Abstract: The present invention is directed to the synthesis of metallic nickel-molybdenum-tungsten films and coatings with direct current sputter deposition, which results in fully-dense crystallographically textured films that are filled with nano-scale faults and twins. The as-deposited films exhibit linear-elastic mechanical behavior and tensile strengths above 2.5 GPa, which is unprecedented for materials that are compatible with wafer-level device fabrication processes. The ultra-high strength is attributed to a combination of solid solution strengthening and the presence of the dense nano-scale faults and twins. These films also possess excellent thermal and mechanical stability, high density, low CTE, and electrical properties that are attractive for next generation metal MEMS applications. Deposited as coatings these films provide protection against friction and wear.

Abstract: A spectral imaging system includes an objective lens system, an optical splitter, a dispersion system, and an optical combiner. The optical splitter is arranged to be in an optical path of an object being imaged through the objective lens system to provide an imaging optical path and a spectrometer optical path. The dispersion system is arranged in the spectrometer optical path. The optical combiner is arranged in the imaging optical path and a path of dispersed light from the dispersion system to combined dispersed light with a corresponding optical image of the object.

Abstract: The present invention is directed to a manifold for directing cooling fluid and/or gas to a heat exchanger in a flow configuration designed to optimize heat transfer from the heat exchanger. The manifold can take many different forms such as a layered construction with distributed inlet paths, local outlet paths, a central collection changer and a path for fluid removal. The manifold can be formed from a metal, plastic, rubber, ceramic, or other heat resistant material known to or conceivable by one of skill in the art. The manifold can also be combined with any type of heat exchanger known to or conceivable by one of skill in the art to form a thermal management unit. To optimize overall properties such as low pressure drop, high heat transfer, and excellent temperature uniformity of the thermal management unit, the manifold can be graded, expanded and scaled as needed.

Abstract: The present invention is directed to devices formed from three dimensional (3D) structures composed of wires, yarns of wires, or 3D printed structures. The devices of the present invention offer the potential for 3D structures with multiple properties optimized concurrently, using optimization within the 3D manufacturing constraints. The 3D structures of the present invention include multiple properties that are optimized for heat transfer applications. The present invention also includes the methods for optimization of the 3D woven lattices as well as methods of use of the 3D woven lattices in heat transfer applications.

Abstract: The present invention is directed to embodiments of reactive material (RM) and an associated chemical time delay that includes an RM, according to an embodiment of the present invention. One embodiment includes a delay material that is an RM patterned on a substrate using lithographic techniques. Another embodiment includes a delay material that is an RM deposited on a patterned substrate such as a mesh. The present invention also includes a chemical time delay that includes either embodiment of the delay material, or any variation on the delay material that would be known to or conceivable to one of skill in the art.

Abstract: The present invention is directed to the synthesis of metallic nickel-molybdenum-tungsten films and coatings with direct current sputter deposition, which results in fully-dense crystallographically textured films that are filled with nano-scale faults and twins. The as-deposited films exhibit linear-elastic mechanical behavior and tensile strengths above 2.5 GPa, which is unprecedented for materials that are compatible with wafer-level device fabrication processes. The ultra-high strength is attributed to a combination of solid solution strengthening and the presence of the dense nano-scale faults and twins. These films also possess excellent thermal and mechanical stability, high density, low CTE, and electrical properties that are attractive for next generation metal MEMS applications. Deposited as coatings these films provide protection against friction and wear.

Abstract: The present invention is directed to three dimensional weaves composed of wires or yarns that offer the potential for damping not achievable with solid materials, including high temperature damping. Three damping mechanisms have been identified: (1) Internal material damping, (2) Frictional energy dissipation (Coulomb damping), and (3) inertial damping (tuned mass damping). These three damping mechanisms can be optimized by modifying the wire material chemistries (metals, ceramics, polymers, etc.), wire sizes, wire shapes, wire coatings, wire bonding, and wire architecture (by removing certain wires). These have the effect of modifying the lattice and wire stiffnesses, masses, coefficients of friction, and internal material damping. Different materials can be used at different locations in the woven lattice. These design variables can also be modified to tailor mechanical stiffness and strength of the lattice, in addition to damping.

Abstract: A method of producing a reactive powder includes providing a bulk structure of reactive material comprising a first reactant and a second reactant, the bulk structure having a preselected average spacing between the first and the second reactants; and mechanically processing the bulk structure of reactive material to produce a plurality of particles from the bulk structure such that each of the plurality of particles comprises the first and second reactants having an average spacing that is substantially equal to the preselected average spacing of the bulk structure of reactive material. The first and second materials of the plurality of particles react with each other in an exothermic reaction upon being exposed to a threshold energy to initiate the exothermic reaction and remain substantially stable without reacting with each other prior to being exposed to the threshold energy.

Abstract: The present invention is directed to composite particles that react with a small and adjustable input energy. The ignition threshold depends primarily upon reactant spacing and chemistry, not overall particle size. Combustion properties, such as burn duration and temperature, are controlled by adjusting particle size or reactant composition. The best performance is achieved by selecting reactants with strong intermetallic formation reaction and that combust in different phases (condensed vs gaseous). These particles are fabricated by various methods, including physical vapor deposition, or ball milling. The concept of purposefully decoupling ignition and combustion properties by fabricating particles where ignition is determined by reactant spacing and/or composition and combustion is determined by adjusting particle size and/or composition is described. Combinations of specific reactants, such as Al, Zr, Ti, Mo, Mg, B, Li, etc.

Abstract: The present invention is directed to embodiments of reactive material (RM) and an associated chemical time delay that includes an RM, according to an embodiment of the present invention. One embodiment includes a delay material that is an RM patterned on a substrate using lithographic techniques. Another embodiment includes a delay material that is an RM deposited on a patterned substrate such as a mesh. The present invention also includes a chemical time delay that includes either embodiment of the delay material, or any variation on the delay material that would be known to or conceivable to one of skill in the art.

Abstract: A reactive composite foil, including metallic fuel particles, oxidizer particles, and a diluent, which, when ignited, produces a self-propagating thermite reaction to produce a molten metal.

Abstract: The present invention is directed to three dimensional weaves composed of wires or yarns that offer the potential for damping not achievable with solid materials, including high temperature damping. Three damping mechanisms have been identified: (1) Internal material damping, (2) Frictional energy dissipation (Coulomb damping), and (3) inertial damping (tuned mass damping). These three damping mechanisms can be optimized by modifying the wire material chemistries (metals, ceramics, polymers, etc.), wire sizes, wire shapes, wire coatings, wire bonding, and wire architecture (by removing certain wires). These have the effect of modifying the lattice and wire stiffnesses, masses, coefficients of friction, and internal material damping. Different materials can be used at different locations in the woven lattice. These design variables can also be modified to tailor mechanical stiffness and strength of the lattice, in addition to damping.

Abstract: The present invention is directed to devices formed from three-dimensional (3D) structures composed of metallic, ceramic or polymeric wires or bundles and yarns of wires that are either solid or hollow like a tube. The devices of the present invention offer the potential for 3D structures with multiple properties optimized concurrently, in some cases using a topology optimization routine that includes the 3D manufacturing constraints. The properties can be optimized in different directions. The 3D structures of the present invention include multiple properties that are optimized for a range of different applications, including heat transfer. The present invention also includes the methods for optimization of the 3D structures as well as methods of use of the 3D structures in heat transfer applications.

Abstract: An embodiment in accordance with the present invention provides a method for creating and consolidating fragments and a useable structure formed from said consolidated fragments. The method includes swaging a metal powder into a first consolidated structure. The consolidated structure is ground to form particles and the particles are sifted to select those with a predetermined diameter. The particles having the predetermined diameter can then be swaged into a second consolidated structure. The resultant second consolidated structure is therefore configured to fragment controllably. The second consolidated structure can also be formed from reactive metal laminates such that the structure also has chemical energy.

Abstract: The present invention is directed to devices formed from three dimensional (3D) structures composed of wires, yarns of wires, or 3D printed structures. The devices of the present invention offer the potential for 3D structures with multiple properties optimized concurrently, using optimization within the 3D manufacturing constraints. The 3D structures of the present invention include multiple properties that are optimized for heat transfer applications. The present invention also includes the methods for optimization of the 3D woven lattices as well as methods of use of the 3D woven lattices in heat transfer applications.

Abstract: The present invention is directed to a manifold for directing cooling fluid and/or gas to a heat exchanger in a flow configuration designed to optimize heat transfer from the heat exchanger. The manifold can take many different forms such as a layered construction with distributed inlet paths, local outlet paths, a central collection changer and a path for fluid removal. The manifold can be formed from a metal, plastic, rubber, ceramic, or other heat resistant material known to or conceivable by one of skill in the art. The manifold can also be combined with any type of heat exchanger known to or conceivable by one of skill in the art to form a thermal management unit. To optimize overall properties such as low pressure drop, high heat transfer, and excellent temperature uniformity of the thermal management unit, the manifold can be graded, expanded and scaled as needed.

Abstract: An embodiment in accordance with the present invention provides a method for creating and consolidating fragments and a useable structure formed from said consolidated fragments. The method includes swaging a metal powder into a first consolidated structure. The consolidated structure is ground to form particles and the particles are sifted to select those with a predetermined diameter. The particles having the predetermined diameter can then be swaged into a second consolidated structure. The resultant second consolidated structure is therefore configured to fragment controllably. The second consolidated structure can also be formed from reactive metal laminates such that the structure also has chemical energy.

Abstract: An energetic composite having a plurality of reactive particles each having a reactive multilayer construction formed by successively depositing reactive layers on a rod-shaped substrate having a longitudinal axis, dividing the reactive-layer-deposited rod-shaped substrate into a plurality of substantially uniform longitudinal segments, and removing the rod-shaped substrate from the longitudinal segments, so that the reactive particles have a controlled, substantially uniform, cylindrically curved or otherwise rod-contoured geometry which facilitates handling and improves its packing fraction, while the reactant multilayer construction controls the stability, reactivity and energy density of the energetic composite.

Abstract: A reactive composite foil, including metallic fuel particles, oxidizer particles, and a diluent, which, when ignited, produces a self-propagating thermite reaction to produce a molten metal.

Abstract: A method of producing a reactive powder includes providing a bulk structure of reactive material comprising a first reactant and a second reactant, the bulk structure having a preselected average spacing between the first and the second reactants; and mechanically processing the bulk structure of reactive material to produce a plurality of particles from the bulk structure such that each of the plurality of particles comprises the first and second reactants having an average spacing that is substantially equal to the preselected average spacing of the bulk structure of reactive material. The first and second materials of the plurality of particles react with each other in an exothermic reaction upon being exposed to a threshold energy to initiate the exothermic reaction and remain substantially stable without reacting with each other prior to being exposed to the threshold energy.