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: A method may include annealing a material including iron and nitrogen in the presence of an applied magnetic field to form at least one Fe16N2 phase domain. The applied magnetic field may have a strength of at least about 0.2 Tesla (T).

Abstract: A cast alloy includes aluminum and from about 5 to about 30 weight percent of at least one material selected from the group consisting of cerium, lanthanum, and mischmetal. The cast alloy has a strengthening Al11X3 intermetallic phase in an amount in the range of from about 5 to about 30 weight percent, wherein X is at least one of cerium, lanthanum, and mischmetal. The Al11X3 intermetallic phase has a microstructure that includes at least one of lath features and rod morphological features. The morphological features have an average thickness of no more than 700 um and an average spacing of no more than 10 um, the microstructure further comprising an eutectic microconstituent that comprises more than about 10 volume percent of the microstructure.

Abstract: A method for producing magnet-polymer pellets useful as a feedstock in an additive manufacturing process, comprising: (i) blending thermoplastic polymer and hard magnetic particles; (ii) feeding the blended magnet-polymer mixture into a pre-feed hopper that feeds directly into an inlet of a temperature-controlled barrel extruder; (iii) feeding the blended magnet-polymer mixture into the barrel extruder at a fixed feed rate of 5-20 kg/hour, wherein the temperature at the outlet is at least to no more than 10° C. above a glass transition temperature of the blended magnet-polymer mixture; (iv) feeding the blended magnet-polymer mixture directly into an extruding die; (v) passing the blended magnet-polymer mixture through the extruding die at a fixed speed; and (vi) cutting the magnet-polymer mixture at regular intervals as the mixture exits the extruding die at the fixed speed. The use of the pellets as feed material in an additive manufacturing process is also described.

Abstract: A method for producing a bonded permanent magnet by additive manufacturing, comprising: (i) incorporating components of a solid precursor material into at least one deposition head of at least one multi-axis robotic arm of a big area additive manufacturing (BAAM) system, the components of the solid precursor material comprising a thermoplastic polymer and hard magnetic powder; said deposition head performs melting, compounding, and extruding functions; and said BAAM system has an unbounded open-air build space; and (ii) depositing an extrudate of said solid precursor material layer-by-layer from said deposition head until an object constructed of said extrudate is formed, and allowing the extrudate to cool and harden after each deposition, to produce the bonded permanent magnet. The resulting bonded permanent magnet and articles made thereof are also described.

Abstract: A method may include annealing a material including iron and nitrogen in the presence of an applied magnetic field to form at least one Fe16N2 phase domain. The applied magnetic field may have a strength of at least about 0.2 Tesla (T).

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: 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: Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.

Abstract: An example apparatus can comprise an emitter to emit radio frequency radiation, an absorber that changes temperature based on emissions from the emitter, and one or more sensors to measure a temperature difference between a sample and a reference coupled to the absorber.

Abstract: A magneto-energy apparatus includes an electromagnetic field source for generating a time-varying electromagnetic field. A graphite foam conductor is disposed within the electromagnetic field. The graphite foam when exposed to the time-varying electromagnetic field conducts an induced electric current, the electric current heating the graphite foam to produce light. An energy conversion device utilizes light energy from the heated graphite foam to perform a light energy consuming function. A device for producing light and a method of converting energy are also disclosed.

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 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: A method and apparatus for additive manufacturing that includes a material guide for directing a supply of working material. An electro-magnetic heater is provided to heat and deposit molten working material as a new supply of working material is forced through the material guide. A single or twin screw extruder is provided within for advancing, mixing and/or depositing the working material through a tip positioned at an end of the material guide.

Abstract: An alloy for structural direct-writing additive manufacturing comprising a base element selected from the group consisting of aluminum (Al), nickel (Ni) and a combination thereof, and a rare earth element selected from the group consisting of cerium (Ce), lanthanide (La) and a combination thereof, and a eutectic intermetallic present in said alloy in an amount ranging from about 0.5 wt. % to 7.5 wt. %. The invention is also directed to a method of structural direct-write additive manufacturing using the above-described alloy, as well as 3D objects produced by the method. The invention is also directed to methods of producing the above-described alloy.

Abstract: Methods of printing a three-dimensional object using co-reactive components are disclosed. Thermosetting compositions for three-dimensional printing are also enclosed.

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: A magneto-energy apparatus includes an electromagnetic field source for generating a time-varying electromagnetic field. A graphite foam conductor is disposed within the electromagnetic field. The graphite foam when exposed to the time-varying electromagnetic field conducts an induced electric current, the electric current heating the graphite foam. An energy conversion device utilizes heat energy from the heated graphite foam to perform a heat energy consuming function. A device for heating a fluid and a method of converting energy are also disclosed.

Abstract: A method for producing a carbon fiber, the method comprising: (i) subjecting a continuous carbon fiber precursor having a polymeric matrix in which strength-enhancing particles are incorporated to a stabilization process during which the carbon fiber precursor is heated to within a temperature range ranging from the glass transition temperature to no less than 20° C. below the glass transition temperature of the polymeric matrix, wherein the maximum temperature employed in the stabilization process is below 400° C., for a processing time within said temperature range of at least 1 hour in the presence of oxygen and in the presence of a magnetic field of at least 1 Tesla, while said carbon fiber precursor is held under an applied axial tension; and (ii) subjecting the stabilized carbon fiber precursor, following step (i), to a carbonization process. The stabilized carbon fiber precursor, resulting carbon fiber, and articles made thereof are also described.

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.