Abstract: A high density carbon material produced from coal is described. The carbon material may have a density ranging from about 1.0 g/cc to about 1.6 g/cc and may have a crush strength of up to about 20,000 psi. The high density carbon material is produced by slowly heating comminuted swelling bituminous coal particles under pressures of 400 psi to about 500 psi to a first temperature at about the initial plastic temperature of the coal. The material is held at this temperature for a period of time sufficient to provide for a uniform temperature throughout the coal. The material is then heated to a second temperature for a period of time sufficient to provide for the coal achieving an essentially uniform temperature. The resulting product is a three-dimensional, self-supporting carbon that has a substantially continuous carbon matrix defining grain boundaries within the carbon matrix.

Abstract: Tools for the forming of composite parts from composite forming materials, having tool bodies that comprise, at least in part, high density carbon foam where a surface of the high density carbon foam may comprise a tool face or support tool face materials. The tools of the present invention may be lighter, more durable, and less costly to produce and/or use than conventional tools used for the production of composite parts, particularly those tools used for the production of carbon composites. Additionally, such tools may be reusable, repairable, and more readily modifiable.

Abstract: Tools for the forming of composite parts from composite forming materials, having tool bodies that comprise, at least in part, carbon foam and high density carbon foam are described. In some embodiments, a surface of the carbon foam or high density carbon foam may comprise a tool face. In other embodiments, the carbon foam or high density carbon foam may support an other material, referred to as tool face material, wherein a surface of the tool face material may comprise a tool face. The tools of the present invention may be lighter, more durable, and less costly to produce and/or use than conventional tools used for the production of composite parts, particularly those tools used for the production of carbon composites. Additionally, such tools may be reusable, repairable, and more readily modifiable.

Abstract: A shield for deflecting or shielding exhaust gas streams is described. The exhaust shield may comprise a shielding layer comprised of high density carbon foam. The exhaust shield may include an exhaust shield support layer affixed to the shielding layer. In some embodiments the exhaust shield support layer comprises carbon foam. If desired the exhaust shield may be comprised of more than one layer of high density carbon foam or carbon foam. The layers of carbon foam and high density carbon foam may be arranged sequentially through the thickness of the panel. The exhaust shield may be used to protect structures from exhaust gas streams such as those from engines or motors, including jet engines or rocket motors.

Abstract: A discontinuously reinforced metal matrix composite wherein the reinforcing material is a particulate binary intermetallic compound is described along with methods for preparing the same. The binary intermetallic compound includes the same type of metal as is the principal matrix metal in combination with one other metal. The particle size of the particulate binary intermetallic compound may be less than about 20 ?m and may be between about 1 ?m and about 10 ?m. The intermetallic particles may be present in the discontinuously reinforced metal matrix composites in an amount ranging from about 10% to about 70% by volume. The discontinuous reinforced metal matrix composites of the invention may be used in structures requiring greater strength and stiffness than can be provided by matrix metal alone. The materials of the invention may be used for vehicle parts, structural materials, and the like.

Abstract: Metal matrix composites having open or closed channels extending longitudinal through the length of the composite as well as methods and apparatus for forming the same are described. The shaped metal matrix composites are made of continuous fiber reinforced metal matrix composite materials. They have an integrally formed, non-cast, metal matrix composite body portion where the walls have a substantially uniform distribution of continuous fibers in a matrix metal throughout the volume of the walls and have at least one channel extending through the body of the shaped metal matrix composite.

Abstract: Methods for the production of carbon foam from swelling coals that do not require the use of high process pressures, oxidized coal, devolatized coal, or high-strength, foam expansion confining molds are described. In some embodiments, a comminuted swelling bituminous coal is heated to a first elevated temperature sufficient to result in the coal particles softening and melting together to form a substantially homogeneous open cell plastic carbon material. The substantially homogeneous open cell plastic carbon material may then be heated to a second elevated temperature at a slow rate to form carbon foam. In some embodiments, the resulting carbon foam may be heated to a higher third elevated temperature. The resulting carbon foam may be subsequently heated to elevated temperatures as great as 3200° C. or more.

Abstract: A method for increasing the yield of carbon foam is described. The method includes placing a foaming sheet over the top surface of the material to be foamed. In certain embodiments, the foaming sheet is placed over the top surface of particulate coal prior to and during the foaming process. In some embodiments the foaming sheet is a smooth, continuous sheet, such as aluminum foil or the like. The resulting carbon product includes an increased amount of usable carbon foam.

Abstract: A blast energy mitigating composite useful for protecting a surface or an object from a blast, shock waves, or stress waves caused by a sudden, violent release of energy is described. Certain configurations of the blast energy mitigating composite may include a energy mitigating units contained in an energy mitigating matrix. The energy mitigating units may comprise a porous energy mitigating material such as carbon foam.

Abstract: An assembly comprising carbon foam and high density carbon foam is described. In some embodiments, such an assembly may be a composite or composite assembly. One or more pieces of carbon foam and high density carbon foam may comprise the assembly. The assembly may comprise other materials in addition to the carbon foam and high density carbon foam. One or more of any given type of other material may be incorporated into the composite. Additionally, a given other material may be incorporated in more than one volume or location on or in the assembly. The other materials may provide for bonding of the elements of the assembly together, strengthening of the assembly, increased assembly oxidation and weathering resistance, modification of the electrical, thermal, or fluid transport properties of the assembly, and any of a number of other purposes.

Abstract: Tools for the forming of composite parts from composite forming materials, having tool bodies that comprise, at least in part, carbon foam and graphite are described. In some embodiments, a surface of the carbon foam or graphite may comprise at least a portion of a tool face. In other embodiments, the carbon foam or graphite may support another material, referred to as tool face material, wherein a surface of the tool face material, may comprise at least a portion of a tool face. The tools of the present invention may be lighter, more durable, and less costly to produce and/or use than conventional tools used for the production of composite parts, particularly those tools used for the production of carbon composites. Additionally, such tools may be reusable, repairable, and more readily modifiable.

Abstract: A wet filament winding method and apparatus for producing a consolidated metal matrix composite is described. The methods are directed to winding a softened metal infiltrated fiber bundle and layering the resulting softened metal infiltrated fiber bundle onto a rotating mandrel in a prescribed pattern on the surface of the mandrel to form a consolidated metal matrix composite. Upon cooling, the matrix metal solidifies and the resulting consolidated metal matrix composite may be removed from the mandrel. The consolidated metal matrix composites may be produced in a variety of shapes, such as cylinder, a tapered cylinder, a sphere, an ovoid, a cube, a rectangular solid, a polygonal solid, and panels.

Abstract: A microsystem manipulation apparatus and an associated kit is described that may be used to facilitate the assembly and testing of Microsystems and microsystem components. The microsystem manipulation apparatus may include a scanning electron microscope imaging system, a stage, and at least one manipulator having an associated tool. The microsystem manipulation apparatus may be partially or fully automated to provide for routine microsystem assembly, disasembly, and/or testing. The associated kit may include one or more manipulators and associated tools for retrofitting an existing scanning electron microscope to produce a microsystem manipulation apparatus.

Abstract: The present invention includes methods for simultaneously producing, within a single container, two or more sections of high density carbon foam materials of defined shape. A method used to prepare high density carbon foam sections may involve heating a comminuted agglomerating bituminous coal bed, that is at least partially divided into two or more sections by the use of partitions within the coal bed, to an elevated temperature sufficient to result in the coal particles softening and melting together to form sections of a generally homogeneous, continuous, open cell carbon material. The sections of homogeneous open cell carbon material are then maintained at an elevated temperature for a period of time sufficient to substantially reduce or essentially eliminate the plastic properties of the bituminous coal. As desired, the resultant high density carbon foam sections may be cooled to essentially ambient temperatures or immediately or subsequently heated to elevated temperatures as great as about 3200° C.

Abstract: A method and apparatus for the production of long lengths of continuous-fiber metal matrix composite prepeg ribbon or tape. The tape or ribbon is produced by bringing together multiple fiber tows into a formed bundle of fibers and infiltrating the bundle with metal using a continuous pultrusion process. Pultrusion is a preferred method of tape or ribbon manufacture since it places the fibers in tension during manufacture and avoids subsequent issues associated with buckling stress.

Abstract: According to the present invention there is provided a porous coal-based material having a density of between about 0.1 g/cm3 and about 0.6 g/cm3 that is produced by the controlled heating of small coal particulate in a “mold” and under a non-oxidizing atmosphere. The coal starting material preferably exhibits a free swell index of between about 3.5 and about 5.0 and most preferably between about 4.0 and about 4.5. The porous product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, heat or electrical insulator etc. Such porous products, without further treatment exhibit compressive strengths of up to about 6000 psi. Further treatment by carbonization or graphitization yields products that can be used as electrical or heat conductors. Methods for the production of these coal-based cellular products are also described.

Abstract: According to the present invention there is provided a coal-based carbon foam having a density of between about 0.1 g/cm3 and about 0.8 g/cm3, preferably between about 0.2 g/cm3 and about 0.6 g/cm3 and most preferably between about 0.3 g/cm3 and about 0.4 g/cm3 that is produced by the controlled heating of high volatile bituminous coal particulate in a “mold” and under a non-oxidizing atmosphere. The high volatile bituminous coal starting material preferably exhibits a free swell Index of between about 3.5 and about 5.0 and most preferably between about 3.75 and about 4.5. A number of additional highly desirable characteristics of the high volatile bituminous coal starting material are also described. The carbon foam product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, beat or electrical insulator etc.

Abstract: An ablation resistant, monolithic, activated, carbon foam produced by the activation of a coal-based carbon foam through the action of carbon dioxide, ozone or some similar oxidative agent that pits and/or partially oxidizes the carbon foam skeleton, thereby significantly increasing its overall surface area and concurrently increasing its filtering ability. Such activated carbon foams are suitable for application in virtually all areas where particulate or gel form activated carbon materials have been used. Such an activated carbon foam can be fabricated, i.e. sawed, machined and otherwise shaped to fit virtually any required filtering location by simple insertion and without the need for handling the “dirty” and friable particulate activated carbon foam materials of the prior art.

Abstract: A lightweight, high strength structure is described where a core material has a first and second metal matrix composite layer on surfaces of the core material. A sandwich type structure may be formed. The core material may be a solid material, a foam, a honeycomb structure, or may be a channeled material. The metal matrix composite layers may include fiber reinforced metal matrix composites.

Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.