Abstract: The present invention provides strategies for making high quality CIGS photoabsorbing materials from precursor films that incorporate a sub-stoichiometric amount of chalcogen(s). Chalcogen(s) are incorporated into the CIGS precursor film via co-sputtering with one or more other constituents of the precursor. Optional annealing also may be practiced to convert precursor into more desirable chalcopyrite crystalline form in event all or a portion of the precursor has another constitution. The resultant precursors generally are sub-stoichiometric with respect to chalcogen and have very poor electronic characteristics. The conversion of these precursors into CIGS photoabsorbing material via chalcogenizing treatment occurs with dramatically reduced interfacial void content. The resultant CIGS material displays excellent adhesion to other layers in the resultant photovoltaic devices.

Abstract: The present invention provides strategies for making high quality CIGS photoabsorbing materials from precursor films that incorporate a sub-stoichiometric amount of chalcogen(s). Chalcogen(s) are incorporated into the CIGS precursor film via co-sputtering with one or more other constituents of the precursor. Optional annealing also may be practiced to convert precursor into more desirable chalcopyrite crystalline form in event all or a portion of the precursor has another constitution. The resultant precursors generally are sub-stoichiometric with respect to chalcogen and have very poor electronic characteristics. The conversion of these precursors into CIGS photoabsorbing material via chalcogenizing treatment occurs with dramatically reduced interfacial void content. The resultant CIGS material displays excellent adhesion to other layers in the resultant photovoltaic devices.

Abstract: The present invention provides strategies for making high quality CIGS photoabsorbing materials from precursor films that incorporate a sub-stoichiometric amount of chalcogen(s). Chalcogen(s) are incorporated into the CIGS precursor film via co-sputtering with one or more other constituents of the precursor. Optional annealing also may be practiced to convert precursor into more desirable chalcopyrite crystalline form in event all or a portion of the precursor has another constitution. The resultant precursors generally are sub-stoichiometric with respect to chalcogen and have very poor electronic characteristics. The conversion of these precursors into CIGS photoabsorbing material via chalcogenizing treatment occurs with dramatically reduced interfacial void content. The resultant CIGS material displays excellent adhesion to other layers in the resultant photovoltaic devices.

Abstract: The present invention provides strategies for making high quality CIGS photoabsorbing materials from precursor films that incorporate a sub-stoichiometric amount of chalcogen(s). Chalcogen(s) are incorporated into the CIGS precursor film via co-sputtering with one or more other constituents of the precursor. Optional annealing also may be practiced to convert precursor into more desirable chalcopyrite crystalline form in event all or a portion of the precursor has another constitution. The resultant precursors generally are sub-stoichiometric with respect to chalcogen and have very poor electronic characteristics. The conversion of these precursors into CMS photoabsorbing material via chalcogenizing treatment occurs with dramatically reduced interfacial void content. The resultant CIGS material displays excellent adhesion to other layers in the resultant photovoltaic devices.

Abstract: A ceramic honeycomb filter having improved thermal shock resistance is comprised of a ceramic honeycomb filter that has a heat absorbing material that undergoes a reversible phase change that absorbs at least in part the heat energy, for example, arising from the combustion of Diesel soot entrapped in the filter.

Abstract: The present invention provides strategies for making high quality CIGS photoabsorbing compositions from sputtered precursor film(s). The precursors are converted into CIGS photoabsorbing material via a chalcogenizing treatment (also referred to as “post-chalcogenization,” including, e.g., “post-selenization” when Se is used and/or “post-sulfurization” when S is used) using techniques that allow the post-chalcogenizing treatment to occur under atypically low pressure conditions. Consequently, the strategies of the invention are readily incorporated into batch processes or continuous processes such as roll-to-roll process occurring under vacuum. The present invention is useful at lab, pilot plant, and industrial scales.

Abstract: The present invention provides strategies for making high quality CIGS photoabsorbing materials from precursor films that incorporate a sub-stoichiometric amount of chalcogen(s). Chalcogen(s) are incorporated into the CIGS precursor film via co-sputtering with one or more other constituents of the precursor. Optional annealing also may be practiced to convert precursor into more desirable chalcopyrite crystalline form in event all or a portion of the precursor has another constitution. The resultant precursors generally are sub-stoichiometric with respect to chalcogen and have very poor electronic characteristics. The conversion of these precursors into CMS photoabsorbing material via chalcogenizing treatment occurs with dramatically reduced interfacial void content. The resultant CIGS material displays excellent adhesion to other layers in the resultant photovoltaic devices.

Abstract: An improved soot catalyst is comprised of an alkali compound at least partially coated by a ceramic coating comprised of C bonded to a metal, semimetallic element or combination thereof. The improved soot catalyst may be employed in catalyzed Diesel particulate filters. In one method to make a catalyzed Diesel particulate filter, the improved filter is made by contacting a porous ceramic body having an alkali catalyst thereon, coating the alkali catalyst with an organic ceramic precursor, heating the ceramic body to a temperature in an atmosphere sufficient to decompose the organic ceramic precursor to form the soot catalyst on the porous ceramic body without volatilizing substantial amount of the alkali catalyst away.

Abstract: An improved soot catalyst is comprised of an alkali compound at least partially coated by a ceramic coating comprised of C bonded to a metal, semimetallic element or combination thereof. The improved soot catalyst may be employed in catalyzed Diesel particulate filters. In one method to make a catalyzed Diesel particulate filter, the improved filter is made by contacting a porous ceramic body having an alkali catalyst thereon, coating the alkali catalyst with an organic ceramic precursor, heating the ceramic body to a temperature in an atmosphere sufficient to decompose the organic ceramic precursor to form the soot catalyst on the porous ceramic body without volatilizing substantial amount of the alkali catalyst away.

Abstract: A porous mullite composition is made by Forming a mixture of one or more precursor compounds having the elements present in mullite (e.g., clay, alumina, silica) and a property enhancing compound. The property enhancing compound is a compound having an element selected from the group consisting of Mg, Ca, Fe, Na, K, Ce, Pr, Nd, Sm, Eu, Gd, Th, Dy, Ho, Er, Tm, Yb, Lu, B, Y, Sc, La and combination thereof. The mixture is shaped and to form a porous green shape which is heated under an atmosphere having a fluorine containing gas to a temperature sufficient to form a mullite composition comprised substantially of acicular mullite grains that are essentially chemically bound.

Abstract: A ceramic honeycomb filter having improved thermal shock resistance is comprised of a ceramic honeycomb filter that has a heat absorbing material that undergoes a reversible phase change that absorbs at least in part the heat energy, for example, arising from the combustion of Diesel soot entrapped in the filter.

Abstract: A porous mullite composition is made by forming a mixture of one or more precursor compounds having the elements present in mullite (e.g., clay, alumina, silica) and a property enhancing compound. The property enhancing compound is a compound having an element selected from the group consisting of Mg, Ca, Fe, Na, K, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, B, Y, Sc, La and combination thereof. The mixture is shaped and to form a porous green shape which is heated under an atmosphere having a fluorine containing gas to a temperature sufficient to form a mullite composition comprised substantially of acicular mullite grains that are essentially chemically bound.

Abstract: A porous ceramic body having increased strength is formed by exposing a porous ceramic body to a source of boron and heating the porous body to a sufficient temperature in an oxygen containing atmosphere to form the porous ceramic body. The porous ceramic body has a boron containing oxide glassy phase on at least a portion of the ceramic grains of the porous ceramic body.

Abstract: A porous ceramic body having increased strength is formed by exposing a porous ceramic body to a source of boron and heating the porous body to a sufficient temperature in an oxygen containing atmosphere to form the porous ceramic body. The porous ceramic body has a boron containing oxide glassy phase on at least a portion of the ceramic grains of the porous ceramic body.

Abstract: A consolidated complex shaped article having a density of at least about 95 percent of theoretical density is prepared by placing a plurality of separate bodies in an arrangement, such that each separate body is in contact with at least one other separate body to form an aggregate body and wherein at least one of the separate bodies is essentially dense. The material of each separate body is comprised of a ceramic, a cermet or a metal. The aggregate body is then consolidated at a consolidating temperature, superatmospheric pressure and time at temperature and time at superatmospheric pressure sufficient to form a consolidated shaped article. In consolidating the aggregate body, the consolidating temperature is a temperature that fails to form a liquid within at least one separate body and the superatmospheric temperature is applied for at least a portion of the time at the consolidating temperature.

Abstract: A consolidated complex shaped article having a density of at least about 95 percent of theoretical density is prepared by placing a plurality of separate bodies in an arrangement, such that each separate body is in contact with at least one other separate body to form an aggregate body and wherein at least one of the separate bodies is essentially dense. The material of each separate body is comprised of a ceramic, a cermet or a metal. The aggregate body is then consolidated at a consolidating temperature, superatmospheric pressure and time at temperature and time at superatmospheric pressure sufficient to form a consolidated shaped article. In consolidating the aggregate body, the consolidating temperature is a temperature that fails to form a liquid within at least one separate body and the superatmospheric temperature is applied for at least a portion of the time at the consolidating temperature.

Abstract: A consolidated complex shaped article having a density of at least about 95 percent of theoretical density is prepared by placing a plurality of separate bodies in an arrangement, such that each separate body is in contact with at least one other separate body to form an aggregate body and wherein at least one of the separate bodies is essentially dense. The material of each separate body is comprised of a ceramic, a cermet or a metal. The aggregate body is then consolidated at a consolidating temperature, superatmospheric pressure and time at temperature and time at superatmospheric pressure sufficient to form a consolidated shaped article. In consolidating the aggregate body, the consolidating temperature is a temperature that fails to form a liquid within at least one separate body and the superatmospheric temperature is applied for at least a portion of the time at the consolidating temperature.

Abstract: A process for preparing complex-shaped, ceramic-metal composite articles, comprising: (a) contacting a non-wettable powder that is non-wetting to a metal to be used for infiltration with a shaped ceramic body to form a layer of the non-wettable powder on one or more surfaces of the shaped ceramic body, wherein the shaped ceramic body has a region where there is no layer of the non-wettable powder, and (b) infiltration the shaped ceramic body with the metal through the region or regions where there is no layer of the non-wettable powder, such that a complex-shaped ceramic-metal composite comprising one or more metal phases and one or more ceramic phases is formed, wherein the article has substantially the net shape of the shaped ceramic body and undesirable regions of excess metal on the surface and undesirable phases within the complex-shaped ceramic-metal composite article near the surface are located only in the region or regions where there is no layer of the non-wettable powder.

Abstract: A process for preparing complex-shaped, ceramic-metal composite articles, comprising:a) contacting a non-wettable powder that is non-wetting to a metal to be used for infiltration with a shaped ceramic body to form a layer(s) of the non-wettable powder on one or more surface(s) of the shaped ceramic body wherein the shaped ceramic body has a region(s) where there is no layer of the non-wettable powder;b) infiltrating the shaped ceramic body with the metal through the region(s) where there is no layer of the non-wettable powder such that a complex-shaped ceramic-metal composite comprising one or more metal phases and one or more ceramic phases is formed, wherein the article has substantially the net shape of the shaped ceramic body and the undesirable regions of excess metal on the surface and undesirable phases within the complex-shaped ceramic-metal composite article near the surface are located only in the region(s) where there is no layer of the non-wettable powder.

Abstract: A cemented tungsten carbide body having a transition metal binder phase selected from the group consisting of iron, nickel and cobalt is formed, wherein the WC grains have an average WC grain size of at most about 0.5 micrometer in diameter and a maximum WC grain size of at most about 0.8 micrometer in diameter. Also, about 50 percent by volume of the WC grains in the body are angular grains and the body (1) contains an amount of the transition metal ranging from about 3 percent to about 18 percent by weight of the body, (2) is essentially free of grain growth inhibitors and (3) is essentially pore free.