Abstract: A method of fabricating a film of magnetic nanocomposite particles including depositing isolated clusters of magnetic nanoparticles onto a substrate surface and coating the isolated clusters of magnetic nanoparticles with an insulator coating. The isolated clusters of magnetic nanoparticles have a dimension in the range between 1 and 300 nanometers and are separated from each other by a distance in the range between 1 and 50 nanometers. By employing PVD, ablation, and CVD techniques the range of useful film thicknesses is extended to 10-1000 nm, suitable for use in wafer based processing. The described methods for depositing the magnetic nanocomposite thin films are compatible with conventional IC wafer and Integrated Passive Device fabrication.

Abstract: A contiguous duplex microstructured material comprises a nanostructured material having two structural states, for example, a duplex microstructured coating. One state comprises substantially nanostructured features, while the second state substantially comprises microstructured features. A duplex nanostructured coating can be made by thermal spraying a reconstituted nanostructured material onto a substrate under conditions effective to form a coating comprising more than one structural state.

Abstract: A contiguous duplex microstructured material comprises a nanostructured material having two structural states, for example, a duplex microstructured coating. One state comprises substantially nanostructured features, while the second state substantially comprises microstructured features. A duplex nanostructured coating can be made by thermal spraying a reconstituted nanostructured material onto a substrate under conditions effective to form a coating comprising more than one structural state.

Abstract: A multi-layer coating is particularly useful for the coating of implants such as orthopedic and dental implants, particularly metallic implants. The multi-layer coating has both high bond strength to implants and excellent bioactivity with the surrounding body tissue. A method of making a coated implant includes depositing a first layer on a metallic substrate, wherein the first layer comprises a material selected from the group consisting of nitride compounds, boride compounds, carbide compounds, and mixtures of two or more of the foregoing materials; forming at least one slurry comprising an apatite and a binder, wherein the apatite has greater than about 90% crystallinity, and wherein the binder is inert in body fluids; depositing the slurry on the first layer to form a green coating; and sintering the green coating to form a second layer.

Abstract: A multi-layer coating is particularly useful for the coating of implants such as orthopedic and dental implants, particularly metallic implants. The first layer comprises a dense material insoluble and inert in body fluids. The second layer comprises apatite and a binder. The first layer protects the metallic implants from corrosion, apatite dissolution, and interfacial reaction with apatite and the binder. The binder allows adjustment of the thermal expansion coefficient between the coating and the metallic substrate. This multi-layer coating has both high bond strength to implants and excellent bioactivity with the surrounding body tissue.

Abstract: Thin electrodes produced by thermal spray techniques are presented, wherein the thermal spray feedstock comprises an active material and a protective barrier coating. In a particularly advantageous feature, the active material feedstock is a metal sulfide, metal selenide, or metal telluride which ordinarily decomposes at thermal spray temperatures or which transforms to a material unsuitable for use as an electrode at thermal spray temperatures. The electrodes find particular utility in thermal batteries.

Abstract: A method for the synthesis of an electrode, and the resulting article therefrom, comprising coating an active material feedstock with an additive material suitable for preventing thermal decomposition of said feedstock during thermal spray, thermal spraying the coated feedstock onto a substrate for an electrode, thereby forming a coating on the substrate, thereby providing an electrode.

Abstract: A method for the synthesis of an electrode (1), and the resulting article (1) therefrom, comprising coating an active material feedstock (3) with an additive material suitable for preventing thermal decomposition of said feedstock (3) during thermal spray, thermal spraying the coated feedstock (3) onto a substrate (2) for an electrode, thereby forming a coating on the substrate (2), thereby providing an electrode (1).