Abstract: Highly reflective surfaces, e.g. for headlight reflectors for automotive vehicles can be made by low temperature arc vapor deposition from a mixed metal electrode in which the electrode consists of a mixture of powders of a reflective or relative low melting metal and a ceramic forming high melting metal. The deposit is formed under conditions in which the mixed metals are fully reacted on deposition so that the coating is not susceptible to oxidation in use and requires no protective coating.

Abstract: The formation of an openwork structure e.g., of metal, utilizing low-temperature arc vapor deposition on a foam which is destroyed by pyrolysis is enhanced by applying a portion of the metal in a metal spray of powders in a binder which is also pyrolytically destroyed. The product has essentially the same properties as one made exclusively by the low-temperature arc vapor deposition method.

Abstract: An openwork nickel structure having a high surface area to volume ratio and a porosity which is largely independent of the degree to which the metal structure may be compressed, is formed by depositing on a pyrolyzable support, preferably a reticulated open-pore polyurethane support, a coating of metal by arc-striking utilizing at least one electrode of that metal and by bringing the electrodes out of contact with one another. The metal-covered support is then subjected to pyrolysis to form the metal skeleton which is then sintered. The resulting metal structure has been found to be suitable for use as an electrode in a Ni-Cd cell.

Abstract: Matrix composites and especially metal matrix composites are formed by coating a foam with a metal or ceramic to form a continuous structure from which the foam material is removed by pyrolysis. If this structure is composed of a metal it is subjected to treatment to transform the metal to a ceramic and the resulting ceramic structure is then filled with another material such as a matrix metal. The product is then compacted and heat treated if desired. The coating of the foam and the filling of the porous ceramic structure are effected preferably by low temperature arc vapor deposition.

Abstract: A method and apparatus for deep penetration deposition of material in a porous substrate utilizes a pressure differential across the substrate to effect penetration of arc-produced vapor from one chamber through the body. The one chamber can be held at a pressure of 10.sup.-2 to 10.sup.-3 torr while the other chamber is at a pressure of 10.sup.-5 to 10.sup.-6 torr.

Abstract: A method and apparatus for deep penetration deposition of material in a porous substrate utilizes a pressure differential across the substrate to effect penetration of arc-produced vapor from one chamber through the body. The one chamber can be held at a pressure of 10.sup.-2 to 10.sup.-3 torr while the other chamber is at a pressure of 10.sup.-5 to 10.sup.-6 torr.

Abstract: Hard difficult-to-roll alloys are shaped by forming a mold of plastic, especially a polyacrylate, with a highly smooth surface onto which the alloy is deposited by low-temperature arc vapor deposition. The alloy layer is then separated from the plastic substrate and subjected to heat treatment to increase its density.

Abstract: An electric arc vapor deposition apparatus for coating the internal surface of a metal gas-pressure tank has a sealing plug, a means on the plug coupled with a vacuum pump for evacuating the tank, a material-supplying electrode mounted on the plug and an electrical source connectable between the tank and the electrode to supply electric arc energy.

Abstract: Gas-pressure bottles are internally coated by plugging the mouth of the bottle and evacuating the bottle. The coating material is formed by striking repeatedly electric arcs between the electrode deposed within the bottle and the wall of the latter.

Abstract: Ceramic substrates, e.g. of silicon carbide or silicon nitride are protected against mechanical surface wear at high temperatures by an arc coating with a refractory metal followed by coating with another metal and then with a wear-reducing high density layer, e.g. of a metal oxide, nitride or carbide.

Abstract: Complex shapes are coated with material at least in part evaporated from an elongated electrode shaped to conform to the substrate and juxtaposed therewith over the length of the electrode. An arc is struck at one end and depositions occur over a surface of the electrode which recedes from the arc. The other end of the electrode is heated to maintain the electrode during deposition at a constant temperature.

Abstract: The adhesion of conductive layers to ceramic substrates in the application of such layers by low-energy techniques is improved by interposing between the high-conductivity metal layer and the substrate a layer of refractory metal which is preferably also applied by low-energy vaporization. The metal layers can be provided in succession by reversing the polarity of electrodes composed of the metals of these layers which strike an arc vaporizing the metal to be deposited. One of the electrodes can be shifted out of position and replaced by a substitute electrode and the process repeated to deposit a further layer of metal from the substitute electrode on the substrate.

Abstract: High-purity silicon bars can be produced by electrically melting a portion of a mass of silicon granules in a crystal so that the mass around the melt isolates the melt from the crucible wall and thereby prevents contamination of the melt from the crucible and softening of the crucible wall by the melting heat. The current flow is promoted by the heating of the silicon granules and/or electrodes and a seed can be lowered into the melt so that a bar can be withdrawn therefrom for cutting up into wafers for use in the production of semiconductors.

Abstract: Rock is melted between electrodes and the resulting melt is subjected to electrolysis to recover oxygen and selected metals therefrom and to produce a melt of a unique composition so that it can be cast to produce structures with various properties.

Abstract: An apparatus for producing high purity silicon melts utilizes a solid silicon body which is drilled to provide bores into which electrodes are inserted. The electrodes preferably are also of silicon and an electric arc-current is passed through the electrodes to generate an arc which melts out the body to define a cavity therein containing the melt. The melt may be used for the drawing of a silicon bar or for the deposition of silicon in vapor form from the melt upon a substrate in a vacuum chamber.

Abstract: A silicon crucible for use in holding a silicon melt in the drawing of silicon bars for the production of silicon wafers in the semiconductor industry is provided with a protective coating, e.g. of silicon nitride, by the use of a vapor generator in which granules of a low electrical conductivity and low thermal conductivity material are disposed between a pair of electrodes and an electric current is supplied with induces localized vaporization from the granules at their contact points but without bodily melting the granules. Nitrogen can be applied to the mass as a carrier gas and to react with the silicon vapor thus formed.

Abstract: A high-purity method of forming a silicon melt utilizes a solid silicon body which is drilled to provide bores into which electrodes are inserted. The electrodes preferably are also of silicon and an electric arc-current is passed through the electrodes to generate an arc which melts out the body to define a cavity therein containing the melt. The melt may be used for the drawing of a silicon bar or for the deposition of silicon in vapor form from the melt upon a substrate in a vacuum chamber.

Abstract: The adhesion of conductive layers to ceramic substrates in the application of such layers by low-energy techniques is improved by interposing between the high-conductivity metal layer and the substrate a layer of a refractory metal which is preferably also applied by low-energy vaporization. The metal layers can be provided in succession by reversing the polarity of electrodes composed of the metals of these layers which strike an arc vaporizing the metal to be deposited.

Abstract: Quartz crucibles for the melting of silicon and ceramic substrates are coated with protective materials or metals at least in part evaporated from an electrode with which an arc is struck at low voltage and current to deposit material from the electrode on the substrate in a vacuum chamber. The electrode may be heated and the substrate may be sandblasted and preheated.

Abstract: A method of and apparatus for depositing material upon a surface, e.g. to coat the surface or to form compounds containing this material by bonding with the substrate material of the surface, in which an arc is struck between at least one solid electrode and a pool of molten metal to vaporize the molten metal and permit transfer of the metal vapors to the substrate.