Abstract: The present disclosure is directed to systems and methods for producing a metal-containing powder useful for additive manufacturing. The metal-containing powder includes a plurality of metal-containing platelets having a defined physical geometry and a defined aspect ratio. The metal platelets may be produced by depositing a metal layer on a substrate that includes one or more recessed or raised surface features. The one or more recessed or raised surface features create a fracture pattern in a metal layer deposited across at least a portion of the one or more surface features. By separating the metal layer from the substrate and fracturing the metal layer along the fracture pattern, a plurality of metal platelets are produced. In some embodiments, a release agent may be disposed between the metal layer and the substrate to facilitate the separation of the metal layer from the substrate.

Abstract: The present disclosure is directed to systems and methods for producing a metal-containing powder useful for additive manufacturing. The metal-containing powder includes a plurality of metal-containing platelets having a defined physical geometry and a defined aspect ratio. The metal platelets may be produced by depositing a metal layer on a substrate that includes one or more recessed or raised surface features. The one or more recessed or raised surface features create a fracture pattern in a metal layer deposited across at least a portion of the one or more surface features. By separating the metal layer from the substrate and fracturing the metal layer along the fracture pattern, a plurality of metal platelets are produced. In some embodiments, a release agent may be disposed between the metal layer and the substrate to facilitate the separation of the metal layer from the substrate.

Abstract: A method and system for generating a surface treating plasma. Gas is provided to a power conducting electrode and flows through the power conducting electrode. Power pulses are applied to the power conducting electrode in the range of 40 kW to 100 kW with a DC generator, at a frequency in the range of 1 Hz to 62.5 kHz, and with a pulse duration in the range of 0.1 microseconds to 3,000 microseconds. Peak currents in the range of 100 Amps to 400 Amps are produced and plasma is formed from the gas. A substrate surface may then be treated with the plasma.

Abstract: An atmospheric pressure pulsed arc plasma source and method of using including a housing having a housing opening therein; an insulator tube having an insulator tube opening therein, retained within the housing opening; and a conductive tube, retained within the insulator tube opening. A nozzle is retained by the housing. A feed path is defined in the conductive tube and the nozzle and a gas feed port is operatively coupled to the feed path. Feedstock is provided in the feed path and electrically coupled to the conductive tube. A pulsed DC power source provides a pulsed voltage to the conductive tube. The plasma source emits a discharge stream having a temperature that is less than 50° C. from the nozzle and a coating is formed on a substrate.

Abstract: Carbon nanotubes grown on nanostructured flake substrates are disclosed. The nanostructured flake substrates include a catalyst support layer and at least one catalyst layer. Carbon nanotubes grown on the nanostructured flake substrates can have very high aspect ratios. Further, the carbon nanotubes can be aligned on the nanostructured flake substrates. Through routine optimization, the nanostructured flake substrates may be used to produce single-wall, double-wall, or multi-wall carbon nanotubes of various lengths and diameters. The nanostructured flake substrates produce very high yields of carbon nanotubes per unit weight of substrate. Methods for making the nanostructured flake substrates and for using the nanostructured flake substrates in carbon nanotube synthesis are disclosed.

Abstract: An atmospheric pressure pulsed arc plasma source and method of using including a housing having a housing opening therein; an insulator tube having an insulator tube opening therein, retained within the housing opening; and a conductive tube, retained within the insulator tube opening. A nozzle is retained by the housing. A feed path is defined in the conductive tube and the nozzle and a gas feed port is operatively coupled to the feed path. Feedstock is provided in the feed path and electrically coupled to the conductive tube. A pulsed DC power source provides a pulsed voltage to the conductive tube. The plasma source emits a discharge stream having a temperature that is less than 50° C. from the nozzle and a coating is formed on a substrate.

Abstract: A method and system for generating a surface treating plasma. Gas is provided to a power conducting electrode and flows through the power conducting electrode. Power pulses are applied to the power conducting electrode in the range of 40 kW to 100 kW with a DC generator, at a frequency in the range of 1 Hz to 62.5 kHz, and with a pulse duration in the range of 0.1 microseconds to 3,000 microseconds. Peak currents in the range of 100 Amps to 400 Amps are produced and plasma is formed from the gas. A substrate surface may then be treated with the plasma.

Abstract: A method of coating a substrate, with the method comprising: providing a substrate; dispersing nanodiamond powder in a liquid to provide a coating precursor; converting the liquid of the coating precursor to a vapor; introducing the coating precursor to a vapor deposition process; and operating the vapor deposition process to produce a nanocrystalline diamond-containing nanocomposite coating on the substrate, the nanocomposite coating produced using the coating precursor and comprising the nanodiamond particles.

Abstract: A membrane composition and process for its formation are disclosed from the removal of carbon dioxide (CO2) from mixed gases, such as flue gases of energy production facilities. The membrane includes a substrate layer comprising inorganic oxides, a barrier layer of in-situ formed Li2ZrO3, a Li2ZrO3 sorbent layer and an inorganic oxide cap layer. The membrane has a feed side for introduction of mixed gases containing nitrogen (N2) and a sweep side for recovery of CO2 wherein the membrane has a relatively high selectivity for CO2 transport at temperatures in the range of 400° to 700° C.

Abstract: A membrane composition and process for its formation are disclosed from the removal of carbon dioxide (CO2) from mixed gases, such as flue gases of energy production facilities. The membrane includes a substrate layer comprising inorganic oxides, a barrier layer of in-situ formed Li2ZrO3, a Li2ZrO3 sorbent layer and an inorganic oxide cap layer. The membrane has a feed side for introduction of mixed gases containing nitrogen (N2) and a sweep side for recovery of CO2 wherein the membrane has a relatively high selectivity for CO2 transport at temperatures in the range of 400° to 700° C.

Abstract: The present disclosure relates to a method of coating a substrate, with the method comprising: providing a substrate; dispersing nanodiamond powder in a liquid to provide a coating precursor; converting the liquid of the coating precursor to a vapor; introducing the coating precursor to a vapor deposition process; and operating the vapor deposition process to produce a nanocrystalline diamond-containing nanocomposite coating on the substrate, the nanocomposite coating produced using the coating precursor and comprising the nanodiamond particles.

Abstract: Carbon nanotubes grown on nanostructured flake substrates are disclosed. The nanostructured flake substrates include a catalyst support layer and at least one catalyst layer. Carbon nanotubes grown on the nanostructured flake substrates can have very high aspect ratios. Further, the carbon nanotubes can be aligned on the nanostructured flake substrates. Through routine optimization, the nanostructured flake substrates may be used to produce single-wall, double-wall, or multi-wall carbon nanotubes of various lengths and diameters. The nanostructured flake substrates produce very high yields of carbon nanotubes per unit weight of substrate. Methods for making the nanostructured flake substrates and for using the nanostructured flake substrates in carbon nanotube synthesis are disclosed.

Abstract: Opaque glitter particles that are uniform in size and shape are disclosed that have an optically variable color with a change in angle of incident light. The glitter particles have an organic substrate and an optical interference structure on one or both sides of the organic substrate. The optical interference design can be a Fabry-Perot structure or can be an optically variable ink.

Abstract: A flake-based pigment is provided having improved specular reflectance characteristics in the visible wavelength range. The flake-based pigment has a plurality of composite reflective flakes each formed of a support layer and a reflector layer on one or both opposing sides of the support layer. This flake structure exhibits a uniaxial compressive strength much greater than a corresponding uniaxial tensile strength. The structure of the flakes provides the benefits of rigidity and brittle fracture during manufacture and application processes, which ultimately provides favorable planar and specular reflectance characteristics to the pigment in the visible wavelength range. A variety of outer coating layers can be formed around the composite reflective flakes, such as various dielectric and/or absorber layers, to produce desired optical characteristics in the pigment.

Abstract: A flake-based pigment is provided having improved specular reflectance characteristics in the visible wavelength range. The flake-based pigment has a plurality of composite reflective flakes each formed of a support layer and a reflector layer on one or both opposing sides of the support layer. This flake structure exhibits a uniaxial compressive strength much greater than a corresponding uniaxial tensile strength. The structure of the flakes provides the benefits of rigidity and brittle fracture during manufacture and application processes, which ultimately provides favorable planar and specular reflectance characteristics to the pigment in the visible wavelength range. A variety of outer coating layers can be formed around the composite reflective flakes, such as various dielectric and/or absorber layers, to produce desired optical characteristics in the pigment.

Abstract: A flake-based pigment is provided having improved specular reflectance characteristics in the visible wavelength range. The flake-based pigment has a plurality of composite reflective flakes each formed of a support layer and a reflector layer on one or both opposing sides of the support layer. This flake structure exhibits a uniaxial compressive strength much greater than a corresponding uniaxial tensile strength. The structure of the flakes provides the benefits of rigidity and brittle fracture during manufacture and application processes, which ultimately provides favorable planar and specular reflectance characteristics to the pigment in the visible wavelength range. A variety of outer coating layers can be formed around the composite reflective flakes, such as various dielectric and/or absorber layers, to produce desired optical characteristics in the pigment.

Abstract: A flake-based pigment is provided having improved specular reflectance characteristics in the visible wavelength range. The flake-based pigment has a plurality of core flake sections each formed of a central reflector layer and dielectric support layers on opposing sides of the reflector layer. The resulting core flake section is a very thin three-layered structure that exhibits a uniaxial compressive strength much greater than a corresponding uniaxial tensile strength. This structure provides the benefits of rigidity and brittle fracture during manufacturing and application processes, which ultimately provides favorable planar and specular reflectance characteristics for the pigment in the visible wavelength range. A variety of outer coating layers can be formed around the core flake sections, such as various dielectric and absorber layers having thicknesses dependent upon the desired optical characteristics of the pigment.

Abstract: A flake-based pigment is provided having improved specular reflectance characteristics in the visible wavelength range. The flake-based pigment has a plurality of core flake sections each formed of a central reflector layer and dielectric support layers on opposing sides of the reflector layer. The resulting core flake section is a very thin three-layered structure that exhibits a uniaxial compressive strength much greater than a corresponding uniaxial tensile strength. This structure provides the benefits of rigidity and brittle fracture during manufacturing and application processes, which ultimately provides favorable planar and specular reflectance characteristics for the pigment in the visible wavelength range. A variety of outer coating layers can be formed around the core flake sections, such as various dielectric and absorber layers having thicknesses dependent upon the desired optical characteristics of the pigment.

Abstract: A flake-based pigment is provided having improved specular reflectance characteristics in the visible wavelength range. The flake-based pigment has a plurality of core flake sections each formed of a central reflector layer and dielectric support layers on opposing sides of the reflector layer. The resulting core flake section is a very thin three-layered structure that exhibits a uniaxial compressive strength much greater than a corresponding uniaxial tensile strength. This structure provides the benefits of rigidity and brittle fracture during manufacturing and application processes, which ultimately provides favorable planar and specular reflectance characteristics for the pigment in the visible wavelength range. A variety of outer coating layers can be formed around the core flake sections, such as various dielectric and absorber layers having thicknesses dependent upon the desired optical characteristics of the pigment.