Abstract: A system for electro-hydrodynamically extracting energy from wind includes an upstream collector that is biased at an electric potential and induces an electric field. An injector introduces a particle into the electric field. The wind drag on the particle is at least partially opposed by a force of the electric field on the particle. A sensor monitors an ambient atmospheric condition, and a controller changes a parameter of the injector in response to a change in the atmospheric condition.

Abstract: A system for energy and particle extraction from an exhaust stream containing entrained particles, the system including an ionizer, a downstream collector, and an electrical couple. The ionizer is configured to charge the particles within the exhaust stream to a first charge polarity. The downstream collector is disposed downstream from the ionizer within the exhaust stream, and is configured to collect the charged particles. The electrical couple is configured to electrically couple a load between the ionizer and the downstream collector, wherein the load converts energy of the exhaust stream into electric power.

Abstract: An electro-hydrodynamic system that extracts energy from a gas stream, which includes an injector that injects a first species of particles having the same polarity into the gas stream, wherein particle movement with the gas stream is opposed by a first electric field; an electric field generator that generates a second electric field opposing the first, such that the net electric field at a predetermined distance downstream from the injector is approximately zero; an upstream collector that collects a second species of particles having a polarity opposite the first particle species; a downstream collector that collects the charged particle; and a load coupled between the downstream collector and the upstream collector, wherein the load converts the kinetic energy of the gas stream into electric power.

Abstract: A system for electro-hydrodynamically extracting energy from wind includes an upstream collector that is biased at an electric potential and induces an electric field. An injector introduces a particle into the electric field. The wind drag on the particle is at least partially opposed by a force of the electric field on the particle. A sensor monitors an ambient atmospheric condition, and a controller changes a parameter of the injector in response to a change in the atmospheric condition.

Abstract: Provided are electro-hydrodynamic (EHD) system for extracting energy from wind. Also provided are injectors for producing particles in an EHD system. Additionally, methods for producing particles in an EHD system is also provided. Further provided are displays comprising an EHD wind energy system. Also, an electro-hydrodynamic wind energy system integrated with a display is provided. A method of generating electricity is also provided. Additionally, a method of displaying a message is provided.

Abstract: A system for electro-hydrodynamically extracting energy from wind includes an upstream collector that is biased at an electric potential and induces an electric field. An injector introduces a particle into the electric field. The wind drag on the particle is at least partially opposed by a force of the electric field on the particle. A sensor monitors an ambient atmospheric condition, and a controller changes a parameter of the injector in response to a change in the atmospheric condition.

Abstract: Anti-tamper enclosures for electronic devices incorporate a variety of passive and active anti-tampering techniques in a novel way, using highly specialized manufacturing techniques that uniquely and innovatively allow such enclosures to be fabricated. Different embodiments include, alone or in combination, enclosures that prevent x-ray and field-ion-beam characterization of the device; detect attempts to mechanically open the enclosure via prying, cutting, machining, etc.; support wireless communication out of the enclosure so that attempts to tamper with the device can be reported to a user; allow insertion of “decoy” devices; and provide a method of destroying the device as a response to a tampering attempt.

Abstract: This invention improves upon existing approaches by providing a method for improving the uniformity of additive manufacturing processes of the type wherein material increments are consolidated to produce a three-dimensional object. According to one aspect of the invention, the method comprises the steps of tacking an increment during the method to minimize creep, then fully consolidating that increment to the underlying material. According to a different aspect of the invention, the method includes a step of steering the welding head or the feeding of the increments to ensure that the relative orientation of the contact line of the welding head as defined by the lowest surface is parallel to the central axis. As yet a further aspect of the invention, a different method includes a step of placing the increment so as to minimize the ratio of deformed to undeformed material. Such placement may be carried out manually over automatically.

Abstract: Orthopaedic implants are formed using processes whereby a metal alloy is cooled at a rate rapid enough that an amorphous or partially amorphous structure is retained. In the preferred embodiment, the metal alloy is a calcium-based metal alloy. The fabrication process may include die-casting or additive manufacturing process of the type wherein material increments are consolidated in accordance with the description without melting the material in bulk. Such processes include ultrasonic consolidation, electrical resistance consolidation, and frictional consolidation. The material increments are provided in the form of sheets, elongated tapes, filaments, dots or droplets. A preferred method includes a casting process to produce an initial form having an outer surface followed by an additive manufacturing process used to build up at least a portion of the outer surface. For example, the portion may include an intramedullary stem, bone-ingrowth surface, or articulating surface.

Abstract: Materials and methods inhibit the localized build-up of material with respect to certain additive manufacturing processes, including those based on ultrasonic consolidation. Where an object is fabricated by consolidating material increments from a feedstock in accordance with a description of the object, the invention prevents the consolidation in specified regions to provide for an intrinsic support or to otherwise build a part or component in accordance with the description. The object being fabricated, the feedstock, or both, may be treated so as to inhibit the consolidation of material increments in the localized area. That is, such treatment may affect the surface chemistry of the feedstock to prevent local bonding, or the treatment may be applied to a previously built surface of the object.

Abstract: Solid-state bonding technologies are combined with other solid-state consolidation techniques to create new processes, applications, and structures. One embodiment uses metal or plastic spraying techniques with the intention of only partially bonding the droplets to the substrate, while employing a secondary process such as ultrasonic and/or electrical resistance consolidation to achieve complete agglomeration and eliminate porosity. This opens new opportunities with regard to materials, powder types, applications, and automated machinery. Some examples of these hybrids and their applications are provided, however, along with the identification of other combinations.

Abstract: Disclosed is method of enhancing bond quality in an ultrasonic consolidation process using a sonotrode having a power output level. The preferred embodiment includes the steps of inputting a plurality of process parameters associated with a localized geometry over which the ultrasonic consolidation is occurring, and varying the relationship between these parameters to control the power output level to optimize bond quality between layers of material as they are consolidated. The process parameters, alone or in combination, may include the speed of the consolidation; the amplitude of the ultrasonic energy; applied force; and/or temperature.

Abstract: Methods of fabricating a metal-matrix composite materials comprise the steps of providing a plurality of fibers, providing a plurality of metal wires, positioning the wires and fibers in alternating fashion on a substrate, covering the wires and fibers with a layer of metal to create a multi-layer composite, and ultrasonically consolidating the composite. Titanium, aluminum and alloys and other metals are applicable to the process. The fibers may be boron, silicon carbide, glass, alumina and other common reinforcements or, alternatively, optical fibers, shape-memory fibers, piezo-ceramic fibers may be used. The fibers or the wires may be of uniform or varying composition, and may b are applied to a working surface separately or simultaneously, in which case they may be collimated and delivered to a working surface in aligned fashion.

Abstract: In ultrasonic object consolidation, the location of the sonotrode may be independent, and selected (like other processing parameters such as amplitude, frequency, force, and speed), for optimum processing. According to one preferred embodiment, the improvement includes welding certain regions of the object multiple times. Alternatively or in conjunction with other steps, the method includes the act of selecting sonotrode position to minimize bulk motion of the object. The invention improves upon the existing art by optimizing the positioning of the sonotrode relative to the geometry. This may, for example, comprise independently positioning the horn to treat one or more features within a cross section of the object differently, or determining tape placement location and tacking the feedstock in advance of welding. The feedstock may be provided in any suitable form, including wires, tapes and dots.

Abstract: A system, method, and articles are disclosed with respect to depositing aluminum or alloys thereof, utilizing ultrasonic object consolidation. The method aspect of the invention comprises the steps of heat-treating an aluminum-based feedstock and ultrasonically consolidating the feedstock to a substrate to produce a part or a repair of a part, as might be required in an aerospace or aircraft structure. The feedstock may be solution heat-treated. This would include situations wherein the feedstock is solution heat treated off-line and maintained under controlled temperature conditions to prevent precipitation of solutes prior to the ultrasonic consolidation. Alternatively, the feedstock may be heat-treated on-line by passing it through a temperature- and/or atmosphere-controlled chamber prior to ultrasonic consolidation. The feedstock may be supported to minimize slumping due to creep. The feedstock may be T4, or may be aged, to T6, for example.

Abstract: Fibers and layers are co-applied using ultrasonic consolidation and providing steps and/or materials to maintain collimation of the fibers. According to one preferred embodiment the mechanism is a scrim. Alternatively the mechanism may include a material having one or more fibers under a foil layer. The mechanism may further include embedding a layer of fibers in a foil in a “tacking” process, and consolidating the result with an underlying substrate. Yet a further alternative includes interspersing metal fibers between reinforcing fibers. The reinforcing fibers may include SiC, B or Al2O3 fibers. A different preferred method of co-applying fiber and metal using ultrasonic consolidation, comprises the steps of alternating either an encapsulation material or another metal with optical, ceramic, shape-memory, or other fibers of interest, and encapsulating the result between layers of foil.

Abstract: A system and a method of fabricating a three-dimensional object consolidates material increments in accordance with a description of the object using a process that produces an atomically clean faying surface between the increments without melting the material in bulk. The CAD system (60) interfaces with a numerical controller (70), which controls an actuation system. The actuation system brings the support feed unit (62) the support ultrasonic welding unit (66), the object feed unit (64) and the object ultrasonic welding unit (68) into proper position in the work area (75), so that the ultrasonic consolidation of the layers takes place according to the CAD description of the object. In alternative embodiments, electrical resistance, and frictional methodologies are used for object consolidation. The invention further facilitates the construction and repair of dense objects, including fiber-reinforced composites and aerospace structures.

Abstract: Additive and subtractive manufacturing processes are combined to produce objects having a desired geometry specified by a computerized description. According to the invention, a software system is provided which is capable of creating both additive and subtractive toolpaths, and automatically distinguishing between regions in which addition and subtraction must occur. The additive manufacturing aspect may include solid-state or fusion welding processes of all types (including but not limited to, arc welding, laser welding, resistance welding, friction welding, friction stir welding, ultrasonic welding, laser cladding, plasma welding), laser material deposition, metal spraying, adhesive bonding, vapor or electrochemical deposition and other processes not listed which may suggest themselves to those knowledgeable in the field.

Abstract: Materials and methods inhibit the localized build-up of material with respect to certain additive manufacturing processes, including those based on ultrasonic consolidation. Where an object is fabricated by consolidating material increments from a feedstock in accordance with a description of the object, the invention prevents the consolidation in specified regions to provide for an intrinsic support or to otherwise build a part or component in accordance with the description. The object being fabricated, the feedstock, or both, may be treated so as to inhibit the consolidation of material increments in the localized area. That is, such treatment may affect the surface chemistry of the feedstock to prevent local bonding, or the treatment may be applied to a previously built surface of the object.

Abstract: Apparatus and methods are directed to producing consistent bond-zone consolidation quality during additive manufacturing processes, even under constantly changing joining conditions, and regardless of location within the part being built. Various alternative techniques are disclosed involving the energy delivery to the bond zone, stiffness and mechanical resistance to vibration in the bond zone, and thermal conditions in the bond zone. These methods can be used independently or in combination, using a variety of control schemes, hierarchical or parallel. Also, although the examples generally employ a tape-type feedstock, these teachings apply equally well to sheet, tape, filament, dot type, and other feedstock geometries. In addition, although the invention is described in terms of Ultrasonic Object Consolidation (UOC), the disclosed apparatus and methods apply equally well to electrical resistance and frictional consolidation processes through appropriate engineering modification.