Abstract: A method and device for performing fluid analysis by separating cells and/or particles from a fluid, such as a biological, vehicular or industrial fluid. The device is a micromachined filtering device comprising a substrate with through-thickness vias having approximately equal diameters that prevent passage through the substrate of a first material while permitting passage through the substrate of other materials having diametrical dimensions less than the diameter of the vias. Electrodes are located on a surface of the substrate between vias so that as the first material collects at the surface of the substrate, the electrodes become electrically connected to produce an output signal in some proportion to the amount of the first material collected. The device can incorporate multiple micromachined substrates, yielding an analysis system that produces an electrical output for each of a number of properties or parameters.

Abstract: A method of forming a welded assembly, wherein an electron beam is used to form a weldment that joins two or more articles to form the welded assembly. The method involves directing a second electron beam onto the weldment in the wake of the welding beam, in a manner that inhibits precipitation of a solutioned precipitation-strengthening phase so as to reduce the incidence of strain-age cracking in the weldment.

Abstract: A process of forming a ceramic coating on a component. The process generally entails placing the component in a coating chamber containing oxygen and an inert gas, heating a surface of the component to a temperature of about 100 to about 150° C., and then generating a metal vapor from at least one metal target using a microwave-stimulated, oxygen-containing sputtering technique. The metal vapor is then caused to condense on the component surface to form a metal layer, after which the metal layer is treated with a microwave-stimulated plasma to oxidize the metal layer and form an oxide layer having a columnar microstructure. The generating, condensing and treating steps can be repeated any number of times to form multiple oxide layers that together constitute the ceramic coating.

Abstract: A protective coating system and method for protecting a thermal barrier coating from CMAS infiltration. The coating system comprises inner and outer alumina layers and a platinum-group metal layer therebetween. The outer alumina layer is intended as a sacrificial layer that reacts with molten CMAS, forming a compound with a melting temperature significantly higher than CMAS. As a result, the reaction product of the outer alumina layer and CMAS resolidifies before it can infiltrate the TBC. The platinum-group metal layer is believed to serve as a barrier to infiltration of CMAS into the TBC, while the inner alumina layer appears to enhance the ability of the platinum-group metal layer to prevent CMAS infiltration.

Abstract: A multilayer thermal barrier coating (TBC) and method for forming the coating on a component intended for use in a hostile environment. The coating includes layers of particle-free yttria-stabilized zirconia alternating with layers of yttria-stabilized zirconia containing at least three volume percent up to about fifty volume percent of alumina and/or chromia particles and/or precipitates. In the form of particles and/or precipitates in these amounts, sufficient alumina and/or chromia is present to significantly increase the impact and wear resistance of the coating while avoiding discrete and homogeneous layers of alumina and/or chromia and abrupt compositional interfaces that increase the incidence of spallation.

Abstract: A predominantly beta-phase NiAl overlay coating for use as an environmental coating or a TBC bond coat for articles used in hostile thermal environments, such as components of a gas turbine engine. The coating contains up to about 4 atomic percent hafnium, such as in excess of 1.0 atomic percent hafnium. The coating may also contain about 2 to about 15 atomic percent chromium.

Abstract: A thermal barrier coating (TBC) for a component intended for use in a hostile environment, such as the superalloy turbine, combustor and augmentor components of a gas turbine engine. The TBC is formed of at least partially stabilized zirconia, preferably yttria-stabilized zirconia (YSZ), and exhibits improved erosion and impact resistance as a result of containing a dispersion of alumina precipitates or particles. The TBC preferably consists essentially of YSZ and the alumina particles, which are preferably dispersed throughout the microstructure of the TBC, including the YSZ grains and grain boundaries. The alumina particles are present in an amount sufficient to increase the impact and erosion resistance of the TBC, preferably at least 5 volume percent of the TBC.

Abstract: A process and apparatus for separating element isotopes in space by heating a stream of raw materials using concentrated sunlight and ionizing radiation, followed by electromagnetic separation, and collection of the desired isotopes in appropriate receptacles. The unique design of this invention allows flexibility of implementation, very high separation efficiency, and minimal waste. The intent of collecting a multiplicity of isotopes simultaneously is a key feature of this invention. The goal for this work is to greatly reduce the cost of producing purified finished materials in space. This capability makes economical the fabrication of complex and large structures for space-based industry and habitation. This invention builds upon the sciences of plasma physics, ion separation, and microgravity processing, and incorporates new concepts of the integral design and efficient process operation, taking advantage of the peculiar properties of a microgravity environment.

Abstract: A component formed at least in part by a CMC material and equipped with an integrally-formed surface feature, such as an airflow enhancement feature in the form of a turbulator or flow guide. The CMC material comprises multiple sets of tows woven together to form a preform that is infiltrated with a matrix material. The surface feature is integrally defined at a surface of the cooling passage by an insert member disposed between adjacent tows of at least one of the tow sets. The insert member has a cross-sectional size larger than the adjacent tows, forming a protrusion in the preform that defines the surface feature in the infiltrated, consolidated and cured CMC material.

Abstract: Manifold for a heat exchanger intended to be joined by brazing or soldering to heat transfer tubes. A portion of a surface of the manifold that will be joined to the tubes is proved with at least one recess in which a brazing material is mechanically locked.

Abstract: An aluminum alloy and a process for treating the aluminum alloy. The alloy contains 0.5 to 2.5% by weight of an alloying mixture of magnesium and silicon, in which the molar ratio of Mg/Si is 0.70 to 1.25, the alloy optionally containing an additional amount of silicon up to about ⅓ of any iron, manganese and chromium in the alloy, as expressed by weight percent, the balance of the alloy being aluminum, optional alloying elements and unavoidable impurities. The process entails an ageing technique that includes a first stage in which an extrusion of the aluminum alloy is heated at a rate above 100° C./hour to 100-170° C., a second stage in which the extrusion is heated at a rate of 5 to 50° C./hour to a final hold temperature, wherein the total ageing operation is performed in 3 to 24 hours.

Abstract: A MOS structure processed to have a semiconductor-dielectric interface that is passivated to reduce the interface state density. An example is a MOSFET having a gate dielectric on which an electrode is present that is substantially impervious to molecular hydrogen, but sufficiently thin to be pervious to atomic hydrogen, enabling atomic hydrogen to be diffused therethrough into an underlying semiconductor-dielectric interface. Atomic hydrogen diffusion can be achieved by subjecting such an electrode to hydrogen plasma, forming the electrode of an aluminum-tungsten alloy in the presence of hydrogen, and implanting atomic hydrogen into the electrode. The latter two techniques are each followed by an anneal to cause the atomic hydrogen to diffuse through the electrode and into the semiconductor-dielectric interface.

Abstract: A SOI structure and a method for its fabrication, in which a strained silicon layer lies directly on an insulator layer, contrary to the prior requirement for strained-Si layers to lie directly on a strain-inducing (e.g., SiGe) layer. The method generally entails the forming a silicon layer on a strain-inducing layer so as to form a multilayer structure, in which the strain-inducing layer has a different lattice constant than silicon so that the silicon layer is strained as a result of the lattice mismatch with the strain-inducing layer. The multilayer structure is then bonded to a substrate so that an insulating layer is between the strained silicon layer and the substrate, and so that the strained silicon layer directly contacts the insulating layer.

Abstract: A method of welding articles formed of single-crystal superalloys, particularly single-crystal nickel-base superalloys containing 10 weight percent or more of refractory metals, and welded assemblies formed thereby. A shim is positioned between the articles, and a backing strip is preferably positioned to contact both articles and bridge the gap between the articles. The articles are then welded together using a high energy beam with a low current pulse frequency and low travel speed.

Abstract: An electron beam physical vapor deposition (EBPVD) apparatus and a method for using the apparatus to produce a coating material (e.g., a ceramic thermal barrier coating) on an article. The EBPVD apparatus generally includes a coating chamber that is operable at elevated temperatures and subatmospheric pressures. An electron beam gun projects an electron beam into the coating chamber and onto a coating material within the chamber, causing the coating material to melt and evaporate. An article is supported within the coating chamber so that vapors of the coating material deposit on the article. The operation of the EBPVD apparatus is enhanced by the inclusion of a crucible that supports the coating material and is configured to be efficiently cooled so as to reduce the rate at which the process temperature increases within the coating chamber.

Abstract: A thermal barrier coating (TBC) for a component intended for use in a hostile environment, such as the superalloy turbine, combustor and augmentor components of a gas turbine engine. The TBC is formed of zirconia that is partially stabilized with yttria (YSZ), preferably not more than 3 weight percent yttria, and to which one or more additional metal oxides are alloyed to increase crystallographic defects and lattice strains in the TBC grains and/or form precipitates of zirconia and/or compound(s) of zirconia and/or yttria and the additional metal oxide(s), the inclusion of which reduces the thermal conductivity of the YSZ to levels lower than conventional 6-8% YSZ. Improvements are particularly contemplated for TBC having a columnar grain structure, such as those deposited by EBPVD and other PVD techniques.

Abstract: A heating apparatus and method for pre-weld heat treating, welding and post-weld heat treating a superalloy article in a single enclosure while avoiding oxidation of the article. The enclosure is preferably equipped with a one-way valve that permits the escape of gases, but otherwise seals the enclosure to prevent the ingress of air during welding and heat treatment as a result of thermal gradients induced when the article is inductively heated. To provide access to the article and a device used to weld the article, the enclosure is equipped with gloves by which the welding device and the article can be manipulated while a nonreactive atmosphere is fully maintained within the enclosure and the article is inductively heating.

Abstract: An anti-stick coating that inhibits the adhesion of contaminants that form deposits on the internal cooling passages of gas turbine engine components. The anti-stick coating is formed as an outer coating of the internal cooling passages, and preferably overlies an environmental coating such as a diffusion aluminide coating formed on the passage surfaces. The outer coating has a thickness of not greater than three micrometers, and is resistant to adhesion by dirt contaminants as a result of comprising at least one layer of tantala, titania, hafnia, niobium oxide, yttria, silica and/or alumina. The outer coating is preferably deposited directly on the environmental coating by chemical vapor deposition.

Abstract: A ferromagnetic film suitable for ultra-high density perpendicular recording, and a process for producing the film. The process generally entails forming a film of ferromagnetic material on a surface of a substrate, such that the film is characterized by perpendicular magnetic anisotropy and comprises a plurality of magnetic domains defined by domain walls perpendicular to a major surface of the film. The ferromagnetic film is formed to have a linear strain defect for the purpose of smoothing and stabilizing the domain walls during subsequent magnetization reversal of the ferromagnetic material. Such smoothing and stabilizing serves to control temporal magnetic noise due to motion of magnetic domains, arrest domain wall motion (reducing velocity) when the film is subjected to the magnetic reversal fields, and controls spatial magnetic noise due to domain wall jaggedness.

Abstract: A stabilizer-isolator device for a weightlifting bar, in which the stabilizer-isolator device is capable of stabilizing and isolating exercised muscles with less stress on the tendons. The stabilizer-isolator device generally includes a pair of brace bars having corresponding first and second ends, an annular-shaped collar interconnecting the second ends of the brace bars, and at least one isolator bar substantially transverse to the brace bars and interconnecting the brace bars so as to be spaced apart from the first and second ends of the brace bars. The first ends of the brace bars are adapted to be permanently or removable attached to the weightlifting bar. The collar is disposed in a plane substantially transverse to the brace bars and defines an opening therein. The at least one isolator bar may comprise a single member with a flat surface, or at least two parallel members spaced apart from each other.