Abstract: Method and apparatus incorporating an infrared sensor, in the form of a two-wavelength imaging pyrometer into a metallic spray form process for providing real-time measurement of the surface temperature distribution of a steel billet thereby formed. The steel billets may be advantageously used as tools in metal forming processes, injection molding, die casting tooling and other processes that require hard tooling, such as in the automotive industry. The steel billet is formed based on a goal of uniform surface temperature distribution thereby minimizing thermal stresses induced within the steel article thereby produced.

Abstract: Spray form cell including a two-wavelength imaging pyrometer adapted to provide real-time measurement of the surface temperature distribution of a metal billet thereby formed. The steel billets may be advantageously used as tools in metal forming processes, injection molding, die casting tooling and other processes that require hard tooling, such as in the automotive industry. The steel billet is formed based on a goal of uniform surface temperature distribution thereby minimizing thermal stresses induced within the steel article thereby produced.

Abstract: A method of manufacturing a seamless self-supporting metal part using nickel vapor deposition, where the part has a selected minimum thickness, a first aerodynamically contoured surface and a second substantially parallel surface. The method replaces labor intensive welding of individually manufactured sheet metal segments for complex aerodynamic shapes, and produces a part with higher accuracy, less cost, controlled strength and hardness properties. Nickel vapor deposition is commonly used for plating electronic components, and for producing a metallic lining for plastic injection moulds. The seamless sheet metal part is cast by: fabricating a mould with at least one mould surface being a negative of the first surface of the part; enclosing the mould in a nickel vapor deposition chamber; depositing nickel on the mould surface by nickel vapor deposition until a blank of nickel is deposited having at least the minimum thickness and an external deposition surface; and separating the blank from the mould.

Abstract: Nucleated casting systems and methods comprise the addition of powders into a liquidus portion of the casting. The casting system forms a casting comprising a liquidus portion that receives the refined liquid metal and a solidified portion, the casting further comprising a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free and segregation defect free. The casting system comprises a source of refined liquid metal, the refined liquid metal having oxides and sulfides refined out of the metal; a solid metal particle addition system that adds solid metal particles to a surface of the liquidus portion of the casting; and a nucleated casting system for forming the casting. The solid metal particle addition system adds solid metal particles that serve as nucleation centers during solidification of the casting.

Abstract: A metallic shell used, for example as a mold, is formed by spray deposition connected to a base by rods or other supports connected to mounting elements which are incorporated in the shell during the deposition process. The shell can incorporate different metals to provide different thermal conductivity in various regions.

Abstract: A casting system with auxiliary cooling onto a liquidus portion of the casting can produce a metal casting that comprises a fine-grain, homogeneous microstructure. The microstructure is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification of the metal from a liquidus state to a solid state. The casting system with auxiliary cooling onto a liquidus portion of the casting can comprises an electroslag refining system as a source of liquid metal; a nucleated casting system; and at least one cooling system that supplies coolant onto a liquidus portion of the casting. The liquidus portion of the casting is cooled in a manner sufficient to provide a casting microstructure that comprises a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification from a liquidus state to a solid state.

Abstract: The present invention relates to a method for manufacturing a tube-type spray formed product and, in particular, to a method for manufacturing a tube-type spray formed product without using a core. The present invention provides a method for manufacturing a tube-type spray formed product in which a tube-type spray formed product is formed by spraying droplets through an atomizer installed at the position separated from the center portion of a rotating plate as much as the droplets should not sprayed on the center portion of the rotating plate.

Abstract: A compact body is made by thermal spraying by high-velocity flame spraying or by cold-gas spraying. By heating the compact body to a temperature equal to or preferably above the breakdown temperature of the blowing agent, followed by cooling, porous hollow bodies or metal foams are produced.

Abstract: A method of making a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of heating the ceramic pattern and thermally spraying a metal material against the ceramic pattern to form a desired tool.

Abstract: In a rapid prototyping system, a part is formed by depositing a bead of slurry that has a sufficient high concentration of particles to be pseudoplastic and almost no organic binders. After deposition the bead is heated to drive off sufficient liquid to cause the bead to become dilatant.

Abstract: A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.

Abstract: A method of fabricating a needle via conformal deposition in a two-piece mold includes the step of attaching a top mold member to a bottom mold member such that the top mold member and the bottom mold member define an enclosed, elongated needle trench with a deposition aperture. A conformal substance, such as polysilicon, is then passed through the deposition aperture such that the conformal substance is deposited within the enclosed, elongated needle trench to form a needle. The method is used to form needles with prongs, multiple channels, multiple ports, barbs, strength enhancement features, and circuitry.

Abstract: An aluminum-based alloy having the general formula Al100−(a+b)QaMb (wherein Q is V, Mo, Fe, W, Nb, and/or Pd; M is Mn, Fe, Co, Ni, and/or Cu; and a and b, representing a composition ratio in atomic percentages, satisfy the relationships 1≦a≦8, 0<b<5, and 3≦a+b≦8) having a metallographic structure comprising a quasi-crystalline phase, wherein the difference in the atomic radii between Q and M exceeds 0.01 Å, and said alloy does not contain rare earths, possesses high strength and high rigidity. The aluminum-based alloy is useful as a structural material for aircraft, vehicles and ships, and for engine parts; as material for sashes, roofing materials, and exterior materials for use in construction; or as materials for use in marine equipment, nuclear reactors, and the like.

Abstract: A method of producing a silicon based alloy is described which comprises melting a silicon alloy containing greater than 50 wt. % silicon and preferably including aluminium. The melted alloy is then inert gas atomized to produce powder or a spray formed deposit in which the silicon forms a substantially continuous phase made up of fine, randomly oriented crystals in the microstructure. The alloy produced by the method has particularly useful application in electronics packaging materials and a typical example comprises an alloy of 70 wt. % silicon and 30 wt. % aluminium. Such an alloy is an engineering material which, for example, is machinable.

Abstract: The present invention relates to a method of making a molding tool comprising a core die and a cavity die. The method comprises (a) providing a first metal deposit comprising one of the cavity die or the core die, the first metal deposit having a die face, (b) providing a spray forming pattern on a portion of the die face of the first metal deposit,(c) spraying metal particles onto the first metal deposit and the spray forming pattern to form a second metal deposit comprising the other of the cavity die or the core die, and (d) removing the spray forming pattern from the first and second metal deposits.

Abstract: Method of making valve seats by thermally spraying bulk material. The method includes the steps of: (i) preparing a cylindrical polymeric mandrel having an outside dimension not greater than the desired inside dimension of the desired insert, the mandrel having no means to provide for separation of the sprayed material from the mandrel, (ii) thermal spraying separate particles of one or more types of steel or nickel alloys in the presence of a controlled oxidizing medium under conditions that allow firstly, melting of the mandrel and its infiltration into the sprayed material and secondly to form a subsequent polymer free dense metallic bulk composite material (iii) after cooling, machining and cutting into discrete seat shapes for implanting into the final product.

Abstract: A method of solid free form fabrication of an object includes the steps of providing a substrate, forming a plurality of molten droplets, and spraying the molten droplets upward against the substrate to form a net shape object.

Abstract: In order to provide a heat pipe for transporting heat from an evaporation area to a condensation area, comprising a housing with housing walls, a capillary structure arranged in the housing and thermally coupled to the respective, corresponding housing wall in the evaporation area as well as in the condensation area, a vapor channel arranged in the housing and leading from the evaporation area to the condensation area as well as a heat transport medium, as well to make available a process for the production of such a heat pipe it is suggested that the capillary structure be an open-pored capillary layer produced by way of thermal plasma spraying of powder particles.

Abstract: A method of integrating wear plates into a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of locating at least one wear plate on the ceramic pattern and thermally spraying a metal material against the wear plate and ceramic pattern to form the desired tool and embedding the wear plate into the desired tool.

Abstract: Spraycasting method involves directing an atomized metal or alloy spray at a collector disposed in a spray chamber and controlling temperature of the spray in flight in the spray chamber and of the atomized metal or alloy as it is deposited on the collector by a spray chamber pressure control technique that involves in-situ evacuation of the spray chamber during spray deposition to a maintain spray chamber gas partial pressure less than about 400 torr. Such low spray chamber gas partial pressure provides a higher temperature of the atomized spray in flight in the spray chamber and of the sprayed material as it is deposited on a collector in the spray chamber effective to reduce deposit porosity, reduce grain layering or banding, and provide a uniform grain through the thickness of the deposit.

Abstract: A method of spray forming a weldable metal deposit. The method comprises (a) providing a ceramic spray forming pattern, (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in deposited carbon steel having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern, (c) spraying metallic particles onto the spray forming pattern heated to the sustained temperature, and (d) allowing the sprayed metallic particles to cool to form a metal deposit. The metallic particles have a carbon content which is sufficient to result in metal particles having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern. The resulting deposit has a carbon content of less than about 0.3 weight percent.

Abstract: The purpose of the present invention is to improve releasability from the jig of a method of producing a minute metal ball by heating and melting and then cooling a metal piece of specific dimensions and further, to present a metal ball with very good dimensional accuracy and sphericity, even though diameter is minute. By means of the above-mentioned method, very good releasability between the metal ball and jig after melting and cooling is obtained and long-term use of the tool becomes possible by placing a metal piece on a jig with a layer of fine powder of BN, AlN or C having low wettability with the metal piece in between, or by making a layer of fine powder adhere to the surface of the metal piece and then placing this metal piece on the jig or shaking and arranging individual metal pieces in holes in the same.

Abstract: A method of making a spray formed rapid tool includes the steps of making a model of a desired tool and directly constructing a sand pattern as the inverse of the model. The method also includes the steps of thermally spraying metal material against the sand pattern to form the desired tool.

Abstract: A method of manufacturing a metal and polymeric composite article by the following steps. Droplets of spray deposited metal and spray deposited polymeric material are combined to form an article having the polymeric material interspersed within the metal. A carrier or form that shaped to receive the metal and polymeric layers is provided. The carrier may be made either stationary or movable. Layers of spray deposited metal and spray deposited polymeric material are applied atop the carrier. The spray deposited metal is between 90 and 95 percent by volume of the article. The polymeric layers do not completely cover the metal layers. Succeeding spray deposited metal layers contact bond to previous metal layers. The polymeric material between imbedded between the interconnected metal layers.

Abstract: A method of spray forming a weldable metal deposit. The method comprises (a) providing a ceramic spray forming pattern, (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in deposited carbon steel having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern, (c) spraying metallic particles onto the spray forming pattern heated to the sustained temperature, and (d) allowing the sprayed metallic particles to cool to form a metal deposit. The metallic particles have a carbon content which is sufficient to result in metal particles having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern. The resulting deposit has a carbon content of less than about 0.3 weight percent.

Abstract: A method and apparatus is provided for producing a porous metal. The method broadly includes the steps of first, providing a molten metal and second, introducing a gas into said molten metal. The method then includes spray casting the molten metal containing the gas onto a surface thereby producing the porous metal. The method further provides for controlling the amount and size of the porosity contained within the porous metal by controlling the parameters at which the gas is introduced into the molten metal, as well as, controlling the parameters surrounding the spray casting of the molten metal. Additionally, the method also provides for producing a porous metal having either an isolated or interconnected pore structure. The present invention also provides for a porous metal product, as well as a porous aluminum alloy product, made by the described method. The apparatus includes a means for containing the molten metal wherein the containing means has a discharge end.

Abstract: A process for manufacturing an Al—Si alloy for use in a vehicle propeller shaft is provided. The Al—Si alloy manufacturing process includes the steps of heating and melting Al—Si alloy where Si contains 13-40 weight percentage (wt %) of the whole alloy, to thereby prepare melt, maintaining the melt at 700-900° C. and then spraying an high pressure inert gas to the melt and rapidly solidifying the same to thereby obtain a forming body, and extruding the forming body at 400-550° C. The physical properties of the Al—Si alloy manufactured by a spray forming process is at least similar to that of the vehicle propeller shafts which have been already known, and also spotlighted as new alloy compositions which can replace the conventional propeller shaft material.

Abstract: Improved assembly and methods for manufacturing a three-dimensional object are described. The assembly includes a crucible for holding molten metal, an orifice disposed in the bottom of the crucible through which a jet of molten metal can flow towards a movable substrate, and a mechanically oscillating member immersed in the molten metal for controlling the flow of molten metal through the orifice and for breaking the flow of molten metal into the sequence of molten metal drops. As the drops land on the movable substrate, a three-dimensional object is built up. Continuously variable diameter or controllable planar jets may be used as the orifices. In forming drops from the output of a planar jet, the jet is first broken up by the oscillating member into horizontal cylindrical ligaments and the ligaments are then broken up into drops by acoustic energy applied by audio loudspeakers adjacent the falling ligaments. The assembly and methods are useful in the fields of rapid prototyping and materials processing.

Abstract: A method and associated apparatus for increasing the over cladding rate in perform production while maintaining the integrity of the glass quality of the cladding. The method and apparatus are designed to utilize the full capacity of the generator to thereby improve the overall deposition speed without sacrificing the glass quality. In particular, it is estimated that the process of the present invention will increase the deposition speed by approximately 50% and still obtain suitable glass quality. This object is achieved by utilizing two plasma torches, instead of just one, that are driven by the same power generator.

Abstract: The apparatus comprises a device for supplying molten metal, a device for heating molten metal such that it remains fluid while within the apparatus, a device for applying a magnetic field in a direction perpendicular to the device for supplying molten metal, a device for transmitting electric current directly through molten metal to exert a force in a first direction on molten metal, where the device for transmitting can reverse the direction of the current to a second direction, opposite of the first direction, to form a droplet of molten metal, and a receiver for the droplet where the accumulation of a multitude of droplets upon the receiver results in the formation of the desired metal part. The mixing chamber can include a rotary electrode arrangement which mixes the molten metal by movement.

Abstract: A method of reducing distortion in a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of building a thermal model of the desired tool from a solid model of the ceramic pattern and applying thermal boundary conditions to the thermal model based on known conditions. The method also includes the steps of running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value. The method further includes thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value.

Abstract: The present invention relates to a method and apparatus of manufacturing nickel-metal-hydride alloy powder material. The furnace charge of nickel-metal-hydride alloy is melted in vacuum or argon atmosphere in this invention. After melting, the molten alloy is gas atomized to fine spherical powder or centrifugal atomized to flaky shape. Then the powders are fed into a hydrogen heat treatment chamber for hydrogen heat treatment and pulverization. This invention integrates the melting, pulverizing and hydrogen treatment of nickel-metal hydride alloy powder into a whole step. It can charge and pulverize continuously and is suitable for the large-scale industrialized production of homogeneous composition and least segregation nickel-metal hydride alloy powder.

Abstract: The method comprises the production of a first positive model of an item to be cast. The positive model is produced with a flange extending in an imaginary separation line of the item. The flange extends both inwardly in the item within an outer periphery of the item and outwardly outside the outer periphery of the item. The flange establishes an artificial increase of the thickness of the item. Through different intermediate steps at least a first mould part and a second mould part of a mould are produced. The first and the second mould part of the mould initially have a separation zone forming a contact surface between the first and the second mould part. The mould parts are treated in the separation zone so that the negative moulds of an upper and a lower surface of the part of the flange extending outside the item will subsequently form a contact surface of the first and the second mould part.

Abstract: A spray forming pattern of a first metal having a melting point at a first temperature is formed. The spray forming pattern has a surface defining a cavity that has the shape of a master pattern. Steel particles having a carbon content in the range of 0.01-0.9% by weight are sprayed onto the spray forming pattern to form a deposit on the spray forming pattern. The deposit has a thickness of at least 0.5 inches and the temperature of the steel particles increases as the thickness of the steel deposit increases. The spraying conditions are controlled so that the steel particles coming into contact with the spray forming pattern results in a surface temperature of the spray forming pattern of less than about 80.degree. C. The deposit and the spray forming pattern are heated to a second temperature, which is higher than the first temperature, to melt the spray forming pattern from the deposit. The resulting deposit has the general shape of the master pattern.

Abstract: A method for spot-welding aluminum workpieces with copper electrodes that comprises the steps of: (a) dissolving copper and one or more alloying elements X to yield an alloy that increases the liquidus of Al when dissolved in molten Al, super heating the alloy of copper and one or more elements X that normally have little or nor solubility in copper at room temperature, such super heating being a temperature at which X is soluble in copper, X being selected from the group of Mo, Ta, V, and W, elements that form monotectic or peritectic phases with copper and aluminum devoid of an eutectic, X being present in an amount of 4-15% by weight of the copper; (b) rapidly cooling the alloy to room temperature to retain such elements in solid solution; (c) either concurrently or subsequent to step (b), forming the alloy as an electrode shape; and (d) passing current through the electrode shape to effect spot-welding of the aluminum workpieces when pressed thereagainst while extending the welding life of the electrode.

Abstract: A metal alloy is melted in a crucible and ejected from the bottom of the crucible as a descending stream of molten metal. The descending stream is impacted with a plurality of primary inert gas jets surrounding the molten metal stream to produce a plume of atomized molten metal droplets. An inert gas is blown onto a lower portion of the plume with a plurality of auxiliary inert gas jets to deflect the plume into a more restricted pattern of high droplet density, thereby substantially eliminating unwanted overspray and resulting wasted material. The plume is projected onto a moving substrate to form a monolithic metallic product having generally parallel sides.

Abstract: A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.

Abstract: The present invention provides a thixoformable Al alloy composites wherein Si is added to ASTM 2000 series aluminum alloy so that the total Si content thereof may be 1-5 at. % and also a manufacturing method of thixoformable Al alloy composites comprising: obtaining a matrix of the composite containing 1-5 at. % of the total Si content by adding Si to ASTM 2000 series aluminum alloy; holding the matrix in the temperature range of 560-610.degree. C. to obtain a liquid fraction of 40-70% and thereafter performing a thixoforming process.

Abstract: A neutron absorbing material and method utilizing rare earth elements such as gadolinium, europium and samarium to form metallic glasses and/or noble base nano/microcrystalline materials, the neutron absorbing material having a combination of superior neutron capture cross sections coupled with enhanced resistance to corrosion, oxidation and leaching.

Abstract: Finely divided embossed metal particles are prepared by forming an embossment on a carrier surface in which the embossment comprises a machine readable image produced by a diffraction grating pattern, a holographic image pattern or an image visible solely by optical magnification. A layer of metal is applied to the surface so the layer adopts the complement or the embossment. The layer is then separated from the surface and reduced to embossed particles. Alternatively, the embossment can be formed on the carrier sheet directly or on the outer surface of a release coating formed on the carrier sheet. When removing the film of metal from the release-coated carrier, the carrier sheet with the release coating and film of metal can be passed through a release environment which causes the release coating to separate the film and carrier, but which is nondestructive of the metal.

Abstract: A method for the forming of semi-solid nucleated metallic alloys that have been sprayed in molten form into a container for intermediate casting. According to the present invention, a molten stream of metallic alloy is disrupted into a plurality of molten metallic alloy droplets, and the droplets are partially solidified as a plurality of degenerative dendritic globules so that approximately 5% to 60% by volume of each average degenerative dendritic globule is solid and the remainder is molten. The partially solidified globules are collected to form a semi-solid mass, and a portion of the semi-solid mass is forced into a die cavity prior to solidification to form a shaped metallic alloy.

Abstract: A method of making a metal slab with a non-uniform cross-sectional shape including providing a spray casting apparatus including a substrate and a plurality of spaced atomization nozzles, the nozzles having a discharge opening and introducing molten metal into the nozzles. The method then includes atomizing the molten metal as it is discharged from the nozzles through the discharge openings by subjecting the discharged molten metal to jets of an atomizing gas in order to form metal droplets for deposition onto the substrate. The deposition of the metal droplets onto the substrate is controlled in order to form the metal slab having a non-uniform cross-sectional shape. A method of making an integrally stiffened metal structure as well as metal and aluminum products made by the above methods are also provided.

Abstract: Method of making seat inserts by thermally spraying bulk material. The method includes the steps of: (i) preparing a mandrel having an outside dimension not greater than the desired inside dimension of the desired insert, the mandrel having a part to provide for separation of the sprayed bulk material from the mandrel, (ii) thermal spraying separate particles of one or more types of steel or nickel alloys in the presence of a controlled oxidizing medium to form a bulk composite material on the mandrel with a density of at least 99% and, (iii) after cooling the bulk material, removing such material from the mandrel and slicing it into discrete seat shapes for implanting into the final product.

Abstract: A high speed tool steel and a manufacturing method therefor are disclosed, in which carbides are formed in the matrix in a uniform manner, thereby obtaining a high toughness and a high abrasion resistance. The high speed tool steel according to the present invention includes a basic composition of W.sub.a Mo.sub.b Cr.sub.c Co.sub.d V.sub.x C.sub.y Fe.sub.z where the subscripts meet in weight %: 5.0%.ltoreq.a.ltoreq.7.0%, 4.0%.ltoreq.b.ltoreq.6.0%, 3.0%.ltoreq.c.ltoreq.5.0%, 6.5%.ltoreq.d.ltoreq.9.5%, 2.2%.ltoreq.x.ltoreq.8.3%, 1.1%.ltoreq.y.ltoreq.2.18%, and 66.52%.ltoreq.z.ltoreq.73.7%. The final structure has carbides uniformly distributed within a martensite matrix, which are mainly MC and M.sub.6 C carbides. The method includes the steps of melting the above-defined alloy composition, gas spraying the melted alloy to form a bulk material, heat treating the bulk material to decompose the M.sub.2 C carbides to stabilize M.sub.6 C carbides and hot working the heat treated bulk material to a desired shape.

Abstract: A method of integrating detailed features into a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of locating at least one detailed feature insert on the ceramic pattern and thermally spraying metal material against the detailed feature insert and ceramic pattern to form the desired tool and embedding the detailed feature insert into the desired tool.

Abstract: A process for manufacturing large diameter, spray formed billets, rings, or tubular forms by spraying atomized molten metal onto a rotating surface. The rotating surface has a collector surface that is maintained at a predetermined temperature or reheated to the predetermined temperature by an external heat source. The external heat source impinges upon the collector surface to form a reheated or preheated zone. The external heat may be provided by a laser, high temperature flame, plasma arc, electric induction or radiation source. The molten metal is sprayed onto the collector surface in the reheated or preheated zone. Apparatus for carrying out the process is also disclosed.

Abstract: A method of manufacturing metallic droplets (9), comprising the following steps:(a) providing a substrate (1) which is substantially transparent to radiation of wavelength .lambda., one face (1a) of the substrate (1) being provided with a metallic layer (3) which is partitioned into an array of lands (5);(b) directing a laser beam (7) of wavelength .lambda. through the substrate (1) onto a land (5), thereby causing rapid melting of the land (5) and its detachment from the substrate (1) in the form of a molten droplet (9). In a preferential embodiment of the method, the molten droplet (9) is "shot" onto a target substrate (21) before solidifying.

Abstract: A procedure for making zinc particles of a size, shape and composition such that the particles can be subsequently used in a process for manufacturing zinc parts from such particles in either molten or powder form includes the initial step of heating zinc to a temperature at least as high as 720.degree. C. The molten zinc is passed through a screen having small openings, on the order of about 1/4".times.1/4" into a cooling region formed by a movable surface which is at a temperature of on the order of about -200.degree. C. The zinc forms small particles as it passes through the openings in the screen and essentially instantaneously solidifies as it contacts the movable surface. Thereafter, the solidified zinc particles are subjected to a grinding process to reduce their size to a powder having a surface area in the range of 2 mm.sup.2 to 20 mm.sup.2.

Abstract: A method of encapsulating a material in a carbon nanotube comprising generating a vapor of the material to be encapsulated, generating a hydrogen arc discharge that discharges encapsulating products, and contacting the vapor of the material and the products discharged from the hydrogen arc discharge proximate a surface to encapsulate the material in a carbon nanotube. A carbon nanotube encapsulating a metallic material (e.g. copper), a semi-conductor material (e.g. germanium) and other materials can be produced.

Abstract: Metallic articles having heat transfer channels are produced by solidification of molten metallic material about pre-formed channel defining members such that a solidified metallic deposit having heat transfer channels is formed. The channel defining members may be in the form of either solid elements (which are subsequently removed to leave the channels), or conduit elements (which may remain permanently embedded in the article). Moulds, dies, cores and other tools for use in moulding or casting of plastics and metals are particularly suitably formed by the process, the heat transfer channels being used for cooling of the respective articles during use. The molten metallic material is preferably deposited by spray forming utilizing one or more sprays of molten metallic material.