Abstract: A metal foam, such as copper metal foam, is used for water filtration and purification. A method is used to manufacture a new water purification device with the capability of killing bacteria and viruses using three dimensionally connected copper foam filter consisting of random or elongated channel pores and large surface area, thereby increasing the copper surface area in contact with contaminated water drops and purifying them. The copper foam water filter has pores on the order of several to tens of micrometers and porosity ranging from 50 percent to 75 percent to properly control the water filtration time and the contact time between the copper foam pore surface and water drops during filtration.

Abstract: Porous aluminum nitride (AlN) provides a greater surface area and higher permeability, which is especially desirable for advanced functional application. Porous or bulk aluminum nitride is very difficult to manufacture due mainly to its high melting point (e.g., 2200 degrees Celsius). A new processing method synthesizes porous aluminum nitride through a complete transformation from porous aluminum using a remarkably low nitriding or sintering temperature. The manufactured porous aluminum nitride foam can be used for such applications as filters, separators, heat sinks, ballistic armor, electronic packaging, light- and field-emission devices, and highly wear-resistant composites when infiltrated with metal such as aluminum, titanium, or copper.

Abstract: A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

Abstract: Using metal foams for the electrode of secondary lithium battery, preparing method thereof, and secondary lithium battery including the metal foam. A metal foam is used in an electrode of secondary lithium battery where the surface and the inner pore walls are coated with the active materials, a method of manufacturing such metal foam, and secondary lithium battery including the metal foam.

Abstract: A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

Abstract: Using metal foams for the electrode of secondary lithium battery, preparing method thereof, and secondary lithium battery including the metal foam. A metal foam is used in an electrode of secondary lithium battery where the surface and the inner pore walls are coated with the active materials, a method of manufacturing such metal foam, and secondary lithium battery including the metal foam.

Abstract: A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

Abstract: An electrode for the use of an advanced lithium battery is fabricated using three-dimensionally structured metal foam coated with an active material. The metal foam is porous metal foam that can be used as an anode current collector of a lithium-ion battery and is coated with an anode active material, such as tin, through a sonication-assisted electroless plating method. Additionally, the coated metal foam is heat-treated at an appropriate temperature in order to improve the integrity of the coating layer and hence, the cyclic performance of the lithium-ion battery.

Abstract: Using metal foams for the electrode of secondary lithium battery, preparing method thereof, and secondary lithium battery including the metal foam. A metal foam is used in an electrode of secondary lithium battery where the surface and the inner pore walls are coated with the active materials, a method of manufacturing such metal foam, and secondary lithium battery including the metal foam.

Abstract: A dye-sensitized solar cell has a working electrode, electrolyte, and counter electrode. The counter electrode includes a nickel (Ni) foam, titanium (Ti) foam, manganese (Mn) foam, or molybdenum (Mo) foam, and has a surface that is nitrided. The reaction efficiency for the solar cell is enhanced by the increased surface area reacting with the electrolyte, which results from using a metal foam. Mechanical properties, such as strength and ductility, and electroconductivity are improved due to the use of metals. The production costs are reduced by using substitute materials, which are low-cost and have oxidation-reduction efficiency.

Abstract: An innovative fuel cell system with MEAs includes a polymer electrolyte membrane, a gas diffusion layer (GDL) made of porous metal foam, and a catalyst layer. A fuel cell has a metal foam layer that improves efficiency and lifetime of the conventional gas diffusion layer, which consists of both gas diffusion barrier (GDB) and microporous layer (MPL). This metal foam GDL enables consistent maintenance of the suitable structure and even distribution of pores during the operation. Due to the combination of mechanical and physical properties of metallic foam, the fuel cell is not deformed by external physical strain. Among many other processing methods of open-cell metal foams, ice-templating provides a cheap, easy processing route suitable for mass production. Furthermore, it provides well-aligned and long channel pores, which improve gas and water flow during the operation of the fuel cell.

Abstract: A method of making an earth-boring rotary drill bit including a bit body configured to carry one or more cutters for engaging a subterranean earth formation. The method includes providing a plurality of hard particles in a mold to define a particle precursor of the bit body. The method also includes infiltrating the particle precursor of the bit body with a molten matrix material comprising a shape memory alloy forming a hard particle-molten matrix material mixture, wherein the hard particles are randomly dispersed within the molten matrix material. The method further includes cooling the molten matrix material to solidify a matrix material and form the bit body comprising a particle-matrix composite material having the plurality of hard particles randomly dispersed throughout the matrix material.

Abstract: Methods of manufacturing rotary drill bits for drilling subterranean formations include forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit, infiltrating the plurality of boron carbide particles with a molten aluminum or aluminum-based material, and cooling the molten aluminum or aluminum-based material to form a solid matrix material surrounding the boron carbide particles. In additional methods, a green powder component is provided that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based alloy material. The green powder component is at least partially sintered to provide a bit body, and a shank is attached to the bit body.

Abstract: An earth-boring rotary drill bit includes a bit body configured to carry one or more cutters for engaging a subterranean earth formation, the bit body comprising a particle-matrix composite material having a plurality of hard particles dispersed throughout a matrix material, the matrix material comprising a shape memory alloy. The matrix material comprises a metal alloy configured to undergo a reversible phase transformation between an austenitic phase and a martensitic phase. The matrix material may include an Ni-based alloy, Cu-based alloy, Co-based alloy, Fe-based alloy or Ti-based alloy.

Abstract: Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of silicon carbide particles dispersed throughout a matrix material, such as, for example, an aluminum or aluminum-based alloy. In some embodiments, the silicon carbide particles comprise an ABC-SiC material. Methods of manufacturing such tools include providing a plurality of silicon carbide particles within a matrix material. Optionally, the silicon carbide particles may comprise ABC-SiC material, and the ABC-SiC material may be toughened to increase a fracture toughness exhibited by the ABC-SiC material. In some methods, at least one of an infiltration process and a powder compaction and consolidation process may be employed.

Abstract: An earth-boring rotary drill bit includes a bit body configured to carry one or more cutters for engaging a subterranean earth formation, the bit body comprising a particle-matrix composite material having a plurality of hard particles dispersed throughout a matrix material, the matrix material comprising a shape memory alloy. The matrix material comprises a metal alloy configured to undergo a reversible phase transformation between an austenitic phase and a martensitic phase. The matrix material may include an Ni-based alloy, Cu-based alloy, Co-based alloy, Fe-based alloy or Ti-based alloy.

Abstract: Methods of manufacturing rotary drill bits for drilling subterranean formations include forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit, infiltrating a plurality of boron carbide particles with a molten aluminum or aluminum-based material, and cooling the molten aluminum or aluminum-based material to form a solid matrix material surrounding the boron carbide particles. In additional methods, a green powder component is provided that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based alloy material. The green powder component is at least partially sintered to provide a bit body, and a shank is attached to the bit body.

Abstract: A method of making an earth-boring rotary drill bit comprising a bit body configured to carry a cutter for an earth formation includes providing a plurality of hard particles in a mold to define a particle precursor of the bit body; wherein the particle precursor is configured for infiltration by a molten matrix material, the resulting particle-matrix composite material having a first coefficient of thermal expansion. The method also includes disposing an insert within the particle precursor, the insert having a second coefficient of thermal expansion that is greater than the first coefficient of thermal expansion. The method further includes infiltrating the particle precursor of the bit body and insert with the molten matrix material and cooling the molten particle-matrix mixture to solidify the molten matrix material and form a bit body comprising a particle-matrix composite material having a plurality of hard particles and an insert disposed in the matrix material.

Abstract: Earth-boring rotary drill bits include bit bodies comprising a composite material including a plurality of hard phase regions or particles dispersed throughout a titanium or titanium-based alloy matrix material. The bits further include a cutting structure disposed on a face of the bit body. In some embodiments, the bit bodies may include a plurality of regions having differing material compositions. For example, the bit bodies may include a first region comprising a plurality of hard phase regions or particles dispersed throughout a titanium or titanium-based alloy matrix material, and a second region comprising a titanium or a titanium-based alloy material. Methods for forming such drill bits include at least partially sintering a plurality of hard particles and a plurality of particles comprising titanium or a titanium-based alloy material to form a bit body comprising a particle-matrix composite material. A shank may be attached directly to the bit body.

Abstract: Rotary drill bits for drilling subterranean formations include a bit body and at least one cutting structure disposed on a face thereof. The bit body includes a crown region comprising a particle-matrix composite material that includes a plurality of boron carbide particles dispersed throughout an aluminum or aluminum-based alloy matrix material. In some embodiments, the matrix material may include a continuous solid solution phase and a discontinuous precipitate phase. Methods of manufacturing rotary drill bits for drilling subterranean formations include infiltrating a plurality of boron carbide particles with a molten aluminum or aluminum-based material. In additional methods, a green powder component is provided that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based alloy material. The green powder component is at least partially sintered to provide a bit body, and a shank is attached to the bit body.