Abstract: Disclosed herein are optical interference multilayer coatings having region provided by a physical vapor deposition process and region provided by a chemical vapor deposition process. Also disclosed herein are methods of making such coatings, as well as lamps comprising a light-transmissive envelope, at least a portion of the surface of the light-transmissive envelope being provided with the optical interference multilayer coating noted above. Such coatings, when used on lamps, may advantageously offer improved energy efficiencies for such lamps.

Abstract: A method for manufacturing a multi-layered structure can include annealing a stack, where the annealing can include heating the stack in the presence of an inert gas, and where the stack includes a layer including cadmium and tin.

Abstract: A photovoltaic device can include a transparent conductive oxide layer adjacent to a substrate and a barrier layer, which can include a silicon-containing material.

Abstract: A photovoltaic device can include a transparent conductive oxide layer adjacent to a substrate and one or more barrier layers, which can include a silicon oxide or a silicon nitride.

Abstract: A photovoltaic device can include a semiconductor absorber layer with improved cadmium telluride orientation.

Abstract: Disclosed herein are optical interference multilayer coatings comprising a plurality of alternating low refractive index and high refractive index layers, where the high refractive index layers comprise at least one mixed metal oxide selected from: NbTaX oxide where X is selected from the group consisting of Hf, Al and Zr; NbTiY oxide where Y is selected from the group consisting of Ta, Hf, Al and Zr; and TiAlZ oxide where Z is selected from the group consisting of Ta, Hf and Zr. Also disclosed herein are lamps comprising a light-transmissive envelope, at least a portion of the surface of the light-transmissive envelope being provided with the optical interference multilayer coating noted above. Such coatings, when used on lamps, may advantageously offer improved energy efficiencies for such lamps.

Abstract: A nozzle assembly for a kinetic spray system includes a convergent portion, a throat portion, and a divergent portion, each cooperating together to define a passage therethrough for passing a mixture of powder particles suspended in a flow of a high pressure heated gas. The nozzle assembly further includes an extension portion attached to the divergent portion and extending to a distal end a pre-determined length from the divergent portion of the nozzle assembly. The extension portion permits a dragging force exerted on the powder particles by the flow of high pressure heated gas to act upon the powder particles for a longer duration of time, thereby permitting the powder particles to accelerate to a greater velocity than has been previously achievable.

Abstract: A nozzle assembly for a kinetic spray system includes a convergent portion, a throat portion, and a divergent portion, each cooperating together to define a passage therethrough for passing a mixture of powder particles suspended in a flow of a high pressure heated gas. The nozzle assembly further includes an extension portion attached to the divergent portion and extending to a distal end a pre-determined length from the divergent portion of the nozzle assembly. The extension portion permits a dragging force exerted on the powder particles by the flow of high pressure heated gas to act upon the powder particles for a longer duration of time, thereby permitting the powder particles to accelerate to a greater velocity than has been previously achievable.

Abstract: A low cost transistor package is provided for high power applications. The package provides high thermal conductivity and dissipation for a silicon transistor die, high current carrying capability and isolation, and high power and thermal cycle life performance and reliability. A dielectric layer is fixed to a silicon transistor die, for coupling to a heat conducting buffer and attachment to a substrate. The dielectric layer is fixed to the die by growing the dielectric layer, depositing the dielectric layer, or applying the dielectric layer using a plasma spray. In an aspect, a conductive layer is formed to the silicon transistor die by a thermal or kinetic spray process, and the dielectric layer is applied to the conductive layer. The dielectric layer may also be established either before or after the transistor fabrication. Electrical and thermal interconnects are advantageously positioned from opposite sides of the silicon transistor die.

Abstract: An improved kinetic spray nozzle system design is disclosed. The nozzle includes an improved powder injector having an injector tube and a sleeve wherein the injector tube is received in the sleeve and secured to the sleeve. The powder injector further includes an air gap defined between an inner diameter of the sleeve and an outer diameter of the injector tube wherein the air gap is from 50 to 200 microns. The improved injector is capable of spraying a variety of powder materials including hard and “gummy” powders for without clogging for extended periods of time whereas under similar spray conditions previous designs became completely plugged within minutes. The improved injector design enabled the use of higher main gas temperatures to achieve improved coating formation and deposition efficiencies.

Abstract: The present invention is directed to a process for preparing substrates, such as aluminum and aluminum alloy surfaces in heat exchangers, for brazing by depositing thereon a kinetic sprayed brazing composition. The process simultaneously deposits composite particles that include all braze materials, i.e., both filler alloy and brazing flux, and corrosion protection materials used in the brazing of aluminum fins to plates and tubes in a single stage.

Abstract: A nozzle assembly for a kinetic spray system includes a convergent portion, a throat portion, and a divergent portion, each cooperating together to define a passage therethrough for passing a mixture of powder particles suspended in a flow of a high pressure heated gas. The nozzle assembly further includes an extension portion attached to the divergent portion and extending to a distal end a pre-determined length from the divergent portion of the nozzle assembly. The extension portion permits a dragging force exerted on the powder particles by the flow of high pressure heated gas to act upon the powder particles for a longer duration of time, thereby permitting the powder particles to accelerate to a greater velocity than has been previously achievable.

Abstract: A brake assembly is provided that includes a wear-resistant surface, or a surface prone to corrosion, wherein the surface is coated with a coating that optimizes wear-resistance, corrosion-resistance, adhesiveness, and friction factors of the coating. The coating includes a sacrificial corrosion constituent and a second constituent that is relatively harder than the sacrificial corrosion constituent wherein typical metals often employed as sacrificial anodes for example are contemplated. These include aluminum, zinc, and alloys thereof. The second constituent is potentially formed from a carbide, nitride, oxide, transitional metals and alloys thereof, and mixtures thereof.

Abstract: An improved kinetic spray system and a method for using the same in a high speed manufacturing environment are disclosed. The improved kinetic spray nozzle system comprises: a gas/powder exchange chamber connected to a first end of a powder/gas conditioning chamber having a length along a longitudinal axis of equal to or greater than 20 millimeters; a converging diverging supersonic nozzle, the supersonic nozzle having a converging section separated from a diverging section by a throat, the diverging section comprising a first portion and a second portion, with the first portion having a cross-sectional area that increases along a length of the first portion and with the second portion having a substantially constant cross-sectional area along a length of the second portion; and the converging section connected to a second end of the powder/gas conditioning chamber opposite the first end.

Abstract: An improved kinetic spray nozzle system is disclosed in addition to improved methods for injection particle powders into a nozzle. Utilization of the nozzle enables one to dramatically increase the deposition efficiency of a variety of particles using a kinetic process. The improved nozzle includes a powder/gas conditioning chamber that increases the particle residence time within the nozzle enabling one to achieve higher particle temperatures prior to their acceleration in the supersonic portion of the kinetic spray nozzle.

Abstract: The present invention is directed to a process for preparing aluminum and aluminum alloy surfaces in heat exchangers for brazing by depositing thereon a kinetic sprayed brazing composition. The process simultaneously deposits monolith or composite coatings that can include all braze materials and corrosion protection materials used in the brazing of aluminum fins to plates and tubes in a single stage.

Abstract: Disclosed is a method for direct application of a catalyst to a substrate for treatment of atmospheric pollution including ozone. The method includes applying a catalytic metal to a substrate utilizing a thermal spray process. The process can be utilized to apply a base metal such as copper to a substrate and the base metal becomes the catalytically active oxide during and following application to the substrate. This system replaces a multi-step process within a single step process to provide a catalytically active surface that can be utilized to reduce ground level ozone and other atmospheric pollutants.

Abstract: A method is disclosed for direct application of a brazing flux material to a brazing surface. The method includes the step of applying a brazing filler material to a substrate utilizing a kinetic spray process to form a brazing surface. Following application of the brazing filler material to the substrate brazing flux material can be directly applied to the brazing surface as either a dry powder or a wet slurry. The nature of the brazing surface allows the applied flux material to adhere to the surface without the utilization of additional binders or resin materials.

Abstract: A new gas collimator for use in a kinetic spray system is disclosed. The collimator reduces turbulence of the main gas and results in significant increases in the amount of particles deposited on a substrate using the system. Kinetic spray nozzles incorporating the new collimator also have significantly higher deposition efficiencies. The new collimator enables the main gas temperature to be reduced while permitting much higher depositions and deposition efficiencies compared to the prior art collimator. Also disclosed is a low pressure injection method for a kinetic spray system. The coaxial, low pressure injection method enables the use of low pressure powder feeders, which are low cost, technologically mature, and widely available commercially. The coaxial injection method overcomes several undesirable effects associated with prior art high pressure injection methods.

Abstract: A method is for direct application of a brazing flux material to a brazing surface. The method includes the step of applying a brazing filler material to a substrate utilizing a kinetic spray process to form a brazing surface. Following application of the brazing filler material to the substrate brazing flux material can be directly applied to the brazing surface as either a dry powder or a wet slurry. The nature of the brazing surface allows the applied flux material to adhere to the surface without the utilization of additional binders or resin materials.