Abstract: A lithium metal negative electrode for an electrochemical cell for a secondary lithium metal battery includes a polycrystalline metal substrate having a major facing surface with a defined crystallographic texture. An epitaxial lithium metal layer is formed on the major facing surface of the polycrystalline metal substrate. The epitaxial lithium metal layer exhibits a predominant crystal orientation. The predominant crystal orientation of the epitaxial lithium metal layer is derived from the defined crystallographic texture of the major facing surface of the polycrystalline metal substrate.

Abstract: An electrode assembly includes a current collector, a lithium metal foil, and an alloyed interface that chemically binds the current collector and the lithium metal foil. In certain variations, the alloyed interface includes an intermediate layer disposed between the current collector and the lithium metal foil, a portion of the current collector adjacent to the intermediate layer is alloyed with the indium, gallium, or alloy of indium and gallium defining the intermediate layer, and a portion of the lithium metal foil adjacent to the intermediate layer is alloyed with the indium, gallium, or alloy of indium and gallium defining the intermediate layer. In other variations, the alloyed interface includes a copper-lithium alloy.

Abstract: A method of forming a plurality of embossments in a sheet of metal includes: (i) placing the sheet onto a first surface of a die having a plurality of embossment cavities thereon, wherein the sheet has a bottom surface in contact with the first surface of the die and a top surface having an ablative coating formed thereon; and (ii) directing a laser beam at the ablative coating at one or more loci on the top surface of the sheet which correspond to the plurality of embossment cavities on the first surface of the die, so as to locally ablate the ablative coating at the one or more loci and turn the ablative coating at the one or more loci into plasma, thereby causing a plasma pressure shock wave at each of the one or more loci which presses the sheet into the embossment cavities to form the embossments.

Abstract: A process for making a hollow electrical coil for an electric motor includes forming a sacrificial insert material into a coil shaped insert. The coil shaped insert is placed into a copper plating bath and a copper plated coil shaped member is removed from the copper plating bath. The sacrificial material is removed from within the copper plated coil shaped member to create a hollow passage through a hollow copper coil shaped member. An exterior of the hollow copper coil shaped member is coated with an insulating adhesive material and the copper coil shaped member is compressed until the insulating adhesive material is set.

Abstract: An electroactive material for an electrochemical cell that cycles lithium ions is provided. The electroactive material includes a plurality of atomic layers and a plurality of cations disposed between the atomic layers. The plurality of atomic layers includes an atom selected from the group consisting of: silicon, germanium, boron, and combinations thereof. The plurality of cations is selected from the group consisting of: calcium, magnesium, zinc, copper, nickel, potassium, sodium, and combinations thereof. A ratio of the cations to atoms that define the atomic layer may be less than about 1:2.

Abstract: A process for making a ribbon-shaped hollow thermal conductor includes forming a sacrificial material into an insert including a plurality of parallel strands. Plating the sacrificial insert with copper to form a ribbon-shaped structure and removing the sacrificial material from within the ribbon-shaped structure to create a hollow passage through a ribbon-shaped hollow copper thermal conductor.

Abstract: A method of manufacturing a brake rotor or brake drum having a composite structure includes casting an aluminum alloy to form a core of the brake rotor or brake drum, the core defining a core surface, depositing a high entropy alloy or yttrium stabilized zirconia on the core surface to form a thermal barrier layer on the core surface, and depositing an iron-aluminum-silicon-zirconium alloy on the thermal barrier layer to form a wear-resistant layer on the thermal barrier layer, the wear-resistant layer defining a friction surface of the brake rotor or brake drum.

Abstract: A brake drum having a composite structure includes a cylindrical body defining an inner friction surface and an outer surface. The cylindrical body includes a drum core comprising an Al—Si alloy, the drum core including an inner surface, and an outer surface of the drum core defining the outer surface of cylindrical body. The cylindrical body includes a thermal barrier layer comprising a thermally insulating material on the inner surface of the drum core, and a wear-resistant layer comprising an Fe—Al—Si—Zr alloy on the inner surface of the drum core over the thermal barrier layer, the wear-resistant layer defining the inner friction surface of the cylindrical body.

Abstract: A gradient steel includes a first layer, a second layer near a first surface of the first layer, and a third layer near a second surface of the first layer. The first layer includes a first ferrite phase volume. The second and third layers include a second ferrite phase volume greater than the first ferrite phase volume. The gradient steel may also include a fourth layer near the second layer and a fifth layer near the third layer. The fourth and fifth layers may each include a third ferrite phase volume greater than the second ferrite phase volume. The gradient steel may also include a sixth layer near the fourth layer and a seventh layer near the fifth layer. The sixth and seventh layers may each include a fourth ferrite phase volume greater than the third ferrite phase volume.

Abstract: An electrode assembly includes a current collector, a lithium metal foil, and an alloyed interface that chemically binds the current collector and the lithium metal foil. In certain variations, the alloyed interface includes an intermediate layer disposed between the current collector and the lithium metal foil, a portion of the current collector adjacent to the intermediate layer is alloyed with the indium, gallium, or alloy of indium and gallium defining the intermediate layer, and a portion of the lithium metal foil adjacent to the intermediate layer is alloyed with the indium, gallium, or alloy of indium and gallium defining the intermediate layer. In other variations, the alloyed interface includes a copper-lithium alloy.

Abstract: An electroactive material for an electrochemical cell that cycles lithium ions is provided. The electroactive material includes a plurality of atomic layers and a plurality of cations disposed between the atomic layers. The plurality of atomic layers includes an atom selected from the group consisting of: silicon, germanium, boron, and combinations thereof. The plurality of cations is selected from the group consisting of: calcium, magnesium, zinc, copper, nickel, potassium, sodium, and combinations thereof. A ratio of the cations to atoms that define the atomic layer may be less than about 1:2.

Abstract: A cooling system includes a housing including a base portion with sides and a bottom surface that define a cavity and a cover portion to enclose the base portion and including cooling members attached thereto. A shield is arranged in the cavity. A vertical member is arranged below the shield to define a first fluid chamber between one side of the vertical member and one side of the base portion and a second fluid chamber between an opposite side of the vertical member and another side of the base portion. The electronic components are arranged in the second fluid chamber. Cooling fluid is arranged in the cavity and has a fluid level below at least a portion of the shield. The housing is mounted at an inclined angle relative to horizontal or the housing is mounted parallel to horizontal and the shield is mounted at the inclined angle.

Abstract: A structural assembly includes a frame and a plurality of panels. The frame includes a wall that at least partially defines an interior region. The plurality of panels is disposed at least partially in the interior region and is coupled to the frame. The plurality of panels includes a first panel and a second panel. The first panel includes a first surface and a second surface opposite the first surface. The first surface defines a first plurality of depressions and the second surface defines a first plurality of protrusions complementary to the first plurality of depressions. The second panel includes a third surface and a fourth surface opposite the third surface. The third surface defines a second plurality of depressions. The fourth surface defines a second plurality of protrusions complementary to the first plurality of depressions. The first panel is coupled to the second panel.

Abstract: A bi-material permanent magnet for an electric machine includes a core including a first magnetic material and a shell portion located on the core and made of a second magnetic material. The first magnetic material comprises a magnet material with an energy less than 20 Mega Gauss Oersteds (MGOe). The second magnetic material comprises a magnet material with an energy greater than 30 MGOe.

Abstract: A brake rotor having a composite structure may include an annular body defining opposite friction surfaces of the brake rotor. The annular body may include a core made of an Al—Si alloy, a thermal barrier layer made of a thermally insulating material disposed on the core, and a wear-resistant layer made of an Fe—Al—Si—Zr alloy disposed on the core over the thermal barrier layer. The wear-resistant layer may define a first one of the opposite friction surfaces of the annular body.

Abstract: An energy-dissipating cover for covering a component sensitive to mechanical impulse includes a sheet of selected ferrous or aluminum alloy, the sheet having a top surface, a bottom surface, an outer perimeter, an overall area within the outer perimeter and a nominal thickness of no more than 2.5 mm. The sheet is configured for connection with one or more external structures at a plurality of connection points within the outer perimeter, wherein the overall area comprises a plurality of supported areas and at least one unsupported area. Embossments are formed within the at least one unsupported area and extend outward from the bottom surface. The embossments are shaped, sized and arranged so as to limit orthogonal deflection of the sheet from a mechanical impulse directed normal to the bottom surface of the sheet at the plurality of embossments.

Abstract: A damping panel includes a first metal and a second metal. The first metal has a first surface and a second surface opposite the first surface. The second metal portion has a third surface and a fourth surface opposite the third surface. A fixed region is where the second surface of the first metal is fixed to the third surface of the second metal. A non-fixed region is where the second surface is not fixed to the third surface. A cavity is disposed between the second surface and the third surface at the non-fixed region. A damping material is disposed on at least one of: at least a portion of the cavity on the second surface, at least a portion of the cavity on the third surface, at least a portion of the first surface, and at least a portion of the fourth surface.

Abstract: A method of making a battery current collector foil includes heat treating a foil sheet and mechanically roughening the heat treated foil sheet to create a surface roughness of between 2-4 ?m. The heat treating and mechanical roughening of the foil sheet provides improved coating adhesion. One of an anode and cathode coating is then applied to the roughened, heat treated, foil sheet.

Abstract: A brake rotor having a composite structure may include an annular body defining opposite friction surfaces of the brake rotor. The annular body may include a core made of an Al—Si alloy, a thermal barrier layer made of a thermally insulating material disposed on the core, and a wear-resistant layer made of an Fe—Al—Si—Zr alloy disposed on the core over the thermal barrier layer. The wear-resistant layer may define a first one of the opposite friction surfaces of the annular body.

Abstract: A compressor assembly may include a compressor housing and a compressor impeller disposed within the compressor housing. The compressor housing may have an internal aerodynamic surface that defines a circumferentially extending volute, and the compressor impeller may have an external aerodynamic surface that faces toward at least a portion of the internal aerodynamic surface of the compressor housing. A nonstick coating may be formed on the internal aerodynamic surface of the compressor housing or on the external aerodynamic surface of the compressor impeller. The nonstick coating may prevent foreign material introduced into the compressor assembly from collecting on the internal aerodynamic surface of the compressor housing or on the external aerodynamic surface of the compressor impeller.