Abstract: A method of aligning a wire with a pathway inlet includes directing a feeding end of a wire toward a pathway inlet of a feed pathway, creating a pressure differential between the pathway inlet and a pathway outlet of the feed pathway thus creating a pressure-driven gas flow around the wire and into the pathway inlet. The wire is urged along the feed pathway toward the pathway outlet via the shear force of the gas flow created by the pressure differential. A method of preventing stiction of a wire with an inner wall of a thin pathway includes creating a pressure differential between a pathway inlet and a pathway outlet thus creating a pressure-driven gas flow around a feeding end of the wire and into the pathway inlet of the pathway, and inducing one of a flutter or vibration in the wire at the feeding end of the wire.

Abstract: A method of forming one of a plurality of encapsulated crystalline particles includes feeding a coaxial feed wire downwardly such that a first wire end of the coaxial feed wire is positioned at a heating source. The coaxial feed wire includes a crystalline wire core, and an amorphous shell surrounding the crystalline wire core. The first end of the coaxial feed wire is heated at the heating source, thereby forming a molten pendant drop at the first wire end. The plurality of encapsulated crystalline particles are emitted from the molten pendant drop onto a collector located below the molten pendant drop.

Abstract: A method of forming one of a plurality of encapsulated crystalline particles includes feeding a coaxial feed wire downwardly such that a first wire end of the coaxial feed wire is positioned at a heating source. The coaxial feed wire includes a crystalline wire core, and an amorphous shell surrounding the crystalline wire core. The first end of the coaxial feed wire is heated at the heating source, thereby forming a molten pendant drop at the first wire end. The plurality of encapsulated crystalline particles are emitted from the molten pendant drop onto a collector located below the molten pendant drop.

Abstract: A method of forming one of a plurality of encapsulated crystalline particles includes feeding a coaxial feed wire downwardly such that a first wire end of the coaxial feed wire is positioned at a heating source. The coaxial feed wire includes a crystalline wire core, and an amorphous shell surrounding the crystalline wire core. The first end of the coaxial feed wire is heated at the heating source, thereby forming a molten pendant drop at the first wire end. The plurality of encapsulated crystalline particles are emitted from the molten pendant drop onto a collector located below the molten pendant drop.

Abstract: A method of forming a polymer-metal nanocomposite (PMNC) material with a substantially uniform dispersion of metal particles includes forming a composite solid preform by mixing a blend of micrometer-sized metal particles and polymer particles and subjecting the mixture to compression followed by sintering. The composite solid preform is drawn through a heated zone to form a reduced size fiber. The reduced size fiber is cut into segments and a next preform is formed using the bundle of the segments. The next preform is then drawn through the heated zone to form yet another reduced size fiber. This reduced size fiber may undergo one or more stack-and-draw operations to yield a final fiber having substantially uniform dispersion of nanometer-sized metal particles therein.

Abstract: A method of forming one of a plurality of encapsulated crystalline particles includes feeding a coaxial feed wire downwardly such that a first wire end of the coaxial feed wire is positioned at a heating source. The coaxial feed wire includes a crystalline wire core, and an amorphous shell surrounding the crystalline wire core. The first end of the coaxial feed wire is heated at the heating source, thereby forming a molten pendant drop at the first wire end. The plurality of encapsulated crystalline particles are emitted from the molten pendant drop onto a collector located below the molten pendant drop.

Abstract: A heat source sensor includes a plurality of first wires extending in a first direction, a plurality of second wires extending in a second direction different from the first direction and crossing the plurality of first wires, and a plurality of nodes. Each node is defined at a crossing of a first wire of the plurality of first wires and a second wire of the plurality of second wires. The first wire is secured to the second wire at the node. Each node of the plurality of nodes defines a measurement point of the heat source sensor, with a difference in thermoelectric electromotive forces between two nodes of the plurality of nodes indicative of a temperature difference between the two nodes.

Abstract: A method of thermally drawing fibers containing continuous crystalline metal nanowires therein includes forming a preform comprising an inner core and an outer cladding, wherein at least one of the core and cladding has nanoelements dispersed therein. The preform is drawn through a heated zone to form a reduced size fiber. A second preform is then created from a plurality of fibers created from the reduced size fiber. The second preform is then drawn through the heated zone to form an elongated fiber containing continuous crystalline metallic nanowires therein having a maximum cross-sectional dimension of less than 100 nm. Optionally, a third or additional preforms are created from fibers made from the previous thermal drawing operation that are then drawn through the heated zone to form a fiber containing even smaller crystalline metal continuous nanowires therein. In some embodiments, only a single pass through the heated zone may be needed.

Abstract: A vibration welding system includes an anvil, a welding horn, a thin film sensor, and a process controller. The anvil and horn include working surfaces that contact a work piece during the welding process. The sensor measures a control value at the working surface. The measured control value is transmitted to the controller, which controls the system in part using the measured control value. The thin film sensor may include a plurality of thermopiles and thermocouples which collectively measure temperature and heat flux at the working surface. A method includes providing a welder device with a slot adjacent to a working surface of the welder device, inserting the thin film sensor into the slot, and using the sensor to measure a control value at the working surface. A process controller then controls the vibration welding system in part using the measured control value.

Abstract: A vibration welding system includes an anvil, a welding horn, a thin film sensor, and a process controller. The anvil and horn include working surfaces that contact a work piece during the welding process. The sensor measures a control value at the working surface. The measured control value is transmitted to the controller, which controls the system in part using the measured control value. The thin film sensor may include a plurality of thermopiles and thermocouples which collectively measure temperature and heat flux at the working surface. A method includes providing a welder device with a slot adjacent to a working surface of the welder device, inserting the thin film sensor into the slot, and using the sensor to measure a control value at the working surface. A process controller then controls the vibration welding system in part using the measured control value.