Abstract: Removal of waste heat from a fuel cell is necessary for continuous operation. Evaporation, can be used to remove the heat produced by the exothermic reaction within the fuel cell. Water sprayed into a gaseous fuel stream is evaporated in an evaporative cooler adjacent to the fuel cell. The fuel/steam stream can then be utilized in the various other fuel cell system operations.

Abstract: Chemical vapor deposition (CVD) techniques for forming tough silicon carbide (SiC) matrix composites. The introduction of methyldichlorosilane (MDS) to a reactor containing a fiber preform which been flushed with a noble gas, causes the formation of a carbon layer around the fibers. The carbon interlayer improves the fracture toughness of the composite.

Abstract: Reversing the flow of conventional furnace/retort systems prevents damaging exhaust gases from entering the furnace while still maintaining a gas flow through the retort. The gases exit the retort into a treatment system; preventing contamination of any apparatus and the escape of any hazardous gases.

Abstract: A modified class of nickel aluminide (NiAl) type material is disclosed having useful amounts of toughness and ductility at low temperatures, e.g. room temperature. The basic NiAl material is modified with an additional of the material such as cobalt which produces a structure which is susceptible to undergoing a martensitic transformation. The martensitic structure when produced results in a significant increase in toughness and ductility at low temperatures.

Abstract: Technique for producing hollow composite articles utilizing vapor deposition. Fibers, wound around a supply reel, are fed to a take-up reel, while glass matrix is deposited on the fiber substrate via a vapor deposition process. The layers of fiber/matrix on the take-up reel are heated to fuse the composite, producing a glass matrix composite.

Abstract: Improved technology for the melting and casting of a particular class of true beta-type titanium alloys is described. A typical alloy is titanium--35% vanadium--15% chromium. By providing carbon surfaces for contacting molten beta titanium alloys of this type improved melting and casting procedures are effectuated.

Abstract: Corrosion in manifolds and ducts in phosphoric acid fuel cells can be reduced by electroplating a chromium-fluorocarbon polymer composite coating onto the exposed metal surfaces. The chromium-fluorocarbon coating displays superior corrosion protection and improved adhesion after being subjected to a plurality of heating and cooling cycles. The improved corrosion protection enhances fuel cell operating reliability and allows the use of less expensive materials in the construction of the manifolds and ducts.

Abstract: An optical light source is interfaced to an optical fiber by mounting the optical light source on a source carrier, mounting the optical fiber on a fiber carrier, aligning the optical fiber with the optical light source and bonding the source carrier to the fiber carrier thereby securing the alignment of the optical fiber and the optical light source. The fiber carrier can be made to have the same or substantially the same thermal expansion characteristics of those of said source carrier. A lens may be interposed between the light source and the fiber, typically by forming a convex surface on the tip of the fiber. The apparatus so made thus comprises an optical fiber carrier, an optical fiber attached to the fiber carrier, a source carrier and an optical light source mounted on the source carrier aligned with the optical fiber. A lens may be provided between the source and the fiber, typically formed on the tip of the fiber.

Abstract: An abradable coating is described for interaction with a abrasive gas turbine engine component to provide sealing. The abradable coating comprises yttria stabilized zirconia with intentional porosity which is applied by plasma spraying to a MCrAlY bond coat which in turn rest on a superalloy substrate. The coating system is applied by plasma spraying. The coating system is adapted to interact with an abrasive coated abrasive treated gas turbine engine component.

Abstract: Methods for enhancing the toughness of otherwise brittle powder metallurgy materials are presented. Adding moderate amounts of tough particulate to such brittle material enhances their ductility in excess of that which would be predicted mathematically.

Abstract: A microstructurally toughened metallic article is disclosed. The article includes discrete metal regions which are enclosed within and separated from each other by a network of metal. The regions are bonded to the network to form stable interfacial boundaries. The article exhibits high impact resistance. The process for making the article is also disclosed. The process includes positioning a plurality of structural elements within a container to define one or more void spaces within the container, introducing a quantity of metallic particles into the void spaces, and then consolidating the container, structural elements, and particles to form the microstructurally toughened article.

Abstract: Coated gas turbine engine hardware is described. The hardware comprises a titanium alloy substrate having a coating thereon consisting essentially of titanium nitride wherein the ratio of nitrogen to titanium is greater than one. Such coatings have a residual compressive stress state which aids in minimizing the fatigue debit which would otherwise result from the use of a hard coating on a titanium substrate. Coatings are applied by the use of a vacuum arc deposition process.

Abstract: Geometries are described for joining superalloy articles by inertia welding. First and second hollow superalloy articles are joined wherein the first article has an inside and an outside diameter which are less than the inside and outside diameter of the second article. This produces a staggered joint geometry which results in curved "S" shaped weld zone and beneficial control of the residual weld notch.

Abstract: A molten carbonate fuel cell system wherein the cathode effluent gases are utilized in an autothermal autothermal reformer, and the anode gas is not recycled.

Abstract: A stable age hardenable aluminum alloy which has useful mechanical properties at temperatures up to at least 900.degree. F. (482.degree. C.). The alloy contains 5-15% iron, 1-5% molybdenum and 0.2-6% vanadium with balance aluminum and is processed by rapid solidification from the melt to form a particulate which is consolidated to form a bulk article.

Abstract: Removal of ceramic thermal barrier coatings from metallic substrates is achieved by contacting the coated article with fluorine containing gas at an elevated temperature. The gas penetrates the ceramic to attack the interface between the substrate and ceramic causing the ceramic to spall.

Abstract: An improved ternary alloy catalyst for fuel cells containing platinum and gallium. The method of fabricating the catalyst in a high surface area supportive form is also described. The resultant fuel cell catalyst displays a substantial resistance to sintering during operation combined with a resistance to a chemical dissolution during operation. These enhancements permit improved long-term operation of fuel cells.

Abstract: Compositions and articles are described which have particular utility in gas turbine engine parts and which can be used at temperatures up to and in excess of 2,000.degree. F. without the usual protective coatings. Compositions are described which can be formed into single crystal articles which are alumina formers upon exposure to oxidation and in which develop an adherent spall resistant alumina scale during oxidation. The adherence and spall resistance of the alumina surface scale results from the presence of a small but critical quantity of zirconium.

Abstract: Techniques for fabricating or repairing integrally bladed rotors are developed. A new or replacement blade is bonded to a projecting stub. The new blade has a collar through which bonding forces are transmitted. After bonding with heat and pressure, final machining and heat treatment operations are performed.

Abstract: A silver base electrical contact material is described which contains a dispersion of particles consisting of cadmium oxide and nickel. The nickel particles are surrounded by a continuous adherent coating of nickel oxide which eliminates the detrimental reaction which would otherwise occur between nickel and cadmium oxide. The invention contact materials have improved lives and are fabricated by any one of several different powder metallurgy techniques.