Abstract: A composite material including a first carbon foam structure including a network of pores and a second carbon foam structure including a network of pores. An intermediate bonding structure is disposed at least in part between the first and second carbon foam structures.

Abstract: A metal oxide coating has a nanotextured surface defined by a plurality of capillary openings arranged in a pattern on the surface of the coating. Each of the capillary openings have a diameter defined by a previously present organic macromolecule. The metal oxide coating is formed by depositing a solution containing uniformly dispersed micelles composed of amphiphilic molecules on a metal, oxide, or plastic substrate. The micelles are self-arranging, in solution, as a result of mutually repulsive electrostatic forces on the surface of the micelles, and form a uniformly patterned organic template when the solution is deposited on the surface of the substrate. A metal oxide coating is then applied to the substrate, which forms a ceramic monolayer that is a negative image of the organic template. The organic template is then removed, thereby forming a metal oxide coating having a plurality of macromolecular-sized apertures formed therein.

Abstract: A composite material including a first carbon foam structure including a network of pores and a second carbon foam structure including a network of pores. An intermediate bonding structure is disposed at least in part between the first and second carbon foam structures.

Abstract: Method of manufacturing a piezoelectric actuator. The method includes a pre-cure step in which the adhesive is heated to a temperature below the melting point of the adhesive. A stack is formed having a piezoelectric layer and at least one supporting layer with the pre-cured adhesive therebetween. The stack is then cured to form a bonded laminate. The temperature at which the pre-cure occurs allows for the pre-stress in the piezoelectric layer to be modified without changing the material of the supporting layer.

Abstract: A battery cell includes a negative current collector and at least one carbon foam positive current collector disposed within the cell such that the negative current collector at least partially surrounds the at least one carbon foam positive current collector. An insulating mat is disposed between the negative current collector and the at least one carbon foam positive current collector.

Abstract: A method for forming a corrosion resistant electrode for a battery includes supplying an electrode for use in the battery and exposing the electrode to an environment including vaporized carbon. At least some of the carbon from the environment may be transferred to the electrode.

Abstract: A method for coating materials on substrates is disclosed which includes providing a dispersion of the coating material in a liquid carrier wherein the material includes individual, non-agglomerated particles having diameters of less than 500 nanometers, injecting the dispersion into a thermal spray to form droplets of liquid carrier and particles, burning the droplets of liquid carrier and particles within the thermal spray so the particles begin to melt and wherein, as the droplets burn, at least some of the particles begin to form agglomerates of particles within the droplets and directing the droplets containing the agglomerates of particles toward the substrate to coat the substrate with the particles.

Abstract: A metal oxide coating has a nanotextured surface defined by a plurality of capillary openings arranged in a pattern on the surface of the coating. Each of the capillary openings have a diameter defined by a previously present organic macromolecule. The metal oxide coating is formed by depositing a solution containing uniformly dispersed micelles composed of amphiphilic molecules on a metal, oxide, or plastic substrate. The micelles are self-arranging, in solution, as a result of mutually repulsive electrostatic forces on the surface of the micelles, and form a uniformly patterned organic template when the solution is deposited on the surface of the substrate. A metal oxide coating is then applied to the substrate, which forms a ceramic monolayer that is a negative image of the organic template. The organic template is then removed, thereby forming a metal oxide coating having a plurality of macromolecular-sized apertures formed therein.

Abstract: A metal oxide coating has a nanotextured surface defined by a plurality of capillary openings arranged in a pattern on the surface of the coating. Each of the capillary openings have a diameter defined by a previously present organic macromolecule. The metal oxide coating is formed by depositing a solution containing uniformly dispersed micelles composed of amphiphilic molecules on a metal, oxide, or plastic substrate. The micelles are self-arranging, in solution, as a result of mutually repulsive electrostatic forces on the surface of the micelles, and form a uniformly patterned organic template when the solution is deposited on the surface of the substrate. A metal oxide coating is then applied to the substrate, which forms a ceramic monolayer that is a negative image of the organic template. The organic template is then removed, thereby forming a metal oxide coating having a plurality of macromolecular-sized apertures formed therein.

Abstract: A piezoelectric pressure sensor for detecting pressure in a combustion chamber of an internal combustion engine includes a backing plate secured within a housing. The sensor also includes a resilient prestress plate stacked on the backing plate. The resilient plate is formed of silicone elastomer. A sensor element is stacked on the resilient plate. The sensor element is composed of a piezoelectric material formed from a mixture of lead titanate and lead zirconate. A thermally insulating plate is stacked on the sensor element and a diaphragm plate is stacked on the thermally insulating plate and also secured to the housing. The diaphragm plate is exposed to combustion atmosphere and is adapted to transmit a pressure being determined onto the sensor element.

Abstract: This invention relates to a process for making powders for plasma spray coatings from single components and multiple component having dissimilar particle size and density, which can withstand temperatures in excess of 200.degree. C. within a plasma spray gun and still be freely flowable. In this invention a process for enhancing the high temperature flowability of a powder for spray coatings is disclosed. The process includes the following steps. A powder selected from one of a metal, a ceramic, or mixtures thereof is mixed with a blend of polymeric cellulose ether and water to a dough-like consistency. The powder and the blend are mixed in a volumetric ratio in the range of about 90:10 to about 99:1, powder:blend and a paste is formed. The paste is dried. The dry paste is particulated and a flowable powder having a particle size the range of about 50 .mu.m to about 300 .mu.m is formed.

Abstract: A process for enhancing the flowability of a powder is disclosed. In this process, a powder of metal, ceramic, or mixtures thereof is mixed with polyvinyl alcohol. A paste of the powder-polyvinyl alcohol mixture is formed and dried. The dry paste is particulated and a flowable powder having a particle size the range of about 50 .mu.m to about 300 .mu.m is formed.

Abstract: A process and composition are disclosed for slip casting a ceramic powder in a porous mold. In this invention, a ceramic powder is blended with a polymeric cellulose ether. A slurry of ceramic powder-cellulose ether is formed. A porous mold is coated with a hydrophilic colloid of ammonium alginate to form a treated mold. The slurry is then poured in the treated mold and a slip is formed. This invention is particularly useful for forming crack-free slips made from difficult to cast ceramic powders.

Abstract: In an apparatus for thermally spraying a coating on a work piece, an improvement is disclosed. The improvement comprises a flexible elastomeric mask for protecting the apparatus. The mask is made from silicone rubber having a composition comprising, silicone polymer in the range of about 40% to about 70% by weight, and silica in the range of about 30% to about 60% by weight.

Abstract: A process for forming elements for use in high temperature environments includes the following steps. The process mixes metal and/or metal compounds with orthophosphoric acid and adds a filler to form a moldable material. The moldable material is dried at a temperature less than about 100 degrees to form a stable unitary mass and thereafter the temperature is increased to its "false melt" temperature. Pressure is then subjected on the element while maintaining the element at its false melt temperature for densifying the element to a preselected porosity and deforming the element to preselected final dimensions.

Abstract: A spring of a position sensor is coated with a coating which consists of diglycidyl ether of bisphenol A, polysebacice polyanhydride and polytetrafluoroethylene which is hardened by the process of this invention and forms a hardened protective coating which promotes extended life of the sensor.

Abstract: A spring of a position sensor is coated with a coating which consists of diglycidyl ether of bisphenol A, polysebacice polyanhydride and polytetrafluoroethylene which is hardened by the process of this invention and forms a hardened protective coating which promotes extended life of the sensor.

Abstract: A spring of a position sensor is coated with a coating which consists of diglycidyl ether of bisphenol A, polysebacice polyanhydride and polytetrafluoroethylene which is hardened by the process of this invention and forms a hardened protective coating which promotes extended life of the sensor.

Abstract: A ceramic adhesive comprises a ceramic matrix formed from a mixture of a metallic oxide and an alkali silicate in water, the ceramic matrix further having a sealed porosity, and silicon carbide whiskers dispersed within the ceramic matrix. Further, a ceramic adhesive comprises a ceramic matrix formed from a mixture of magnesium oxide in the range of about 50% to about 80% by weight and sodium silicate in water in the range of about 50% to about 20% by weight, and silicon carbide whiskers dispersed within said ceramic matrix, the whiskers being in the range of about 3% to about 25% by weight of the ceramic matrix. The porosity of the ceramic adhesive is sealed by an organic epoxy resin. A ceramic adhesive of the present invention is particularly useful in mounting and bonding in-cylinder sensors to steel internal engine parts.

Abstract: A ceramic adhesive comprises a ceramic matrix formed from a mixture of a metallic oxide and an alkali silicate in water, and silicon carbide whiskers dispersed within the ceramic matrix. Further, a ceramic adhesive comprises a ceramic matrix formed from a mixture of magnesium oxide in the range of about 50% to about 80% by weight and sodium silicate in water in the range of about 50% to about 20% by weight, and silicon carbide whiskers dispersed within said ceramic matrix, the whiskers being in the range of about 3% to about 25% by weight of the ceramic matrix. A ceramic adhesive of the present invention is particularly useful in mounting and bonding in-cylinder sensors to steel internal engine parts.