Abstract: In a process for making superplastic steel powder or flakes, molten steel rapidly solidified to form a solidified material comprising substantially single-phase austenitic steel powder or flakes having a grain size of no greater than about 2 .mu.m. The powder or flakes are heated at a temperature of 300.degree. C. to 600.degree. C. to produce superplastic steel comprising a mixture of ferrite steel and at least one metal carbide, the ferrite steel having a randomly oriented structure and having a grain size of no greater than about 2 .mu.m, the at least one metal carbide having a grain size no greater than about 0.5 .mu.m. The steel powder or flake is then recovered for further processing. A consolidated superplastic steel can be formed from the powder or flake by hot pressing the powder or flake at a temperature of between about 650.degree. C. and about 950.degree. C. and at a pressure of about 10 MPa to about 100 MPa for a time sufficient to form a fully dense consolidate.

Abstract: The present invention is a process for making a honeycomb structure of a ected material, having the steps: (a) disposing molten material in a melt container disposed over a mold, where the melt container has an opening for releasing molten material into the mold, where the mold is shaped for molding the honeycomb structure; (b) moving the melt container relative to the mold, where the molten material flows out of the opening into the mold; and (c) removing the mold from the material. Another aspect of the invention is an apparatus for making a honeycomb structure of a selected material, including: (a) a mold shaped for molding the honeycomb structure; (b) a melt container, disposed over the mold, having an opening for releasing molten material into the mold; and (c) a conveyor, for moving the melt container relative to the mold as the melt container releases the molten material into the mold.

Abstract: In a process for making superplastic steel powder or flakes, molten steel is rapidly solidified to form a solidified material comprising substantially single-phase austenitic steel powder or flakes having a grain size of no greater than about 2 .mu.m. The powder or flakes are heated at a temperature of 300.degree. C. to 600.degree. C. to produce superplastic steel comprising a mixture of ferrite steel and at least one metal carbide, the ferrite steel having a randomly oriented structure and having a grain size of no greater than about 2 .mu.m, the at least one metal carbide having a grain size no greater than about 0.5 .mu.m. The steel powder or flake is then recovered for further processing. A consolidated superplastic steel can be formed from the powder or flake by hot pressing the powder or flake at a temperature of between about 650.degree. C. and about 950.degree. C. and at a pressure of about 10 MPa to about 100 MPa for a time sufficient to form a fully dense consolidate.

Abstract: A field-emitting array is provided which comprises at least one thin wafer aving electrically conducting filaments extending through a glass matrix between a first and second parallel surface of the wafer. At the first surface, the filaments extend beyond the plane of the glass matrix. The filaments extending beyond the first surface have an electron-emitting coating on their cylindrical surfaces. The coating extends beyond the filament end to create a shape that emits electrons when an electrical field is applied between the filaments and an anode. In an alternative embodiment, the filaments are recessed below the first surface and a conducting coating forms an extractor on that surface.

Abstract: A field-emitting array is provided which comprises at least one thin wafer aving electrically conducting filaments extending through a glass matrix between a first and second parallel surface of the wafer. At the first surface, the filaments extend beyond the plane of the glass matrix. The filaments extending beyond the first surface have an electron-emitting coating on their cylindrical surfaces. The coating extends beyond the filament end to create a shape that emits electrons when an electrical field is applied between the filaments and an anode. In an alternative embodiment, the filaments are recessed below the first surface and a conducting coating forms an extractor on that surface.

Abstract: A process is provided for forming a glass fiber having one or more metal aments in its core. In the process, a metal rod or particles of a metal or semiconducting material optionally mixed with glass powder is introduced into a hollow glass tube closed at one end, and the tube is evacuated while the closed end is heated and a fiber drawn therefrom. The resultant glass fiber contains one or more discrete filaments of the metal or semiconducting material.

Abstract: Fine metal alloy powders coated with a protective film are disclosed which re produced by the gas atomization process. The protective films are formed during the gas atomization process by gas atomizing a molten mixture of a metal alloy containing an alloy addition agent in an atomizing gas which will selectively react with the alloy addition agent to form a thin protective film on the surface of the metal powder.

Abstract: An apparatus and process for the continuous casting of tubular shapes wherein molten metal from which the tubular shape is formed is centrifugally deposited adjacent to the outlet of a fluid-cooled mold by a nozzle assembly, with the metal being cooled and rapidly solidified by the mold to form a cylindrical shell upon which additional metal is deposited to incrementally build the thickness of the tubular shape. The tubular shape being formed is withdrawn continuously from the mold, and is further cooled by coolant directed thereon. The nozzle assembly may be rotated to discharge the molten metal or, alternatively, the mold may be rotated as the metal is deposited thereon. Single-layer tubular shapes, with or without reinforcing material, may be cast and multiple-layer composite shapes may be produced having layers of different material composition and thicknesses. An inert atmosphere is maintained to prevent oxidation of the molten metal.

Abstract: A method for generating fine sprays of molten metal for spray coating and wder making is disclosed. Liquid metal is fed via a melt tube to a nozzle that is shaped like the frustrum of a cone. The nozzle is surrounded with gas jets in a coaxial pattern around the melt tube orifice. High pressure gas causes the formation of a low pressure region immediately next to the melt tube orifice that draws metal out of the orifice at a higher rate than would otherwise be the case. The coaxial gas stream atomizes the metal into droplets and thereafter forms a narrow, supersonic spray containing very fine metal droplets suitable for powder making or application of a coating.

Abstract: A method of impregnating the surface of a metal substrate with wear resist particles to impart wear resisting characteristics to the surface. The substrate surface is subjected to a relatively moving high-powered laser beam to cause localized surface melting in passes thereacross, and hard wear resistant particles are forcibly velocity injected into the melt. The particles are captured upon solidification of the melt pool and retained therein by metallurgical bond. A wear resistant layer is formed which is an integral part of the underlying material.

Abstract: A method and apparatus for spraying a surface which comprises: introducing into a laser beam, a powder with a vapor pressure from 10.sup.-2 to 10.sup.-1 atm. in excess of the ambient pressure at a temperature up to about 500.degree. C. above the melting point thereof and with a heat-absorption coefficient from 0.2 to 1; and passing the laser beam over said surface. Since the method and apparatus can coat or alloy or dope a surface, a wide variety of protective coatings can be fabricated.

Abstract: The present invention is a method for making radar chaff consisting of metal rings having varying diameters, using photolithographic processes. One aspect of the invention has the steps of: providing a metal foil having a thickness suitable for use in radar chaff; overcoating the metal foil with a photoresist, to form a layered structure; undercoating the metal foil with a removable backing; exposing the photoresist to a quantity of actinic radiation for chemically modifying the photoresist into a photoproduct suitable for subsequent development, where the actinic radiation is patterned into a series of concentric rings; developing the photoresist, to expose the underlying metal in a series of concentric rings; removing the exposed metal to form a series of concentric metal rings on the removable backing; and removing the removable backing. Another aspect of the invention is a metal chaff precursor, comprising: a removable backing, coated with a plurality of concentric metal foil rings.