Abstract: Various structures, such as microstructures and wall-like structures, can include parts or surfaces that are oblique. In some implementations, a cantilevered element includes a spring-like portion with a uniformly oblique surface or with another artifact of an oblique radiation technique. In some implementations, when a deflecting force is applied, a spring-like portion can provide deflection and spring force within required ranges. Various oblique radiation techniques can be used, such as radiation of a layer through a prism, and structures having spring-like portions with oblique radiation artifacts can be used in various applications, such as with downward or upward deflecting forces.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface, a gas subsystem configured to introduce one or more reactive gases to an area proximate in-flight droplets. The one or more reactive gases creates an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface, a spray subsystem configured to direct a spray of an agent at deposited droplets on the surface. The agent creates insulation layers on the deposited droplets such that the droplets form a material having domains with insulated boundaries on the surface.

Abstract: A system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material is provided. The system includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material. The heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on the support to form the bulk material having insulated boundaries.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a combustion chamber, a gas inlet configured to inject a gas into the combustion chamber, a fuel inlet configured to inject a fuel into the combustion chamber, an igniter subsystem configured to ignite a mixture of the gas and the fuel to create a predetermined temperature and pressure in the combustion chamber, a metal powder inlet configured to inject a metal powder comprised of particles coated with an electrically insulating material into the combustion, wherein the predetermined temperature creates conditioned droplets comprised of the metal powder in the chamber, and an outlet configured to eject and accelerate combustion gases and the conditioned droplets from the combustion chamber and towards a surface such that conditioned droplets adhere to the surface to form a material having domains with insulated boundaries thereon.

Abstract: This invention provides a mold for injection molding and a method of manufacturing thereof. The method of manufacturing a mold for injection molding includes the following steps. At least one temperature control element is provided. The temperature control element is covered with a first material. The first material is mechanically processed to form a mold body with a cavity. The mold for injection molding includes a mold body, a temperature control element, and a heat insulating layer.

Abstract: A method for producing a pipe, a carrier element being coated by means of a thermal spraying method, the material of the pipe formed later being selected as the coating material, and the coating forming the pipe being detached from the carrier element, the spraying angle, at which the coating material is sprayed onto the carrier element, being selected such that a low level of adhesion of the coating on the carrier element is achieved.

Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.

Abstract: A method for producing a pipe, a carrier element being coated by means of a thermal spraying method, the material of the pipe formed later being selected as the coating material, and the coating forming the pipe being detached from the carrier element, the spraying angle, at which the coating material is sprayed onto the carrier element, being selected such that a low level of adhesion of the coating on the carrier element is achieved.

Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.

Abstract: Liquid aluminum is sprayed as a fine mist onto an alloyed iron article to produce a thin tenacious non-corrodible layer. In some embodiments, air is heated and delivered through insulated tubing to a container having solid aluminum therein. In some embodiments the air is heated by an electric induction coil. In some embodiments, the container is heated independently of the heated air. In some embodiments, the container is heated by an electric induction coil.

Abstract: The invention provides method for metallic nanonstructures self-assembly methods and materials testing. Preferred embodiment methods permit for the formation of individual nanostructures and arrays of nanostructures. The nanostructures formed can have a metal alloy crystal structure. Example structures include slender wires, rectangular bars, or plate-like structures. Tips can be shaped, single layer and multiple layer coatings can be formed, tips can be functionalized, molecules can be adhered, and many testing methods are enabled.

Abstract: An endoluminal stent composed of a plurality of circumferential expansion elements arrayed to form the circumference of the stent and extending along the longitudinal axis of the stent, and a plurality of interconnecting members that interconnect adjacent pairs of circumferential expansion elements, the interconnecting members joining struts of adjacent pairs of interconnecting members at approximate mid-points of the struts.

Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.

Abstract: Disclosed is a method for making a non-metallic, fiber-reinforced barrel tube having particular application for use in a barrel system to be attached to a paintball marker in order to direct paintballs propelled by the marker towards a target. A mandrel is first dipped in a releasing agent. The mandrel is then coated with a thin layer of metal (e.g., nickel or chrome) by means of a nano vapor deposition process. Next, a fiber-reinforced resinous sheet is wrapped over the thin metal layer to establish a tube therearound. A heat-sensitive plastic tape is wound around the tubular resinous sheet. The mandrel is heated in an oven to cause the thin metal layer to bond to the tubular resinous sheet. At the same time, the heat-sensitive tape shrinks to squeeze any air bubbles from the resinous sheet.

Abstract: The present invention relates to novel non-ferromagnetic amorphous steel alloys represented by the general formula: Fe—Mn-(Q)-B—M, wherein Q represents one or more elements selected from the group consisting of Se, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu, and M represents one or more elements selected from the group consisting of Cr, Co, Mo, C and Si. Typically the atomic percentage of the Q constituent is 10 or less.

Abstract: A Co—Cr—Mo alloy fine wire has superior biocompatibility, corrosion resistance, wear resistance, processability, and flexibility. A manufacturing method and a planar body or the like formed by processing this fine wire. This is a fine wire of diameter of 200 micrometers or less comprising 26 to 31 weight % of Cr, 8 to 16 weight % of Mo, and the remainder of Co and inevitable impurities, in which the degree of roundness (minor diameter/major diameter) of lateral cross section is 0.6 or more, and the internal structure is uniform with the concentration ratio of high Mo concentration phase to low Mo concentration phase of 1.8 or less.

Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.

Abstract: A method for producing high strength aluminum alloy product from powder containing L12 intermetallic dispersoids using high pressure gas atomization to deposit droplets on a substrate prior to complete solidification to form a billet. The sprayed deposit is hot worked using extrusion, forging and rolling to densify the structure by eliminating porosity, improving mechanical properties and to produce different shapes of components.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.

Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.

Abstract: The invention relates to a self-fluxing brazing piece. The piece comprises a composite material comprising at least one inorganic material distributed in a metal or metal alloy matrix, the inorganic material forming a flux during brazing to promote the formation of a thermally induced metallic bond. The matrix may be an aluminium silicon brazing alloy and the inorganic material may be a potassium-fluoro-aluminate flux. The piece is made by spray forming.

Abstract: The present invention provides a jetting process for the production of flakes with uniform size distribution to be used in pigments comprising the steps of ejecting molten metal from a jet head and collecting droplets of metal on a solid collecting substrate or collecting droplets of metal in or on a collecting substrate.

Abstract: A method for forming an electronic device provides a casting master having a casting surface, and deposits a substrate material onto the casting surface to form a flexible substrate sheet of predetermined thickness, wherein the flexible substrate sheet has a circuit-side surface that is formed against the casting surface. The flexible substrate sheet is released from the master and secured against a carrier, with the circuit-side surface facing outward. An electronic device is then formed on the circuit-side surface.

Abstract: An object of the present invention is to provide an Al—Zn—Mg—Cu 7000-series Al alloy having high ductility as well as having high strength. For attaining this purpose, an Al alloy having a structure in which an inclusion is not included is produced by reducing an amount of oxygen contained in an Al alloy that is obtained by solidifying a preform resulting from rapid solidification by preferably spray forming a molten metal of an Al—Zn—Mg—Cu 7000-series Al alloy with an inert gas. This Al alloy has, as mechanical properties at an ordinary temperature, a tensile strength of 600 MPa or more, and an elongation of 15% or more when the tensile strength is from 600 MPa or more and less than 800 MPa or an elongation of 10% or more when the tensile strength is 800 MPa or more, and is excellent in cold workability such as rollability.

Abstract: A heterogeneous body having ceramic rich cermet regions in a more ductile metal matrix. The heterogeneous bodies are formed by thermal spray operations on metal substrates. The thermal spray operations apply heat to a cermet powder and project it onto a solid substrate. The cermet powder is composed of complex composite particles in which a ceramic-metallic core particle is coated with a matrix precursor. The cermet regions are generally comprised of complex ceramic-metallic composites that correspond approximately to the core particles. The cermet regions are approximately lenticular shaped with an average width that is at least approximately twice the average thickness. The cermet regions are imbedded within the matrix phase and generally isolated from one another. They have obverse and reverse surfaces. The matrix phase is formed from the matrix precursor coating on the core particles.

Abstract: A method of fabricating a material having a high concentration of a carbide constituent. The method may comprise adding a carbide source to a biocompatible material in which a weight of the carbide source is at least approximately 10% of the total weight, heating the carbide source and the biocompatible material to a predetermined temperature to melt the biocompatible material and allow the carbide source to go into solution to form a molten homogeneous solution, and impinging the molten homogeneous solution with a high pressure fluid to form spray atomized powder having carbide particles. The size of a particle of carbide in the atomized powder may be approximately 900 nanometers or less. The biocompatible material may be cobalt chrome, the carbide source may be graphite, and the fluid may be a gas or a liquid.

Abstract: An implantable endoluminal device which is fabricated from materials which present a blood or body fluid and tissue contact surface which has controlled heterogeneities in material constitution. An endoluminal stent which is made of a material having controlled heterogeneities in the stent material along the blood flow surface of the stent and the method of fabricating the stent using vacuum deposition methods.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.

Abstract: A method to manufacture a steel die having a Physical Vapor Deposition wear resistant coating on a profile surface and a steel die formed thereby is disclosed. The steel die is subjected to quenching and tempering to achieve a Rockwell hardness in the range of about 40-45 Rc and then subjected to machining to form a profile surface. The surface is then subjected to Physical Vapor Deposition of a wear resistant coating that may be multiple layers of CrN, AlCrN, TiCrN, TiN, TiCN or TiAlN, and preferably is alternating layers of TiN—TiCN—TiN. The coating is applied at a sufficient thickness to impart wear resistance to the steel die. The steel dies are useful in sheet metal stamping operations.

Abstract: A method for spray forming a metal component (11, 17, 21, 27) having an elongated open channel (10, 20, 22, 28) therein comprises firstly spray forming a layer (8, 19, 24) of the desired metal onto a deposition substrate (2), placing then an elongated spray blocking object (9, 18, 26, 29) on the already sprayed layer for forming the channel, and continuing then the spray forming process until the desired total thickness of the component is achieved. According to the present invention, the spray blocking object is a strip (18, 26, 29), the cross-sectional profile of the strip being fully open in the direction of an axis (a) in a cross-sectional plane of the strip, and the strip is placed on the already deposited layer (8, 19, 24) with said axis directed substantially parallel to the direction of the incident metal spray (6).

Abstract: The invention concerns an article of a steel which is characterized in that it consists of an alloy which contains in weight-%: 1.2-2.0 C, 0.1-1.5 Si, 0.1-2.0 Mn, max. 0.2 N, max. 0.25 S, 4-8 Cr, 0.5-3.5 (Mo+W/2), 5-8 V, max. 1.0 Nb, balance essentially only iron and unavoidable impurities, and that the steel has a micro-structure obtainable by a manufacturing of the steel which comprises spray forming of an ingot, the micro-structure of which contains 8-15 vol-% carbides of essentially only MC-type where M substantially consists of vanadium, of which carbides at least 80 vol-% have a substantially rounded shape and a size in the longest extension of the carbides amounting to 1-20 ?m.

Abstract: A spraying apparatus for forming low-melting-point metal mold. The spraying apparatus includes a frame body having a platform. A close space having an operation area is defined above the platform. An adjustment seat having an operation table is arranged on one side of the platform corresponding to the operation area. The adjustment seat is multidirectionally displaceable and 360-degree rotatable and adjustable in angle. A spraying system is mounted on the other side of the platform. The spraying system includes a material-supplying container, a high-pressure pump and a spraying gun. A temperature-controlling box is disposed on a lower side of the frame body. The temperature-controlling box has a power switch, a first-stage temperature control, a second-stage temperature control and a third-stage temperature control which are respectively electrically connected to the material-supplying container, the high-pressure pump and the spraying gun for heating the same to a set temperature.

Abstract: A vortex generator uses a single piece to generate the vortex and hold the electrode. The single piece may be a non-conductive material such as a ceramic. The vortex generator may use threads to hold the electrode. The threads and holes for generating the vortex may be bored into the base material of the vortex generator before the base material is hardened.

Abstract: A method is provided for making a mask configured to improve the depth of focus of an eye of a patient. A substrate is provided with a mask forming feature. The mask forming feature comprises an annular surface that has a curved profile that corresponds to the curvature of a corneal layer of the eye. A release layer is formed on the annular surface. A mask layer of a biocompatible metal is formed above the release layer. The mask layer is separated from the substrate.

Abstract: A method for manufacturing metal components (9) by spray forming comprises depositing by spray forming a first layer (8) of a first metal on a mould, and depositing by spray forming a second layer (10) of a second metal on the first layer, wherein the materials to be deposited and the process conditions of the deposition are selected to produce the microstructure of the first layer (8) being optimised for the final use of the first layer surface (7) defined by the mould (2) on which the first layer is deposited, and the microstructure of the second layer (10) differing from that of the first layer and being optimised for the further actions to be performed to the second layer.

Abstract: Provided are a target material for manufacturing an electrode film of a semiconductor device, methods of manufacturing the target material and manufacturing the electrode film. The target material comprises Al-RE alloy or Al—Ni-RE alloy, in which RE is a mixture of rare earth elements comprising La, Ce, Pr, and Nd.

Abstract: A tissue repair matrix has an intricate pattern of loops, struts and bridges and is made of a super elastic alloy. The repair matrix includes hooks which improve the ingrowth when implanted and amorphic circles which provide rounded surfaces to the outer edges which made the repair matrix a-traumatic when implanted. When the repair matrix is cooled the molecular phase becomes martensitic which allows the tissue repair matrix to be compressed for easier insertion into a patient. When the tissue repair matrix is heated, the molecular phase changes to austenitic which causes the tissue repair matrix to expand to a size suitable for medical procedure.

Abstract: A method of forming metal spheres includes ejecting a precisely measured droplet of molten metal from a molten metal mass, buffering the molten metal droplet to reduce the internal kinetic energy of the droplet without solidifying the droplet and cooling the buffered droplet until the droplet solidifies in the form of a metal sphere. An apparatus for fabricating metal spheres includes a droplet generator that generates a droplet from a molten metal mass, a buffering chamber that receives the droplet from the droplet generator, and diminishes internal kinetic energy of the droplet without solidifying the droplet, and a cooling drum that receives the droplet from the buffering chamber, and cools the droplet to the extent that the droplet solidifies into a metal sphere. The apparatus may further include a collector arrangement that receives the metal spheres from the cooling drum and makes the metal sphere available for collection.

Abstract: Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.

Abstract: An apparatus for casting metals by a nucleated casting technique to create a preform, the apparatus including a mold having a base and a side wall where the base can be moved relative to the side wall to withdraw the preform as it is being created. In various circumstances, portions of a droplet spray created by an atomizing nozzle, i.e., overspray, may accumulate on a top surface of the side wall and prevent or inhibit the preform from being moved relative to the side wall. The atomizing nozzle can be oriented such that the droplet spray passes over the top of the side wall to remelt and remove at least a portion of the overspray that has accumulated thereon. The mold can be rotated such that the overspray formed on a region of or on the entire perimeter of the top surface can pass through the droplet spray and can be removed from the side wall.

Abstract: A lightweight mold structure is disclosed, which includes a metal layer and a polymer filled with metal support. The support provides strength to the mold, without the added weight of a solid metal structure. The metal utilized in the polymer is preferably a plurality of metal spheres. Methods of forming the lightweight mold are also disclosed.

Abstract: The present invention relates to a novel method of venting a spray metal molding surface. More particularly the invention relates to a method of manufacturing a mold using a thermal spray process to produce a metal surface containing passages in the spray metal to vent fluid or gas from the forming surface. The present invention is primarily intended for mold tools, such as vacuum molds, injection molds or blow molds having vents or a multiplicity of holes in the forming surface to evacuate or supply gas in a mold.

Abstract: A spraying apparatus for forming low-melting-point metal mold. The spraying apparatus includes a frame body having a platform. A close space having an operation area is defined above the platform. An adjustment seat having an operation table is arranged on one side of the platform corresponding to the operation area. The adjustment seat is multidirectionally displaceable and 360-degree rotatable and adjustable in angle. A spraying system is mounted on the other side of the platform. The spraying system includes a material-supplying container, a high-pressure pump and a spraying gun. A temperature-controlling box is disposed on a lower side of the frame body. The temperature-controlling box has a power switch, a first-stage temperature control, a second-stage temperature control and a third-stage temperature control which are respectively electrically connected to the material-supplying container, the high-pressure pump and the spraying gun for heating the same to a set temperature.

Abstract: The present invention is in the field of methods and formulations for applying a protective coating onto a substrate, and more particularly, methods and formulations for applying a protective coating by application of a metal compound onto the hot glass surfaces using a chemical-vapor deposition (CVD) technique.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

Abstract: Material is incrementally deposited using material directed toward a deposition zone. The scan path of the directed material is controlled according to a path plan derived to reduce derivation from an ideal uniform temperature profile for the deposition during the deposition process. A path plan having angled scan passes that intersect (or overcross one another), for example in a mirrorbox path plan, is preferred.

Abstract: A method is proposed for the determination of process parameters in a thermal spraying process, in which particles are melted or made plastic or vaporized by means of a thermal spraying apparatus (1) and are transported by a flow of fluid (G) to a substrate (6). In said method an operating model is constructed for the thermal spraying process or for the thermal spraying apparatus, with which a simulation of the thermal spraying process can be done and which includes a flow mechanical model and also an electromagnetic model, wherein the flow mechanical model and the electromagnetic model are coupled together and at least one process parameter is determined by means of the operating model.

Abstract: Method and arrangement for spray forming an article. The method includes spraying a plurality of metal streams upon a low-heat resistant model and thereby forming a spray formed article. Each of the plurality of metal streams is composed of moltenized droplets, and as between the plurality of metal streams, each is composed of different constituent elements. In the spray form process, conditions of the metal streams are controlled, particularly around the time that the droplets land, to prevent adverse affects such as melting or burning the master model. The spray conditions are controlled in such a manner that the individual metal droplets forming the metal streams remain substantially segregate. The segregated state is maintained through out solidification so that the resulting spray formed article is composed at least partially of psuedo-alloy.