for Ni-base superalloys, particularly those which comprise a mixture of .gamma. and .gamma.' phases, and most particularly those which contain at least about 40 percent by volume of .gamma.'. The method permits the manufacture of forged articles having a fine grain size in the range of 20 .mu.m or less. The method comprises the selection of a fine-grained forging preform formed from a Ni-base superalloy, isothermal forging to develop the shape of the forged article, subsolvus forging to impart a sufficient level of retained strain to the forged article to promote subsequent recrystallization and avoid critical grain growth, and annealing to recrystallize the microstructure. The method permits the forging of relatively complex shapes and avoids the problem of critical grain growth. The method may also be used to produce location specific grain sizes and phase distributions within the forged article.

Abstract: A method for directional solidification (DS) of a molten material, and an apparatus therefor. The method generally entails the use of a container having a base and peripheral wall that define an interior of the container, an induction coil for heating the contents of the container and generating an electromagnetic field, and means for controllably separating the container from the heating means and the electromagnetic field, such as by withdrawing the container from the heating means and electromagnetic field. Using such an apparatus, a material is heated within the container to yield a melt that is substantially prevented from contacting the wall of the container as a result of being at least partially levitated by the electromagnetic field. The container is then separated, e.g.

Abstract: A high temperature insulating composite composition comprising at least one ground silicate mineral and at least one silicone polymer. The at least one ground silicate mineral is at least one mineral selected from the group of olivine group; garnet group; aluminosilicates; ring silicates; chain silicates; and sheet silicates. The high temperature insulating material has particular usefulness for insulating electrical wires.

Abstract: A gas sensor determines the presence of at least one designated gas in a gaseous environment. The gas sensor comprises a semiconductor substrate; a thin insulator layer disposed on the semiconductor substrate; a catalytic metallic gate disposed on the thin insulator layer; and a chemically modified layer disposed on the catalytic metal gate. The chemically modified layer comprises a material that protects the sensor from corrosive gases and interference from at least one foreign matter and water, alters at least one of surface chemical properties and surface physical properties of the sensor, and passes only the designated gas therethrough.

Abstract: An apparatus for sorting fragments of titanium-based sponge on the basis of color is disclosed. The apparatus captures at least one color image of each fragment, inserts relevant color values from the image into an automated color-sorting system to determine the color of the fragment, and segregates the fragments according to color or range-of-color, by way of a physical segregation apparatus controlled by the color sorting system. The color sorting systems usually involve the conversion of color images from the fragments into color signals, which are in turn transformed into color values. The color images are usually represented by a pattern of pixels. The color values are automatically compared to values, which are part of a look-up table based on data sets, which embrace acceptable or rejectable color values. Comparison of color values determined for the fragments with those in the look-up table results in the acceptance or rejection of each fragment.

Abstract: A Ni-base alloy composition comprises of Zr, B, and Si. Zr and B are coupled to each other to form ZrB.sub.2, the B and Zr suppress melting points of the Ni-base alloy composition. Further, a Ni-base alloy composition also comprises Cr, Ti, and Ni, where the Ti and Cr suppress melting points.

Abstract: An improved method and apparatus for monitoring the concentration of contaminants, including volatile organic compounds, in groundwater is provided comprising a semipermeable membrane defining an inner chamber. The chamber is carried within a mesh protective sleeve of cover to prevent abrasion or puncture of the chamber. The membrane is permeable to contaminants but impermeable to a reference fluid, which is distilled water. The method of sampling comprises placing the semipermeable membrane chamber, which contains the reference fluid, in contact with contaminated groundwater, thereby allowing contaminants to diffuse through the semipermeable membrane.

Abstract: Systems and methods of electroslag refining of metal include the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The cold finger bottom pour spout comprises a plurality of copper segments having gaps. The gap between the segments is established and maintained by insulation structure and sealing structure positioned in each gap.

Abstract: An electroslag refining starter includes a refined disk fixedly joined in a central aperture of a mounting ring. The mounting ring supports the starter in a crucible below an ingot being electroslag refined. The disk is consumed during starting and is replaceable in the same mounting ring for subsequent reuse.

Abstract: A current limiting device utilizes an electrically conductive composite material and an inhomogeneous distribution of resistance structure. The current limiting device has a conducting filler and at least two electrodes, where at least one of the electrodes comprises a grooved electrode structure. The grooved electrode structure maintains contact between the electrodes and the composite material, even with consumption of the composite material and production of residue during a high current condition.

Abstract: A method and a HIP can structure for hot isostatically pressed (HIP) production of flat sheet metal matrix composites having a dimension greater than about 4.times.5 inches. The HIP can is constructed so that most of the expensive components are reusable for further processing of other composites. The side walls of the HIP can have reduced thickness relative to the top and bottom walls and the can has a reinforced centerpiece between the two composites used in the example. Molybdenum foils are utilized to separate the composites from the stiffening structure so that when the HIP can is opened by breaking the weld at one of its wings, the components of the can and the composites come apart so that the most expensive structural members of the HIP can be reused.