Abstract: A method and apparatus for additive manufacturing that includes a material guide for directing a supply of working material and a plurality of rollers for advancing the working material. An electromagnetic heater is provided to heat and deposit molten working material as a new supply of working material is forced through the material guide.

Abstract: A composite Si-carbon fiber comprising a carbon matrix material with 1-90 wt % silicon embedded therein. The composite carbon fibers are incorporated into electrodes for batteries. The battery can be a lithium ion battery. A method of making an electrode incorporating composite Si-carbon fibers is also disclosed.

Abstract: Disclosed herein is a method comprising disposing a container containing a metal and/or ferromagnetic solid and abrasive particles in a static magnetic field; where the container is surrounded by an induction coil; activating the induction coil with an electrical current, to heat up the metallic or ferromagnetic solid to form a fluid; generating sonic energy to produce acoustic cavitation and abrasion between the abrasive particles and the container; and producing nanoparticles that comprise elements from the container, the metal and/or the ferromagnetic solid and the abrasive particles. Disclosed herein too is a composition comprising first metal or a first ceramic; and particles comprising carbides and/or nitrides dispersed therein. Disclosed herein too is a composition comprising nanoparticles comprising chromium carbide, iron carbide, nickel carbide, ?-Fe and magnesium nickel.

Abstract: Disclosed herein is a method comprising disposing a container containing a metal and/or ferromagnetic solid and abrasive particles in a static magnetic field; where the container is surrounded by an induction coil; activating the induction coil with an electrical current, to heat up the metallic or ferromagnetic solid to form a fluid; generating sonic energy to produce acoustic cavitation and abrasion between the abrasive particles and the container; and producing nanoparticles that comprise elements from the container, the metal and/or the ferromagnetic solid and the abrasive particles. Disclosed herein too is a composition comprising first metal or a first ceramic; and particles comprising carbides and/or nitrides dispersed therein. Disclosed herein too is a composition comprising nanoparticles comprising chromium carbide, iron carbide, nickel carbide, ?-Fe and magnesium nitride.

Abstract: Embodiments of surface-hardened aluminum-rare earth alloys and methods of making the alloys are disclosed. In some embodiments, the alloy comprises aluminum and 4 wt % to 60 wt % of a rare earth component X having a maximum solid solubility of ?0.5 wt % in aluminum. The surface-hardened alloy component has an alloy bulk portion and a hardened alloy surface portion. At least a portion of the hardened alloy surface portion has a Vickers hardness that is at least 30% greater than a Vickers hardness of the alloy bulk portion.

Abstract: A bulk high performance permanent magnet comprising a neodymium-iron-boron core having an outer surface, and a coercivity-enhancing element residing on at least a portion of said outer surface, with an interior portion of said neodymium-iron-boron core not having said coercivity-enhancing element therein. Also described herein is a method for producing the high-coercivity bulk permanent magnet, the method comprising: (i) depositing a coercivity-enhancing element on at least a portion of an outer surface of a neodymium-iron-boron core substrate to form a coated permanent magnet; and (ii) subjecting the coated permanent magnet to a pulse thermal process that heats said outer surface to a substantially higher temperature than an interior portion of said neodymium-iron-boron core substrate, wherein said substantially higher temperature is at least 200° C.

Abstract: A method and apparatus for additive manufacturing that includes a material guide for directing a supply of working material. An advancement mechanism comprising one or more pistons, pushers, plungers and/or pressure regulation systems are positioned behind at least a portion of the supply of working material for advancing the working material forward. The working material is heated using an electro-magnetic heating element and the melted or molten working material is deposited from a tip positioned at an end of the material guide.

Abstract: Disclosed herein is a method comprising disposing a container containing a metal and/or ferromagnetic solid and abrasive particles in a static magnetic field; where the container is surrounded by an induction coil; activating the induction coil with an electrical current, to heat up the metallic or ferromagnetic solid to form a fluid; generating sonic energy to produce acoustic cavitation and abrasion between the abrasive particles and the container; and producing nanoparticles that comprise elements from the container, the metal and/or the ferromagnetic solid and the abrasive particles. Disclosed herein too is a composition comprising first metal or a first ceramic; and particles comprising carbides and/or nitrides dispersed therein. Disclosed herein too is a composition comprising nanoparticles comprising chromium carbide, iron carbide, nickel carbide, ?-Fe and magnesium nitride.

Abstract: Described herein are liquid crystalline elastomer compositions comprising aromatic epoxy units crosslinked with alkylene diacid units having alkylene segments containing at least one methylene unit, and/or aromatic epoxy units crosslinked with polyphenolic units, wherein the aromatic epoxy units and alkylene diacid units and/or polyphenolic units are in a molar ratio that results in the liquid crystalline elastomer composition exhibiting a glass transition temperature (Tg) and a thermal stability of the liquid crystalline phase (Tlc) that make them particularly suitable as shape memory materials and for use in methods of additive manufacturing. Methods for producing these compositions and their use in additive manufacturing processes are also described.

Abstract: Disclosed herein is a method comprising disposing a container containing a metal and/or ferromagnetic solid and abrasive particles in a static magnetic field; where the container is surrounded by an induction coil; activating the induction coil with an electrical current, to heat up the metallic or ferromagnetic solid to form a fluid; generating sonic energy to produce acoustic cavitation and abrasion between the abrasive particles and the container; and producing nanoparticles that comprise elements from the container, the metal and/or the ferromagnetic solid and the abrasive particles. Disclosed herein too is a composition comprising first metal or a first ceramic; and particles comprising carbides and/or nitrides dispersed therein. Disclosed herein too is a composition comprising nanoparticles comprising chromium carbide, iron carbide, nickel carbide, y.-Fe and magnesium nitride.

Abstract: A solid aluminum-fiber composite comprising: (i) an aluminum-containing matrix comprising elemental aluminum; (ii) coated or uncoated fibers embedded within said aluminum-containing matrix, wherein said fibers have a different composition than said aluminum-containing matrix and impart additional strength to said aluminum-containing matrix as compared to said aluminum-containing matrix in the absence of said fibers embedded therein; and (iii) an intermetallic layer present as an interface between each of said fibers and the aluminum-containing matrix, wherein said intermetallic layer has a composition different from said aluminum-containing matrix and said fibers, and said intermetallic layer contains at least one element that is also present in the aluminum-containing matrix and at least one element present in the fibers, whether from the coated or interior portion of the fibers. Methods of producing the above-described composite are also described.

Abstract: Liquid crystalline network compositions comprising azo-containing aromatic epoxy units cross-linked with alkylene diacid units having alkylene segments containing at least one methylene unit, wherein the azo-containing aromatic epoxy units and alkylene diacid units are connected by ester linkages resulting from ring-opening esterification between the epoxy units and alkylene diacids, and wherein the azo-containing aromatic epoxy units and alkylene diacid units are in a molar ratio that results in the liquid crystalline network composition exhibiting a glass transition temperature (Tg) of at least 25° C. Methods for producing these compositions and their use in light- or thermal-activated physical deformation, shape memory applications, and self-healing, as well as their ability to be recycled and used in additive manufacturing processes are also described.

Abstract: Disclosed herein are embodiments of aluminum-based alloys having improved intergranular corrosion resistance. Methods of making and using the disclosed alloy embodiments also are disclosed herein.

Abstract: An electrode and a related method of manufacture are provided. The electrode includes a self-aligning active material having short fiber powders with a cylindrical morphology to increase the packing density from 0.74 to nearly 0.91. The short fiber powders self-align during a slurring coating process as a result of shear forces between a die and a foil. The resulting coating includes parallel short fibers in a closed packed arrangement, providing an increased volumetric capacity of at least approximately 17%.

Abstract: A method and apparatus for additive manufacturing that includes a nozzle and/or barrel for extruding a plastic material and a supply of polymeric working material provided to the nozzle, wherein the polymeric working material is magnetically susceptible and/or electrically conductive. A magneto-dynamic heater is provided for producing a time varying, high flux, frequency sweeping, alternating magnetic field in the vicinity of the nozzle to penetrate into and couple the working material to heat the material through at least one of an induced transient magnetic domain and an induced, annular current.

Abstract: A magnetic ink composition for three-dimensional (3D) printing a bonded magnet is provided. The magnetic ink composition includes magnetic particles, a polymer binder and a solvent. A 3D printing method for fabrication of a bonded magnet using the magnetic ink composition is also provided.

Abstract: Disclosed herein are embodiments of rapidly solidified alloys that comprise aluminum, a rare earth element, one or more additional alloying elements, such as aluminum, and an optional additive component. The alloy embodiments exhibit a unique microstructure as compared to microstructures obtained from other alloys that are not rapidly cooled. The disclosed aluminum-rare earth element alloys also exhibit improved mechanical properties without the need for post-processing heat treatments and further do not exhibit substantial coarsening.

Abstract: A method of thermomagnetically processing an aluminum alloy entails heat treating an aluminum alloy, and applying a high field strength magnetic field of at least about 2 Tesla to the aluminum alloy during the heat treating. The heat treating and the application of the high field strength magnetic field are carried out for a treatment time sufficient to achieve a predetermined standard strength of the aluminum alloy, and the treatment time is reduced by at least about 50% compared to heat treating the aluminum alloy without the magnetic field.

Abstract: A method for producing a bonded permanent magnet, comprising: (i) incorporating a solid precursor material comprising a thermoplastic crosslinkable polymer and magnetic particles into an additive manufacturing device, wherein the crosslinkable polymer has a delayed crosslinking ability; (ii) melting the precursor material by heating it to a temperature of at least and no more than 10° C. above its glass transition temperature; (iii) extruding the melt through the additive manufacturing device and, as the extrudate exits from the nozzle and is deposited on a substrate as a solidified preform of a desired shape, exposing the resultant extrudate to a directional magnetic field of sufficient strength to align the magnetic particles; and (iv) curing the solidified preform by subjecting it to conditions that result in crosslinking of the thermoplastic crosslinkable polymer to convert it to a crosslinked thermoset. The resulting bonded permanent magnet and articles made thereof are also described.

Abstract: A method for producing a bonded permanent magnet by additive manufacturing, the method comprising: (i) incorporating components of a reactive precursor material into an additive manufacturing device, the reactive precursor material comprising an amine component, an isocyanate component, and particles having a permanent magnetic composition; and (ii) mixing and extruding the crosslinkable reactive precursor material through a nozzle of the additive manufacturing device and depositing the extrudate onto a substrate under conditions where the extrudate is permitted to cure, to produce a bonded permanent magnet of desired shape. The resulting bonded permanent magnet and articles made thereof are also described.