Abstract: A method of controlling the final coating thickness of a diffused aluminide coating on a metal substrate. The method includes: (a) depositing an alumina-doped platinum-silicon powder onto a metal substrate, (b) heating the coated substrate to diffuse the platinum-silicon powder into the substrate and removing the undiffused scale, (c) depositing an aluminum-bearing powder onto the platinum-silicon-enriched substrate, and (d) heating the coated substrate to diffuse the aluminum-bearing powder into the substrate and removing the undiffused scale. The depositions are preferably done electrophoretically, in which case the Pt--Si deposition bath is doped with alumina or some other inert particulate. Alternatively, slurry deposition may be used. The method may also be used to deposit Pd--Si coatings onto metal substrates.

Abstract: Electrophoretically active sol-gel processes to fill, seal, and/or density porous, flawed, and/or cracked coatings on electrically conductive substrates. Such coatings may be dielectrics, ceramics, or semiconductors and, by the present invention, may have deposited onto and into them sol-gel ceramic precursor compounds which are subsequently converted to sol-gel ceramics to yield composite materials with various tailored properties.

Abstract: A method of electrophoretic deposition of a ceramic green body. A ceramic powder is optionally washed with a polar solvent such as deionized water, dried, and suspended in a polar organic solvent in a proportion of at least 20% by weight. A positive surface charge is imposed on the suspended particles by conventional means such as ball milling or ultrasonic treatment. A green body is deposited on a cathode by passing a direct electric current of constant current density through the suspension. The density of the green body generally is at least 70% of theoretical. The density of the fired body generally is at least 98% of theoretical. A layered green body may be deposited by using several suspensions of differing global ceramic composition and depositing each microlayer in a different suspension.

Abstract: A process for preparing a phosphor layer of a cathode ray tube. To prepare a phosphor layer located on the display screen rear side of the cathode ray tube, the display screen rear side is first coated with an electrically conductive electrode layer consisting of electrically conductive polymers; a solution containing the phosphors or their precursors as well as a solution containing an electrolyte are deposited on the electrode layer; an electric field is applied between the electrode layer and the solution; and the phosphors are electrophoretically deposited on the electrode layer to form the phosphor layer. Since polymers with an evaporation temperature below the destruction temperature of the phosphors are selected, the electrode layer can subsequently be removed by evaporating the polymers.

Abstract: Phosphor screens are disclosed that exhibit decreased Coulombic aging and/or lower threshold voltages. The phosphor compositions and electrochemical methods for making those screens are also disclosed.

Abstract: A method and apparatus for two-coat one-fire electrophoretic enameling of a work piece made of metal, wherein a first undercoat enamel slip deposit bath is followed by at least one excess slip removing bath before the undercoated work piece is submerged in a process bath including an additive for reducing the electrical resistance of the enamel biscuit followed sequentially by another rinsing bath, a finish enamel coating bath and not less than one final rinsing bath before the coated work piece is subjected to an enamel firing step.

Abstract: Phosphor screens are disclosed that exhibit decreased Coulombic aging and/or lower threshold voltages. The phosphor compositions and electrochemical methods for making those screens are also disclosed.

Abstract: A method for producing by electrophoretic deposition multi-layer, polyfunctional, catalyst members for use in catalytic converters having a plurality of suitably porous and adherent catalyst support coatings of substantially uniform thickness, a plurality of non-identical catalytic agents imbued therein/on, and a flexible metal substrate, are disclosed. Such process involves maintaining electrical interaction between a metal substrate previously coated with catalyst-catalyst support material, the power source, and the electrodes disposed in the electrophoretic deposition ("EPD") cell containing a slurry of a second catalyst support material and a second catalyst composition non-identical to that found in the first catalytically-active layer.

Abstract: A method for manufacturing a thin zirconia film comprises the steps: (a) preparing a suspension in which partially-stabilized or stabilized zirconia particles having electric charges are dispersed in a solvent; (b) positioning a pair of electrodes in the suspension; (c) applying an electric field between the electrodes, said zirconia particles moving to the electrode and said zirconia particles being deposited on the electrode electrochemically; and (d) sintering the zirconia film to form a partially-stabilized or stabilized thin zirconia film.

Abstract: A method for forming a low-energy electron excited fluorescent screen. First, there is dissolved in a non-aqueous solvent a charging material. The charging material when dissolved forms a cation which is susceptible to forming an oxide, which oxide is a first essential component of a low-energy electron excited fluorescent phosphor composition. In addition to the charging material, there is suspended in the non-aqueous solvent a phosphor which naturally adopts a positive charge in the non-aqueous solvent. The phosphor is a second essential component of the low-energy electron excited fluorescent phosphor composition. There is then electrophoretically deposited from the non-aqueous solvent the cation and the phosphor to form a low-energy electron excited fluorescent phosphor precursor composition. The electrophoretic deposition occurs upon a fluorescent screen substrate which serves as a cathode.

Abstract: A method of manufacturing a composite material in which a fibre matt is placed adjacent a plate electrode in ceramic sol. The application of an electric field to the sol via the electrode results in the deposition of sol particles on the electrode which subsequently permeate the fibre matt. The permeated fibre matt is then removed from the sol, dried out and heated to sinter the sol particles.

Abstract: A method of fabricating an anode plate 18 for use in a field emission device comprising the steps of providing a transparent substrate 20 and depositing a layer of a transparent, electrically conductive material 24 on a surface of the substrate. Next, portions of the layer of conductive material 24 are removed to form regions of the conductive material. Luminescent material 26 is then applied to the conductive regions 24, and a layer of electrically conductive material 23 is applied to the luminescent material 26. Outer portions of the conductive material 23 and an outer portion 27 of at least some of the particles 25 of the luminescent material are thereafter removed.

Abstract: Phosphor color screens with triad pitches of 150 .mu.m and less are fabricated by a combination of modified microelectronic processing techniques and electrophoretic coating of the phosphors and black screen. Indeed, triad pitches based on 15 .mu.m color line width and 5 .mu.m black matrix between colors are achievable.

Abstract: A method of manufacturing a composite material which comprises ceramic fibers in a matrix of a ceramic material. A woven mat of ceramic fibers having an electrically conductive coating thereon is immersed in a sol. The sol comprises surface-charged ceramic particles. A potential difference is applied between the fibers and a second electrode placed in the sol. The applied potential difference is continued until the mat is permeated by the ceramic particles in the sol. The mat is removed from the sol and is then heated to sinter the permeated ceramic particles.

Abstract: A system and method for producing thin, uniform powder phosphors for field emission display screens wherein a planarization of the phosphor powder layer is accomplished by placing the deposited phosphor layer in an anode plate between two optical flats, which are then mounted within a mechanical press.