Abstract: Radar emission absorbing materials that are moldable or that may be coated on a surface are described. A moldable radar emission absorbing material may include commuted carbon foam particles blended with a moldable matrix. In other embodiments, a radar emission absorbing surface coating material may include comminuted carbon foam particles blended with a solvent-solid system.

Abstract: A method for the fabrication of metal matrix composite structures comprising the continuous joining by brazing, soldering or welding of aluminum matrix tape using a laser to melt the surface of the tape while applying pressure to the tape and simultaneously contacting it with previously applied tape layers on a surface. The apparatus utilized to accomplish this fabrication process may include a variety of pre and post-contact heaters and preferably includes instruments for the continuous monitoring and control of the process.

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: An apparatus for the fabrication of metal matrix composite structures comprising the continuous joining by brazing, soldering or welding of aluminum matrix tape using a laser to melt the surface of the tape while applying pressure to the tape and simultaneously contacting it with previously applied tape layers on a surface. The apparatus utilized to accomplish this fabrication process may include a variety of pre and post-contact heaters and preferably includes instruments for the continuous monitoring and control of the process.

Abstract: A method for the fabrication of large metal matrix composite structures comprising the continuous joining by brazing or welding of aluminum matrix tape using an infrared laser to melt the surface of the tape while applying pressure to the tape and simultaneously contacting it with previously applied tape layers on a rotating mandrel. The apparatus utilized to accomplish this fabrication process may include a variety of pre and post-contact heaters and preferably includes instruments for the continuous monitoring and control of the process.

Abstract: Coal based carbon foams that are produced by the controlled beating of coal particulate in a mold and under a non-oxidizing atmosphere and subsequently graphitized have been found to provide excellent electrode materials for electrochemical cell applications.

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.

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.

Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of: starting materials, thermal treatment conditions and/or mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold and/or the use of fibrous carbonaceous layers to obtain selected reinforcement to enhance bending and/or impact resistance. Carbon foams of a homogeneous composition comprising at least fibrous carbonaceous mat as a reinforcing element are also described.

Abstract: A discontinuously reinforced metal composite, having a metal matrix and a plurality of intermetallic particles comprising at least two different metals, the intermetallic particles having a size ranging from 1 ?m to about 10 ?m and being dispersed within the metal matrix in an amount of at least 20% by volume, wherein the intermetallic particles are particles having at least one same metal as the metal in the metal matrix.

Abstract: Carbonaceous, composite tooling fabricated from pitch-based or coal-based cellular or porous products, “carbonaceous foams” having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 that are produced by: 1) conventional pitch foaming processes or; 2) the controlled beating of coal particulate preferably up to ¼ inch in diameter in a “mold” and under a non-oxidizing atmosphere. According to a specifically preferred embodiment, the starting material coal has a free swell index as determined by ASTM test D720 of between about 3.5 and about 5.0.

Abstract: Petroleum or coal tar pitch-based cellular or porous products having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 are produced by the controlled heating of mesophase carbon materials derived from coal tar or petroleum pitch having a softening point in excess of about 300° C. and preferably between about 300 and about 400° C. in a “mold” and under a non-oxidizing atmosphere. The porous product thereby produced, preferably as a net shape or near net shape, can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products.

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: 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, heat or electrical insulator etc.

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: A thermal protection system (TPS) that combines a structural thermal insulator (carbon foam) with a high specific strength metal matrix composite. According to a specifically preferred embodiment, the structural thermal insulator is overcoated with a protective antioxidant layer or incorporates an antioxidant compound therein.

Abstract: A method for the fabrication of large metal matrix composite structures comprising the continuous brazing of aluminum matrix braze-clad tape using an infrared laser to melt the braze clad on the tape while applying pressure to the tape and simultaneously contacting it with previously applied tape layers on a rotating mandrel. The apparatus utilized to accomplish this fabrication process may include a variety of pre and post-contact heaters and preferably includes instruments for the continuous monitoring and control of the process.

Abstract: The application discloses an apparatus for measuring interfacial properties of a fiber-matrix composite material, such as a ceramic-matrix, metal-matrix or continuous fiber metal-matrix composite; or a support material, such as a fiber-optic fiber support medium. The apparatus includes a linear motion feedthrough having an indentor for pushing a fiber end, a load cell for sensing debonding and frictional sliding loads, and a scanning electron microscope (SEM) for magnifying the material in order to align the indentor with the fiber end. The feedthrough may push the fiber at a predetermined velocity with up to about a 20 pound load force. The SEM may include a vacuum chamber for housing the material, the indentor, the load cell, and a hot stage module. The hot stage module may increase the temperature of the material to about 1500.degree. C.