Abstract: A method of producing an electrically conductive line, the method including providing a substrate, printing a first layer on the substrate, applying a powdered conductive material to the first layer, and bonding the powdered conductive material to the first layer.

Abstract: Systems, apparatus, and method for manufacturing a structure are disclosed. The structure includes a first portion, a second portion, and a structural joint. The apparatus is configured to receive instructions for printing the structural joint. The instructions are based on a data model of the structural joint. The apparatus is also configured to receive the first portion and the second portion, the first portion having a first conical tip and the second portion having a second conical tip. The apparatus is further configured to receive material. Additionally, the apparatus is configured to print the structural joint based on the instructions. The printing may include spray forming the material to produce the structural joint. The structural joint connects the first portion to the second portion.

Abstract: Systems and methods are provided for applying cold spray erosion protection to an airfoil. One embodiment is a method for applying an abrasion coating to a fiber-reinforced composite substrate. The method includes applying a bond layer to the fiber-reinforced composite substrate by emitting, with a supersonic nozzle of a High Pressure Cold Spray (HPCS) system, a first gas stream including a first metal powder at a first speed below supersonic speed. The method further includes applying a cold spray deposit layer to the bond layer by emitting, with the supersonic nozzle, a second gas stream including a second metal powder at a second speed above supersonic speed.

Abstract: Tunable thermoplastic polymer sealants and tunable conductive thermoplastic polymer sealants, and edge seals and fillet seals produced from such sealants; and substrates, components and objects comprising the tunable edge seals and fillet seals, and methods for making and applying such edge seals and fillet seals are disclosed.

Abstract: A method of manufacturing a heat dissipation device is disclosed. The heat dissipation device manufactured with the method includes two titanium metal sheets, which are subjected to a heat treatment before undergoing mechanical processing, plastic working and surface modification. With these arrangements, the titanium metal sheets can be freely plastically deformed and possess a capillary force, and can therefore be used in place of the conventional copper material to serve as a material for making heat dissipation devices, and the heat dissipation devices so produced can have largely reduced weight and largely improved heat dissipation performance.

Abstract: A method for forming a component includes providing a first layer of a mixture of first and second powders. The method includes determining the frequency of an alternating magnetic field to induce eddy currents sufficient to bulk heat only one of the first and second powders. The alternating magnetic field is applied at the determined frequency to a portion of the first layer of the mixture using a flux concentrator. Exposure to the magnetic field changes the phase of at least a portion of the first powder to liquid. A change in power transferred to the powder during a phase change in the powder is calculated to determine the quality of component formation.

Abstract: A method of fabricating a part includes: a) supplying powder particles; b) melting a first quantity of power with a beam and forming, on a support, a first pool including the melted powder and a portion of the support; c) forming a second pool by melting a second quantity of powder on the support; d) repeating c) to form a first layer; e) heating an [n]th quantity of the powder, and forming an [n]th pool above the first layer; f) heating an [n+1]th quantity of the powder, and forming an [n+1]th pool downstream from the [n]th pool above the first layer; g) repeating f) to form a second layer above the first layer; and h) repeating e) to g) until the part is constructed. The powder particles reaching each pool are at a temperature well below the pool temperature.

Abstract: Methods of making functional surfaces, including liquid repellant surfaces that can exhibit selective wetting properties. Methods of forming the functional surfaces can comprise providing a dispersion of nanoparticles; and applying the dispersion to a polymer surface to form a multiplicity of re-entrant structures embedded within and protruding from the polymer surface. The re-entrant structures are formed from aggregates of the nanoparticles. Functional surfaces are prepared by these methods, as well as articles comprising these functional surfaces.

Abstract: A method is provided for coating the substrate of a component, such as a zirconium alloy cladding tube, for use in a water cooled nuclear reactor under normal operating conditions and under high temperature oxidation conditions. The method includes heating a pressurized carrier gas to a temperature between 200° C. and 1200° C., adding chromium or chromium-based alloy particles having an average diameter of 20 microns or less to the heated carrier gas, and spraying the carrier gas and particles onto the substrate at a velocity, preferably from 800 to 4000 ft./sec. (about 243.84 to 1219.20 meters/sec.), to form a chromium and/or chromium-based alloy coating on the substrate to a desired thickness.

Abstract: A reactive hopper assembly for feeding a low pressure cold spray applicator for applying powder coatings is disclosed. A powder feed cartridge provides powder feed to a reaction chamber. An impeller housing is interconnected with the reaction chamber for receiving powder feed from the reaction chamber for metering powder feed received from the reaction chamber. A hopper vessel receives metered powder feed from the impeller housing for providing powder to the low pressure cold spray applicator. The reaction chamber is fluidly connected to a source of a reactive gas for chemically modifying the powder feed for in situ reducing surface oxidation of the powder feed.

Abstract: A hard-clad coating composition for hardfacing is described. Also described is a weld hardfacing method for applying a coating composition to a base metal, and an apparatus for introducing the coating composition to the weld process.

Abstract: An inlet port provides a fluid entrance to a body. A chamber has an inner surface. An outlet port is in fluid communication with the chamber and provides a fluid exit from the body. The piston is moveable within the chamber between a first set position, in which the inlet port is not in fluid communication with the outlet port, and a second open position, in which the inlet port is in fluid communication with the outlet port through the chamber. A seal guard is slidably disposed within the chamber. The seal guard is moveable between a first seal-guard position and a second seal-guard position in which the seal guard shields the seal. The seal guard is in the first seal-guard position when the piston is in its first set position and in the second seal-guard position when the piston is in its second open position.

Abstract: Disclosed are an open-porous metal foam and a method for manufacturing the same. An open-porous metal foam according to an exemplary embodiment of the present invention is made of an iron-based alloy including 15 wt % or more of chrome and 5 wt % or more of aluminum. The open-porous metal foam is a semi-product that is formed of iron or the iron-based alloy that does not include chrome and aluminum or includes a smaller amount of chrome and aluminum in the powder when manufacturing, and the surface and the open pore thereof are uniformly coated with the powder of the iron-chrome-aluminum alloy and the organic binding agent. When heat treatment is performed under a reduction atmosphere, sintering is performed.

Abstract: The present invention provides a method for manufacturing a compound heat sink. Firstly, providing an artificial graphite sheet, and then performing a surface treatment process on the artificial graphite sheet to form a rugged structure on the artificial graphite sheet as a first embedding structure. Finally, forming a metal layer covering the rugged structure, and performing a pressing bonding process to form a second embedding structure corresponding to the first embedding structure to bond the metal layer and the artificial graphite sheet. Namely, the artificial graphite sheet and the metal layer are bonded by the first and second embedding structures for increasing the bonding strength between two heterogeneous materials as well as reducing the interfacial heat resistance. Thereby, the stability of heat dissipation performance can be improved, and a volumetric heat capacity of the compound heat sink from 1.1 to 3.5 J/(cm3·K) is provided.

Abstract: According to the present invention, a metal nanoparticle dispersion suitable to multiple layered coating by jetting in the form of fine droplets is prepared by dispersing metal nanoparticles having an average particle size of 1 to 100 nm in a dispersion solvent having a boiling point of 80° C. or higher in such a manner that the volume percentage of the dispersion solvent is selected in the range of 55 to 80% by volume and the fluid viscosity (20° C.) of the dispersion is chosen in the range of 2 mPa·s to 30 mPa·s, and then when the dispersion is discharged in the form of fine droplets by inkjet method or the like, the dispersion is concentrated by evaporation of the dispersion solvent in the droplets in the course of flight, coming to be a viscous dispersion which can be applicable to multi-layered coating.

Abstract: Methods for making an environmental barrier coating using a sintering aid involving: applying a bond coat layer to the ceramic component; combining at least water and a primary transition material selected from a rare earth disilicate or a doped rare earth disilicate to produce a transition layer slurry; applying at least the transition layer slurry, and optionally an outer layer slurry and/or compliant layer slurry to the component; and sintering the component to produce the environmental barrier coating. The sintering step causes a reaction between a slurry sintering aid and constituents of at least one of the transition, outer and compliant layers to form a secondary material and reduce porosity in the coating.

Abstract: A method generates an abrasive wear-resistant layer on a substrate. The layer is formed of particles of a ductile material, in particular Zn, wherein the parameters of the cold spraying process are set such that a comparatively loose laminate having pores is formed by the spray particles. The laminate advantageously and surprisingly exhibits high resistance to abrasive wear (for example by a particle) because the layer can avoid the attack by the particle by plastic deformation and closure of the pores, whereby abrasive removal of the layer is advantageously low. The cold gas-sprayed layer is used as a protective layer against abrasive wear.

Abstract: The invention relates to a device for creating and conveying a gas-powder mixture having a powder receiving space (3) that is connected to a vacuum creation device via a vacuum line (19) that discharges to the upper region of said powder receiving space. A reduced pressure in comparison to a mixing chamber (7) can be created within the powder receiving space (3), and thus a gas flow directed against the powder flow direction within a powder supply channel (6).

Abstract: A pipe or pipe fitting for use in harsh environment such as in petroleum refinery processes for cracking petroleum feedstocks, the pipe or pipe fitting comprising a 0.25 to 2.5 mm thick Co-based metallic coating on an internal surface of the pipe body, the coating having a hypereutectic microstructure characterized by carbides in a cobalt matrix and an average carbide grain size of less than 50 microns, and the Co-based metallic composition overlays the pipe internal surface at an interface which is free of heat-affected zone and which has a diffusion zone which is less than 0.002 inches thick.

Abstract: Nanoparticle inks and powders are sintered using an applied mechanical energy, such as uniaxial pressure, hydrostatic pressure, and ultrasonic energy, which may also include applying a sheer force to the inks or powders in order to make the resultant film or line conductive.

Abstract: A powder spray nozzle includes an inlet portion having an inlet diameter and an inlet length and an outlet portion having outlet diameter and an outlet length. The nozzle also includes an interface region between the inlet portion and the outlet portion having an interface diameter. A ratio of the inlet diameter to the inlet length is in a range of about 0.15 to 0.5.

Abstract: The described embodiments relate generally to methods to enhance cosmetic surfaces of friction stir processed parts. More specifically a method for applying cold spray over a weld line generated by the friction stir processing is disclosed. Methods are also disclosed for blending the cold spray applied over the weld line in with a cosmetic surface portion of friction stir processed parts. In some embodiments cold spray can be used to on its own to create a cosmetic join between various parts.

Abstract: The present invention relates to a preparation method for porous hydroxyapatite coatings. In particular, it is a method of using suspension plasma spraying to prepare porous hydroxyapatite coatings, which belongs to the technical field of biomedical material preparations. The present invention added a pore-forming agent into the hydroxyapatite suspension with a solid content of 16%-45%. After full stirring, the feedstock materials for plasma spraying were transferred into the injection system, and injected into the high temperature area of the central plasma flame. Then, the feedstock materials made the heat exchange with the high plasma flame of plasma spraying gun. Then the sprayed raw materials were subjected to breakup and refinement of the droplets, solvent evaporation, the decomposition and gasification of the pore-forming agent and melting of feedstock materials. Finally, the porous hydroxyapatite coatings are directly deposited onto the substrate surfaces of the biomedical materials.

Abstract: One exemplary embodiment may include a method comprising: depositing a solution comprising an organometallic compound on a substrate, drying the solution to provide a film of the organometallic compound and at least partially oxidizing an organic component of the organometallic compound to provide nanoparticles including metal oxides on the substrate which would have multiuse industrial applications.

Abstract: Particles are embedded in a substrate by applying to at least a portion of the substrate a fluid and a population of particles, such that the substrate is softened to at least a degree that particles are at least partially embedded in the softened portion of the substrate. The softened portion of the substrate is hardened so as to securely embed the particles in the substrate.

Abstract: The present invention belongs to the field of biomedical material, and is particularly related to a method of preparing bioactive glass coatings by liquid precursor thermal spray. The objective of the present invention is to overcome the shortcomings of the air plasma spraying where the powder feedstock preparation is complicated and time-consuming, and sol-gel or other wet chemistry method where the synthesized coating generally has thin coating thickness and with low production efficiency. Therefore, a new method is provided for preparation of bioactive glass coatings. In this method, organic and inorganic raw materials were first weighed in accordance with the chemical composition of bioactive glasses, and sol or suspension was prepared; then the sol or suspension was used as the feedstock for thermal spray, and was deposited on the biomedical materials substrate, at high temperature to form the bioactive glass coating.

Abstract: Methods and devices are provided for high-throughput printing of semiconductor precursor layer from microflake particles. In one embodiment, the method comprises of transforming non-planar or planar precursor materials in an appropriate vehicle under the appropriate conditions to create dispersions of planar particles with stoichiometric ratios of elements equal to that of the feedstock or precursor materials, even after settling. In particular, planar particles disperse more easily, form much denser coatings (or form coatings with more interparticle contact area), and anneal into fused, dense films at a lower temperature and/or time than their counterparts made from spherical nanoparticles. These planar particles may be microflakes that have a high aspect ratio. The resulting dense film formed from microflakes are particularly useful in forming photovoltaic devices.

Abstract: Forming a wear- and corrosion-resistant coating on an industrial component such as a chemical processing or nuclear power valve component by applying a cobalt-based dilution buffer layer to an iron-based substrate by slurry coating, and then applying by welding a cobalt-based build-up layer over the cobalt-based dilution buffer layer. An industrial component having a dilution buffer layer and a welding build-up layer thereover.

Abstract: Disclosed is a process for the reprocessing or production of a sputter target or an X-ray anode wherein a gas flow forms a gas/powder mixture with a powder of a material chosen from the group consisting of niobium, tantalum, tungsten, molybdenum, titanium, zirconium, mixtures of two or more thereof and alloys thereof with at least two thereof or with other metals, the powder has a particle size of 0.5 to 150 ?m, wherein a supersonic speed is imparted to the gas flow and the jet of supersonic speed is directed on to the surface of the object to be reprocessed or produced.

Abstract: There is provided a pre-treatment method for improving an adhesion of a thin film which includes: preparing a base metal including a single metal or alloy; preparing a coating powder including powder of one or more single metals or an alloy thereof; forming a porous metal coating layer on a surface of the base metal, on which a thin film is to be deposited, by cold-spraying the coating powder and a process gas to the surface of the base metal; and depositing the thin film on the coating layer, wherein the thin film includes metal.

Abstract: A joined sputtering target comprising a sputtering material is formed by disposing two discrete sputtering-target tiles comprising the sputtering material proximate each other, thereby forming an interface between the tiles, the interface comprising at least one of an interlocking joint therein or a recess in a top surface thereof, and spray-depositing a spray material over at least a portion of the interface, thereby joining the tiles to form the joined sputtering target.

Abstract: A device and method relating to a layer system is provided. A substrate with a multi-layer system disposed on the substrate is provided. The multi-layer system has at least one upper layer and at least one layer. A contact element is applied through cold-gas spraying in such a manner that the contact element penetrates the upper layer and contacts the lower layer. The upper layer of the multi-layer system has a scratch-resistant top-layer.

Abstract: A molding method for a thin-profile composite capillary structure includes the steps of preparing a metal grid and metal powder separately; attaching a liquid medium onto the metal grid by means of spraying or brushing or steeping; attaching uniformly the metal powder onto the grid with the liquid medium; and fixing the metal powder onto the surface of the grid by means of sintering, such that a sintered powder layer is formed onto the surface of the grid. The structure includes a metal grid, which is of planar grid pattern made of woven metal wires. A sintered powder layer is sintered onto a lateral surface of the metal grid from the metal powder. The thickness of the sintered powder layer is 0.1 mm-0.7 mm. The total thickness of the thin-profile composite capillary structure is 0.2 mm-0.8 mm, thus presenting flexibility. The thin-profile composite capillary structure is particularly suitable for a heat pipe.

Abstract: A method of making a sputtering target includes providing a backing structure, and forming a copper indium gallium sputtering target material on the backing structure by cold spraying. The step of cold spraying includes spraying a powder comprising copper, indium and gallium in a process gas stream, and at least one of an average particle size of the powder is at least 35 ?m, a velocity of the process gas stream is at least 150 m/s, or a process gas pressure is 20 bar or less.

Abstract: Methods of coating a magnesium substrate are provided along with coated magnesium substrates. A low melting point material is cold sprayed onto a region of the magnesium substrate. A corrosion resistant material or a zinc material is cold sprayed over at least a portion of the low melting point material to form a coated magnesium substrate. The coated magnesium substrate is then heated.

Abstract: In various embodiments, a joined sputtering target is formed by filling at least a portion of a gap between two discrete sputtering-target tiles with a gap-fill material, spray-depositing a spray material to form a partial joint, removing at least a portion of the gap-fill material, and, thereafter, spray-depositing the spray material to join the tiles.

Abstract: The present invention relates to a method for producing a coating on a gas turbine component, in which particles at least of parts of a material to be applied as coating are accelerated by means of kinetic gas dynamic cold spraying in a spray jet onto the surface (2) of the component (1) to be coated, wherein a reactive gas is fed into the spray jet (6), so that the reactive gas reacts at least partially with the particles of the coating material when the particles impinge on the surface (2) to be coated and/or wherein the deposited layer (9) is heated locally and/or over a large area and impacted with a reactive gas, as well as a gas turbine component produced in this way.

Abstract: A method is provided for manufacturing an engine component. The method includes providing a structural bridge device on a base block; forming a component portion on the structural bridge device with an additive manufacturing technique; removing the component portion from the base block and the structural bridge device; and finishing the component portion to form the engine component.

Abstract: Disclosed is a method for preparing a multifunctional technical textile that exhibits multiple functional properties comprising flame or fire-retardancy, EMI shielding, anti-odorous property, UV protection, oil-repellency, anti-soiling property, antimicrobial property, anti-creasing property, water-proof, and antistatic property. The method comprises washing a textile product in a water solution comprising water mixed with a predetermined quantity of non-ionic detergent, storing the textile product at a predetermined temperature and a predetermined relative humidity, and subjecting the textile product to plasma treatment by placing the same in a plasma stream within a reaction chamber.

Abstract: A deposition method includes placing fine particles in an airtight container, the fine particles being obtained by forming a coating layer on a surface of a matrix, the coating layer being more liable to be charged than the matrix with respect to a material of a conveying path, generating an aerosol of the fine particles by introducing a career gas into the airtight container, transporting the aerosol via a transfer tubing to a deposition chamber which is maintained at a pressure lower than that in the airtight container while charging the fine particles by friction with the inner surface of the transfer tubing, the transfer tubing being connected to the airtight container and having a nozzle at the tip, and depositing the charged fine particles on a substrate placed in the deposition chamber by spraying the aerosol from the nozzle.

Abstract: The disclosure provides a method for the production of composite particles utilizing a mechano chemical bonding process following by high energy ball milling on a powder mixture comprised of coating particles, first host particles, and second host particles. The composite particles formed have a grain size of less than one micron with grains generally characterized by a uniformly dispersed coating material and a mix of first material and second material intermetallics. The method disclosed is particularly useful for the fabrication of oxide dispersion strengthened coatings, for example using a powder mixture comprised of Y2O3, Cr, Ni, and Al. This particular powder mixture may be subjected to the MCB process for a period generally less than one hour following by high energy ball milling for a period as short as 2 hours. After application by cold spraying, the composite particles may be heat treated to generate an oxide-dispersion strengthened coating.

Abstract: A method for brazing a component in a power generation system, the brazed power generation system component, and braze are provided to improve repairing power generation systems. The method includes providing the component having a feature in a surface of the component and coating a particulate material with a filler material to obtain a coated particulate material. The method includes preparing the feature to obtain a treatment area and filling the treatment area in the surface of the component with the coated particulate material. The method includes heating the treatment area and surrounding component to a brazing temperature and applying oxidation protection to the treatment area. After the brazing temperature is obtained, the method includes brazing the treatment area and the screen and cooling the component to obtain a brazed joint.

Abstract: A method for manufacturing a component having increased thermal conductivity through layer-by-layer construction. At least one section of the component is constructed by applying a layer section having predetermined dimensions of a composite material of a metal and/or a metal alloy and particles of a highly heat-conducting material, including diamond and/or cubic boron nitride, in a predetermined area on a base layer by melting the metal or the metal alloy a heat source, in such a way that the metal and/or metal alloy form(s) within the predetermined dimensions a cohesive matrix, in which particles of the highly heat-conducting material are embedded, and then cooling.

Abstract: A dual brazing alloy element for a materially integral connection of a ceramic surface to a metallic surface includes a first layer having a Ni-based brazing alloy with a Ni content of at least 50% by weight and having at least one component configured to lower a melting point of the Ni-based brazing alloy selected from the group consisting of Si, B, Mn, Sn and Ge. A second layer includes an active brazing alloy material having a total content of 1-15% by weight of at least one active element selected from the group consisting of Ti, Hf, Zr and V.

Abstract: A method for making a riser tensioner component is provided. The method comprises the steps of (a) applying a cold spray composition to a metal substrate to achieve a first coating on the metal substrate, wherein the cold spray composition comprises a metal alloy, and wherein the first coating has a thickness in a range from about 5 to about 50 mils; and (b) rough finishing the first coating to achieve a second coating having an average roughness, Ra of less than about 32 micro-inches. A riser tensioner component is also provided, wherein the riser tensioner component comprises a cold spray applied coating on a metal substrate, wherein the coating comprises a metal alloy, and wherein the coating has a thickness in a range from about 5 to about 50 mils; and an average roughness, Ra of less than about 32 micro-inches.

Abstract: A device for coating at least one substrate or for producing at least one molding by means of at least one cold gas spraying pistol, wherein the cold gas spraying pistol and the substrate or molding to be coated are arranged in a vacuum chamber, and also a method for cold gas spraying relating thereto in such a manner that while eliminating the wire production, the coil winding and also the cast in procedure, a thoroughly compact coil without a degree of freedom of movement (elimination of the quench risk) can be produced, it is suggested that the particles have at least to some extent an electrically conducting, in particular superconducting, property and at least to some extent an electrically poorly conducting or electrically insulating property.

Abstract: A molding method for a thin-profile composite capillary structure includes the steps of preparing a metal grid and metal powder separately; attaching a liquid medium onto the metal grid by means of spraying or brushing or steeping; attaching uniformly the metal powder onto the grid with the liquid medium; and fixing the metal powder onto the surface of the grid by means of sintering, such that a sintered powder layer is formed onto the surface of the grid. The structure includes a metal grid, which is of planar grid pattern made of woven metal wires. A sintered powder layer is sintered onto a lateral surface of the metal grid from the metal powder. The thickness of the sintered powder layer is 0.1 mm-0.7 mm. The total thickness of the thin-profile composite capillary structure is 0.2 mm-0.8 mm, thus presenting flexibility. The thin-profile composite capillary structure is particularly suitable for a heat pipe.

Abstract: Provided herein are nanoparticulate coated structures and methods of making structures. The structures comprise a support element, a nanoparticulate layer, and a binder disposed on the support element, wherein the binder comprises an alkali silicate or borate. In addition, methods of making the structures and uses of the described structures are described herein.

Abstract: A process of applying a porous metallic structure and a cold-sprayed article are disclosed. The process includes cold spraying a solid feedstock and a low-melt material onto an article and removing at least a portion of the low-melt materials or applying a porous metallic structure includes cold spraying onto an article with two converging-diverging nozzles. The cold-sprayed article includes a porous metallic structure having a portion formed from cold spraying a solid feedstock. The portion includes the phases and microstructure of the solid feedstock.

Abstract: A thin zinc diffusion coating, the diffusion coating including: (a) an iron-based substrate, and (b) a zinc-iron intermetallic layer coating the iron-based substrate, the intermetallic layer having a first average thickness of less than 15 ?m, as measured by a magnetic thickness gage, the intermetallic layer having a second average thickness as measured by an X-Ray fluorescence thickness measurement, and wherein a difference between the first average thickness and the second average is less than 4 ?m.