Abstract: A thermal spray mixed with a substrate using a non-consumable cylindrical rotating tool. The process may be repeated to create a composite-like coating or material. The coating or material may be machine to improve surface quality.

Abstract: A thermal spray mixed with a substrate using a non-consumable cylindrical rotating tool. The process may be repeated to create a composite-like coating or material. The coating or material may be machine to improve surface quality.

Abstract: A method of forming luninescent films or coatings from a liquid precursor mixture utilizing a RF-induced plasma spraying process is disclosed. The inventive method results in the formation of luminescent films that have spherical, nano to micron sized particles associated therewith.

Abstract: A method of producing a nanocomposite coating without gaseous precursor reactants. A non-nanocrystalline particulate containing a polymorphic material in an atmospheric phase is introduced into a high-velocity gas jet. The projected particulate is allowed to impact a substrate at a velocity effective to cause at a least a portion of the polymorphic material to transform to a nanocrystalline, high pressure phase.

Abstract: A system for fine feature spray deposition includes a substrate platform for supporting a substrate on which the features are to be deposited. A spray assembly is provided which includes a spray source for providing a stream of material to be deposited on a substrate, a collimator which is positioned in a path of the stream from said spray source and an aperture assembly, which is positioned downstream of the collimator with respect to the spray source and above the substrate platform. The aperture assembly defines at least one opening to pass a portion of the stream of material onto a surface of the substrate. A drive mechanism is provided which is coupled to at least one of the spray assembly and the substrate platform for inducing relative motion there between. A controller is coupled to the spray assembly and the drive mechanism to control the relative motion and the stream of material. The system allows fine features to be printed directly on a substrate with requiring a predefined mask.

Abstract: A method of producing a nanocomposite coating without gaseous precursor reactants. A non-nanocrystalline particulate containing a polymorphic material in an atmospheric phase is introduced into a high-velocity gas jet. The projected particulate is allowed to impact a substrate at a velocity effective to cause at a least a portion of the polymorphic material to transform to a nanocrystalline, high pressure phase.

Abstract: A system for fine feature spray deposition includes a substrate platform for supporting a substrate on which the features are to be deposited. A spray assembly is provided which includes a spray source for providing a stream of material to be deposited on a substrate, a collimator which is positioned in a path of the stream from said spray source and an aperture assembly, which is positioned downstream of the collimator with respect to the spray source and above the substrate platform. The aperture assembly defines at least one opening to pass a portion of the stream of material onto a surface of the substrate. A drive mechanism is provided which is coupled to at least one of the spray assembly and the substrate platform for inducing relative motion there between. A controller is coupled to the spray assembly and the drive mechanism to control the relative motion and the stream of material. The system allows fine features to be printed directly on a substrate with requiring a predefined mask.

Abstract: A method of producing a nanocomposite coating without gaseous precursor reactants. A non-nanocrystalline particulate containing a polymorphic material in an atmospheric phase is introduced into a high-velocity gas jet. The projected particulate is allowed to impact a substrate at a velocity effective to cause at a least a portion of the polymorphic material to transform to a nanocrystalline, high pressure phase.

Abstract: A cylindrical tube is provided of a mechanically strong and flexible electrical conductor such as a metal and has a plurality of separated regions. An electrically insulating layer such as a ceramic is applied on the outer surface except for one exposed portion. Electrically resistive heaters are then applied to the insulated regions and are electrically connected at one end to the underlying electrical conducting region. The electrical conductor is connected to the negative terminal of a power source. The other end of all the heaters are adapted to be connected to the positive terminal of the source. Accordingly, an electrically resistive heating circuit is formed wherein the tube serves as a common for all of the heating elements. The tubular heater can comprise an exposed end hub with a plurality of blades extending therefrom. Each blade can have an individual heater deposited thereon. Alternatively, every other blade can have a heater deposited thereon.

Abstract: The vacuum plasma spray process produces well-bonded, dense, stress-free coatings for a variety of materials on a wide range of substrates. The process is used in many industries to provide for the excellent wear, corrosion resistance, and high temperature behavior of the fabricated coatings. In this application, silicon metal is deposited on graphite. This invention discloses the optimum processing parameters for as-sprayed coating qualities. The method also discloses the effect of thermal cycling on silicon samples in an inert helium atmosphere at about 1600.degree.C. which transforms the coating to silicon carbide.

Abstract: A smoking article is provided in which a flavor-generating medium is heated electrically to release an aerosol for inhalation by a consumer. The smoking article includes a heater having resistive heating elements printed on a flexible substrate. The heater can be manufactured by circuit board mass production techniques, and can be formed to fit inside an article of the same shape and size as a conventional cigarette. Alternatively, the heater comprises an array of heating elements onto which charges of flavor-generating medium are deposited. The heating elements are connected in a manner which allows the temperature increase in the heater to be concentrated in individually selected heating elements, and requires a minimal number of electrical conductors.

Abstract: The plasma generating apparatus and method of this invention is particularly, although not exclusively, suitable for plasma spraying. The plasma spray apparatus and method of this invention generates a free-standing electromagnetically coalesced stable plasma through which feedstock may be fed, eliminating problems with conventional radial feed plasma guns. The plasma spray apparatus of this invention includes a plurality of pilot plasma guns preferably displaced symmetrically about a common axis and a main transfer electrode located downstream of the pilot plasma guns having a nozzle bore coaxially aligned with the common axis. The plasmas generated by the pilot plasma guns are directed into the throat of the main transfer electrode bore and a second plasma gas is supplied to the throat of the main transfer electrode bore which is ionized and coalesced with the plasmas generated by the pilot plasma guns, generating a free-standing electromagnetically coalesced plasma.

Abstract: The plasma generating apparatus and method of this invention is particularly, although not exclusively, suitable for plasma spraying. The plasma spray apparatus and method of this invention generates a free-standing electromagnetically coalesced stable plasma through which feedstock may be fed, eliminating problems with conventional radial feed plasma guns. The plasma spray apparatus of this invention includes a plurality of pilot plasma guns preferably angularly displaced symmetrically about a common axis and a main transfer electrode located downstream of the pilot plasma guns having a nozzle bore coaxially aligned with the common axis. The plasmas generated by the pilot plasma guns are directed into the throat of the main transfer electrode bore and a second plasma gas is supplied to the throat of the main transfer electrode bore which is ionized and coalesced with the plasmas generated by the pilot plasma guns, generating a free-standing electromagnetically coalesced plasma.

Abstract: Method and apparatus for coating ball bearings and like spherically shaped objects with a coating composition entrained in a plasma jet, the ball bearings being held captured in an open-sided cage during the coating operation.

Abstract: An improved lithographic printing plate which comprises (a) a substrate with (b) a substantially planar porous metal coating on at least one surface of the substrate and (c) a light-sensitive coating on the porous metal coating on the substrate. The substrate (a) can be made by a process for forming a substantially planar porous metal coating on a substrate which comprises thermal spraying of the metal on the substrate to form a porous metal coating on the substrate, rolling the sprayed coating to render it substantially planar and in the process close the pores, and the removing part of the surface to improve planarity and to reopen the surface-connected pores. The metal to be sprayed may be in the form of a wire, powder or molten metal mass and be selected from the group consisting of aluminum, zinc, tin, copper, nickel, or their alloys. Preferably, the substrate is selected from the gorup consisting of steel, aluminum, aluminized or galvanized steel, tin plate, and plastic.

Abstract: A process for forming a substantially planar porous metal coating on a substrate which comprises thermal spraying of the metal on the substrate to form a porous metal coating on the substrate, rolling the sprayed coating to render it substantially planar and in the process close the pores, and then removing part of the surface to improve planarity and to reopen the surface-connected pores of the surface. The metal to be sprayed may be in the form of a wire, powder or molten metal mass and be selected from the group consisting of aluminum, zinc, tin, copper, nickel, or their alloys. Preferably, the substrate is selected from the group consisting of steel, aluminum, aluminized or galvanized steel, tin plate, and plastic. The spraying is preferably conducted in a non-oxidizing or reducing atmosphere. Preferably, the coating on the substrate is subjected to cold rolling. Most preferably, the rolling is conducted so as to reduce the coating thickness to approximately half of its original thickness.

Abstract: Cordierite coatings capable of withstanding severe mechanical and thermal conditions. Methods of applying such coatings and components protected thereby.

Abstract: Cordierite coatings capable of withstanding severe mechanical and thermal conditions. Methods of applying such coatings and components protected thereby.