Abstract: The successful fabrication of alloy foam (or porous alloy) is very rare, despite their potentially better properties and wider applicability than pure metallic foams. The processing of three-dimensional copper-nickel alloy foams is achieved through a strategic solid-solution alloying method based on oxide powder reduction or sintering processes, or both. Solid-solution alloy foams with five different compositions are successfully created, resulting in open-pore structures with varied porosity. The corrosion resistance of the synthesized copper-nickel alloy foams is superior to those of the pure copper and nickel foams.

Abstract: Morphology, microstructure, compressive behavior, and biocorrosive properties of magnesium or magnesium alloy foams allow for their use in biodegradable biomedical, metal-air battery electrode, hydrogen storage, and lightweight transportation applications. Magnesium or Mg alloy foams are usually very difficult to manufacture due to the strong oxidation layer around the metallic particles; however, in this invention, they can be synthesized via a camphene-based freeze-casting process with the addition of graphite powder using precisely controlled heat-treatment parameters. The average porosity ranges from 45 to 85 percent and the median pore diameter is about a few tens to hundreds of microns, which are suitable for bio and energy applications utilizing their enhanced surface area.

Abstract: Methods for building a neutron detector are disclosed, in which the neutron detector comprises at least two conductive cathode sheets lying parallel to one another and coated with neutron reactive material on at least one side thereof; dielectric material separating the cathode sheets and covering less than about 80% of their surface area; and a plurality of anode wires lying generally parallel to the cathode sheets and separated from them by the dielectric, with the distance between adjacent anode wires being no more than twenty times the distance between said cathode sheets. The cathode sheets may be flat or curved; they may be separate plates or they may be successive folds or windings of a single folded or spiral-shaped metal sheet.

Abstract: A neutron detector comprises at least two conductive cathode sheets lying parallel to one another and coated with neutron reactive material on at least one side thereof; dielectric material separating the cathode sheets and covering less than about 80% of their surface area; and a plurality of anode wires lying generally parallel to the cathode sheets and separated from them by the dielectric, with the distance between adjacent anode wires being no more than twenty times the distance between said cathode sheets. The cathode sheets may be flat or curved; they may be separate plates or they may be successive folds or windings of a single folded or spiral-shaped metal sheet. Related methods for building the detector are disclosed.

Abstract: A neutron detector comprises a gas-filled dielectric shell, preferably a glass balloon, having opposite electrodes. An electric field is established whereby ionizing particles may be detected via ionization and current flow in the gas, using a pulse height analyzer or other conventional means. The dielectric shell preferably has low gas permeability and a bulk resistivity in the range of 108 to 1017 ?-m, and is preferably in the millimeter to centimeter size range. Multiple balloons may be arranged in parallel or may be individually addressable by the detector electronics.

Abstract: A neutron detector has a volume of neutron moderating material and a plurality of individual neutron sensing elements dispersed at selected locations throughout the moderator, and particularly arranged so that some of the detecting elements are closer to the surface of the moderator assembly and others are more deeply embedded. The arrangement captures some thermalized neutrons that might otherwise be scattered away from a single, centrally located detector element. Different geometrical arrangements may be used while preserving its fundamental characteristics. Different types of neutron sensing elements may be used, which may operate on any of a number of physical principles to perform the function of sensing a neutron, either by a capture or a scattering reaction, and converting that reaction to a detectable signal. High detection efficiency, an ability to acquire spectral information, and directional sensitivity may be obtained.

Abstract: A neutron detector has a volume of neutron moderating material and a plurality of individual neutron sensing elements dispersed at selected locations throughout the moderator, and particularly arranged so that some of the detecting elements are closer to the surface of the moderator assembly and others are more deeply embedded. The arrangement captures some thermalized neutrons that might otherwise be scattered away from a single, centrally located detector element. Different geometrical arrangements may be used while preserving its fundamental characteristics. Different types of neutron sensing elements may be used, which may operate on any of a number of physical principles to perform the function of sensing a neutron, either by a capture or a scattering reaction, and converting that reaction to a detectable signal. High detection efficiency, an ability to acquire spectral information, and directional sensitivity may be obtained.

Abstract: A ferromagnetic powder comprising ferromagnetic particles coated with a material that does not degrade at temperatures above 150° C and permits adjacent particles to strongly bind together after compaction such that parts made from the ferromagnetic powder have a transverse rupture strength of about 8,000 to about 20,000 pounds/square inch before sintering. The coating includes from 2 to 4 parts of an oxide and one part of a chromate, molybdate, oxalate, phosphate, or tungstate. The coating may be substantially free of organic materials. The invention also includes a method of making the ferromagnetic powder, a method of making soft magnetic parts from the ferromagnetic powder, and soft magnetic parts made from the ferromagnetic powder.

Abstract: A ferromagnetic powder comprising ferromagnetic particles coated with a material that does not degrade at temperatures above 150° C. and permits adjacent particles to strongly bind together after compaction such that parts made from the ferromagnetic powder have a transverse rupture strength of about 8,000 to about 20,000 pounds/square inch before sintering, The coating includes from 2 to 4 parts of an oxide and one part of a chromate, molybdate, oxalate, phosphate, or tungstate. The coating may be substantially free of organic materials. The invention also includes a method of making the ferromagnetic powder, a method of making soft magnetic parts from the ferromagnetic powder, and soft magnetic parts made from the ferromagnetic powder.

Abstract: An apparatus and method are provided for coating particles in a rotating container. A cathode forms an electrically conductive inner surface of a side wall of the container. An anode is positioned relative to the cathode so as to permit both the cathode and the anode to be immersed together in an electrically conductive fluid. A motor is connected to the container and arranged to cause the container to rotate so as to generate a centrifugal force. Particles are placed in the container, the container is filled with the electrically conductive fluid, and electrical current is caused to pass from the cathode to the anode through the electrically conductive fluid while the container is rotated. The particles rest against the electrically conductive inner surface of the side wall of the container while the electrical current passes from the cathode to the anode, so as to result in deposition of a coating material from the electrically conductive fluid onto the particles.

Abstract: A method for coating particulate substrate materials is provided which comprises (a) combining particles and an electrolyte in an imperforate container; (b) vibrating the container to generate a fluidized bed of particles in the electrolyte; and (c) electrochemically depositing a coating on the particles from reactants in the electrolyte. An apparatus for coating particles is also provided which comprises an imperforate container for receiving particles to be coated and an electrolyte and a device for generating a fluidized bed in the container, the device being operatively associated with the container.

Abstract: The invention is directed to a method of forming parts having complex geometries made by coating ferrous based powders with a metallurgical coating, pressing the powder to make the parts, and using a low temperature heating step to diffuse the coating into the ferrous based powders.

Abstract: A ferromagnetic powder comprising ferromagnetic particles coated with a material that does not degrade at temperatures above 150° C. and permits adjacent particles to strongly bind together after compaction such that parts made from the ferromagnetic powder have a transverse rupture strength of about 8,000 to about 20,000 pounds/square inch before sintering. The coating includes from 2 to 4 parts of an oxide and one part of a chromate, molybdate, oxalate, phosphate, or tungstate. The coating may be substantially free of organic materials. The invention also includes a method of making the ferromagnetic powder, a method of making soft magnetic parts from the ferromagnetic powder, and soft magnetic parts made from the ferromagnetic powder.

Abstract: A powder feed system for delivering a quantity of particulate material to a die cavity of a powder press is provided. The powder press has a table-like platen surface which is flush with and surrounds a die in which the die cavity sits, an upper punch appending from an upper ram and a lower punch. The powder feed delivery system includes a receptacle for receiving and delivering particulate material to the cavity. The receptacle has an ingress through which particulate material is received under pressure and an egress for registering with the interior of the cavity and through which particulate material is delivered under pressure from a feed conduit to the cavity. The feed conduit is attached at a first end to the receptacle ingress. At least one pressure generator is attached to a top end of a pressure vessel attached at a second end to the feed conduit.

Abstract: A plurality of particles include a first material. A coating including a second material is formed on surfaces of the particles, until a selected ratio of the volume of the coating relative to the volume of the particles is achieved. A plurality of particles, including the coated particles, are consolidated in a manner such that the particles are caused to be joined to each other, to form an article. The ratio of the volume of the coating relative to the volume of the particles is selected in a manner such that the article is engineered to have a selected volume fraction representing the volume of the second material in the article relative to the volume of the first material in the article. The first material, the second material, and the volume fraction are selected in a manner such that the article is engineered to exhibit a selected intrinsic property.

Abstract: A ferromagnetic powder comprising ferromagnetic particles coated with a material that does not degrade at temperatures above 150.degree. C. and permits adjacent particles to strongly bind together after compaction such that parts made from the ferromagnetic powder have a transverse rupture strength of about 8,000 to about 20,000 pounds/square inch before sintering. The coating includes from 2 to 4 parts of an oxide and one part of a chromate, molybdate, oxalate, phosphate, or tungstate. The coating may be substantially free of organic materials. The invention also includes a method of making the ferromagnetic powder, a method of making soft magnetic parts from the ferromagnetic powder, and soft magnetic parts made from the ferromagnetic powder.

Abstract: Steel powder for use in case hardenable steels is provided. The steel powder is made from a plurality of pre-alloyed iron-molybdenum particles. Each of the particles has from about 1.5 to about 3.5 percent by weight of molybdenum and have a diameter of from about 20 to about 200 microns. The powders further have from about 0.001% by weight to about 0.5% by weight of a coating. The coating is made up of from about 40% to about 85% by weight of one or more of FeO, Fe.sub.3 O.sub.4, Fe.sub.2 O.sub.3, (Fe.sub.2 O.sub.3.H.sub.2 O) and combinations thereof; and from about 15% to about 60% by weight of one or more of FePO.sub.4, Fe.sub.3 (PO.sub.4).sub.2, FeHPO.sub.4, Fe.sub.3 (PO.sub.4).sub.2.2H.sub.2 O, Fe.sub.2 (PO.sub.4).sub.3.8H.sub.2 O, FeCrO.sub.4, FeMoO.sub.4, FeC.sub.2 O.sub.4, and FeWO.sub.4.Also provided is a steel powder composition for use in manufacturing sinter hardenable structural parts. The powder is made from a plurality of pre-alloyed steel particles of from about 0.5 to about 3.

Abstract: A process for consolidating powder, particulates, foils or sheets of metal coated composites, elemental metallic or metallic alloy or intermetallic compounds into net shapes having increased green strength at or near ambient temperature comprises treating the material with an aqueous activation solution. The aqueous activation solution is selected from dilute acids, reducing agents, molten salt electrolytes and mixtures thereof. Pressure is used to consolidate the treated powders, particulates, foils or sheets into a net shape at or near ambient temperature.

Abstract: A metallic composite solid, containing alloys and/or intermetallics, is formed by compacting at moderate pressure a mixture of powder particles, foils or sheets at a temperature close to room temperature, well below the melting temperature of the constituent components and without the addition of low melting metals such as mercury, indium or gallium acting as a sintering agent. This low temperature consolidation of the powder mixture is enhanced by having the surface oxide of the powder particles removed, prior to consolidation, and/or by coating the particles with an oxide-replacing metal such as silver or gold. The coating process may be replacement reactions, autocatalytic reduction or electrolytic reduction. The composite formation is assisted by the addition of a liquid acid such as fluoroboric acid, sulfuric acid, fluoric acid, adipic acid, ascorbic acid, or nitric acid.

Abstract: A ferromagnetic powder comprising ferromagnetic particles coated with a material that does not degrade at temperatures above 150.degree. C. and permits adjacent particles to strongly bind together after compaction such that parts made from the ferromagnetic powder have a transverse rupture strength of about 8,000 to about 20,000 pounds/square inch before sintering. The coating includes from 2 to 4 parts of an oxide and one part of a chromate, molybdate, oxalate, phosphate, or tungstate. The coating may be substantially free of organic materials. The invention also includes a method of making the ferromagnetic powder, a method of making soft magnetic parts from the ferromagnetic powder, and soft magnetic parts made from the ferromagnetic powder.