Abstract: Elements formed from magnetic materials and their methods of manufacture are presented. Magnetic materials include a magnetic alloy material, such as, for example, an Fe-Co alloy material (e.g., the Fe-Co-V alloy Hiperco-50(R)). The magnetic alloy materials may comprise a powdered material suitable for use in additive manufacturing techniques, such as, for example direct energy deposition or laser powder bed fusion. Manufacturing techniques include the use of variable deposition time and energy to control the magnetic and structural properties of the materials by altering the microstructure and residual stresses within the material. Manufacturing techniques also include post deposition processing, such as, for example, machining and heat treating. Heat treating may include a multi-step process during which the material is heated, held and then cooled in a series of controlled steps such that a specific history of stored internal energy is created within the material.

Abstract: Aspects disclosed herein include graphite and hexagonal boron nitride bimaterials, methods of making these bimaterials, and electric propulsion devices or thrusters with these bimaterials. Aspects disclosed herein include electric propulsion devices comprising: at least one portion comprising or formed of a monolithic bimaterial; wherein the monolithic bimaterial comprises a graphite material and a hexagonal boron nitride material; and wherein the graphite material and hexagonal boron nitride material are monolithically integrated in the bimaterial.

Abstract: Systems and methods of additively manufacturing multi-material electromagnetic shields are described. Additive manufacturing processes use co-deposition to incorporate multiple materials and/or microstructures selected to achieve specified shield magnetic properties. Geometrically complex shields can be manufactured with alternating shielding materials optimized for the end use application. The microstructures of the printed shields can be tuned by optimizing the print parameters.

Abstract: Elements formed from magnetic materials and their methods of manufacture are presented. Magnetic materials include a magnetic alloy material, such as, for example, an Fe-Co alloy material (e.g., the Fe-Co-V alloy Hiperco-50(R)). The magnetic alloy materials may comprise a powdered material suitable for use in additive manufacturing techniques, such as, for example direct energy deposition or laser powder bed fusion. Manufacturing techniques include the use of variable deposition time and energy to control the magnetic and structural properties of the materials by altering the microstructure and residual stresses within the material. Manufacturing techniques also include post deposition processing, such as, for example, machining and heat treating. Heat treating may include a multi-step process during which the material is heated, held and then cooled in a series of controlled steps such that a specific history of stored internal energy is created within the material.

Abstract: Systems and methods of additively manufacturing multi-material electromagnetic shields are described. Additive manufacturing processes use co-deposition to incorporate multiple materials and/or microstructures selected to achieve specified shield magnetic properties. Geometrically complex shields can be manufactured with alternating shielding materials optimized for the end use application. The microstructures of the printed shields can be tuned by optimizing the print parameters.

Abstract: Elements formed from magnetic materials and their methods of manufacture are presented. Magnetic materials include a magnetic alloy material, such as, for example, an Fe—Co alloy material (e.g., the Fe—Co—V alloy Hiperco-50®). The magnetic alloy materials may comprise a powdered material suitable for use in additive manufacturing techniques, such as, for example direct energy deposition or laser powder bed fusion. Manufacturing techniques include the use of variable deposition time and energy to control the magnetic and structural properties of the materials by altering the microstructure and residual stresses within the material. Manufacturing techniques also include post deposition processing, such as, for example, machining and heat treating. Heat treating may include a multi-step process during which the material is heated, held and then cooled in a series of controlled steps such that a specific history of stored internal energy is created within the material.

Abstract: Elements formed from magnetic materials and their methods of manufacture are presented. Magnetic materials include a magnetic alloy material, such as, for example, an Fe—Co alloy material (e.g., the Fe—Co—V alloy Hiperco-50®). The magnetic alloy materials may comprise a powdered material suitable for use in additive manufacturing techniques, such as, for example direct energy deposition or laser powder bed fusion. Manufacturing techniques include the use of variable deposition time and energy to control the magnetic and structural properties of the materials by altering the microstructure and residual stresses within the material. Manufacturing techniques also include post deposition processing, such as, for example, machining and heat treating. Heat treating may include a multi-step process during which the material is heated, held and then cooled in a series of controlled steps such that a specific history of stored internal energy is created within the material.

Abstract: The disclosure herein includes methods of preparing ceramic beads, useful as proppant materials, by mixing ceramic precursors, such as slag, fly ash, or aluminum dross, forming bead precursors from the mixture, and heating the bead precursors to drive a chemical reaction between the ceramic precursors to form the ceramic beads. The resultant ceramic beads may be generally spherical particles that are characterized by diameters of about 0.1 to 2 mm, a diametral strength of at least about 100 MPa, and a specific gravity of about 1.0 to 3.0. A coating process may optionally be used to increase a diametral strength of a proppant material. A sieving process may optionally be used to obtain a smaller range of sizes of proppant materials.

Abstract: A fluid tube routes a fluid adjacent to a source of heat to heat the fluid. The heated fluid is passed adjacent to cells which receive infrared radiation from the heated fluid. An anti-corrosion member is positioned on a portion of the tube adjacent to the cells. The anti-corrosion member is spaced from an outer periphery of the tube to provide a chamber between the portion of the tube and the anti-corrosion member.

Abstract: A fluid tube routes a fluid adjacent to a source of heat to heat the fluid. The heated fluid is passed adjacent to cells which receive infrared radiation from the heated fluid. An anti-corrosion member is positioned on a portion of the tube adjacent to the cells. The anti-corrosion member is spaced from an outer periphery of the tube to provide a chamber between the portion of the tube and the anti-corrosion member.

Abstract: A nanocomposite ceramic includes a uniform combination of a ceramic spinel phase and an alumina phase, wherein each phase exhibits a grain size in the range of from about 0.1 nm to 10,000 nm.