Abstract: Material treatment is effected in a treatment region by at least two energy sources, such as (i) an atmospheric pressure (AP) plasma and (ii) an ultraviolet (UV) laser directed into the plasma and optionally onto the material being treated. During processing, the material being treated may remain substantially at room temperature. Precursor materials may be dispensed before, and finishing material may be dispensed after treatment. Precursors may be combined in the plasma, allowing for in situ synthesis and dry treatment of the material. Electrodes (e1, e2) for generating the plasma may comprise two spaced-apart rollers which, when rotating, advance the material through a treatment region. Nip rollers adjacent the electrode rollers define a semi-airtight cavity, and may have a metallic outer layer. Loose fibers and fragile membranes may be supported on a carrier membrane, which may be doped. Individual fibers may be processed. Electrostatic deposition may be performed. Topographical changes may be effected.

Abstract: Material treatment is effected in a treatment region by at least two energy sources, such as (i) an atmospheric pressure plasma and (ii) an ultraviolet laser directed into the plasma and optionally onto the material being treated. Precursor materials may be dispensed before, and finishing material may be dispensed after treatment. Electrodes for generating the plasma may comprise two spaced-apart rollers. Nip rollers adjacent the electrode rollers define a semi-airtight cavity, and may have a metallic outer layer.

Abstract: Material treatment is effected in a treatment region by at least two energy sources, such as (i) an atmospheric pressure (AP) plasma and (ii) an ultraviolet (UV) laser directed into the plasma and optionally onto the material being treated. During processing, the material being treated may remain substantially at room temperature. Precursor materials may be dispensed before, and finishing material may be dispensed after treatment. Precursors may be combined in the plasma, allowing for in situ synthesis and dry treatment of the material. Electrodes (e1, e2) for generating the plasma may comprise two spaced-apart rollers which, when rotating, advance the material through a treatment region. Nip rollers adjacent the electrode rollers define a semi-airtight cavity, and may have a metallic outer layer. Loose fibers and fragile membranes may be supported on a carrier membrane, which may be doped. Individual fibers may be processed. Electrostatic deposition may be performed. Topographical changes may be effected.

Abstract: Material treatment is effected in a treatment region by at least two energy sources, such as (i) an atmospheric pressure plasma and (ii) an ultraviolet laser directed into the plasma and optionally onto the material being treated. Precursor materials may be dispensed before, and finishing material may be dispensed after treatment. Electrodes for generating the plasma may comprise two spaced-apart rollers. Nip rollers adjacent the electrode rollers define a semi-airtight cavity, and may have a metallic outer layer.

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: 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: Diamond materials are formed by sandwiching a carbon-containing material in a gap between two electrodes. A high-amperage electric current is applied between the two electrode plates so as cause rapid-heating of the carbon-containing material. The current is sufficient to cause heating of the carbon-containing material at a rate of at least approximately 5,000.degree. C./sec, and need only be applied for a fraction of a second to elevate the temperature of the carbon-containing material at least approximately 1000.degree. C. Upon terminating the current, the carbon-containing material is subjected to rapid-quenching (cooling). This may take the form of placing one or more of the electrodes in contact with a heat sink, such as a large steel table. The carbon-containing material may be rapidly-heated and rapidly-quenched (RHRQ) repeatedly (e.g., in cycles), until a diamond material is fabricated from the carbon-containing material.

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: 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: 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: Diamond materials are formed by sandwiching a carbon-containing material in a gap between two electrodes. A high-amperage electric current is applied between the two electrode plates so as cause rapid-heating of the carbon-containing material. The current is sufficient to cause heating of the carbon-containing material at a rate of at least approximately 5,000.degree. C./sec, and need only be applied for a fraction of a second to elevate the temperature of the carbon-containing material at least approximately 1000.degree. C. Upon terminating the current, the carbon-containing material is subjected to rapid-quenching (cooling). This may take the form of placing one or more of the electrodes in contact with a heat sink, such as a large steel table. The carbon-containing material may be rapidly-heated and rapidly-quenched (RHRQ) repeatedly (e.g., in cycles), until a diamond material is fabricated from the carbon-containing material.

Abstract: A wall ironing ring (8, 11, 14) for use in cooperation with a punch (1) to reduce the thickness of a sidewall of a cup (17) drawn from a laminate of a polyester film and sheet aluminum or sheet aluminum alloy has a frusto conical entry surface (24) to the ring which converges at an angle between 1.degree. and 4.degree. to a central axis perpendicular to the plane of the ring and terminates at a land of short length, measured at said axis; and divergent exit surface extends from said land at an angle in the range from 5.degree. to 15.degree.. The ironing ring may be made from a material having a thermal conductivity greater than 50 W/m.degree.C. used in cooperation with a like ring of smaller land diameter held apart from the first ring by a spacer (7) in which coolant is applied to the cup.

Abstract: In a method of joining a metal matrix composite (cermet) or ceramic tool material 1 to a metallic holder 2 by diffusion bonding through an intermediate metallic layer, the tool material 1 includes at least one carbide, nitride or boride in the matrix. In one example, the tool material includes titanium carbide and titanium nitride in the metal matrix. The intermediate metallic layer is chosen from a group consisting of nickel, titanium and tungsten. The tool holder metal 2 is a ferrous alloy. The intermediate metallic layer is placed between the tool material and the metallic holder, and heat and pressure are applied for a controlled period to diffusion bond the tool material to the metallic holder. Articles made by the method include a blank holder, a punch, a die and various wear surfaces of a continuous extrusion apparatus.