Abstract: An aluminum-iron alloy for casting includes aluminum, iron, silicon, and niobium present in the aluminum-iron alloy in an amount according to formula (I): (Al3Fe2Si)1-x+x Nb, wherein x is from 0.25 parts by weight to 2.5 parts by weight based on 100 parts by weight of the aluminum-iron alloy. A method of forming a component including forming the aluminum-iron alloy is also described.

Abstract: Methods of pretreating an electroactive material comprising lithium titanate oxide (LTO) include contacting a surface of the electroactive material with a pretreatment composition. In one variation, the pretreatment composition includes a salt of lithium fluoride salt selected from the group consisting of: lithium hexafluorophosphate (LiPF6), lithium tetrafluoroborate (LiBF4), and combinations thereof, and a solvent. In another variation, the pretreatment composition includes an organophosphorus compound. In this manner, a protective surface coating forms on the surface of the electroactive material. The protective surface coating comprises fluorine, oxygen, phosphorus or boron, as well as optional elements such as carbon, hydrogen, and listed metals, and combinations thereof.

Abstract: In an embodiment, a high temperature component comprises an aluminum iron alloy. The aluminum iron alloy comprises 52 to 61 atomic percent of aluminum based on the total atoms of aluminum and iron and comprises a first, B2 phase comprising FeAl and a second, triclinic phase comprising FeAl2. The aluminum iron alloy can comprise an additional element, for example, at least one of silicon or zirconium.

Abstract: A method of manufacturing a crystalline aluminum-iron-silicon alloy and a crystalline aluminum-iron-silicon alloy part. An aluminum-, iron-, and silicon-containing composite powder is provided that includes an amorphous phase and a first crystalline phase having a hexagonal crystal structure at ambient temperature. The composite powder is heated at a temperature in the range of 850° C. to 950° C. to transform at least a portion of the amorphous phase into the first crystalline phase and to transform the composite powder into a crystalline aluminum-iron-silicon (Al—Fe—Si) alloy. The first crystalline phase is a predominant phase in the crystalline Al—Fe—Si alloy.

Abstract: Al—Fe—Si alloys having optimized properties through the use of additives are disclosed. In some aspects, an alloy includes aluminum in a first amount, iron in a second amount, silicon in a third amount, and an additive in a fourth amount. The additive is selected from the group consisting of a non-metal additive, a transition-metal additive, a rare-metal additive, and combinations thereof. The first amount, the second amount, the third amount, and the fourth amount produce an alloy with a stoichiometric formula (Al1-xAx)3Fe2Si where A is the additive.

Abstract: In an embodiment, a high temperature component comprises an aluminum iron alloy. The aluminum iron alloy comprises 52 to 61 atomic percent of aluminum based on the total atoms of aluminum and iron and comprises a first, B2 phase comprising FeAl and a second, triclinic phase comprising FeAl2. The aluminum iron alloy can comprise an additional element, for example, at least one of silicon or zirconium.

Abstract: An aluminum-iron alloy for casting includes aluminum, iron, silicon, and niobium present in the aluminum-iron alloy in an amount according to formula (I): (Al3Fe2Si)1-x+x Nb, wherein x is from 0.25 parts by weight to 2.5 parts by weight based on 100 parts by weight of the aluminum-iron alloy. A method of forming a component including forming the aluminum-iron alloy is also described.

Abstract: An oxygen sensor for a motor vehicle includes a substrate and an alumina coating covering the substrate, palladium (Pd) and platinum (Pt) catalyst particles being uniformly distributed in the alumina coating. The substrate includes a first ceramic layer including a Nernst cell, a second ceramic layer including a reference cell, a third ceramic layer, the second ceramic layer positioned between the first ceramic layer and the third ceramic layer, a heater element positioned between the second ceramic layer and the third ceramic layer.

Abstract: Methods of pretreating an electroactive material comprising lithium titanate oxide (LTO) include contacting a surface of the electroactive material with a pretreatment composition. In one variation, the pretreatment composition includes a salt of lithium fluoride salt selected from the group consisting of: lithium hexafluorophosphate (LiPF6), lithium tetrafluoroborate (LiBF4), and combinations thereof, and a solvent. In another variation, the pretreatment composition includes an organophosphorus compound. In this manner, a protective surface coating forms on the surface of the electroactive material. The protective surface coating comprises fluorine, oxygen, phosphorus or boron, as well as optional elements such as carbon, hydrogen, and listed metals, and combinations thereof.

Abstract: A method of manufacturing a crystalline aluminum-iron-silicon alloy and a crystalline aluminum-iron-silicon alloy part. An aluminum-, iron-, and silicon-containing composite powder is provided that includes an amorphous phase and a first crystalline phase having a hexagonal crystal structure at ambient temperature. The composite powder is heated at a temperature in the range of 850° C. to 950° C. to transform at least a portion of the amorphous phase into the first crystalline phase and to transform the composite powder into a crystalline aluminum-iron-silicon (Al—Fe—Si) alloy. The first crystalline phase is a predominant phase in the crystalline Al—Fe—Si alloy.

Abstract: A method of determining a thickness of a submicron carbon of a carbon-coated metal base plate that includes conducting Raman spectroscopy at a target location of the carbon-coated metal base plate to obtain a Raman shift spectrum for the target location. The Raman shift spectrum obtained at the target location is then converted into a calculated thickness of the submicron carbon coating at the target location. The conversion of the Raman shift spectrum into the calculated thickness of the submicron carbon coating at the target location may involve referencing a linear correlation that has been established over the defined wavenumber range between (1) an integrated intensity of a Raman carbon signal obtained from each of a series of reference plates that includes a submicron carbon coating having a verified thickness and (2) the verified thicknesses of the submicron carbon coatings of the series of reference plates.

Abstract: Al—Fe—Si alloys having optimized properties through the use of additives are disclosed. In some aspects, mechanical properties are optimized using mechanical-optimizing additives such as a combination of boron, zirconium, chromium and molybdenum. In some aspects, corrosion-inhibiting properties are optimized using corrosion-inhibiting additives such as chromium, molybdenum, and tungsten. In some aspects, ductility is optimized by the inclusion of twinning additives such as any of zinc, copper, vanadium, and molybdenum.

Abstract: Al—Fe—Si alloys having optimized properties through the use of additives are disclosed. In some aspects, an alloy includes aluminum in a first amount, iron in a second amount, silicon in a third amount, and an additive in a fourth amount. The additive is selected from the group consisting of a non-metal additive, a transition-metal additive, a rare-metal additive, and combinations thereof. The first amount, the second amount, the third amount, and the fourth amount produce an alloy with a stoichiometric formula (Al1-xAx)3Fe2Si where A is the additive.

Abstract: A method of determining a thickness of a submicron carbon of a carbon-coated metal base plate that includes conducting Raman spectroscopy at a target location of the carbon-coated metal base plate to obtain a Raman shift spectrum for the target location. The Raman shift spectrum obtained at the target location is then converted into a calculated thickness of the submicron carbon coating at the target location. The conversion of the Raman shift spectrum into the calculated thickness of the submicron carbon coating at the target location may involve referencing a linear correlation that has been established over the defined wavenumber range between (1) an integrated intensity of a Raman carbon signal obtained from each of a series of reference plates that includes a submicron carbon coating having a verified thickness and (2) the verified thicknesses of the submicron carbon coatings of the series of reference plates.

Abstract: A method of soldering a shape memory alloy (SMA) element to a component includes positioning a tinned end of the SMA element with respect to a surface of the component, and then directly soldering the tinned end to the surface using solder material having a low liquidus temperature of 500° F. or less when an oxide layer is not present on the SMA element. The end may be soldered using lead-based solder material at a higher temperature when an oxide layer is present. The end may be tinned with flux material containing phosphoric acid or tin fluoride prior to soldering the SMA element. The SMA element may be submersed in an acid bath to remove the oxide layer. The solder material may contain tin and silver, antimony, or zinc, or other materials sufficient for achieving the low liquidus temperature. Heat penetrating the SMA element is controlled to protect shape memory abilities.

Abstract: A method of soldering a shape memory alloy (SMA) element to a component includes positioning a tinned end of the SMA element with respect to a surface of the component, and then directly soldering the tinned end to the surface using solder material having a low liquidus temperature of 500° F. or less when an oxide layer is not present on the SMA element. The end may be soldered using lead-based solder material at a higher temperature when an oxide layer is present. The end may be tinned with flux material containing phosphoric acid or tin fluoride prior to soldering the SMA element. The SMA element may be submersed in an acid bath to remove the oxide layer. The solder material may contain tin and silver, antimony, or zinc, or other materials sufficient for achieving the low liquidus temperature. Heat penetrating the SMA element is controlled to protect shape memory abilities.