Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: The present invention provides a reusable mandrel and method of using the mandrel in a SFFF process. A thermally conductive feature is located on the surface of the mandrel. The mandrel does not bond to the deposited part so that it may be easily removed without damaging either the mandrel or the deposited part. The present invention further enables the manufacture of components where the deposition surface is produced to precision, net shape geometries.

Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: A method for producing porous materials which comprises directing a plasma stream containing particles of a base material in liquid or solid/liquid form onto a substrate under controlled conditions in which the particles spot weld to the substrate or to one another without full fusion, and establishing relative movement between the plasma stream and the substrate whereby the material is deposited as a porous structure of desired porosity and shape.

Abstract: A method for producing a pure metal M or metal alloy MxNy, of interest, which comprises electrolyzing a molten salt electrolyte of an alkali-metal or alkaline-earth metal halide AX or AX2, with an anode formed of graphite or made of a composite of a metal oxide of the metal of interest and carbon, to discharge the alkali or alkaline-earth metal A, at the cathode, and to discharge nascent chlorine gas at the anode, whereby to produce a halide of the metal of interest MXn and/or NXn, and metallothermically reducing the metal halide MXn and/or NXn either separately or combined, with the alkali or alkaline-earth metal A, obtained cathodically to produce the metal M or the metal alloy MxNy of interest in particulate form.

Abstract: A system for purification of high value metals comprises an electrolytic cell in which an anode formed of a composite of a metal oxide of the metal of interest with carbon is electrochemically reduced in a molten salt electrolyte.

Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: A method for production of titanium particles or other metal of interest by a metallothermic reduction reaction of TiCl4 or other metal chloride in a reaction zone which comprises conducting the reaction in a fluidized bed reaction zone, and recycling particles to the reaction zone to build up particle size.

Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: The present invention is directed to a nanotube coated with diamond or diamond-like carbon, a field emitter cathode comprising same, and a field emitter comprising the cathode. It is also directed to a method of preventing the evaporation of carbon from a field emitter comprising a cathode comprised of nanotubes by coating the nanotube with diamond or diamond-like carbon. In another aspect, the present invention is directed to a method of preventing the evaporation of carbon from an electron field emitter comprising a cathode comprised of nanotubes, which method comprises coating the nanotubes with diamond or diamond-like carbon.

Abstract: Golf club structures, including club heads and shafts, composed of composites comprised of a matrix of metal, such as an aluminum alloy, or a plastic material and a fiber such as graphite or a ceramic, which may be whiskerized, and which may also be selectively weighted as in the toe and heel of a club head, with heavy particles such as tungsten metal. The club structure may also be surface hardened by applying a coating of fullerenes to a metal club structure and heat treating it to produce a hard coating of metal carbide, preferably by coating a titanium golf club structure with fullerenes and heat treating the coated structure to produce a titanium carbide surface.

Abstract: A novel fluid heat transfer agent suitable for use in a closed heat transfer system, for example, wherein energy is transferred between an evaporator and a condenser in heat exchange relationship with the heat transfer agent that is caused to flow from one to the other. The novel heat transfer agent is a complex comprising a body of heat transfer fluid, for example, ethylene glycol or water, having suspended therein carbon nanoparticles in a quantity sufficient to enhance the thermal conductivity of the body of heat transfers fluid, per se. The carbon nanoparticles are selected from carbon in the form of sp2 type and sp3 type bonding and preferably comprise nanotubes or fullerenes and may have a coupling agent bonded thereto or enclosed therein when the nanotube or fullerene forms a hollow capsule. The coupling agent may be a polar organic group covalently bonded to the carbon nanoparticles and miscible in the fluid medium.

Abstract: The present invention is directed to a nanotube coated with diamond or diamond-like carbon, a field emitter cathode comprising same, and a field emitter comprising the cathode. It is also directed to a method of preventing the evaporation of carbon from a field emitter comprising a cathode comprised of nanotubes by coating the nanotube with diamond or diamond-like carbon. In another aspect, the present invention is directed to a method of preventing the evaporation of carbon from an electron field emitter comprising a cathode comprised of nanotubes, which method comprises coating the nanotubes with diamond or diamond-like carbon.

Abstract: A novel fluid heat transfer agent suitable for use in a closed heat transfer system, for example, wherein energy is transferred between an evaporator and a condenser in heat exchange relationship with the heat transfer agent that is caused to flow from one to the other. The novel heat transfer agent is a complex comprising a body of heat transfer fluid, for example, ethylene glycol or water, having suspended therein carbon nanoparticles in a quantity sufficient to enhance the thermal conductivity of the body of heat transfers fluid, per se. The carbon nanoparticles are selected from carbon in the form of sp2 type and sp3 type bonding and preferably comprise nanotubes or fullerenes and may have a coupling agent bonded thereto or enclosed therein when the nanotube or fullerene forms a hollow capsule. The coupling agent may be a polar organic group covalently bonded to the carbon nanoparticles and miscible in the fluid medium.

Abstract: The present invention is directed to a nanotube coated with diamond or diamond-like carbon, a field emitter cathode comprising same, and a field emitter comprising the cathode. It is also directed to a method of preventing the evaporation of carbon from a field emitter comprising a cathode comprised of nanotubes by coating the nanotube with diamond or diamond-like carbon. In another aspect, the present invention is directed to a method of preventing the evaporation of carbon from an electron field emitter comprising a cathode comprised of nanotubes, which method comprises coating the nanotubes with diamond or diamond-like carbon.

Abstract: A carbon composite structure, for example, an automotive engine piston, is made by preparing a matrix including of a mixture of non crystalline carbon particulate soluble in an organic solvent and a binder that has a liquid phase. The non crystalline particulate also contains residual carbon hydrogen bonding. An uncured structure is formed by combining the matrix mixture, for example, carbon fibers such as graphite dispersed in the mixture and/or graphite cloth imbedded in the mixture. The uncured structure is cured by pyrolyzing it in an inert atmosphere such as argon. Advantageously, the graphite reinforcement material is whiskered prior to combining it with the matrix mixture by a novel method involving passing a gaseous metal suboxide over the graphite surface.

Abstract: Fullerenes are synthesized by subjecting carbon in the form of particulates or as the carbon of a liquid or gaseous hydrocarbon, that can be continuously fed to a variety of intense, heat-generating processes that vaporize the carbon from the fluid comprising the particulates or hydrocarbons into an environment that condenses the vaporized carbon to the new form of carbon fullerenes.

Abstract: An electrochemical cell comprising a body of proton donor electrolyte in effective contact with first and second electrodes one of which consists essentially of a fullerene in contact with a conductive material. By the application of an electric current across the electrodes the cell can be used to hydrogenate the fullerene, thereby storing hydrogen and electric energy.

Abstract: A process for producing chlorides by the chlorination of a material selected from the group consisting of aluminous materials and metal and metalloid oxides in the presence of a reductant. The method comprises calcining a carbonaceous material with added steam to oxidize substantially all precursors of chlorinated hydrocarbons and to form a reductant; and chlorinating a material selected from the group consisting of aluminous materials and metal oxides in the presence of the reductant.

Abstract: A process for the electrolytic deposition of aluminum at low temperatures and low electrical potential in which the anode is the sole source of aluminum and comprises a composite mixture of an aluminous material such as aluminum oxide and a reducing agent. The composite anode is positioned in the electrolyte with at least one active surface of the anode in opposed relationship to but spaced from the surface of the cathode. The greatly increased electrical resistance of the mixture of aluminum oxide and the reducing agent is minimized by passing the anodic current through one or more conductors of low electrical resistivity which extend through the mixture to or approximately to the active reaction face of the mixture in the electrolyte. The position of the ends of said conductors is maintained relative to the reaction face as the mixture is consumed in the electrolysis.