Abstract: A diamond coating formed on a WC—Co substrate prepared through a process including employing a plasma and a variety of interactions from a multiple laser system demonstrates exceptional adhesion and indicates a durable cubic diamond structure. The coating on the WC—Co substrate is typically between 25 and 40 &mgr;m thick and has an average crystal size of between 10 and 20 &mgr;m. Various methods of confirming the cubic diamond structure of the coatings have been employed. The adhesion of the diamond coating to the substrate is very strong. An electron microprobe analysis shows tungsten and cobalt atoms incorporated into the film and a layer depleted in cobalt exists at the diamond-WC—Co interface. Particulates of WC—Co—C alloy are spread over the top surface, apparently formed by condensation from the vapor phase of metal-containing molecules. Carbon is confirmed as being the main component of the surface layer.

Abstract: Energy, such as from one or more lasers, is directed at the surface of a substrate to mobilize and vaporize a constituent element (e.g., carbide) within the substrate (e.g., steel). The vaporized constituent element is reacted by the energy to alter its physical structure (e.g., from carbon to diamond) to that of a composite material which is diffused back into the substrate as a composite material. An additional secondary element, which can be the same as or different from the constituent element, may optionally be directed (e.g., sprayed) onto the substrate to augment, enhance and/or modify the formation of the composite material, as well as to supply sufficient or additional material for fabricating one or more coatings on the surface of the substrate. The process can be carried out in an ambient environment (e.g., without a vacuum), and without pre-heating or post-cooling of the substrate.

Abstract: A method for producing well-crystallized adherent diamond layers on WC—Co substrates. An array of focused laser beams is scanned across the WC—Co sample. Useful lasers include the excimer, YAG:Nd, and carbon dioxide types. The process is conducted in open air with carbon dioxide and nitrogen gases delivered for shrouding the substrate. A luminous plasma is found a few mm above the WC—Co insert. The duration of the deposition process in a typical case is approximately 40 s. This typically gives 20-40 &mgr;m thick coatings. The vertical growth rate is about 1 &mgr;m/s.

Abstract: The preparation and use of diamond as an electron emission material is disclosed. Satisfactory measurements were conducted on diamond coatings deposited on WC-Co alloy by a multiple pulsed laser process. The electron emission was measured in a diode configuration with a diamond surface-anode spacing of 20 and 50 &mgr;m in vacuum at P=10−7 Torr. Current densities of 6 mA/cm were calculated at an applied of voltage of 3000 V (for 20 &mgr;m). Analysis proved that electron field emission provided by a diamond grown by a multiple pulsed laser process proved to satisfactorily meet the specified demands.

Abstract: Solid tungsten carbide is the popular material for these combinations tools. High resultant side forces on the tool during the thread milling phase are caused by relatively high circumferential engagement of the tool and a very low feed per tooth (chip thickness). A combined hole making, threading and chamfering tool with staggered thread cutting teeth doubles chip thickness and reduces side forces (resulting in less engagement), consequently allowing the feed rate to be increased while reducing thread milling time. In addition, this arrangement also reduces tool chatter, thus providing a smoother surface finish in the thread. In one form, the cutting teeth are formed on one or more removable inserts, facilitating replacement or substitution thereof.

Abstract: Thermal stresses normally associated with brazing are alleviated by a low temperature brazing technique of the present invention. A low-temperature brazing paste, preferably suitable to be melted at temperatures of no greater than 200.degree. C. (e.g., 100-200.degree. C.), containing nanoscale (.ltoreq.100 nanometer) size particles of gold, cadmium, copper, zinc, tin, lead, silver, silicon, chromium, cobalt, antimony, bismuth, aluminum, iron, magnesium, nitrogen, carbon, boron, and alloys and composites of these materials, is applied as a bead or as a powder spray at the junction of two components desired to be joined together. Energy from a source such as a laser beam (for example a CO.sub.2 laser, an Nd-Yag laser or an excimer laser), flame, arc, plasma, or the like, is "walked" along the brazing material. The energy beam is sufficient to cause melting and re-crystallization of the nanoscale-particle-containing brazing paste.

Abstract: Thermal stresses normally associated with joining are alleviated by a low temperature joining technique of the present invention. A low-temperature joining material is applied (as a paste, or as a powder spray, or as a tape, or as a paint, or as a putty) at the junction of two components desired to be joined together. Energy from a source such as a laser beam (for example an Nd:YAG or a CO.sub.2 laser) or by a flame, arc, plasma, or the like, is either "walked" along the joining material to react the entire amount of joining material, or the joining material is self-sustaining and simply requires igniting a selected portion of the joining material by the energy source. In an exemplary application of the process, vanes are brazed to the bowl and/or to the shroud of an automatic transmission bowl (impeller or turbine) assembly, preferably using the low-temperature joining material. Systems for delivering the joining material and the energy are described. The fabrication of hollow vanes is described.

Abstract: A very high speed adiabatic face milling machine whose configuration and operation provide a highly efficient machining process suitable for production manufacturing conditions. The milling machine preferably operates at speeds of approximately 15,000 sfm and at efficiencies of approximately 7 cubic inches per minute per horsepower. The preferred milling operation is conducted without the use of cooling liquids, instead employing a chip removal system which enables the milling machine to operate truly adiabatically such that no heat is transferred to the workpiece or the cutter. The efficiency of the chip removal system is such that chip recutting is nearly eliminated and tool life is improved. The milling machine also includes an improved cutter structure, fixturing, and transfer devices.

Abstract: Energy, such as from three different lasers, is directed at the surface of a substrate to mobilize and vaporize a carbon constituent element (e.g., carbide) within the substrate (e.g., steel). The vaporized constituent element is reacted by the energy to alter its physical structure (e.g., from carbon to diamond) to that of a composite material which is diffused back into the substrate as a composite material. An additional secondary element, which also contains carbon, may optionally be directed (e.g., sprayed) onto the substrate to augment, enhance and/or modify the formation of the composite material, as well as to supply sufficient or additional material for fabricating a diamond or diamond-like coating on the surface of the substrate. The process can be carried out in an ambient environment (e.g., without a vacuum), and without pre-heating or post-cooling of the substrate.

Abstract: Energy, such as from one or more lasers, is directed at the surface of a substrate to mobilize and vaporize a constituent element (e.g., carbide) within the substrate (e.g., steel). The vaporized constituent element is reacted by the energy to alter its physical structure (e.g., from carbon to diamond) to that of a composite material which is diffused back into the substrate as a composite material. An additional secondary element, which can be the same as or different from the constituent element, may optionally be directed (e.g., sprayed) onto the substrate to augment, enhance and/or modify the formation of the composite material, as well as to supply sufficient or additional material for fabricating one or more coatings on the surface of the substrate. The process can be carried out in an ambient environment (e.g., without a vacuum), and without pre-heating or post-cooling of the substrate. Articles formed by the disclosed processes are described, including three-dimensional objects.

Abstract: Parallelism between of two opposite surfaces of a workpiece is assured by referencing off of three features on the edge(s) of the workpiece, the three edge features establishing a single, unique plane within the workpiece for referencing the machining operations performed on the two opposite surfaces of the workpiece. The workpiece is held by corresponding two sets of three fixture points, above the surface of two corresponding fixtures, or of one compound fixture, while machining the two opposite surfaces. In this manner, problems associated with referencing off of the first machined surface, to machine the second surface, are completely avoided. This is particularly useful when machining the opposite faces of an automatic transmission valve body. The one set of fixture points is identical to the other set of fixture points, to ensure accurate positioning of the workpiece from fixture-to-fixture (or from set of fixture points to set of fixture points, in a compound fixture).

Abstract: Energy, such as from one or more lasers, is directed at the surface of a substrate to mobilize and vaporize a constituent element (e.g., carbide) within the substrate (e.g., steel). The vaporized constituent element is reacted by the energy to alter its physical structure (e.g., from carbon to diamond) to that of a composite material which is diffused back into the substrate as a composite material. The method of the present invention includes the additional steps of using the energy to move a carbon constituent element in a sub-surface zone of the substrate towards the surface of the substrate, vaporizing selected amounts of the carbon constituent element to produce a vaporized carbon constituent element, reacting the vaporized carbon constituent element to modify its physical structure and properties, reacting the vaporized carbon constituent element to modify its physical structure and properties, and fabricating the diamond coating from the reacted vaporized carbon constituent element.

Abstract: Energy, such as from one or more lasers, is directed at the surface of a substrate to mobilize and vaporize a constituent element (e.g., carbide) within the substrate (e.g., steel). The vaporized constituent element is reacted by the energy to alter its physical structure (e.g., from carbon to diamond) to that of a composite material which is diffused back into the substrate as a composite material. An additional secondary element, which can be the same as or different from the constituent element, may optionally be directed (e.g., sprayed) onto the substrate to augment, enhance and/or modify the formation of the composite material, as well as to supply sufficient or additional material for fabricating one or more coatings on the surface of the substrate. The process can be carried out in an ambient environment (e.g., without a vacuum), and without pre-heating or post-cooling of the substrate. Articles formed by the disclosed processes are described, including three-dimensional objects.

Abstract: In very high speed adiabatic face milling machines whose operation provides a highly efficient machining process suitable for production manufacturing conditions, it is essential that appropriate fixturing is utilized to position and support the workpiece in order to induce added rigidity to the workpiece while reliably clamping and dampening each workpiece to enable machining to withstand small flatness tolerances. Accordingly, primary rests are spaced apart relative to one another to ensure that a stable platform is provided for each workpiece. Force inducement devices are strategically positioned along peripheral edges of the workpiece to selectively deflect the workpiece and thereby significantly add rigidity to the workpiece to better withstand the cutting forces associated with the milling operation.

Abstract: A very high speed adiabatic face milling machine whose configuration and operation provide a highly efficient machining process suitable for production manufacturing conditions. The milling machine preferably operates at speeds of approximately 15,000 sfm and at efficiencies of approximately 7 cubic inches per minute per horsepower. The preferred milling operation is conducted without the use of cooling liquids, instead employing a chip removal system which enables the milling machine to operate truly adiabatically such that no heat is transferred to the workpiece or the cutter. The efficiency of the chip removal system is such that chip recutting is nearly eliminated and tool life is improved. The milling machine also includes an improved cutter structure, fixturing, and transfer devices.

Abstract: Energy, such as from one or more lasers, is directed at the surface of a substrate to mobilize and vaporize a constituent element (e.g., carbide) within the substrate (e.g., steel). The vaporized constituent element is reacted by the energy to alter its physical structure (e.g., from carbon to diamond) to that of a composite material which is diffused back into the substrate as a composite material. An additional secondary element, which can be the same as or different from the constituent element, may optionally be directed (e.g., sprayed) onto the substrate to augment, enhance and/or modify the formation of the composite material, as well as to supply sufficient or additional material for fabricating one or more coatings on the surface of the substrate. The process can be carried out in an ambient environment (e.g., without a vacuum), and without pre-heating or post-cooling of the substrate.

Abstract: Energy, such as from one or more lasers, is directed at the surface of a substrate to mobilize and vaporize a constituent element (e.g., carbide) within the substrate (e.g., steel). The vaporized constituent element is reacted by the energy to alter its physical structure (e.g., from carbon to diamond) to that of a composite material which is diffused back into the substrate as a composite material. An additional secondary element, which can be the same as or different from the constituent element, may optionally be directed (e.g., sprayed) onto the substrate to augment, enhance and/or modify the formation of the composite material, as well as to supply sufficient or additional material for fabricating one or more coatings on the surface of the substrate. The process can be carried out in an ambient environment (e.g., without a vacuum), and without pre-heating or post-cooling of the substrate.

Abstract: A transfer device for a very high speed adiabatic face milling machine whose configuration and operation provide a highly efficient machining process suitable for production manufacturing conditions. The milling machine preferably operates at speeds of approximately 15,000 sfm and at efficiencies of approximately 7 cubic inches per minute per horsepower. The preferred milling operation is conducted without the use of cooling liquids, instead employing a chip removal system which enables the milling machine to operate truly adiabatically such that no heat is transferred to the workpiece or the cutter. The efficiency of the chip removal system is such that chip recutting is nearly eliminated and tool life is improved.

Abstract: Articles, such as plastic parts, having the appearance of a naturally-occurring material such as wood or leather are formed by the techniques of (1) providing a plurality of grooves in a surface of the article, (2) applying a surfactant to the surface of the article, and (3) applying one or more color solutions to the surface of the article. The article may be a solid substrate, a part or a film. A topcoat is preferably applied to the surface of the article. The techniques include controlling movement of an applicator implement for applying the surfactant and color solutions to the surface of the substrate, and controlling movement of a saturator tool for modifying and synthesizing the surfactant and color solutions on the surface of the part and permeating the surfactant and color solutions into the plurality of grooves.

Abstract: A combination tool is disclosed for drilling a hole in a workpiece on the inward feed of the tool and for threading the hole during retraction of the tool. The tool comprises a straight body with a drill point at the forward end, a shank at the rearward end and a threadform mill between the drill point and the shank.