Abstract: A thermal barrier coating for a component includes an insulating layer applied to a surface of a substrate. The insulating layer comprises a plurality of ceramic microspheres. A sealing layer is bonded to the insulating layer. The sealing layer is non-permeable such that the sealing layer seals against the insulating layer. A method for applying a thermal barrier coating to a surface of a substrate of a component includes providing a plurality of ceramic microspheres and applying the plurality of ceramic microspheres to the surface of the substrate. At least one heat treatment is applied to the plurality of ceramic microspheres on the surface of the component to create an insulating layer on the surface of the substrate.

Abstract: A three-dimensional lattice architecture with a thickness hierarchy includes a first surface and a second surface separated from each other with a distance therebetween defining a thickness of the three-dimensional lattice architecture; a plurality of angled struts extending along a plurality of directions between the first surface and the second surface; a plurality of nodes connecting the plurality of angled struts with one another forming a plurality of unit cells. At least a portion of the plurality of angled struts are internally terminated along the thickness direction of the lattice structure and providing a plurality of internal degrees of freedom towards the first or second surface of the lattice architecture.

Abstract: Described is a micro-lattice damping material and a method for repeatable energy absorption. The micro-lattice damping material is a cellular material formed of a three-dimensional interconnected network of hollow tubes. This material is operable to provide high damping, specifically acoustic, vibration or shock damping, by utilizing the energy absorption mechanism of hollow tube buckling, which is rendered repeatable by the micro-lattice architecture.

Abstract: A wire explosion assembly configured to form nanoparticles by exploding at least a segment of an electrically conductive wire. The wire explosion assembly includes a spool supporting the electrically conductive wire, a vessel defining a wire explosion chamber, means in the wire explosion chamber for pulling the electrically conductive wire off of the spool and applying tension on the segment of the electrically conductive wire, and a power source for delivering an electrical current to the segment of the electrically conductive wire. The electrical current is configured to explode the segment of the electrically conductive wire into the nanoparticles.

Abstract: A vessel includes a vessel wall and an insulation assembly coupled to the vessel wall. The insulation assembly includes a stochastic foam material and a microtruss structure encased within the foam material. The microtruss structure includes a plurality of truss members interconnected at a plurality of nodes. Each truss member is in contact with the foam material such that the microtruss structure provides a structural core for the foam material.

Abstract: A three-dimensional lattice architecture with a thickness hierarchy includes a first surface and a second surface separated from each other with a distance therebetween defining a thickness of the three-dimensional lattice architecture; a plurality of angled struts extending along a plurality of directions between the first surface and the second surface; a plurality of nodes connecting the plurality of angled struts with one another forming a plurality of unit cells. At least a portion of the plurality of angled struts are internally terminated along the thickness direction of the lattice structure and providing a plurality of internal degrees of freedom towards the first or second surface of the lattice architecture.

Abstract: Branched hierarchical micro-truss structures may be incorporated into energy-absorbing structures to exhibit a tailored multi-stage buckling response to a range of different compressive loads. Branched hierarchical micro-truss structures may also be configured to function as vascular systems to deliver fluid for thermal load management or altering the aerodynamic properties of a vehicle or structure into which the branched hierarchical micro-truss structure is incorporated. The branched hierarchical micro-truss structure includes a first layer having a series of interconnected struts and a second layer having a series of struts branching outward from an end of each of the struts in the first layer.

Abstract: An energy absorbing structure configured to buckle in response to an impulsive load includes a facesheet and a micro-truss core coupled to the facesheet. The facesheet and the micro-truss core are wound together into a hollow tube structure. The hollow tube structure may have any shape suitable for the intended application of the energy absorbing structure, including prismatic shapes, non-prismatic shapes, axisymmetric shapes, and non-axisymmetric shapes. In one embodiment, the stiffness of the micro-truss core varies axially, radially, and/or circumferentially along the energy absorbing structure.

Abstract: Various implementations and embodiments relate to three-dimensional open cellular diamond micro-truss structures and methods.

Abstract: Novel nanoparticle-coated multilayer shell microstructures are disclosed herein. Some variations of the invention provide a material comprising a plurality of hollow microstructures characterized by an average shortest diameter from about 5 microns to about 1 millimeter, wherein each of the microstructures comprises multiple shells, including at least an inner shell and an outmost shell, with a combined thickness that is less than one-tenth of the average shortest diameter. The inner shell and the outmost shell have different composition. The outmost shell comprises nanoparticles sized between about 10 nanometers to about 500 nanometers, and the nanoparticles each contain an oxide and/or are surrounded by an oxide layer having a layer thickness of at least 1 nanometer. Several microstructure configurations are illustrated in the drawings.

Abstract: A lightweight sandwich panel structure with a complex shape and curvature, and a method to fabricate such a panel out of high temperature alloys. Embodiments of a micro-truss core structure that offer high specific strength and stiffness while allowing for curvature, and methods for depositing multiple layers of metals that can be interdiffused into complex alloys, are provided. A core of a panel may be fabricated from a polymer template, which may be shaped, e.g., curved, and coated with metal layers, which may then be heat treated to cause the layers of metal to interdiffuse, to form an alloy.

Abstract: Thermal barrier materials are provided that possess low heat capacity and low thermal conductivity, while at the same time, high structural integrity and robustness. In some embodiments, the disclosed coating comprises metal-containing spheres that are sintered or glued together and/or embedded in a matrix. The coating has at least 60% void volume fraction and closed porosity. The coating thickness is from 50 microns to 500 microns, and the metal spheres have an average diameter that is from about 5% to about 30% of the coating thickness. In some embodiments, the metal spheres have an average diameter that is 4-10 times smaller than the coating thickness. Thermal barrier materials with these coatings can be beneficial in engine applications, for example.

Abstract: A lightweight sandwich panel structure with a complex shape and curvature, and a method to fabricate such a panel out of high temperature alloys. Embodiments of a micro-truss core structure that offer high specific strength and stiffness while allowing for curvature, and methods for depositing multiple layers of metals that can be interdiffused into complex alloys, are provided. A core of a panel may be fabricated from a polymer template, which may be shaped, e.g., curved, and coated with metal layers, which may then be heat treated to cause the layers of metal to interdiffuse, to form an alloy.

Abstract: A new battery structure as disclosed allows convective flow of electrolyte through three-dimensional structured electrodes. Hierarchical battery structure design enables three-dimensional metal structures with fluid transport capabilities. Some variations provide a lithium-ion battery system with convective electrolyte flow, comprising: a positive electrode comprising a lithium-containing electrode material and a conductive network with hollow liquid-transport conduits; a negative electrode comprising a lithium-containing electrode material in the conductive network; a separator that electronically isolates the positive and negative electrodes; and a liquid electrolyte contained within the hollow liquid-transport conduits of the conductive network. The hollow liquid-transport conduits serve as structural members, and the walls of these conduits serve as current collectors. The conductive networks may include a micro-lattice structure with a cellular material formed of hollow tubes.

Abstract: A sparse micro-truss structure having a series of unit cells arranged in an array is disclosed. Each of the unit cells includes a series of struts interconnected at a node. Adjacent unit cells are spaced apart by a gap. Spacing apart the adjacent unit cells is configured to reduce the sensitivity of the sparse micro-truss structure to premature mechanical failure due to buckling in one or more of the struts compared to related art micro-truss structures having a series of fully interconnected unit cells.

Abstract: A curved, three-dimensional, ordered micro-truss structure including a series of first struts extending along a first direction, a series of second struts extending along a second direction, and a series of third struts extending along a third direction. The first, second, and third struts interpenetrate one another at a series of nodes. The series of first struts, second struts, third struts, and nodes form a series of ordered unit cells within the micro-truss structure. The series of ordered unit cells define a curved surface.

Abstract: Disclosed herein are surface-functionalized powders which alter the solidification of the melted powders. Some variations provide a powdered material comprising a plurality of particles fabricated from a first material, wherein each of the particles has a particle surface area that is continuously or intermittently surface-functionalized with nanoparticles and/or microparticles selected to control solidification of the powdered material from a liquid state to a solid state. Other variations provide a method of controlling solidification of a powdered material, comprising melting at least a portion of the powdered material to a liquid state, and semi-passively controlling solidification of the powdered material from the liquid state to a solid state. Several techniques for semi-passive control are described in detail.

Abstract: A thermal and environmental barrier coating composed of ceramic hollow microspheres sintered together. In one embodiment the microspheres are sintered together with a powder of another material that acts as a binder, or with a powder of a material that may be the same as the material of the hollow microspheres, forming a matrix in which the hollow microspheres are embedded. The hollow microspheres may be composed of a material with a high temperature capability, and with a low coefficient of thermal expansion.

Abstract: This invention describes spherical nanoparticle hydrides and a method for making them. A method of producing spherical nanoparticle hydrides comprises obtaining an electrically conductive or semiconductive wire fabricated from a base material capable of forming a hydride; exposing the wire to a hydrogen-containing processing gas under pressure; vaporizing the wire by electrical discharge, to generate a vapor phase; and reacting with hydrogen and condensing the vapor phase, generating a plurality of spherical nanoparticle hydrides.

Abstract: A curved, three-dimensional, ordered micro-truss structure comprising: a plurality of first struts extending along a first direction; a plurality of second struts extending along a second direction; and a plurality of third struts extending along a third direction, wherein the first, second, and third struts interpenetrate one another at a plurality of nodes, wherein the pluralities of first struts, second struts, third struts, and nodes form a plurality of ordered unit cells within the micro-truss structure, and wherein the plurality of ordered unit cells define a curved surface.