Abstract: An additive manufacturing system configured to manufacture a component including scan strategies for efficient utilization of one or more laser arrays. The additive manufacturing system includes at least one laser device, each configured as a laser array, and a build platform. Each laser device is configured to generate a plurality of laser beams. The component is disposed on the build platform. The at least one laser device is configured to sweep across the component and the build platform in at least one of a radial direction, a circumferential direction or a modified zig-zag pattern and simultaneously operate the one or more of the plurality of individually operable laser beams corresponding to a pattern of the layer of a build to generate successive layers of a melted powdered material on the component and the build platform corresponding to the pattern of the layer of the build. A method of manufacturing a component with the additive manufacturing system is also disclosed.

Abstract: An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

Abstract: An additive manufacturing system is configured to manufacture a component. The additive manufacturing system includes a laser device, a build platform, a first scanning device, and an air knife. The laser device is configured to generate a laser beam. The component is disposed on the build platform. The air knife is configured to channel an inert gas across the build platform. The first scanning device is configured to selectively direct the laser beam across the build platform. The laser beam is configured to generate successive layers of a melted powdered build material on the component and the build platform. The build platform is configured to rotate the component relative to the air knife.

Abstract: A component is fabricated in a powder bed by moving a laser array across the powder bed. The laser array includes a plurality of laser devices. The power output of each laser device of the plurality of laser devices is independently controlled. The laser array emits a plurality of energy beams from a plurality of selected laser devices of the plurality of laser devices to generate a melt pool in the powder bed. A non-uniform energy intensity profile is generated by the plurality of selected laser devices. The non-uniform energy intensity profile facilitates generating a melt pool that has a predetermined characteristic.

Abstract: A recoating device for an additive manufacturing system includes a plurality of recoater blades which include a first stage and a second stage. The first stage includes a plurality of rows of the plurality of recoater blades and extends in the transverse dimension. The second stage includes a plurality of recoater blades and is configured substantially similar to the first stage of the plurality of recoater blades. The second stage of recoater blades is displaced from the first stage of recoater blades in the vertical dimension.

Abstract: The present disclosure is directed to a heat flux assembly for an energy storage device. The energy storage device includes a housing with a plurality of side walls that define an internal volume and a plurality of cells configured within the internal volume. The heat flux assembly includes a plurality of heat flux components configured for arrangement with the side walls of the housing of the energy storage device and one or more temperature sensors configured with each of the plurality of heat flux components. Thus, the temperature sensors are configured to monitor one or more temperatures at various locations in the plurality of heat flux components. The heat flux assembly also includes a controller configured to adjust a power level of each of the heat flux components as a function of the monitored temperature so as to reduce a temperature gradient or difference across the plurality of cells during operation of the energy storage device.

Abstract: An electrochemical cell is presented. The cell includes a housing having an interior surface defining a volume, and an elongated separator disposed in the housing volume. The elongated separator defines an axis of the cell. The separator has an inner surface and an outer surface. The inner surface of the separator defines a first compartment. The outer surface of the separator and the interior surface of the housing define a second compartment having a volume. The cell further includes a conductive matrix disposed in at least a portion of the second compartment volume such that the conductive matrix occupies a gap between the outer surface of the separator and the interior surface of the housing. The gap in the second compartment extends in a direction substantially perpendicular to the axis of the cell.

Abstract: A positive electrode composition is described, containing granules of at least one electroactive metal, at least one alkali metal halide and carbon black. An energy storage device and an uninterruptable power supply device are also described. Related methods for the preparation of a positive electrode and an energy storage device are also disclosed.

Abstract: An electrochemical cell is presented. The cell includes a housing having an interior surface defining a volume, and an elongated separator disposed in the housing volume. The elongated separator defines an axis of the cell. The separator has an inner surface and an outer surface. The inner surface of the separator defines a first compartment. The outer surface of the separator and the interior surface of the housing define a second compartment having a volume. The cell further includes a conductive matrix disposed in at least a portion of the second compartment volume such that the conductive matrix occupies a gap between the outer surface of the separator and the interior surface of the housing. The gap in the second compartment extends in a direction substantially perpendicular to the axis of the cell.

Abstract: Systems and methods for providing the assembly electrochemical cells in neutral materials are described. Components can be eliminated from traditional electrochemical cell designs in this fashion. Embodiments of assemblies include a module block formed of a neutral material including a plurality of cell cavities, the cell cavities having at least an open top end. Each of the plurality of cell cavities is configured as a cell case for an electrochemical cell. The cavities can be provided a feed-through assembly, or have an electrochemical cell assembled therein.

Abstract: A positive electrode composition is provided. The positive electrode composition includes at least one electroactive metal, a first alkali metal halide, an electrolyte comprising a complex metal halide having a second alkali metal halide; and sodium iodide. The electroactive metal is selected from the group consisting of nickel, cobalt, iron, zinc, tin, vanadium, niobium, manganese and antimony; and the first alkali metal halide and the second alkali metal halide independently comprise a halide selected from chlorine, bromine, and fluorine. The composition includes sodium iodide present in an amount in a range from about 0.1 weight percent to about 0.9 weight percent, based on a total weight of metal halides in the positive electrode composition. Related devices also form embodiments of this invention.

Abstract: A positive electrode composition is presented. The composition includes at least one electroactive metal; at least one alkali metal halide; and at least one additive including a plurality of nanoparticles, wherein the plurality of nanoparticles includes tungsten carbide. An energy storage device, and a related method for the preparation of an energy storage device, are also presented.

Abstract: A method of pulse charging a secondary electrochemical storage cell is provided. The secondary cell includes a negative electrode comprising an alkaline metal; a positive electrode comprising at least one transition metal halide; a molten salt electrolyte comprising alkaline metal haloaluminate; and a solid electrolyte partitioning the positive electrode from the negative electrode, such that a first surface of the solid electrolyte is in contact with the positive electrode, and a second surface of the solid electrolyte is in contact with the negative electrode. The method of charging includes polarizing the cell by applying a polarizing voltage greater than about 0.1 V above the cell's rest potential for a first predetermined period of time; depolarizing the cell for a second predetermined period of time; and repeating the polarizing and depolarizing steps until a charging end-point is reached.

Abstract: A system includes a primary source of power, a main battery, a reserve battery, and a battery management system. A method for operating the system is also disclosed. The main battery of the system is electrically connected to the article, and the reserve battery is configured to back-up the main battery. The battery management system is electrically connected to the main battery. The battery management system maintains the reserve battery in a dormant state when the primary source of power is operational. The reserve battery is also maintained at a dormant state when the primary source of power is not operational; and the main battery is discharging and able to effectively back-up the primary source of power in supplying power to the article.

Abstract: An electrochemical cell comprises a negative electrode, an positive electrode, a cell case, and a solid electrolyte. The cell case comprises an outer case and an inner case. The solid electrolyte defines a first chamber to receive the negative electrode and is disposed within the inner case to define a second chamber. The second chamber is separated from and is in ionic communication with the first chamber to receive the positive electrode. The electrochemical cell further comprises a first current collector extending into the first chamber. Wherein an open upper end of the inner case extends beyond an open upper end of the outer case. A cell case and a method for making an electrochemical cell are also presented.

Abstract: An electrochemical cell is provided. The electrochemical cell comprises a cathode compartment, wherein a metal in a solid form is disposed in the cathode compartment. The electrochemical cell further comprises a separator, an anode compartment, and at least one contact device disposed in the cathode compartment or in the anode compartment. The contact device is suspended from the top of the electrochemical cell in the cathode compartment or in the anode compartment. The electrochemical cell is in a ground state. An electrochemical cell during its working is also provided. Methods for using and manufacturing the electrochemical cell are also provided. The electrochemical cell is used to determine a state-of-charge of a source.

Abstract: An asymmetric electrochemical capacitor positive electrode composition including activated carbon and an electrolyte salt which is a reaction product of an alkali metal halide and an aluminum halide is provided. Asymmetric electrochemical capacitor cells and energy storage devices comprising the asymmetric electrochemical capacitor positive electrode composition are also provided.

Abstract: A method of pulse charging a secondary electrochemical storage cell is provided. The secondary cell includes a negative electrode comprising an alkaline metal; a positive electrode comprising at least one transition metal halide; a molten salt electrolyte comprising alkaline metal haloaluminate; and a solid electrolyte partitioning the positive electrode from the negative electrode, such that a first surface of the solid electrolyte is in contact with the positive electrode, and a second surface of the solid electrolyte is in contact with the negative electrode. The method of charging includes polarizing the cell by applying a polarizing voltage greater than about 0.1 V above the cell's rest potential for a first predetermined period of time; depolarizing the cell for a second predetermined period of time; and repeating the polarizing and depolarizing steps until a charging end-point is reached.

Abstract: A positive electrode composition is provided. The composition includes at least one electroactive metal, such as titanium, vanadium, niobium, molybdenum, nickel, cobalt, chromium, manganese, silver, antimony, cadmium, tin, lead, and zinc. The composition further includes iron, at least one first alkali metal halide; and an electrolyte salt. The electrolyte salt can be based on a reaction product of a second alkali metal halide and an aluminum halide, and has a melting point of less than about 300 degrees Celsius. An article, an energy storage device, and an uninterruptable power supply device that includes the positive electrode composition are also described; as is a method of forming the energy storage device.

Abstract: An energy storage device comprising an anode, electrolyte, and cathode is provided. The cathode comprises a plurality of granules comprising a support material, an active electrode metal, and a salt material, such that the cathode has a granule packing density equal to or greater than about 2 g/cc. A cathode comprising greater than about 10 volume % total metallic content in a charged state of the cathode is also provided.